Conditions for Accurate CFD Modeling of Spray-Drying Process

The paper presents concluding results of extensive experimental and theoretical research on confident CFD modeling of spray drying. An earlier developed experimental method to determine spray-drying kinetics in a lab scale allowed us to find a critical material moisture content and to determine generalized spray-drying curves. The generalized drying curves, identical in shape in the laboratory and pilot plant units, were used in the CFD model of spray drying process. Extensive simulations for spray drying of 10, 30, and 50% of initial solid content of maltodextrin proved high accuracy of the predictions of discrete (particle size distribution, particle moisture content, particle velocity, spray temperature) and continuous-phase parameters (gas temperature and humidity). Maximum error of the predictions of discrete-phase parameters was on the level of 20%, which is probably close to the current capacity of the CFD technique for modeling of spray-drying process. Comparison of experimental measurements and theoretical results shows that incorporation of realistic spray-drying kinetics into the CFD model and correct definition of initial drying and atomization parameters enable reliable simulations of spray-drying process.     

The Basics of a Reaction Engineering Approach to Modeling Air-Drying of Small Droplets or Thin-Layer Materials

In this article, the development of a reaction engineering approach (REA) to modeling air drying of thin-layer materials or solids droplet/particles, a 10-year-old approach, is critically reviewed. This approach for drying data reduction has been seen to be successful in several applications (droplet drying and layer drying). The historical aspects and its possible relations to the characteristic drying rate curve (CDRC) model, one of the most well-known drying kinetics models, have been articulated. Possible improvements and future prospects are discussed.     

传递课程教学刍议

本文介绍了传递教学中把握课程的抽象特征、数学特征和方法论特征的一些体会,以及对传质教学内容改革方面的分析与尝试。强化对课程特征的认识,可以使学生理解课程内容的实用性,掌握化工过程建模的思路。     

Surface Stickiness of Drops of Carbohydrate and Organic Acid Solutions During Convective Drying: Experiments and Modeling

Abstract

Drying kinetics of low molecular weight sugars such as fructose, glucose, sucrose and organic acid such as citric acid and high molecular weight carbohydrate such as maltodextrin (DE 6) were determined experimentally using single drop drying experiments as well as predicted numerically by solving the mass and heat transfer equations. The predicted moisture and temperature histories agreed with the experimental ones within 6% average relative (absolute) error and average difference of ± 1°C, respectively. The stickiness histories of these drops were determined experimentally and predicted numerically based on the glass transition temperature (T _g ) of surface layer. The model predicted the experimental observations with good accuracy. A nonsticky regime for these materials during spray drying is proposed by simulating a drop, initially 120 µm in diameter, in a spray drying environment.     

Surface Stickiness of Drops of Carbohydrate and Organic Acid Solutions During Convective Drying: Experiments and Modeling

Drying kinetics of low molecular weight sugars such as fructose, glucose, sucrose and organic acid such as citric acid and high molecular weight carbohydrate such as maltodextrin (DE 6) were determined experimentally using single drop drying experiments as well as predicted numerically by solving the mass and heat transfer equations. The predicted moisture and temperature histories agreed with the experimental ones within 6% average relative (absolute) error and average difference of ± 1°C, respectively. The stickiness histories of these drops were determined experimentally and predicted numerically based on the glass transition temperature (T_g) of surface layer. The model predicted the experimental observations with good accuracy. A nonsticky regime for these materials during spray drying is proposed by simulating a drop, initially 120 µm in diameter, in a spray drying environment.     

Sensitivity Analysis of the Reaction Engineering Approach to Modeling Spray Drying of Whey Proteins Concentrate

Whey proteins concentrate (WPC) powder is an important protein source for humans and is commonly produced from whey using a spray-drying technique. Predicting several drying parameters as well as the parameters that govern the quality of the product is essential before manufacturing WPC in industries. Drying kinetics is an essential tool for predicting the drying rate and various parameters that are rate dependent. However, there have been only a few studies published previously on both modeling WPC drying and dryer-wide simulations using different computational tools. In this article we review the application of a reaction engineering approach (REA) to model the droplet drying process. Results based on dryer-wide simulations using the REA are presented. More importantly, a sensitivity analysis of the REA using drying of WPC and skim milk droplets is reported. This analysis will be helpful to select an appropriate drying kinetics model and forms a benchmark for the future WPC drying modeling work.     

Trends in Modeling and Sensing Approaches for Drying Control

A number of contributions have been made in the field of chemical process monitoring and control with applications ranging from simple flow and temperature control to highly complex inferential adaptive control systems in biochemical and polymer production. These technologies face difficulties when applied to drying equipment, due to the inherent complexity of the operation. This article shows some recent trends in monitoring and control of drying processes. This review is organized in sections according to the transport phenomena involved in the operation of a dryer. In each section, examples of recent trends in monitoring and control strategies of key variables directly related to these transport phenomena are discussed.     

