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DesignofDryers

g
y
Ashok Kumar Dasmahapatra

Department of Chemical Engineering, Indian Institute of Technology Guwahati


September 16, 2013

Drying
Removal of moisture from a substance by exposing it
to a gas stream
Moisture is often water
Gas is often air
Both heat and mass transfer take place during drying
Heat transfer
f from
f
air (mostly
(
hot air)) to wet solid,
evaporates surface moisture
Mass transfer (transfer of internal moisture) to the
surface of the solid and its subsequent evaporation

Types of Moistures: Definitions


Moisturecontent,drybasis(X): kgmoisture/kgdrysolid.
Equilibriummoisture(X*):Moisturecontentofsolidinequilibrium
withagivenpartialpressureofvapor.
FreeMoisture(X X*):Moisturecontentinexcessofequilibrium
moisture.Onlythiscanbeevaporated.
UnboundMoisture:Exertsequilibriumvaporpressureequalto
p
pureliquid.
q
BoundMoisture:Exertsequilibriumvaporpressurelessthan
pure liquid
pureliquid.

GasR
RelativeH
Humidityy,p/p

Types of Moistures: Definitions

SolidMoistureContent,X
FromTreybal,3rd Edn.,pp.661

Dryer Classification

MethodofOperation

Batch

TrayDryer,
y y
TruckDryer,
ShelfDryer

Continuous

TunnelDryer,
RotaryDryer,
DrumDryer,
SprayDryer
p y y

MethodofHeatSupply

Direct

Indirect

Toprevent
contamination,
Oxidationetc.

NatureofSubstance

Sticky,granular,
heatsensitive,
oxidizable

Dryer Design: Rules of Thumb


1.Dryingtimes:
1
Drying times:
Spraydryer:fewseconds
Rotarydryer:Fewminutesto1hr
Tunnel/BeltDryer:severalhourstoevenseveraldays.
Tunnel/Belt Dryer: several hours to even several days
2.Drumdryers(forpastesandslurries):
Contacttime:3
Contact time: 312
12seconds
seconds
Produceflakes13mmthickwithevaporationratesof1530kg/m2 hr.
Diameter:1.55.0ft;
Rotationrate:2
Rotation rate: 210
10rpm.
rpm.
3.Pneumaticconveyingdryers:
Particlesize:13mmdia,upto10mm(surfacedrying).
, p
(
y g)
Airvelocity:1030m/sec.
Singlepassresidencetime:0.53.0sec,upto60secwithnormalrecycling
4.Fluidizedbeddryers:
Particlesize:fewtenthsofammdia,butupto4mmdia.
Gasvelocity:twicetheminimumfluidizationvelocity.
Dryingtime:12min(continuous),2 3hrs(batch,especiallyforpharmaceutical
products).
(Ref:Walas,ChemicalProcessEquipment,2e)

Dryer Design: Rules of Thumb


5.Rotarydryer:
5
Rotary dryer:
Superficialairvelocities:510ft/sec,sometimesupto35ft/secforcoarsematerials.
Residencetimes:590min.
Solidholdup:78%.
Solid holdup: 78%
Usually,an85%freecrosssectionistakenfordesignpurposes.
Incountercurrentflow,theexitgasis1020oC abovethesolid;inparallelflow,the
temperature of the exit solid is 100 oC.
temperatureoftheexitsolidis100
C
Rotationspeeds(s):~4rpm
D(feet)*s(rpm)~15 25.
6.Spraydryers:
Forheatsensitivematerials.
Dryingtime:lessthan60sec.
y g
Parallelflowofairandslurryismostcommon.
Atomizingnozzleshaveopenings0.0120.15inwithanoperatingpressuresof3004000
psi.
Atomizingspraywheelsrotateatspeedsto20,000rpmwithperipheralspeedsof250600
ft/sec.
Withnozzles,thelengthtodiameterratioofthedryeris45;
Withspraywheels,theratiois0.51.0.
(Ref:Walas,ChemicalProcessEquipment,2e)

Design
g of Spray
p y Dryer
y

Spray Dryer
Removalofmoistureisdonebyconvertingthe
y
g
solutiontosprayandexposingittohotgasstream
Atomizationofthefeedintosmalldropletsincreasesthe
surfaceareforheatandmasstransfer
Usedinfoodanddairyindustry,pharmaceuticalindustry,
detergents,pigmentsetc.
g
,pg
Characteristicsofdriedproductsuchasparticlesize,
density,morphology,moisturecontentcanbecontrolled

Spray Dryer Schematic

Spray Drying: Stages

FEED
(slurry)

ATOMIZATION

PRODUCT
SEPARATION

SPRAY AIR
SPRAY-AIR
CONTACT

SPRAY
EVAPORATION

Spray Dryer Layouts

Cocurrent

Countercurrent

Mixed

Cocurrentisthemost
Co
current is the most
commonlyemployedarrangement

Types of Atomizer

RotaryDisc
Rotary
Disc
Atomizer

RotationRate:
500060000rpm
ParticleSize:
Particle Size:
30120m
Highcapacity
Largedroplet
trajectory

Pressure
Nozzle

Pneumatic
P
ti
Nozzle

Pressure:
1060kPa
ParticleSize:
P ti l Si
180250m
p
g
Simpledesign
Viscositylimitation

