ENCH 371 Chemical Engineering Laboratories 2005

SPRAY DRIER EXPERIMENT

Introduction:
Spray drying is widely used in the food industry, examples are skim milk, fruit juices, coffee, and
vegetable extracts. Also, the same process is frequently used in the chemical industry; examples are
washing powders (detergents, enzymatic powders) and variety of dried salts.
Aim of experiment:
The aim of this experiment is to provide a reasonable description of the spray-drying process through the
analysis of the energy, mass balances and the thermal efficiency and to teach students some practical
skills required to operate modern commercial spray drying equipment.
Apparatus and Process:
The spray-drier Mobile Minor 2000 is located in the Particle Technology Laboratory. It has been
designed and constructed as a valuable research tool and to handle small quantities of product. The
process involves the atomisation of the feed solution into a spray of very small droplets using a rotary
atomiser (30,000 rpm) powered by a compressed air supply. These droplets are exposed to a fast current
of hot air. Because these droplets have a very large surface area in comparison to the bulk feed liquid,
water evaporation takes place almost instantaneously despite the short residence time in the drier. The
droplets are transformed into dry powder particles then separated from the utilised air using a powder
recovery system (cyclone). The dried powder particles are collected in a glass sample collection jar
attached to the cyclone. The exhaust air is drawn out of the top of the cyclone and through the exhaust
fan before being emitted to atmosphere.
System Interlocks
Heater:
If the Chamber Outlet Process Gas Temperature exceeds 120C, the heater will automatically turn off and
an alarm light, Chamber Outlet Temperature High will light red. The temperature must drop
below 120C and the alarm must be reset using the Alarm Reset button on the Spray Drier
Control Panel before the Heater can be restarted. The Heater cannot be started without the
Exhaust Fan being started first. The heater is interlocked with a pressure detection system,
such that if a leakage should occur in the system that causes a reduction in the air drawn into
the system through the filtering unit into the heater, the heater will be shut off.

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Atomiser:
The only safety interlock for the atomiser is with the Main Switch located on the Spray Drier Control
Panel. Thus the compressed air hose MUST be detached from the atomiser before the atomising unit is
removed from the chamber roof, and certainly before the chamber roof is opened.
Feed Pump:
The feed pump can also be started with the minimum of the Main Switch being on. Care must thus be
taken to start the drying process in the specific order indicated in the Start Up Procedure
section of the operating procedure, or flooding of the drying chamber could occur. This could
lead to wall deposits or blockages in the pipe-work.

BEFORE YOU START UP

Check that the air inlet filter is clean.

Check that the atomiser wheel rotates freely and the silencer is mounted on the rotary atomiser.

Check that the atomiser is properly mounted on the chamber roof and is not screwed down or
restricted in any way from easy removal.

Check the mounting of the feed and compressed air hose (from the supply, and to the atomiser).

Ensure that the feed system is set up to run water on start-up.

Check that the glass sample collection jar under the cyclone is fastened securely, clean and dry.
Ensure that the butterfly valve into the sample collection jar is open.

Ensure that the compressed air is turned on, and the supply is pressurised to approximately 6 bar.

The atomiser must be removed before lifting up the roof.

Do not open any doors or remove any covers while the equipment is in operation.

START UP PROCEDURE
1. Switch power on the isolation switch located on the wall to the left of the Control Panel.
2. Switch power on by turning the Main Switch on the Control Panel.
3. Check that the Chamber Roof is fully shut (by pressing the Release Chamber Roof (V2) and Chamber
Roof Down () buttons at the same time).
4. Open the cyclone exhaust butterfly valve lever pointing right i.e. in the direction of desired flow.
5. Start the Exhaust Fan.
6. Turn on the chamber observation light.