A Multiphase Model to Analyze Transport Phenomena in Food Drying Processes

The aim of the present work is the development of a theoretical model describing the transport phenomena involved in food drying. A fundamental multiphase approach was utilized to account for the simultaneous presence of both liquid water and vapor within the sample undergoing drying. The transport equations referred to the food were coupled, by a proper set of boundary conditions, to momentum and heat and mass transfer equations referred to the drying air, thus obtaining a general model that did not rely on the specification of any heat and mass transfer coefficient at the food/air interfaces.     

Validation of the Lagrangian Approach for Predicting Turbulent Dispersion and Evaporation of Droplets within a Spray

The accuracy of the Lagrangian approach for predicting droplet trajectories and evaporation rates within a simple spray has been addressed. The turbulent dispersion and overall evaporation rates of droplets are modeled reasonably well, although the downstream velocity decay of the larger droplets is underpredicted, which is attributed to a poor estimate of the radial fluctuating velocity of these droplets at the inlet boundary. Qualitative agreement is found between the predicted and experimental evolution of the droplet size distribution downstream of the nozzle. These results show that smaller droplets evaporate preferentially to larger droplets, because they disperse more quickly toward the edge of the jet, where the entrainment of fresh air from the surroundings produces a significant evaporative driving force. Droplet dispersion and evaporation rates are highly influenced by the rate of turbulence generation within the shear layer. This work demonstrates the potential of the Lagrangian approach for analyzing particle trajectories and drying within the more complex spray dryer system.     

Validation of the Lagrangian Approach for Predicting Turbulent Dispersion and Evaporation of Droplets within a Spray

The accuracy of the Lagrangian approach for predicting droplet trajectories and evaporation rates within a simple spray has been addressed. The turbulent dispersion and overall evaporation rates of droplets are modeled reasonably well, although the downstream velocity decay of the larger droplets is underpredicted, which is attributed to a poor estimate of the radial fluctuating velocity of these droplets at the inlet boundary. Qualitative agreement is found between the predicted and experimental evolution of the droplet size distribution downstream of the nozzle. These results show that smaller droplets evaporate preferentially to larger droplets, because they disperse more quickly toward the edge of the jet, where the entrainment of fresh air from the surroundings produces a significant evaporative driving force. Droplet dispersion and evaporation rates are highly influenced by the rate of turbulence generation within the shear layer. This work demonstrates the potential of the Lagrangian approach for analyzing particle trajectories and drying within the more complex spray dryer system.     

A Comparative Study Between Spray-Drying and Fluidized Bed Coating Processes for the Preparation of Pramipexole Controlled-Release Microparticles for Orally Disintegrating Tablets

In the present study, controlled-release microparticles for orally disintegrating tablets (ODT) were prepared using two different processes, spray drying and fluidized bed coating processes. Pramipexole dihydrochloride monohydrate (PRM), an anti-Parkinson's disease agent, was selected as a model drug. The in vitro release rate and morphology of microparticles were evaluated and compared. The size of microparticles prepared by spray drying (SD microparticles) and fluidized bed coating (FC microparticles) was around 10 and 200 µm, respectively. The latter size was defined by the size of an inert core bead. The release behavior of SD microparticles was characterized by a large initial burst release prior to slow release. In the case of FC microparticles, the initial burst release was smaller than that of SD microparticles and the compression process damaged the release-controlling layer, which led to a change in release rate. The results indicated the importance of carefully considering the manufacturing process for microparticles during the design of controlled-release ODT.     

DYNAMICS AND CONTROL OF CROSS-FLOW GRAIN DRYERS I. MODEL DEVELOPMENT AND TESTING

A general dynamic model for a cross-flow dryer is developed from fundamental balance equations. Six dimensionless groups that govern the process are defined and the resulting dimensionless equations are solved with the method of lines, using the Advanced Continuous Simulation Language software package ACSL (1986). The mesh influence on the numerical solution is investigated, and the assumption of quasi-steady state for the air is discussed. Application of the model to rice-drying experiments shows good agreement, and the results underline the potential of the model and the numerical solution strategy in obtaining critical physical insight towards the operation of cross-flow rice dryers.     

Partial Crystallization Behavior during Spray Drying: Simulations and Experiments

Simulations of crystallization behavior in a spray dryer have been performed using modifications to a model developed by previous workers and applied to a Buchi-290 laboratory-scale dryer. The potential crystallization behavior has been modeled using Williams-Landel-Ferry kinetics. Explorations using the model have suggested that the air inlet temperature is an important variable affecting crystallization in the dryer. The explorations suggested drying conditions that permitted reasonable drying while controlling the degree of crystallization. These conditions were examined and tested experimentally, also showing that the apparent degree of crystallinity was affected by the inlet air temperature over the range of inlet temperatures from 134°C (∼55% crystalline) to 210°C (∼76% crystalline). The simulation also predicted the trends in the experimental results from previous workers where their experimental results are considered in terms of the measurement techniques used in each case, suggesting that the simulation is a reasonable tool for developing operating conditions for drying equipment to give low or high degrees of crystallinity in the products.     