AirPressure:
13kPa
ParticleSize:
Particle Size:
20250m
Canhandlethick,
viscousfeed
Expensive

Rotary Disc Atomizer

AtomizingDisc
g

AtomizerAssembly
Ni TypeFS1
Niro
T
FS1

TypicalSpray
Typical
Spray
Pattern

Drying Chamber Shape


RotaryAtomizer

Nozzle

LLargeL/D
L/D
ratio

SmallL/Dratio

Steps to Design Spray Dryer


Material(moisture)andenergybalancetofindoutunknown
parameters
Designofatomizer(speed)
Powerconsumptionbyatomizer
Calculateairvelocity(operating)
Calculate air velocity (operating)
Designofspraychamber(heightanddiameter)
Calculateresidencetime
Calculatevolumeofspraychamber
Calculateheightandangleofconicalbottom

Design Output
AtomizerDetails
Atomizer Details

Rotarytype:RPM,Diameter
SprayChamberDiameter
SprayChamberHeight(Cylinder)
S
Ch b H i h (C li d )
SprayChamberTotalVolume
Spray Chamber Total Volume
BottomConeHeightandAngle
ResidenceTime
PowerConsumption
P
C
ti

Material and Energy Balance


GS,Y1, GAS
TG1,H
HG1

DRYER

SS,X1, SOLID
TS1,H
HS1

GAS

GS,Y2,
TG2,H
HG2

SOLID

SS,X2,
TS2,HS2

CocurrentOperation
Material(Moisture)Balance:

ObtainGS andY2

S S' X 2 X 1 G S' Y1 Y2

EnthalpyBalance:
S S' H S 2 H S 1 G S' H G 1 H G 2

Assumingadiabaticoperationofdryer,heatlossQ=0

Material and Energy Balance


SOLID

GAS
GS,Y1,
HG1
TG1,H

SS,X1,
TS1,HS1

DRYER
SOLID
SS,X2,
TS2,H
HS2

GAS
GS,Y2,
TG2,H
HG2

Atomizer Design
Assume a reasonable
mean droplet size,
say 150 microns and disc
diameter, say 150 mm

Alternatively, based on
mean particle size and
feed rate, table below can
be used to obtain disc
peripheral speed

Use the correlation below


to estimate disc RPM
Davg 1.62 103 N 0.53 S S 0.21 (2r ) 0.39

N :speedofatomizer,rps
SS :feedrate(kg/sec)
: feed rate (kg/sec)
2r :discdiameterinm
Davg:averageparticlediameter,mm
(Ref.: Handbook of Industrial Drying, Edited by Arun Mujumdar, Taylor & Francis, 2006, Chapter-10. )

Power Consumed: Atomization


The power required for atomization depends on solid
((slurry)
y) feed rate,, p
peripheral
p
velocity
y of the atomizer and
the efficiency of the chamber, and is approximated as:

SS v
P
2
Ss

Feed rate
Peripheral velocity,
Chamber efficiency

v 2Nr

(Ref.: Handbook of Industrial Drying, Edited by Arun Mujumdar, Taylor & Francis, 2006, Chapter-10. )

Operating Air Velocity


Assumeoperatingairvelocityastwice
the particle settling velocity vs
theparticlesettlingvelocity,
Calculate settling velocity using Stokess law:
CalculatesettlingvelocityusingStoke

vs

2
p

f g

d p : Particle diameter
p : Particle density

f : Air density

18

Check Reynolds number,

N Re

: Air
Ai viscosity
i
it

d p vs f

It should be sufficiently low to apply Stokes law

Operating air velocity,

vop 2vs

Spray Chamber Dimensions


From material and energy balance, get air flow rate, G ' (Kg/s)
Get operational air velocity, vop (m/s)
Get density of air, (Kg/m3)
Y1 Y2

G'
'
'
G Gs 1
Cross sectional are of spray chamber: A

f vop

Assuming circular cross-section,


Diameter: D

4A

F cylindrical
For
li d i l section,
ti
it is
i assumed
d that
th t height,
h i ht H = D
Residence time (in sec
sec.):
): tr 50

Weight fraction of water in feed


Weight fraction of solid in feed

Volume of spray chamber:


(residence time) X (volumetric flow rate of air)

Spray Chamber Dimensions


Volume of spray chamber

Volume of cylindrical portion

Volume of conical section

Height of the conical section

Angle of the conical section

Vtot qG tr
Dc2 H
Vcyl
4

Vcone Vtot Vcyl


H cone

12Vcone

Dc2

(Diameter is same
as cylindrical
y
section))

Dc
tan 2
2 H cone

Usually, an angle of 60o is used.


Revise the volume calculation based on 60o angle.

Spray Chamber Dimensions


Modified calculation: if the angle is too small, a reasonable value could be 60o
Height of the conical section H cone

Dc

2 tan 2

Vcone

Dc2 H cone

12

Volume of the conical section

Total volume of the spray chamber

R id
Residence
ti
time

Vtot
tr
qG

(Diameter is same
as cylindrical section)

Vtot Vcyl Vcone


(Volume of the cylindrical
section does not change)

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