DESIGN OF SPRAY DRIER

Process Equipment and Design – II

Reference-Mass Transfer Operations by Alapati
Suryanarayana (page 571-578)

• 08010734-RAHUL MAYANK
•08010736-SANGADE MAHESH SITARAM
•08010737-SANGISHETTY TARUN
PROBLEM STATEMENT
 Design of Spray Drier with the data given below:

 Centrifuged Urea to be dried from 1.5 wt % to 0.3 wt %

 Feed rate of solid = 1200 kg/hr
 Inlet heated air of (TDB) = 1500 C & (TWB) = 500 C
 Outlet air Temperature = 1200 C
 Inlet temperature of solid = 500 C
 Outlet temperature of solid = 650 C
 Specific heat of solid = 0.32 cal/gm/0C
SPRAY DRYER

 Spray drying is a method of producing a dry powder from

a liquid or slurry by rapidly drying with a hot gas. This is
the preferred method of drying of many thermally-
sensitive materials such as foods and pharmaceuticals.
 It is highly suited for the continuous production of dry
solids in either powder, granulate or agglomerate form
from liquid feedstocks as solutions, emulsions and
pumpable suspensions. Therefore, spray drying is an
ideal process where the end-product must comply to
precise quality standards regarding particle size
distribution, residual moisture content, bulk density, and
particle shape.
ATOMIZER
 Atomization is used to obtain particles of high
surface/weight ratio. It is acquired by passing the liquid
through a nozzle.
 To disperse the liquid or slurry into a controlled drop size
spray.
 Depending on the process needs drop sizes from 10 to 500
micron can be achieved with the appropriate choices.
 Types of atomizer
 Single fluid Pressure Nozzle Atomizer
 Two-Fluid Nozzle Atomizer
 Centrifugal (Disk) Atomizer
 Pressure Nozzle Atomizer

 Pressure nozzle or single fluid

nozzle use pressure energy for
atomization, with feed pressures
in the range of 200 to 600 psi.
The pressure energy is converted
into kinetic energy and the feed
issues from the nozzle has a high-
speed film which readily breaks.
The pressure nozzles are suitable
for feed with relatively low
viscosity and free of lumps.
 Two-Fluid Nozzle Atomizer
 The available energy for atomization in two
fluid atomizers is independent of liquid flow
and pressure. The necessary (kinetic) energy for
atomization is supplied by compressed air in
the range 20 -100 psig. The atomization is
created due to high frictional shearing forces
between the liquid surface and the air having a
high velocity even at sonic velocities and
sometimes rotated to obtain maximum
atomization.
 In pneumatic nozzle the feed can be mixed with
compressed air either internally or externally.
The external mixing types are used for
abrasive feeds. Two Fluid Nozzle atomizer are
convenient for low capacity application and
popularly used for high quality ceramic
powders: Alumina, Bentonite, Carbides, Clays,
Ferrites, Steatites, Titanates and Zirconias.
Centrifugal (Disk) Atomizer

 A spray is created by passing the

fluid across or through a rotating
wheel or disk. The energy
required for atomization is
supplied by the atomizer motor.
SPRAY CHAMBER

 The atomized feed is introduced into a large chamber

where droplets are dispersed into the stream of hot air.

 Drying takes place by contacting the droplets with hot air in a

spray chamber. Evaporation of moisture from the droplets and
formation of dry particles proceed under controlled
temperature and airflow conditions. Powder is discharged
continuously from the drying chamber.

 Evaporation takes place from the surface of the drops and

solid material form an impervious shell at the surface which
collapses inward due to internal pressure.
Mode of contact
 The hot drying gas can be passed as a co-current
or counter-current flow to the atomiser direction.
 The co-current flow enables the particles to have a
lower residence time within the system and the
particle separator (typically a cyclone device)
operates more efficiently.
 The counter-current flow method enables a greater
residence time of the particles in the chamber and
usually is paired with a fluidised bed system.
1. feed storage 2. pump
3. drying chamber 4. air heater
5. Cyclone 6. gas scrubber
7. separator
ADVANTAGES
 Very short drying time, which permits drying of highly heat
sensitive products.