Multiscale Approaches to Processes That Combine Drying with Particle Formation

Spray drying, fluidized bed layering, and fluidized bed agglomeration combine drying with particle formation. To run such processes efficiently and produce products with the desired properties, it is necessary to understand the transition from phenomena that govern the formation of the solid phase at the microscale to the macroscale behavior of particle systems in real equipment. Related recent progress and emerging tasks are discussed in regard of methods for modeling and morphological characterization.     

Modeling of Convective Drying of Sawdust Using a Reaction Engineering Approach

Drying as a simultaneous heat and mass transfer process can be modeled via the reaction engineering approach (REA) where the apparent activation energy of the material is established and related to its moisture content during drying. This relationship is unique as the normalized activation energies can be collapsed into a single equation irrespective of the drying conditions and dryer types. Here, REA was applied to model the drying kinetics of sawdust using convective hot air in a laboratory setup. The normalized (relative) activation energy curve generated from one drying experiment was employed to predict the drying kinetics and temperature profiles. The REA can describe well the convective drying kinetics of sawdust, and major physics of the drying process was captured well with this technique.     

Single Droplet Drying Technique to Study Drying Kinetics Measurement and Particle Functionality: A Review

Advances in the study of the rate processes in spray drying have helped improve product quality. Single droplet drying (SDD) is an established method for monitoring the drying kinetics and morphological changes of an isolated droplet under a controlled drying environment, mimicking the droplet convective drying process in spray drying. To enhance particle quality requires understanding of both the particle formation process and knowledge of how different particle properties are affected by the drying conditions used. The latest development in the SDD technique enables evaluation of these aspects by incorporating a dissolution test in the drying experiment. The experiment is realized by attaching a solvent droplet to a dried/semi-dried single particle in situ and then video-recording the resultant morphological changes. Some of the particle (e.g., crystallinity) properties obtained under different drying conditions can be modelled using the measured droplet drying kinetics. This paper reviews the applications of SDD experiments in measuring the drying kinetics and monitoring the droplet morphological changes during drying. Some examples of extending the glass filament SDD technique to examine particle functionalities are discussed. SDD experiments are shown to be a powerful tool for particle engineering due to its ability to study both the external convective transport process of a single droplet and to understand the different particle functionalities of the resultant single dried particle.     

A successful experience with the flipped classroom in the Transport Phenomena course

Transport Phenomena is a core subject in Chemical Engineering studies. Its fundamentals need significant effort to be understood. Furthermore, students must apply theory to solve practical engineering problems, and it is usually problem resolution which has the largest weight in course assessment. However, due to the high amount of theory that must be covered in Transport Phenomena courses, usually little classroom time is reserved for practice and problem-solving skills are not worked in class. This constitutes a serious misalignment between learning activities, expected outcomes and evaluation. In this article, we propose the flipped classroom as a suitable methodology to solve this issue. As a pilot study, we flipped one unit of the Transport Phenomena course of the Bachelor’s Degree in Chemical Engineering. Theory was provided through whiteboard animated video before the classroom sessions. Classroom time was mainly dedicated to participative discussion and problem solving in small groups. Satisfaction questionnaires were used to monitor student perception of learning quality before and after the methodology update. Student judgement on the interest of the subject and the value of the learnt concepts boosted about 20% on average with the flipped classroom. Around 70% of the surveyed students reported that the new methodology increased their motivation and that it helped them to learn both theory and practice. These results indicate that the flipped classroom is suitable for highly-technical classes with a large amount of complex theory, and it helps in the understanding and application of such theory.     

Modeling Power Transformer Field Drying Processes

Power transformer field drying is becoming a habitual practice because water is damaging for transformer insulation, and its presence increases the probability of unexpected failures. Different drying methods are currently being used by electrical companies but sometimes without a profound knowledge of the drying processes involved, and consequently drying is not as effective as would be desirable.

Physical models have been developed by the authors in order to study power transformer drying processes. The use of the models will help to plan more effective drying processes, tailoring the drying times and drying conditions for each particular case. The models have been tested in a test transformer fitted with sensors. In order to monitor the process, insulation samples were extracted from the transformer before and after the process.

In this article, several transformer drying procedures are described. Theoretical models and their experimental validation processes are reported. Finally, some general recommendations about transformer drying in the field are provided.     

Drying of Foamed Biological Materials: Opportunities and Challenges

An overview is provided on hot air drying of foamed materials in a thin layer (foam-mat drying), foam-spray drying, microwave-assisted drying of liquid foams, as well as microwave drying of frozen foams with and without dielectric solid inserts, used as complementary heat sources. In particular, the mechanisms of heat and moisture transport during the drying of foams are identified. The effects of foam characteristics (e.g., foam density and stability) and drying conditions (temperature, air velocity) on drying kinetics and product quality are examined, and the differences between the drying of non-foamed and foamed materials are discussed.