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Feature Report
Part 1
Vacuum Drying:
Basics and Application
Vacuum drying can be a useful tool for solid products that are heat-sensitive. Here are
some guidelines for the selection and use of various types of vacuum dryers
D
Dilip M. Parikh rying is an essential unit operation Pre-heating Constant Falling
DPharma Group in a variety of chemical process in- period drying period drying period
i
dustries (CPI) sectors. Food, phar-
maceuticals, chemicals, plastics,
Moisture content ( )
timber, paper and other industries use dry-
ing equipment to eliminate moisture during
In Brief product processing. Most dryers are classi-
Drying Principles fied as direct dryers, where hot air (at near
k
atmospheric pressure) is used to supply the
Vacuum-dryer
heat to evaporate water or other solvents
advantages
from the product. Another important dryer o Drying cycle time (t)
Vacuum-dryer category, vacuum dryers, involves the use of Figure 1: Drying processes involve two distinct phases
operation a reduced-pressure atmosphere to surround
Options the product. present as a liquid film on the surface of a
Drying is among the most energy-intensive solid particle, is easily evaporated, while the
Microwave Vacuum
unit operations, due to the high latent heat of bound moisture could be found within the
Drying
vaporization of water and the inherent ineffi- solid material, trapped in the microstruc-
Freeze drying ciency of using hot air as the (most common) ture of the solid. In this case, the moisture
Hybrid Technologies
drying medium. Depending on the specific must travel to the surface to be evaporated.
product attributes required, different indus- When a solid product is subjected to drying,
Applications try sectors require different types of drying removal of unbound and bound moisture de-
Process optimization technology. Drying high-value products that pend on the rates at which these two pro-
are likely to be heat-sensitive, such as food, cesses proceed. Removal of unbound mois-
pharmaceuticals and biological products, ture depends on external conditions of air or
demands special attention. When dried by gas temperature, flow, humidity, area of ex-
convection at higher temperatures, these posed surface and pressure. The movement
heat-sensitive products degrade, change of bound moisture depends on the nature
color and appearance and have lower vita- of the product being dried and the extent of
min or nutrient content. Vacuum dryers offer moisture within the product.
an alternate path. This article discusses the Unbound moisture normally is removed
operation and selection of vacuum dryers, by evaporation and vaporization. Raising the
and provides examples of applications in temperature facilitates the evaporation and air
which vacuum drying is used. draws the moisture away. If the product being
dried is heat-sensitive, then the temperature at
Drying principles which evaporation occurs (at the boiling point
Drying involves two distinct drying periods, of water or other solvent) can be reduced by
known as the constant drying period and the lowering the pressure with a vacuum.
falling drying period (Figure 1). Drying occurs
when liquid is vaporized by supplying heat to Vacuum-drying advantages
the wet feedstock. The liquid removed by the Vacuum drying is a viable technology that
drying process could be either free moisture has been used successfully for many years
(unbound) or bound within the structure of in the pharmaceutical, food, plastics and
the solid. The unbound moisture, normally textile industries, among others in the CPI.
48 Chemical Engineering www.chemengonline.com april 2015
Table 1. Selection Criteria for the indirect dryers [1]
force people to wear protective gar-
Dryer type Plate Drum Tumbling Vibrating Conical Thin Paddle Mixer- ments. With a vacuum dryer, ventila-
film kneader
tion does not occur, and personnel
Requirements
working near the dryer are safer. It is
Continuous x x x yy x x x also possible to recover the precipi-
Discontinuous yy yy x yy x x x tated moisture collected during the
Vacuum x * x x x x drying for further use.
Large surface * o o o * x * x
area Vacuum-drying operation
and volume
The majority of dryers are of the di-
High specific * x o x * x * x rect (or convective) type, where hot
capacity
air is used both to supply the heat for
Materials
evaporation and to carry away the
Friable x yy x x x * x x evaporated moisture from the prod-
Fluid yy X yy yy yy x o x uct. Notable exceptions are freeze
Viscous/pasty yy x yy yy yy yy o x and vacuum dryers, which are used
Crusty yy yy yy yy yy o * x almost exclusively for drying heat-
Processing sensitive products because vacuum
Mechanical x x x o x * * *
dryers tend to be significantly more
expensive than dryers that operate
Thermal * o o * * o o o
near atmospheric pressure.
yy = not suitable, o = sometimes suitable, * = good, x = ideal
Vacuum drying is a process in
which materials are dried in a re-
duced pressure environment, which
lowers the heat needed for rapid
A major advantage to vacuum dry- temperatures, such as developing drying. Vacuum dryers offer low-
ing is its energy conservation — less hard, leathery crusts from heat ex- temperature drying of thermolabile
energy is needed for drying, cutting posure during the drying process. materials and are suitable for solvent
down on the economic and environ- Vacuum drying tends to retain the recovery from solid products con-
mental costs associated with drying integrity of the original item without taining solvents. Heat is usually sup-
a product for storage, sale or other damaging it with heat. For foods and plied by passing steam or hot water
purposes. Vacuum-drying pro- pharmaceuticals, this can be valu- through hollow shelves (Figure 2).
