Superheated Steam Drying of Single Wood Particles: Modeling and Comparative Study with Hot Air Drying

A deterministic model is developed to describe the superheated steam drying process of single wood particles. A comparison between calculated data and experimental observations infers that the moisture‐dependent effective diffusivity is suitable to be used for beechwood material drying. To reduce the computational cost of the deterministic drying model, a semi‐empirical model is proposed within the framework of a reaction engineering approach (REA). The validity of the proposed model is checked by comparing against experimental data from literature. The experimental drying behavior may fairly be reflected by the reduced model. Due to the simplicity and predictive ability of the REA model, this semi‐empirical model can be implemented to describe heat and mass transfer between a population of single particles and a drying agent in dryer models.     

Unraveling the droplet drying characteristics of crystallization‐prone mannitol – experiments and modeling

Spray‐dried mannitol is a potential lactose replacement in pharmaceutical formulations, yet the drying behavior of individual mannitol droplets within the spray chamber has not been fully understood. This work explored the drying characteristics of mannitol by employing the reaction engineering approach (REA) in data analysis. A glass filament single droplet drying technique was used to monitor the changes in droplet temperature, mass, and diameter. The drying kinetics data obtained clearly demonstrated the droplet “wet‐bulb” period, the crust formation, and the crystallization phenomena. The master activation‐energy curves developed from REA modeling responded sensitively to varying drying temperatures, which could have led to different crystallization events. The deviation of these plots from the expected norms that do not encounter a phase change was used effectively to discern the physics involved. A REA kinetic model was proposed to assist in process optimization of large‐scale spray‐drying operations. © 2017 American Institute of Chemical Engineers AIChE J, 63: 1839–1852, 2017     

Optimization of the Spray Drying Operating Parameters—A Quick Trial-and-Error Method

This short communication reports an optimization approach to effectively determine suitable spray drying operating parameters for a pilot-scale dryer. The proposed optimization approach is essential, as pilot-scale investigations and medium-scale contract productions often involve usage of standard spray dryer units which is not specifically designed for the feed material used. This optimization approach was developed based on past studies on the effect and relationship of the many spray drying operating parameters and highlights two factors which has to be solved (or considered) chronologically: dripping problem, followed by product caking problem. Based on this proposed approach, an algorithm was developed in a case study to optimize an available spray dryer for our future experimental study on wall deposition. In this case, the operating parameters were determined under minimal experimental runs. This proposed optimization approach will be a useful tool for operators and experimenters utilizing spray dryers of similar type, particularly in exploring new feed materials. Depending on the optimization objectives and experimental limitations, different algorithms can be developed. Apart from that, interesting deposition pattern was also observed in the case study. This short communication also reported on the design of an internal rig for further studies on wall deposition.     

甘露醇喷雾干燥过程中液滴粒度分布变化的群体粒数衡算模拟和实验研究

利用群体粒数衡算（population balance，PB）计算机模拟和实验研究了甘露醇水溶液的喷雾干燥过程中液滴的粒度分布的变化规律。液滴干燥过程中的颗粒粒度的萎缩速率，在群体粒数衡算模型中描述为液滴的逆（或负）生长项，通过单个液滴反应动力学方法（reaction engineering approach，REA）获得。基于单个液滴干燥的反应工程方法模型REA和群体粒数衡算模型PB集成建立了PBREA模型。PBREA 模型的求解是通过高分辨率数值方法。本文模拟研究了不同工况下，不同粒径液滴的干燥时间、液滴平均含湿量以及液滴粒度分布随时间的变化。结果显示，液滴粒径越大，干燥时间越长，模型预测的颗粒平均粒径为实验值的1.0~1.5倍，粒度分布跨度是实验值的0.61~0.89倍。模拟误差主要来源于液滴及颗粒粒径分布统计精度、单个静止液滴与群体运动液滴干燥的差异、热导率及扩散系数是经验值3个方面。在使用Buchi 290 小型喷雾干燥仪进行的实验中，使用了图像采集和分析方法得到了液滴及颗粒的数密度分布，并和模拟结果做了对比。结果表明该模型可以有效地预测喷雾干燥过程中干燥颗粒的平均粒度及分布跨度。     

Modeling of Muti-layer Far-Infrared Dryer

Abstract

The heat and mass transfer models applicable to biological products at each element in a far-infrared fixed-bed dryer were established. The model was validated by comparing the simulation results with experimental data of black mushrooms (Lentinus edodes) in terms of moisture content and drying rate. The very good agreement suggests that the models for heat transfer and drying rate of biological products in the far-infrared fixed-dryer can be obtained by establishing the equations of radiation and dehydration in interspace elements. An unevenness of change in moisture content and drying rate on the same horizontal layer in the dryer was found. Thus it is necessary to take some measures to solve this nonuniformity in drying if the proposed dryer is employed.     

