SPRAY DRYING SYSTEM

(MAINTENANCE DEPT)
 WHAT IS A SPRAY
DRYING SYSTEM?
A spray dryer is a device used in various
industries to convert liquid or slurry substances
into powder form.

It operates by spraying the liquid or slurry

through a nozzle into a hot gas stream. This
rapid evaporation process dries the liquid,
leaving behind fine particles or powder.

Spray dryers are commonly used in the food,

pharmaceutical, and chemical industries for
purposes like producing powdered milk,
instant coffee, pharmaceuticals, chemical and
more.
 HOW MANY TYPE OF SPRAY DRYER?
There are several types of spray dryers, including:
1. Concurrent Flow Spray Dryers: In concurrent flow spray dryers, hot air and the liquid to be dried enter the drying chamber at the same
end and flow in the same direction.
2. Countercurrent Flow Spray Dryers: Countercurrent flow spray dryers have the hot air entering at the top of the chamber and the liquid
feed at the bottom. This allows for efficient drying and heat transfer.

3. Mixed Flow Spray Dryers: These combine elements of both concurrent and countercurrent flow, and they are often used for specialized

applications.
4. Rotary Atomizer Spray Dryers: In these spray dryers, a rotary atomizer is used to create fine droplets of the liquid feed, which are then
dried by hot air.
5. Pressure Nozzle Spray Dryers: Pressure nozzle spray dryers use high-pressure pumps to force the liquid through nozzles, producing a
fine spray for drying.
6. Centrifugal Spray Dryers: These dryers use a spinning disk to atomize the liquid feed, and hot air is introduced to dry the droplets.
7. Fluidized Bed Spray Dryers: In fluidized bed spray dryers, the liquid feed is atomized into a fluidized bed of drying material, creating
efficient drying and agglomeration.
Each type of spray dryer has its own advantages and is chosen based on the specific requirements of the drying process and the
 IN OUR FACTORY THERE ARE THREE TYPE OF SPRAY DRYER SYSTEM

1. Concurrent Flow Spray Dryers : In concurrent flow spray dryers, hot air and the liquid to
be dried enter the drying chamber at the same end and flow in the same direction.

(ALL OUR SPD ARE OF THIS TYPE)

2. Rotary Atomizer Spray Dryers / Centrifugal Spray Dryers : In these spray dryers, a rotary
atomizer or a spinning disk is used to create fine droplets of the liquid feed, which are then
dried by hot air.

(SPD-2 , 3 , 4 ARE OF THIS TYPE)

3. Pressure Nozzle Spray Dryers: Pressure nozzle spray dryers use high-pressure pumps to
force the liquid through nozzles, producing a fine spray for drying.

(SPD – 1 , 2 , 4 ARE OF THIS TYPE)

1.

Concurrent Flow Spray Dryers :

In concurrent flow spray dryers, hot air

and the liquid to be dried enter the drying
chamber at the same end and flow in the
same direction.
 2.
Rotary Atomizer Spray Dryers / Centrifugal Spray Dryers :

In these spray dryers, a rotary atomizer or a spinning disk is used to create fine droplets of

the liquid feed, which are then dried by hot air.

 3.
Pressure Nozzle Spray Dryers:
Pressure nozzle spray dryers use high-pressure pumps
to force the liquid through nozzles, producing a fine
spray for drying.
SCHEMATIC DIAGRAM OF SPD (SPRAY DRYER)
 WORKING PRINCIPLE OF SPD
An industrial hot spray dryer operates on the principle of atomizing a liquid feedstock into small droplets and
exposing them to a flow of hot air or gas. The working principle can be summarized as follows:

 Atomization: The process begins by feeding a liquid solution or slurry into the dryer. This liquid is typically a solution containing the
material to be dried, such as food ingredients, chemicals, or pharmaceuticals.

 Nozzle or Atomizer: The liquid is forced through a nozzle or atomizer, which breaks it into fine droplets. The choice of atomization method
can vary, including pressure nozzles, centrifugal atomizers, or others, depending on the specific application.

 Hot Air Inlet: A stream of hot air or gas is introduced into the drying chamber. The temperature of this air is carefully controlled and is
significantly higher than the boiling point of the liquid.

 Mixing and Drying: The fine liquid droplets are immediately mixed with the hot air in the drying chamber. Due to the temperature
differential, the liquid quickly evaporates from the droplets, leaving behind solid particles or powder.

 Particle Separation: The solid particles are carried by the flow of hot air or gas through the dryer. To separate the dried material from the
exhaust air, cyclone separators, bag filters, or other separation methods are commonly employed.

 Product Collection: The dried material is collected at the bottom of the dryer or through downstream processing equipment or gyratory
screener (Vibro shifter).

Air Recycling: In some cases, the hot air can be recycled and reheated, reducing energy consumption and improving efficiency.


The hot spray dryer is widely used in various industries for drying heat-sensitive materials and producing powders with specific characteristics.
It offers advantages such as precise control over particle size, rapid drying, and the ability to handle a wide range of feed materials.
WHAT TYPE OF PROBLEM HAVE FACED?
ATOMIZER MAIN SHAFT BENT
ATOMIZER BEARING DAMAGE
SPD FEED PUMP (PLUNGER PUMP)
DUCT JAMMING ISSUE
GYROTARY SCREENER (VIBRO-SHIFTER)
PROBLEMS
ROTARY VALVE PROBLEMS
ID AND FD FAN PROBLEM
HOW DO YOU FIX THEM?
SHAFT BALANCING OR NEW SHAFT
INSTALLATION
ATOMIZER BEARING REPLACEMENT WORK
ALL GENERAL PUMP MAINTENANCE IS DONE
DUCT DISMANTLING AND CLEANING
SIEVE AND ITS RUBBER PACKING
REPLACEMENT OR ECENTRIC WEIGHT
ADJUSTMENT
BEARING REPLACEMENT , GLAND PACKING
REPLACEMENT , GEAR REDUCER, CHAIN
SPROCKET REPLACEMENT OR MACHINING
WORK
BEARING REPLACEMENT AND ALIGNMENT
WORK AND IMPELLER WEIGHT BALANCING
WORK
THANK YOU