Spray Dryers
The process involving conversion of fluid into fine droplets and exposing
them to a hot drying media, so as to achieve defined dry particulate
matter is spray drying. It is a widely used continuous industrial process
which involves particle formation from feed fluid which may be in the form
of solution, emulsion or pumpable suspension into either dry powder or
granules. Spray drying involves following steps.
Spray dryers are primarily used for drying of solutions and slurries into
powders. Acmefil has serviced the industry by offering plants for a
variety of applications ranging from heat sensitive products like enzymes,
blood, flavours, to regular products like plant and animal extracts, milk,
food and pharmaceutical applications, dyes and chemicals, detergents,
catalysts to heat resistant products like ceramics, inorganic salts, glass
and metals etc.
Depending upon the end product requirement there are different designs
like rotary atomizer, pressure nozzle tower or two fluid nozzle type spray
dryer.
Acmefil has an experience to build Spray Dryers from 1kg/hr water
evaporation capacities to 4000 kg/hr water evaporation capacities.
Acmefil Engineering Systems have pilot plant facilities for conducting
trials for products and for development of new procedures of drying. These
facilities are available to end users and research institutes at nominal
charges for development applications at mutually agreed terms
ATOMIZATION
Conversion of the feed into fine droplets is achieved by either pumping
the feed under high pressure through an orifice or by spraying through a
high speed rotating perforated disc. The former is known as Nozzle
Atomization and is popularly used to produce coarse droplets resulting in
large granular particles of dried products. The latter is known as Rotary
Disc Atomization and produces fine droplets resulting in fine powder
particles of dried products.
HOT AIR MIXING
Air, which is, normally the drying media used, is heated to a predefined
temperature depending upon the characteristics of the feed fluid and dried
product either an indirect hot air generator or a direct hot air
generator. This hot air is brought in contact with the spray droplets in
one of the following ways through the air distributor:
Co-current-Air and particles move in the same direction.
Counter-current-air and particles move in the opposite direction.
Mixed flow - particles are subjected to co-current and counter-current
phase.
The thermal energy of the hot air is used for evaporation and the cooled
air pneumatically conveys the dried particles in the system. The contact
time of the hot air and the spray droplets is only a few seconds, during
which drying is achieved and the air temperature drops instantaneously.
The dried particle never reaches the drying air temperature. This enables
efficient drying of heat sensitive materials without thermal
decomposition.
POWDER SEPARATION
Dried powder is discharged continuously from the bottom of the drying
chamber through rotary valve and the air containing fines is taken to
either a cyclone separator or passed through a textile fabric in a bag
filter to recover the fines. The air is further scrubbed in a high
efficiency venturi scrubber before being exhausted out to the atmosphere.
Special powder handling systems are used for industrial applications to
either cool the dried powder or toe pneumatically convey the same to a
product silo. These systems are tailor designed to suit the specific
requirements and layouts. Spray dryer is an ideal choice as it offers
defined end product characteristics in terms of particle size, moisture
content, bulk density and particle shape.
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