Spatial reaction engineering approach as an alternative for nonequilibrium multiphase mass‐transfer model for drying of food and biological materials

Drying is a complex process which involves simultaneous heat and mass transfer. Complicated structure and heterogeneity of food and biological materials add to the complexity of drying. Drying models are important for improving dryer design and for evaluating dryer performance. The lumped reaction engineering approach (L‐REA) has been shown to be an accurate and robust alternative for cost‐effective simulations of challenging drying systems. However, more insightful physics has to be shown spatially. In this study, the REA is coupled with the standard mechanistic drying models to yield the spatial‐REA (S‐REA) as nonequilibrium multiphase mass‐transfer model. The S‐REA consists of a system of equations of conservation with the REA representing the local evaporation and wetting rate. Results of the modeling using the S‐REA match well with the experimental data reported previously. This is the first comprehensive REA approach to model the profiles of water vapor concentration during drying of food and biological materials. This study indicates that the S‐REA can be an accurate nonequilibrium multiphase mass‐transfer model with appropriate account of the local evaporation rate. The overall REA concept is expected to contribute substantially for better and cost‐effective representation of transport phenomena of drying process. © 2012 American Institute of Chemical Engineers AIChE J, 59: 55–67, 2013     

A Three-Dimensional Simulation of a Spray Dryer Fitted with a Rotary Atomizer

Abstract

Spray dryers fitted with rotary atomizers are commonly used in diverse industries to produce engineered powders on a large scale. Scale-up of such units is still largely empirical and based on prior experience and know-how. In the present study, a three-dimensional spray dryer with rotary atomizer is investigated numerically with a commercial CFD code. Continuous-phase, i.e., air, conservation equations are formulated in the Eulerian model while the droplet or particle equations are set up in the Lagrangian model. Two-way coupling between the continuous and dispersed phases is taken into account in the governing equations. The stochastic approach is used to predict the particle trajectories. The RNG k ? ? turbulence model was used. Typical results, viz. air velocity, temperature, humidity profiles, and particle trajectories are presented and discussed. Compared with the pressure nozzle spray dryer, more volume of drying chamber is used effectively by the rotating disc type spray dryer. It is found that evaporation and drying take place mainly in the region and in the vicinity of first contact between air and spray. A parametric study is presented and, where appropriate, comparison is made with experimental data obtained with the simulated spray dryer.     

Application of the reaction engineering approach (REA) for modeling intermittent drying under time-varying humidity and temperature

A ‘good’ drying model is important for the design of dryer, evaluation of dryer performance and prediction of product quality. Among the available models, the reaction engineering approach (REA) is a lumped model, proven to be simple, robust and accurate to model drying of several materials. In this paper, the REA is implemented to model intermittent drying, which is usually practiced for saving energy consumption and maintaining product quality during drying, under time-varying drying air temperature and humidity, which is a challenging drying case to model. For this purpose, the equilibrium activation energy (ΔE_v,b) is defined according to the drying settings in each time period and combined with the relative activation energy (ΔE_v/ΔE_v,b) generated from the convective drying experimental data obtained under constant drying conditions. The mass and heat balances also implement the corresponding drying settings in each time period during the intermittent drying. The results indicate that the REA can describe both the moisture content and temperature profiles of the intermittent drying under time-varying drying air temperature and humidity well. The accuracy, simplicity and robustness of the REA for the intermittent drying under time-varying drying air temperature and humidity are proven here. This has provided a major and significant extension of the REA on modeling challenging drying cases.     

Estimation of the drying rate and moisture profiles in an industrial spray dryer by means of experimental investigations and a simulation study

A spray dryer simulation program is described. It is based on the known conservation laws and permits determination of temperature and moisture profiles and droplet trajectories inside spray dryers. An industrial spray dryer used in the manufacture of detergents serves as an example to demonstrate the applicability of the program; this approach required prior experimental determination of the flow field and an axial temperature profile. On the basis of a rough estimate of the drying rate in the spray dryer, good agreement was observed between experiment and simulation.     

