Pamantasan ng Lungsod ng Maynila

College of Engineering and Technology

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SPRAY DRYER
DESIGN DESCRIPTION
Spray drying is a method of producing a dry powder from a liquid or slurry by rapidly
drying with a hot gas. In a spray dryer a liquid or slurry solution is sprayed into a hot gas
stream in the form of mist of fine droplets. This is achieved with the use of special
nozzles called atomizers. The atomization of the feed creates very large surface area,
followed by intense contact with hot air. Due to this, rapid evaporation occurs from the
surface of each particle or droplet in the spray. (Perry, 2008). The water is rapidly
vaporized from the droplets, leaving particles of dry solid which are separated from the
gas stream. (Genkoplis, 2012)
Depending on the process needs, drop sizes from 10 to 500 m can be achieved
with spray dying. The most common applications are in the 100 to 200 m diameter
range. The dry powder is free-flowing. (Mujumdar, 2007).

DESIGN SELECTION
Spray Dryer is selected because the fine powders generated from it have uniform
particle size. The major and most successful applications of spray dryers are for
slurries which cannot be dewatered mechanically. It is ideal for heat-sensitive materials
and cannot be exposed to high temperature atmospheres short drying periods. Among
the types of spray dryers, centrifugal-disk dryer is used which is particularly
advantageous for atomizing suspensions and pastes that erode and plug nozzles. The
FS1.5 rotary atomizer was selected (Table12-41, Pg. 12-92 of Perry, 8th ed.).

Acid Hydrolysis and Catalytic Condensation of Coconut Coir

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College of Engineering and Technology
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DESIGN PARTS AND ACCESSORIES

Figure 1. Isometric View of Spray Dryer, Parts and Accessories

Figure 2. Schematic Diagram of Spray Dryer, Parts and Accessories

Centrifugal Fan
The centrifugal fan along with its electrical motor drive assembly, is the one that
provides the required drying air for the spray dryer.
Heating Coils
The heating coils provides the heat to increase the temperature of the drying air
which is required to vaporize the feed droplets in the spray dryer. The heating coils are
heated by steam which passes inside the coils.
Feed Inlet
The slurry feed is pumped from the evaporator through a pipeline that is directly
connected to the feed inlet of the spray dryer. The slurry feed enters from to the spray
dryer via the feed inlet and passes through the atomizer.
Atomizer
The wet slurry feed is pumped to an atomizer which disperses the feed into
smaller droplets/particles creating a large surface area resulting to rapid drying time.
Acid Hydrolysis and Catalytic Condensation of Coconut Coir
Dust for Diphenolic Acid Production

Technical
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College of Engineering and Technology
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This is also the main feature that distinguishes the spray dryer from other
types of dryer.
Motor Drive for Atomizer
The atomizer is powered by a motor drive which is placed on top section of the
spray dryer.
Drying Air Inlet
The hot drying air enters the drying chamber through the drying air inlet. The hot
air is supplied by a centrifugal fan which passes to a series of steam heated coils to
impart heat to the air.
Drying Chamber
This is the section of the spray dryer where the atomization of the feed and the
intense contact of the droplets to the hot drying gas occurs. The drying chamber must
provide enough space for the drying air to circulate and induce drying of the droplets.
Product Outlet: Ball Valve
The product is discharged in the bottom of the spray dryer through the product
outlet, which is controlled by a ball valve.
Drying Air Outlet
This is where the drying air containing the moisture removed from the droplets
escapes outside the drying chamber. The air goes to a bag filter prior to its discharge to
the atmosphere, to further purify the air to be discharged.
Bag Filter
This is an emission control accessory incorporated to the spray dryer. Its main
function is to purify the air prior to its release to the environment.

DATA AND ASSUMPTIONS

1

The mass of the entering feed is 467 kg/batch (From material balance, Pg. 215).

Diphenolic acid leaving the dryer is 355 kg/batch (From material balance, Pg. 215)

Initial moisture content of feed is 32% w/w.

Final moisture of diphenolic acid leaving the spray dryer is assumed to be 10%.
5

The density of the feed slurry is 1226 kg/m3.

Drying air enters at 150OC (423 K) and leaves at 81OC (354 K). (Initial temp
from material balance, Pg 210; Final Temp. calculated by interpolation of values
given from Table 12-43, Pg. 12-96 of Perry 8th ed.).

Acid Hydrolysis and Catalytic Condensation of Coconut Coir

Dust for Diphenolic Acid Production

Technical
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College of Engineering and Technology
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7

The densities of air at 150C and 81 C are 0.867 kg/m 3 and 1.024

kg/m3 respectively. (From Geankoplis, Table A.3-3, Pg. 971).