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7. Set the inlet temperature controller (Chamber Inlet Process Gas Temperature E1) to the desired
temperature 200C using and arrows.
8. Turn on the Heater. When running with a closed damper or if any leaks occur in the system the heater
will immediately cease operation (you can check that by closing the cyclone butterfly valve). Also,
the outlet temperature controller turns off the heater if the outlet temperature exceeds 120C.
9. Start the rotary atomiser by turning the knob anticlockwise on the pneumatic control panel for the
spray drier slowly (approximately 0.5 bar at a time) to full speed at 6 bar. The air pressure indicated
on the pressure gauge (E73 Atomiser Air Supply Pressure), located on the Spray Drier Pneumatic
Panel, must be kept constant in order to obtain a homogeneous atomisation. Decreasing speed results
in increasing particle size and can cause wet chamber deposits. If a deep buzzing sound is heard the
atomiser must be stopped immediately and the bearings must be checked.
10. Switch on the feed pump (Feed Pump P1) from the Spray Drier Control Panel. Check that the power
switch located on the back of the pump is also switched on. Ensure that the pump is set up to operate
with rotation in a clockwise (CW) direction. Insert the feed supply tube into the pumping mechanism
on the front face of the pump. Close the front panel. Set the pump rpm to 5 and start the pump until
the water level reaches the top of spray drier then stop the pump and wait until the outlet temperature
reaches 80 C.
11. When the outlet temperature reaches 80C on the outlet indicator push the pump Start button again.
This will pass water to the atomiser. It is recommended that the rpm be slowly ramped up to the
desired operating flow rate (for water about 16 rpm) as the drying chamber continues to heat up until
the required outlet temperature is stable. An outlet temperature of not less than 85C should be aimed
for. This will prevent moisture condensing in the system.
12. Switch from water to the milk solution, and when it reaches the drier, increase the pump speed so that
the total quantity of water being fed to the drier remains the same (work out the new rpm required to
keep the evaporative load constant before you do this step).
13. You can adjust the outlet temperature by changing the feed pump speed. Adjust using and rpm
buttons (measure the diameter of the container and the change of the height during certain time to
calculate the flow rate kg/hr you need to know the density of the milk solution).
14. Bang with the hammer, on the Hammering Point located on the cone of the drying chamber, to
dislodge any residues located on the inner chamber walls. This procedure may need to be carried out
regularly throughout the drying process, or just at the end of the operation depending on the extent of
residue build-up exhibited by the process. It is important not to let residues build up, especially near
the air inlet of the drying chamber as smouldering could be initiated.
15. Examine the dried product frequently for specks of burnt, charred or discoloured product. Stop the
drier immediately if any damaged product is found, and clean the drier thoroughly.
16. If necessary exchange the sample collection jar with the damper closed. Preheat the new glass sample
collection jar to prevent condensation occurring during the drying process.
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MEASUREMENTS
(Ms) , (Ts)i , (hs)i , (Ws)i

(Ma) , (Ta)i , (ha)i , (Wa)i

(Ma) , (Ta)o , (ha)o , (Wa)o

(Ta)2

(Ms) , (Ts)o , (hs)o , (Ws)o

Drier data for calculation of heat and mass balances

All calculations are based on air mass flow rate M a and solid mass flow rate Ms.
Ma

mass flow rate of air kga/s

Ms

mass flow rate of solid particles kgs/s

(Ta)i

temperature of air C at inlet

(Ta)2

temperature of air at end of evaporation (bottom of the chamber)

(Ta)o

temperature of air C at outlet

Ts

temperature of solid particles C

ha

specific enthalpy for air kJ/kga

hs

specific enthalpy for solid particles kJ/kgs

Wa

humidity of airflow kgwater/kga

Ws

humidity (water contents) of solid flow kgwater/kgs

Nearby the filter, measure the ambient temperature and RH to obtain the air humidity (W a)i at the inlet
condition. The air humidity (Wa)i remains constant after heating the air to (T a)i = 200C because there is
no moisture added or removed during this heating process (sensible heating).
At the exit of the exhaust pipe, measure the temperature (T a)o and RH to obtain the air humidity (W a)o and
measure the air speed to obtain the air volumetric flow rate from which you can obtain the air mass flow
rate (Ma).
Calculate the solid mass flow rate (Ms) from the concentration and the solution feed rate (obtained from
measuring the change of the level with respect to the time).
Calculate the humidity (water contents) in the milk solution entering to the chamber (W s)i