Numerical Study of Two-Stage Horizontal Spray Dryers Using Computational Fluid Dynamics

This article presents the findings of a numerical simulation model of the spray-drying process in a two-stage horizontal chamber design with the aid of a computational fluid dynamic (CFD) model. The model describes heat, mass, and momentum transfer between two phases; namely, a continuous gas phase and a discrete phase of droplets (or particles), using the finite volume method. In this study, a new two-dimensional horizontal spray dryer (HSD) geometry is considered as a pilot study into the spray-drying process in this novel chamber configuration. The tested model is able to predict some important features of the spray-drying process, such as air flow patterns indicating recirculation zones and particle trajectory plots. Some performance parameters for spray drying, such as the rate of evaporation, average volumetric heat and mass transfer rates, etc., are calculated and discussed. This two-stage drying process especially applicable for the horizontal spray dryer (HSD) model is investigated and modeled. The bottom wall of the HSD is assumed to be a shallow fluid bed used for second stage drying. In this article, the fluid bed drying conditions are changed and compared. The drying within the fluid bed itself is not modeled in this study, however. It is shown that the particle residence time is higher when the fluid bed is included. The drying performance of this two-stage horizontal spray dryer is expected to be better than that of a single-stage dryer.     

Numerical Study of Two-Stage Horizontal Spray Dryers Using Computational Fluid Dynamics

This article presents the findings of a numerical simulation model of the spray-drying process in a two-stage horizontal chamber design with the aid of a computational fluid dynamic (CFD) model. The model describes heat, mass, and momentum transfer between two phases; namely, a continuous gas phase and a discrete phase of droplets (or particles), using the finite volume method. In this study, a new two-dimensional horizontal spray dryer (HSD) geometry is considered as a pilot study into the spray-drying process in this novel chamber configuration. The tested model is able to predict some important features of the spray-drying process, such as air flow patterns indicating recirculation zones and particle trajectory plots. Some performance parameters for spray drying, such as the rate of evaporation, average volumetric heat and mass transfer rates, etc., are calculated and discussed. This two-stage drying process especially applicable for the horizontal spray dryer (HSD) model is investigated and modeled. The bottom wall of the HSD is assumed to be a shallow fluid bed used for second stage drying. In this article, the fluid bed drying conditions are changed and compared. The drying within the fluid bed itself is not modeled in this study, however. It is shown that the particle residence time is higher when the fluid bed is included. The drying performance of this two-stage horizontal spray dryer is expected to be better than that of a single-stage dryer.     

SCALE-UP OF SPRAY DRYERS WITH THE AID OF COMPUTATIONAL FLUID DYNAMICS

Abstract

The scale-up of spray dryer chambers is difficult because of the complexity of gas and spray flow patterns. The principal concerns in designing a spray drying chamber are to ensure sufficient residence time for drying and to avoid particle-wall collisions. Dimensionless groups are of limited use because it is practically impossible to achieve dynamic similarity between small and large chambers. In the past, empirical, rather than theoretically based, rules generated by experience with existing plant have been used in the design and scale-up of spray dryer chambers but these models, because of their empirical nature, are limited in their range of applicability. Computational fluid dynamics (CFD) is potentially a powerful tool to aid spray dryer design allowing much more flexibility in design but because of the difficulties of modelling such complex phenomena, especially the gas turbulence, its predictions cannot, at present, be considered absolutely reliable and experimental validation of the results is required. However, by considering the principles of similarity, it is shown that validations carried out on pilot scale equipment under the correct conditions will prove the accuracy of CFD applied to spray dryers of any size.     

Eulerian–Lagrangian Simulation and Experimental Validation of Pneumatic Conveying Dryer

This paper explores numerical and experimental studies on the performance of a pneumatic conveying dryer. The four-way coupling Eulerian–Lagrangian approach is utilized in the numerical study and the experimental study is carried out in a pilot-scale vertical pneumatic conveying dryer of diameter 8.1 cm and 4.5 m length. The effects of Reynolds number, particle size, solid mass flow rate, and inlet gas temperature on the dryer performance are investigated. It is found that the present model predictions agree well with the experimental data. Generally, it is concluded that the drying rate increases as the Reynolds number increases, while increasing the particle size or the solid mass flow rate decreases the drying rate.     

Drying of Liquid Feedstocks in a Spout‐Fluid‐Bed with Draft‐Tube Submerged in Inert Solids: Hydrodynamics and Drying Performance

A spout‐fluid bed with draft tube submerged in a bed of polypropylene beads was used for drying maltodextrin solutions. The hydrodynamics of the dryer were studied by determining the annular air flow vertical profile at different spouting velocities, using an additional air flow rate through the annulus equivalent to 0.5 U_mf. The drying performance of the dryer was studied through the determination of several dryer response parameters (product moisture, evaporative capacity and volumetric evaporative capacity). These parameters were compared with those obtained in a conventional spouted bed with inert solids and a spray dryer.     