 Product particle size & density are in controllable limits

 Relatively low operating cost.

 Air is the heated drying media; however, if the liquid is a

flammable solvent such as ethanol or the product is oxygen-
sensitive then nitrogen is used.
Spray drying applications

 Food: milk powder, coffee, tea, eggs, cereal, spices,

flavorings
 Pharmaceutical: antibiotics, medical ingredients,
additives
 Industrial: paint pigments, ceramic materials,
catalyst supports
DESIGN ASPECTS
 Atomizer : its type & design.
 Flow rate of the heated inlet air.
 Settling velocity.
 Solid & Gas operating velocity.
 Chamber Diameter.
 Residence time.
 Design of Conical bottom
 HERE WE ARE CONSIDERING A CO-CURRENT SPRAY DRYER
SINCE IT IS THE MOST COMMON ONE
ATOMIZER
 Centrifugal-disk atomization is particularly
advantageous for atomizing suspensions and
pastes that erode and plug nozzles
 Type of Disk atomizer ( Vane, Kesner , Pin ) Ref. patent
US20040139625
 Diameter of the Disk Atomizer :: 5 – 35 cm .
 Rotational speed :: 4,000 - 65,000 rpm
 Peripheral speed :: 4,500 – 10,000 m/min
 Mean particle size :: 70 – 100 microns
Atomizer design
 Atomiser selected is centrifugal disk atomiser
 Mean particle size assumed = 100 microns

 Feed rate (F) = (1+X1)Ls = 1218 Kg/hr= 44.75

lb/min
 Herring and Marshal chart(Ref. British Chem. Engg.,
Dec 1967,Vol 12,No. 12,P 1892) peripheral speed
vs. mean particle diameter, with feed rate as
parameter
On interpolation , we get
peripheral speed = 570.5 ft/s
v =10433.3 m/min
DISK SELECTION
 Disk selected=B-1
 Diameter of disk = 0.59 ft
 Vane height=0.406ft
 Vane length=1ft
 No of vanes=60
 Rotational speed N= 570.5*60/(periphery of disc)
 =18467.36 rpm
 We take N=18500 rpm
 Ref. Alder and Marshall , CEP 1951 Dec ,p 606)
ATOMIZER ( contd. )
 Power consumption :
P = 1.02*10-8 * F * ( N * d )2
where F = Feed rate of solution in lb/min=44.75 lb/min
N = Rotational speed in rpm=18500 rpm
d= Radius of disk atomizer in ft=0.59 ft
P=power in hp

P=14.744 hp
SPRAY CHAMBER
Gs H1 T1 Ls Hl1 t1

Gs H2 T2 Ls Hl2 t2
Spray Chamber
Gs = Heated Gas Flow Rate in kg/hr
Ls = Solid Flow Rate in kg/hr
X1= Moisture content in the entering solid ( kg moisture / kg solid )
X2= Moisture content in the exit solid ( kg moisture / kg solid )
Y1= Humidity of entering air ( kg moisture / kg air )
Y2= Humidity of outlet air ( kg moisture / kg air )
T1= Temperature of inlet air T2= Temperature of outlet
air
t1= Temperature of inlet solid t2= Temperature of exit solid
EQUATIONS( SPRAY CHAMBER )
 Mass Balance eqn :
Ls X1 + Gs Y1 = Ls X2 + Gs Y2 ---------------(1)

 Enthalpy Balance eqn :

Ls HL1 + Gs H1 = Ls HL2 + Gs H2 -----------(2)