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ANALYSIS
1. Plot the process on Mollier Chart.
2. Dry product balance:
Compare the amount of dry milk powder collected in the jar at the end of the experiment with the amount
entered during the process. Discuss why if there any discrepancy.
3. Moisture balance:
Compare the amount of water flow entered into the process (taken from the milk solution) against the
increase of the humidity of the hot air stream. Discuss why if there any discrepancy.
Moisture entering the in feed

= Ms (Ws)i

Moisture entering in the hot air stream

= Ma (Wa)i

Moisture leaving the drier in the product

= Ms (Ws)o

Moisture leaving in the exhaust air

= Ma (Wa)o

For no product accumulation in the chamber: Input = output

Ms (Ws)i + Ma (Wa)i = Ms (Ws)o + Ma (Wa)o
Assume (Ws)o = 0 (completely dry product)
Ms [ (Ws)i ] = Ma [ (Wa)o - (Wa)i ]
Ms [ (Ws)i ]................................ water evaporated (taken out) from the milk solution
Ma [ (Wa)o - (Wa)i ].....................water gained (added to) the air stream
4. Energy balance:
Compare the sum of the enthalpy input against the sum of the enthalpy output of the system. Discuss why
if you there any discrepancy.
Enthalpy of air entering the drier

= Ma (ha)i

Enthalpy of feed entering the drier

= Ms (hs)i

Enthalpy of exhaust air leaving the drier

Enthalpy of product leaving the drier

= Ma (ha)b
= Ms (hs)o

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The specific enthalpy of the feed (hs)i as it enters the atomiser is the sum of the enthalpies of the dry solid
and the water contents:
(hs)i = cS (Ts)i + (Ws)i cw (Ts)i
where: cS = specific heat of dry solid milk powder [kJ/kgC]
cw = specific heat of water ........................[kJ/kgC]
(Ts)i = temperature C of milk solution at inlet
The specific enthalpy of the solid product (hs)o = cs (Ts)o
The specific enthalpy of the air (h a)i as it enters the drier and (h a)o as it exit to atmosphere can be
determined from Mollier Chart.
5. Efficiency calculations
Spray drier design is directed towards achieving desired-product properties at the highest possible
efficiency. Calculate the highest possible thermal and evaporative efficiencies obtained from the
experiment. Are these acceptable? If not, discuss why.
Thermal efficiency:
The thermal efficiency of a spray drier depends upon the operation temperatures. Overall thermal
efficiency overall is defined as the fraction of total heat supplied to the drier used in the evaporation
process. It can be approximated to the relation:

overall
where T1

T1 T2 ad
100
T1 T0

= air temperature entering into the drier (heated).

T2ad

= air temperature at end of evaporation (adiabatic).

T0

= ambient temperature

Evaporative Efficiency:
Is defined as the ratio of the actual evaporative capacity to the capacity obtained in the ideal case of
exhausting air at saturation:

evaporative

T1 T2 ad
100
T1 Tsaturation

Where Tsaturation = the adiabatic saturation temperature corresponding to the inlet temperature T1.

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SHUT-DOWN & CLEANING PROCEDURE

1. Switch off the heater then change the atomiser feed from product to water. When the water reaches
the drier, reduce the pump speed so that the total quantity of water being fed to the drier remains the
same (ie. keep the evaporative load constant). Run the feed pump for a further 5 to 10 minutes.
2. Adjust the pump speed to retain a constant outlet temperature. Decreasing temperature will result in
absorption of excess water in the powder still being present in the chamber.
3. Repeat steps 2 until a stable inlet temperature of approximately 100C is attained.
4. Switch off the Feed Pump on the Spray Drier Control Panel once the chamber inlet temperature T 1 is
below the alarm temperature (120C).
5. After approximately 3 minutes switch off the atomiser device slowly (approximately 1 bar/min as per
the Start-Up procedure) using the knob located on the Pneumatic Panel. Then turn off the compressor
control.
6. Allow at least 5 minutes to cool the plant down (till the temperature is around 40C).
7. Lift the front panel of the feed pump and unwind the side screws (if necessary) to release the piping.
Remove the tube from the pump to prevent kinking.
8. Replace the sample collection jar (located at the bottom of the cyclone) so that any product brushed
from the chamber walls during cleaning is kept separate from the naturally collected sample.
9. When both the inlet and outlet temperatures are below 50C remove the atomiser.
10. Open the chamber roof by pressing the Release Chamber Roof (V2) button and the Chamber Roof
Up/Down arrow (V2) at the same time.
11. Turn the roof vertically upwards and insert the locking pin.
12. Remaining powder in the chamber can be swept down using the supplied broom while the fan is still
running to collect the particles in the cyclone (take care not to damage the polished surface).
13. Switch off the Exhaust Fan.
14. If deposits are present, turn off the Main Switch on the Spray Drier Control Panel then use a slightly
damp cloth to wipe the interior surface.
15. You need the Main Switch on the Spray Drier Control Panel turned on to close the roof.
16. Turn off the Main Switch on the Spray Drier Control Panel and the Isolating Power Supply Switch
located on the wall to the left of the Spray Drier Control Panel.
17. Fill in the instrument logbook and record operational events, particularly noting any abnormal event
or reading. Any abnormality should be reported immediately.