SCALE-UP OF SPRAY DRYERS WITH THE AID OF COMPUTATIONAL FLUID DYNAMICS

The scale-up of spray dryer chambers is difficult because of the complexity of gas and spray flow patterns. The principal concerns in designing a spray drying chamber are to ensure sufficient residence time for drying and to avoid particle-wall collisions. Dimensionless groups are of limited use because it is practically impossible to achieve dynamic similarity between small and large chambers. In the past, empirical, rather than theoretically based, rules generated by experience with existing plant have been used in the design and scale-up of spray dryer chambers but these models, because of their empirical nature, are limited in their range of applicability. Computational fluid dynamics (CFD) is potentially a powerful tool to aid spray dryer design allowing much more flexibility in design but because of the difficulties of modelling such complex phenomena, especially the gas turbulence, its predictions cannot, at present, be considered absolutely reliable and experimental validation of the results is required. However, by considering the principles of similarity, it is shown that validations carried out on pilot scale equipment under the correct conditions will prove the accuracy of CFD applied to spray dryers of any size.     

A SCACE-UP STUDY OF NOZZLE TOWER SPRAY DRYERS

A quasi-one dimensional model taking into account hindered drying beyond the critical tmisture content and droplet size distribution is used to scale-up nozzle tower type of a spray dryer with uniformly distributed air entry, based on pilot plant data. A pilot plant with 8 m high and 1.7 m diameter spray dryer is used to collect the drying data. Equilibrium and critical mistwe contents of the particles are also experimentally msured. The index of drying rate in the hindered drying period is calculated frun the pilot plant data. This index is used in the M e 1 to determine the drying capacity and thereby the mixinnnn particle size that can be produced ina 3.5 m dimoeter 12 m high nozzle t- type of spray dryer. Experiments are carried out in this spray dryer to verify the calculated values of the spray drying capacity. It is s h m that the model when used along with the pilot plant data is adequate for scale-up calaculations for nozzle taer type of spray dryers.     

A SCACE-UP STUDY OF NOZZLE TOWER SPRAY DRYERS

A quasi-one dimensional model taking into account hindered drying beyond the critical tmisture content and droplet size distribution is used to scale-up nozzle tower type of a spray dryer with uniformly distributed air entry, based on pilot plant data. A pilot plant with 8 m high and 1.7 m diameter spray dryer is used to collect the drying data. Equilibrium and critical mistwe contents of the particles are also experimentally msured. The index of drying rate in the hindered drying period is calculated frun the pilot plant data. This index is used in the M e 1 to determine the drying capacity and thereby the mixinnnn particle size that can be produced ina 3.5 m dimoeter 12 m high nozzle t- type of spray dryer. Experiments are carried out in this spray dryer to verify the calculated values of the spray drying capacity. It is s h m that the model when used along with the pilot plant data is adequate for scale-up calaculations for nozzle taer type of spray dryers.     

A Three-Dimensional Simulation of a Spray Dryer Fitted with a Rotary Atomizer

Spray dryers fitted with rotary atomizers are commonly used in diverse industries to produce engineered powders on a large scale. Scale-up of such units is still largely empirical and based on prior experience and know-how. In the present study, a three-dimensional spray dryer with rotary atomizer is investigated numerically with a commercial CFD code. Continuous-phase, i.e., air, conservation equations are formulated in the Eulerian model while the droplet or particle equations are set up in the Lagrangian model. Two-way coupling between the continuous and dispersed phases is taken into account in the governing equations. The stochastic approach is used to predict the particle trajectories. The RNG k - ε turbulence model was used. Typical results, viz. air velocity, temperature, humidity profiles, and particle trajectories are presented and discussed. Compared with the pressure nozzle spray dryer, more volume of drying chamber is used effectively by the rotating disc type spray dryer. It is found that evaporation and drying take place mainly in the region and in the vicinity of first contact between air and spray. A parametric study is presented and, where appropriate, comparison is made with experimental data obtained with the simulated spray dryer.     

Process Design of a Multistage Drying Process via Flowsheet Simulation

Multistage drying processes including spray drying and fluidized bed unit operations are challenging to design due to the dependencies of the preceding process steps. Flowsheet simulation offers the possibility to simulate a complete process by the application of suitable short-cut models. In this contribution a novel model for a spray dryer based on a population balance approach is presented. Furthermore, a dynamic model for a fluidized bed dryer is introduced. Experimental data is used for validation and parameter optimization. The calibrated models are then used to design an industrial drying process of multiple drying stages.