Lab Name: Separation Process II

Experiment Title: Spray Dryer Apparatus

Grading
Obtained Marks:
Total Marks:

Lab Report
Submitted By: Group # 01
Name Registration No.
Abdullah Afridi 11-3-1-001-2021
Ahmad Kamal Shaheryar 11-3-1-003-2021
Umair Hassan 11-3-1-040-2021
Uzma Tahir 11-3-1-041-2021
Zainab Hameed 11-3-1-042-2021

Pakistan Institute of Engineering and Applied Sciences

P. O. Nilore, Islamabad, Pakistan

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Objective:
To understand the process of determination of drying rate with different air parameters.

Abstract:
In this experiment, we investigated the drying process of disprin in a spray dryer utilizing heated
air and a disprin spray dispersed by an atomizer with pressurized air. We conducted the
experiment using a solution containing 25g of disprin dissolved in water. Various measurements
were recorded at different solution flow rates, adjusted by altering the rpm of the pump. To
solidify the droplets into particles, the air entering the dryer was heated to 260 degrees Celsius
before being introduced into the cylinder from the atomizer.

Apparatus:

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Theory:
Spray Drying is one of the preferred methods for the production of powders from aqueous
(and/or organic-aqueous) solutions or suspensions.
This technique, developed at the end of 1800, involves the atomization of a liquid in a chamber
where a hot gas recirculating. The drying process is almost instantaneous (see image below) as
the material, consisting of nebulized droplets, exposes a very large surface to the drying fluid.
Continuous processing, production speed and low operating costs make spray drying one of the
best drying processes for pharmaceutical and food products.
With the evolution of the technology, the Spray Drying technique today is not only used for
drying liquids, but for microencapsulation of substances and for obtaining powders with
advanced technological characteristics.

Heater:
If the Chamber Outlet Process Gas Temperature exceeds 120 °C, the heater will automatically
turn off and alarm light, ‘Chamber Outlet Temperature High’ will light red. The temperature
must drop below 120 °C 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
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running. The heater is interlocked with a pressure detection system. 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 shut off.
Atomizer:
The only safety interlock for the atomizer is with the Main Switch located on the Spray Drier
Control Panel. The compressed air hose MUST be detached from the atomizer before the
atomizing unit is removed from the chamber roof, (see shut-down procedure) and certainly
before the chamber roof is opened

Procedure:
Start-Up Procedure:
1. Switch on the power at the isolation switch located on the wall to the right of the Control
Panel.
2. Switch power by turning the Main Switch on the Pressurized Control Panel (PCP).
3. Check any valves on the spray drier exhaust path to the fan is open.
4. Switch on the heaters.
5. Wait until the exhaust temperature reaches approximately 70 ⁰C to 80 ⁰C.
Procedure:
i. Firstly, weight the empty jar in which we want the solution of water and solid particle.
ii. Weight the solid particles and note down it.
iii. Add water and solid particles into the jar and mix them, Also note down the solution
weight.
iv. Switch on the main power, turn on heaters for some time then switch on the blower.
v. Turn on the pump and run the water first and adjust the pressure of air for a spray with
the help of the pressure regulator.

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vi. Wait until exhaust temperature reaches 70 ⁰C and then change the jar of water to jar of
solution.
vii. Note down the weight of jar at constant time intervals.
viii. Note the reading until the jar of the solution is almost empty.
ix. Remove the jar of solid particles from the bottom of the cyclone.
x. Then change the jar of the solution with a jar of water and let it run for some time.
Shutdown procedure:
1. Switch off the heater then continually adjust the pump speed to retain a constant outlet
temperature. A decreasing temperature will result in the absorption of excess water in
the powder still present in the chamber.
2. Run the feed pump for 5 to 15 minutes until an inlet temperature of approximately 115
°C is attained. Switch off the Feed Pump on the Spray Drier Control Panel.
3. After approximately 3 minutes switch off the atomizer slowly (approximately 2 bar/min
as per the Start-Up Procedure) using the knob located on the Pneumatic Panel. Then turn
off the compressor control.

OBSERVATIONS:
Sr No# Time (min) Fluid (grams) Pump Speed Air Pressure
(rpm) (psi)
1 1.5 302 10 7
2 3 276 10 7
3 4.5 250 10 7
4 6 224 10 7
5 7.5 196 10 7

Calculations:
Beaker 500ml weight = 128grams
Disprin Weight = 25grams
inlet Temperature = 260 ⁰C
Collection of Disprin after Experiment = 2 grams
Efficiency = (Collection of Disprin after Experiment/ Disprin Weight)*100
= (2.5/25)*100
=10%

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 Discussion and conclusion:

So, we did this experiment to see how good the spray dryer works when we use disprin in it. We
cranked up the gas temperature to 260 degrees Celsius so that most of the dried disprin stuff would
go through the cyclone with the air. We also used pressurized air to make sure the solution sprayed
out of the atomizer properly, but even with all that, the dryer was pretty bad at its job – only 10%
efficient! Turns out, the pump was spinning too fast, drying the solution too quickly. Plus, the glass
in the dryer was super sticky, so lots of particles stuck to it. We also didn't know if the cyclone was
doing its job properly. To make things better, we could try coating the glass with something and
using less pump speed while testing with more solution.