cesses also tend to work faster than able, as other drying processes can Drying temperatures can be care-
other drying methods, cutting down degrade quality and make the food fully controlled and, for the major
on processing times, which can be less appealing or affect potency of part of the drying cycle, the mate-
important in some facilities where heat-sensitive drug product. rial remains at the boiling point of
products are being moved through Using vacuum-drying equipment the wetting agent. Drying times are
quickly. Another advantage of drying also reduces risks to workers. With long, usually about 12 to 48 h. Un-
materials in this way is a less dam- other types of drying equipment, like a direct-heat dryer — in which
aging drying process. Some materi- there are vented fumes and particles the material is immersed directly into
als can experience problems at high that can make people sick or that the heating media (usually a hot gas
FIGURE 2: Vacuum tray dryers are common for laboratory and pilot-scale work Figure 3: Traditional blenders can be modified to be used as vacuum dryers
(Source Patterson Kelley)
Coolant out
Expansion tank
Plant in
Vacuum Manifold
condenser Heat exchanger Steam in
stream) and is dried by convection heat to the dryer, facilitating faster dry- dryer’s upper temperature limit (typi-
— a vacuum dryer is an indirect-heat ing than at normal atmospheric pres- cally about 600°F) is lower than that
dryer (Table 1). That is, the heat is sure. Hence, heat-sensitive materials of a direct-heat dryer. The rate at
transferred to the material as it con- such as foods, pharmaceuticals and which material temperature can
tacts the dryer’s heated surface, dry- antibiotics can be dried with vacuum be raised in a vacuum dryer is also
ing the material by conduction. drying with shorter drying times and limited. This is because the indirect-
Understanding this distinction is at lower temperatures. The closed heat vacuum dryer is limited by the
essential for grasping the advan- system also offers the advantage of surface area available for heat trans-
tages and limitations of vacuum dry- handling reactive compounds or haz- fer, unlike a direct-heat dryer, which
ing, as well as for selecting a vacuum ardous solvents in the product being is limited only by the hot-gas volume
dryer that efficiently and economi- dried. The vacuum dryer safely con- in the drying chamber. The vacuum
cally achieves process goals. tains and condenses the hazardous pump is primarily responsible for the
To understand how vacuum op- vapors from such substances without vacuum level inside the dryer.
eration can aid drying, consider the any threat to the workplace environ-
following equation, which represents ment or to the outside atmosphere. Vacuum drying options
a simplified drying theory: Vacuum drying is predominately Most vacuum dryers are adapted
operated as a batch unit operation. from solids blenders. The two prin-
Q = U A ΔT (1) However, a vacuum-drying unit can cipal types of vacuum dryers are
also be integrated as part of a con- tumble and agitated. A number of
Where Q is the total heat (in British tinuous process. In those cases, traditional blenders can be modified
thermal units [Btu]), U is the over- proper control of the infeed and dis- for use as vacuum processors (Fig-
all heat-transfer coefficient (in Btu/ charge materials is critical, along with ures 3, 4 and 5). Selection of dryers
[ft2/°F]), A is the effective heat trans- proper process-control parameters. in general and vacuum dryers in par-
fer surface area (in ft2), and ΔT is the Limitations of vacuum dryers are ticular are shown in Tables 1–3.
temperature difference between the generally related to the heat-transfer Tray dryers. The most common
liquid’s boiling point (that is, its vapor- mode of the equipment. A vacuum dryer for laboratory and small-scale
ization temperature) and the heating
media’s temperature (in °F). The pro- Filter Seal seat Vacuum valve
cess goal is to achieve an effective Frame Tank
Rotating connector
heat transfer (Q) to the material so
that its liquid content is vaporized.
Most often, the material’s prop-
Heat source
erties and the dryer type effectively
establish the U and A values for the
process. So the process-efficiency
objective should be to maximize
the ΔT value, in order to increase Rotating connector
the Q value. By controlling atmo-
Condensate water
spheric pressure, the vacuum dryer
increases the effective ΔT for a given
process. It reduces the boiling point
(vaporization temperature) required
for removing the liquid.
Effective ΔT can be significantly in-
creased by controlling pressure and Figure 5: This double-cone blender is another example of modified vacuum dryer (Source: Paul O. Abbé)
Figure 7: Microwave radiation frequencies range from 300 GHz to 300 MHz
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