HL1 = Enthalpy of entering solid in kJ/kg of dry solid

HL2 = Enthalpy of exit solid in kJ/kg of dry solid
H1 = Enthalpy of entering air in kJ/kg of dry air
H2 = Enthalpy of exit air in kJ/kg of dry air
EQUATIONS( SPRAY CHAMBER )
 HL1=( Cps + X1*Cpw)*t1

 HL2=( Cps + X2*Cpw)*t2

 H1=( Cpa + Y1*Cpv)*T1 + Y1*λ

 H2=( Cpa + Y2*Cpv)*T2 + Y2*λ

Cps = Specific heat of solid = 1.3395 kJ/kg/0C

Cpw = Specific heat of water = 4.2 kJ/kg/0C
Cpv = Specific heat of water vapor = 1.89 kJ/kg/0C
Cpa = Specific heat of air at avg. temperature = 1.0312 kJ/kg/0C
λ = Latent heat of vaporization= 2510.7 kJ/kg
 CALCULATED DATA ( contd. )

 X1 = 0.015 X2 = 0.003
 Y1 = 0.01317(By psychometric chart at given DB & WB)humidity of inlet
air
 HL1 = 70.125 kJ/kg of dry solid
 HL2 = 87.8865 kJ/kg of dry solid
 H1 = 191.5097 kJ/kg of dry air

 Simultaneously solving Mass balance and Enthalpy balance equations (1)

and (2) we get ::
 Y2 = 0.0206
 Evaporation rate of water=(0.015-0.003)*1200=14.4 Kg/hr
 Since chamber effciency is assumed to be 70% , therfore net
evaporation rate of water is:
14.4/0.7 =20.57 kg water/hr

• Moisture removed per kg of dry air=(0.0206-

0.01317)=0.00743 kg water per kg of dry air

• Gs= 20.57/0.00743 = 2768.5 Kg/hr

 1 Y Tg  273.15
Humid Volume(V ) = 8315 * (  )*( )
Ma Mw P

Ma = Molecular wt of air =29 g/mol

Mw = Molecular wt of water 18 g/mol
Tg = Temperature of gas in 0C
P = Pressure in N/m2
Y = Humidity of air in kg of moisture/ kg of dry air

 Humid Volume :
Inlet ( Vin ) = 1.225 m3/kg dry air
Outlet ( Vout ) = 1.1493 m3/kg dry air
Vavg =(Vin + Vout )/2= 1.1859 m3/kg dry air

 Droplet Diameter assumed to be 100 microns.

Operating Velocity Calculations
 The pressure within the tower is maintained slightly
negative which eliminates the possibility of any dust
getting into the atmosphere and making the area
unfit for work.
 The operating velocity in the case of non-dusting
spray dryer is taken as two times the settling
velocity of the drop.
SETTLING VELOCITY

In Stoke’s law region i.e. for Reynold’s number less than 2

Dp (  p   f ) g
2
vs 
18
Dp = Drop Diameter in m
ρp = Density of droplet in kg/m3
ρf = Density of air at avg temperature in kg/m3
µ = Viscosity of air at avg temperature
vs = Settling velocity
g = Acceleration due to gravity
CALCULATED DATA ( contd. )
 Density of urea = 1323 kg/m3
 Density of water = 1000 kg/m
3

 Density of solid particles = (1.5*1000 + 98.5*1323)/100

ρp = 1318.2 kg/m3
Average temp=(150+120)/2=1350C
 Density of air at avg temperature ρf = 0.865 kg/m3

 Viscosity of air at avg temperature µ = 23.329*10-6 N/m

 Settling velocity vs = 0.3078 m/s

CALCULATED DATA ( contd. )
Dpvs  p
Reynolds Number Re  =1.411 <2



 Thereby , STOKE’s Law is applicable and now :

Operating Velocity ( va ) = 2 * Settling velocity

va = 2 * vs = 0.6155 m/s
COLUMN DIAMETER(SPRAY CHAMBER)