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EMERGENCY PROCEDURES
Emergency Shut Down other than in the case of fire or explosion

1. Turn off the Main Switch on the Spray Dryer Control Panel. Emergency shutdown may result in
damage to the heater elements.
2. Wait for approximately 3 minutes for the atomiser to stop and visually check through the inspection
window that the atomiser wheel has stopped completely.
3. Wait till the plant is cooled down before opening the roof, as the surfaces may be hot.
4. Do not touch the heater body as the surface temperature may increase drastically after emergency
shutdown.
5. Ensure the pressurised air supply to the atomiser is reduced to zero (the knob on the Pneumatic Panel
(PCP) is turned fully clockwise) before restarting the Spray Dryer.

Emergency Shut Down in the Event of a FIRE (or smouldering)

1. Close the cyclone exhaust valve to prevent hot particles progressing into other processing equipment
where they may cause further damage, and to stop the flow of air in the drying chamber. Ensure that
the sample collection jar is also isolated from the system, to prevent further contamination of any
collected product.
2. Switch the product feed to water, and increase the flow rate to douse the fire.
3. Continue dousing the chamber with water for a further 5 to 10 minutes after all signs of smouldering
have been eliminated.
4. Take care when re-opening the drying chamber after a fire or smouldering has occurred as there is
potential for re-ignition.
5. Ensure that the incident is thoroughly reported and the supervisor is contacted.

Emergency Shut Down in the Event of an EXPLOSION

Should an explosion occur in the drying chamber, evacuate the room immediately and turn off the 175
Power Interlock switch. Evacuate the building and follow the departmental safety procedures regarding
fires and explosions.

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PRE-LAB EXERCISE
1 kg of milk solution 50% mass concentration at 15C was pumped at a flow rate of 4.8 kg/h in a spray
drier. At the end of the experiment 300 g dried milk powder produced in the collecting jar. The inlet
process temperature was Ti 200C, and chamber T2 100C.
Ambient conditions: 18C and 50% RH,
Exhaust exit conditions: 70C and 20% RH.
The exhaust pipe diameter is 5 cm where the air exits with a speed of 10 m/s

Plot the following drying process on Mollier chart showing the different air states: ambient, start of
drying, end of drying and exhaust state.

Perform the mass balance on the moisture and powder.

Perform energy balance on the system.

Calculate the overall thermal efficiency and the evaporative efficiency.

Important Difinitions:
Relative humidity (RH)
It is usually expressed as a percentage, which is a measure of how close to saturation condition the airstate is (it gives an indication as to whether the air can carry more moisture or not). It can be measured
directly using a humidity-measuring device.
Humidity (W)
It is the moisture contents (water vapour present) in one kilogram of dry air [kg water/kgair] It can be
obtained from the Mollier Chart at the intersection of the temperature line and the relative humidity line.

References:
1. Spray Drying: An Introduction to Principles, Operational Practice and Applications / Masters, K.
(Keith) 1972.
2. Spray Drying Handbook / Masters, K. (Keith) 5th edition, 1991.

3. Commissioning and Characterisation of the Niro TM Mobile Minor Spray Dryer / final year project
thesis / Redstone, J.E. (1999).
Revised 22 Mar 05

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