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 (T
DB
) = 150
0
C & (T
WB
) = 50
0
C
Outlet air Temperature = 120
0
C
Inlet temperature of solid = 50
0
C
Outlet temperature of solid = 65
0
C
Specific heat of solid = 0.32 cal/gm/
0
C
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+X
1
)L
s
= 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 H2 T2
Gs H1 T1 Ls Hl1 t1
Ls Hl2 t2
Spray Chamber
G
s
= Heated Gas Flow Rate in kg/hr
L
s
= Solid Flow Rate in kg/hr
X
1
= Moisture content in the entering solid ( kg moisture / kg
solid )
X
2
= Moisture content in the exit solid ( kg moisture / kg solid )
Y
1
= Humidity of entering air ( kg moisture / kg air )
Y
2
= Humidity of outlet air ( kg moisture / kg air )
T
1
= Temperature of inlet air T
2
= Temperature of outlet
air
t
1
= Temperature of inlet solid t
2
= Temperature of exit
solid

EQUATIONS( SPRAY
CHAMBER )
Mass Balance eq
n
:
L
s
X
1
+ G
s
Y
1
= L
s
X
2
+ G
s
Y
2
---------------(1)

Enthalpy Balance eq
n
:
L
s
H
L1
+ G
s
H
1
= L
s
H
L2
+ G
s
H
2
-----------(2)

H
L1
= Enthalpy of entering solid in kJ/kg of dry solid
H
L2
= Enthalpy of exit solid in kJ/kg of dry solid
H
1
= Enthalpy of entering air in kJ/kg of dry air
H
2
= Enthalpy of exit air in kJ/kg of dry air

EQUATIONS( SPRAY
CHAMBER )
H
L1
=( C
ps
+ X
1
*C
pw
)*t
1


H
L2
=( C
ps
+ X
2
*C
pw
)*t
2

H
1
=( C
pa
+ Y
1
*C
pv
)*T
1
+ Y
1
*

H
2
=( C
pa
+ Y
2
*C
pv
)*T
2
+ Y
2
*

C
ps
= Specific heat of solid = 1.3395 kJ/kg/
0
C
C
pw
= Specific heat of water = 4.2 kJ/kg/
0
C
C
pv
= Specific heat of water vapor = 1.89 kJ/kg/
0
C
C
pa
= Specific heat of air at avg. temperature = 1.0312 kJ/kg/
0
C
= 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
H
L1
= 70.125 kJ/kg of dry solid
H
L2
= 87.8865 kJ/kg of dry solid
H
1
= 191.5097 kJ/kg of dry air

Simultaneously solving Mass balance and Enthalpy balance
equations (1) and (2) we get ::
Y
2
= 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
Humid Volume :
Inlet ( V
in
) = 1.225 m
3
/kg dry air
Outlet ( V
out
) = 1.1493 m
3
/kg dry air
V
avg
=(V
in
+ V
out
)/2= 1.1859 m
3
/kg dry air

Droplet Diameter assumed to be 100 microns.
1 273.15
( ) = 8315 * ( )*( )
g
a w
Y T
Humid Volume V
M M P
+
+
M
a
= Molecular wt of air =29 g/mol
M
w
= Molecular wt of water 18 g/mol
T
g
= Temperature of gas in
0
C
P = Pressure in N/m
2
Y = Humidity of air in kg of moisture/ kg of dry air
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
2
p D ( )

18
p f
s
g
v

=
D
p
= Drop Diameter in m

p
= Density of droplet in kg/m
3

f
= Density of air at avg temperature in kg/m
3
= Viscosity of air at avg temperature
v
s
= Settling velocity
g = Acceleration due to gravity
In Stokes law region i.e. for Reynolds number less than 2
CALCULATED DATA ( contd. )
Density of urea = 1323 kg/m
3
Density of water = 1000 kg/m
3
Density of solid particles = (1.5*1000 + 98.5*1323)/100


p
= 1318.2 kg/m
3

Average temp=(150+120)/2=135
0
C
Density of air at avg temperature
f
= 0.865 kg/m
3

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

Settling velocity v
s
= 0.3078 m/s




CALCULATED DATA ( contd. )
Reynolds Number =1.411 < 2


Thereby , STOKEs Law is applicable and now :

Operating Velocity ( v
a
) = 2 * Settling velocity
v
a
= 2 * v
s
= 0.6155 m/s

e R
p s p D v

=
COLUMN DIAMETER(SPRAY
CHAMBER)
Column Area A
c
= (G
s
* V
avg
)/ v
a

Gs= 2738.8 Kg/hr
V
avg
= 1.1859 m
3
/kg dry air
v
a


= 0.6155 m/s
A
c
= 1.46578 m
2

Column

Diameter
D
c
= 1.3661 m
For safety purposes , assuming 15%
safety
D
c
= 1.15* D
c
= 1.57104 m

4* c
c
A
D
t
=
RESIDENCE TIME
t
d
= 50X
1
(Ref. Brown et al Unit Operations, p 564)

t
d
= residence time in sec.
X1=mass ratio of water to solids in feed=0.015

t
d
= 6.12372 sec

p
= time required to evaporate moisture from droplet
p=Density of feed.

w
= Latent heat of vaporization at normal boiling pt.

= 2256.9 kJ/kg
K
f
= Thermal conductivity of air at avg temperature = 0.033925 Watt/m/K
T
t
= Temperature driving force
= Drying gas film temp. Temp. of dry solid surface

2
1 X
12
p p
p
f t
w D
K T

u =
A
CALCULATED DATA ( contd. )

T
t
= T
avg
(t
1
+ t
2
) / 2 = 77.5

p
= 0.0142 sec

As
p
is less than t
d
, 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 (V
t
) = G
s
* V
avg
* t
d
= 5.5239
m
3

Minimum height of cylindrical (h
min
)= v
s
*
p
= 0.00437 m

portion

Recommended height of(h
cyl
) = 0.6 * D
c
= 0.9426 m
cylindrical portion

Volume of the conical portion of the chamber
V
cone
= 3.69668 m
3

h
cone
= Height of the conical portion of the chamber
h
cone
= 5.7209 m



Cone angle = 15.6306 degree

2
4
cyl
C
cone t
D h
V V
t
=
2
3 4 cone
cone
c
V
h
D t

=
tan( )
2 2
c
cone
Radiusofchamber D
Conicalheight h
o
= =
MECHANICAL DESIGN
THICKNESS OF CHAMBER
t
min
= t
min
= (D
c
+100)/1000 = 0.1628 inch

D
c
is in inches & t
min
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.
A
d
= 8.3386 * 10
-4
m
2

DUST COLLECTOR
Outlet area of the dust
collector

Diameter of dust collector
D
d
= 32.58 mm = 1.3032 inch ( as this is small , 5
inch nominal diameter is used )


Length of dust collector
L
d
= D
c
/8=0.19698 m


*
s
d
p s
L
A
v
=
4* d
d
A
D
t
=
HOT AIR INLET
Assume operating air velocity v
air
= 10 m/s

Minimum cross sectional area = (G
s
* V
avg
)/ v
air

=
0.07607 m
2

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 m
2

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 m
3

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