Column Area Ac = (Gs * Vavg)/ va

Gs= 2738.8 Kg/hr
Vavg = 1.1859 m3/kg dry air
va = 0.6155 m/s
Ac = 1.46578 m2

 Column Diameter Dc 
4* Ac
Dc = 1.3661 m 
For safety purposes , assuming 15% safety
Dc = 1.15* Dc = 1.57104 m
RESIDENCE TIME
 td = 50√X1 (Ref. Brown et al Unit Operations, p 564)
td = residence time in sec.
X1=mass ratio of water to solids in feed=0.015

td = 6.12372 sec

 w pX1D 2
p 
p

12 Kf Tt
θp = time required to evaporate moisture from droplet
ρp=Density of feed.
λw = Latent heat of vaporization at normal boiling pt. = 2256.9 kJ/kg
Kf = Thermal conductivity of air at avg temperature = 0.033925 Watt/m/K
ΔTt = Temperature driving force
= Drying gas film temp. – Temp. of dry solid surface
CALCULATED DATA ( contd. )

 ΔTt = Tavg – (t1+ t2) / 2 = 77.5

 θp = 0.0142 sec

 As θp is less than td , hence evaporation of the drops can

take place and design is acceptable.
CHAMBER DIMENSIONS
It is a cylindrical chamber with a conical bottom.
 Total Volume of chamber (Vt) = Gs * Vavg * td = 5.5239
m3

 Minimum height of cylindrical (hmin)= vs * θp = 0.00437 m

portion

 Recommended height of(hcyl) = 0.6 * Dc = 0.9426 m

cylindrical portion
  D hcyl
2
Vcone  Vt  C
4
 Volume of the conical portion of the chamber
Vcone = 3.69668 m3
3  4  Vcone
hcone 
 Dc 2
 hcone = Height of the conical portion of the chamber
hcone = 5.7209 m
 Radiusofchamber Dc
tan( )  
2 Conicalheight 2hcone
 Cone angle α= 15.6306 degree
MECHANICAL DESIGN
 THICKNESS OF CHAMBER
 tmin = tmin= (Dc+100)/1000 = 0.1628 inch

Dc is in inches & tmin is in inches

 As the next available thickness is 0.25 inch mild steel.

 Since head and wall are under same stress , so we can
assume the same thickness for both.
 Ad = 8.3386 * 10-4 m2
DUST COLLECTOR
 Outlet area of the dust Ls
collector Ad 
 p * vs
 Diameter of dust collector
Dd = 32.58 mm = 1.3032 inch ( as this is small , 5 inch
nominal diameter is used )
4* Ad
Dd 
 Length of dust collector 
Ld= Dc/8=0.19698 m
HOT AIR INLET
 Assume operating air velocity vair = 10 m/s

 Minimum cross sectional area = (Gs * Vavg)/ vair

0.07607 m2
=

 Contamination of outlet air with fine particles

requires a higher cross sectional area for outlet duct
than that of inlet duct.
CALCULATED DATA ( contd. )
 A rectangular duct having length to breadth ratio 1.2 :1 is
used.
 1.2*(breadth)^2=area of inlet pipe= 0.07607 m2
 Breadth of inlet duct = 0.2517m
 Length of inlet duct =1.2*0.2517= 0.3021 m
 The outlet duct should have a higher cross-sectional area than
inlet duct.
 Length of outlet duct = 0.35 m
 Breadth of outlet duct = 0.264 m
SUMMARY OF DESIGN DATA
 Power consumed=14.744 hp
 Chamber efficiency=70%(assumed)
 Total Volume of the chamber= 5.5239 m3
 Diameter=1.57104 m
 Height: Cylindrical portion(0.6D)= 0.9426 m
 Conical portion= 5.7209 m
 Total height=6.6635 m
 Bottom cone angle= 15.6306 degree
 Mechanical Design: Shell plate thickness= 0.25 inch
 Hot air inlet duct= 0.3021 m x 0.2517m
 Hot air outlet duct= 0.35 m x 0.264 m