8

The kinematic viscosity of air at 150C is 1.495x10 -5m2/s (From Geankoplis,

Table A.3-3, Pg. 971).

DESIGN CONSIDERATIONS
1. Drying air is concurrent to the feed, to prevent degradation of product due to high
temperature and provide product with low final temperature.
2. The material to be handled is diphenolic acid slurry from the evaporator.
3. The material of construction is stainless steel.
4. The insulation material is calcium silicate.
5. For FS1.5 Rotary Atomizer: (From Table 12-41, Pg. 12-92 of Perry 8th ed.)

The speed range is 10,000 rpm to 30,000 rpm. Taking the average; 20,000 rpm,
shall be used in the design.
Atomizer wheel diameter is 90 mm 0.3 ft.
Maximum feed rate is 0.52 t/hr.

6. The mean particle size produced after drying is 100m. (From Mass Transfer
Operations by Alapati Suryanarayana, Page 572).
7. The drying air is driven by a centrifugal fan:
Suction Pressure = 741.7 mmHg (Geankoplis, Pg. 150)
The pressure increase induced by the fan is 1.2% (From Chemical Process
Equipment: Selection and Design 3rd Ed., Pg. 130)
The efficiency of the fan is 80% (Geankoplis, Pg. 150)

DESIGN REQUIREMENTS
1.
2.
3.
4.
5.

Spraying Time
Mass Flow Rate
Drying Air Requirement
Operating Air Velocity
Chamber Dimension
a. Column Area
b. Column Diameter
c. Volume of the Drying Chamber

d. Height of the Drying Chamber

6. Wall thickness
7. Insulation Thickness
8. Power Consumption of Rotary
Atomizer
9. Power Consumption of Centrifugal
Fan

Acid Hydrolysis and Catalytic Condensation of Coconut Coir

Dust for Diphenolic Acid Production

Technical
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College of Engineering and Technology
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10.
11. DESIGN CALCULATIONS
12. 1.

Spraying Time

13. The total spraying (feeding) time of the feed depends on the maximum feed rate
that the atomizer can handle. In case of the FS1.5 rotary atomizer, the maximum
feed rate is 0.52 t/hr. To calculate for the spraying time:
14.

T s=

mass of feed req ' d

1

batch
feed rate

15.

T s=

467 kg
hr
1t
2.2046 lb 60 min

batch 0.52 t 2000 lb

1 kg
1 hr

16.

T s=59.4

min
min
60
batch
batch

17. Use 60 min/batch spraying time.

18.
19. 2.

Mass Flow Rate

20. To determine the actual mass flow rate (mf):

21.

mf =

mass of feed req ' d

spraying time

kg
batch
22. m f =
min
60
batch
467

23.

mf =7.78

kg
kg
7.8
min
min

24. The actual mass flow rate is 7.8 kg/min.

25.
26. 3.

Drying Air Requirement (DAR)

27. The drying air required is dependent on the evaporation rate of water and the
moisture removed per unit mass of air which is determined using the equation
below (From Mass Transfer Operations by Alapati Suryanarayana, Page 574):

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28.

DAR=

evaporation rate of water

moisture removed per kg dry air

29.

evaporation rate of water =( initial m .c .final m . cm. )capacity

30.

evaporation rate of water =( 0.320.1 )7.8

31.

moisture removed per kg dry air=(humidity at T 2humidity at T 1)

kg
kg water
=1.716
min
min

32. The data for humidity with respect to the temperature of air was gathered from
the humidity chart of Perry, pg. 12-7
33. At T1 = 150OC, H1 = 0.01 kg water / kg d.a.
34. At T2 = 81OC, H2 = 0.0305 kg water/ kg d.a.
35.

moisture removed per kg dry air=( 0.03050.01 )=0.0205

36.

DAR=

kg water
kg d . a .

1.716
kg d . a .
kg d .a .
kg d . a .
=83.71
=5,022.44
5,023
0.0205
min
h
h

37. Drying air requirement is 5,023 kg d.a./h.

38.

39. 4.

Operating Air Velocity

40. The operating air velocity (va) is estimated based on the settling velocity of the
droplets from the atomized feed inside the drying chamber. From Geankoplis, eq.
14.3-9 Page 921:

D p 2 ( P F ) g
41. v s=
18
42. Where:

46.

43. Dp = Drop Diameter

47. = Viscosity of air at average

44. p = Density of droplet

45.F = Density of air at average
temperature

temperature
48. vs = Settling velocity
49.g = Acceleration due to gravity

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1226 kg 0.867 kg

9.81 m
m3
m3
6
2
(100 x 10 ft )
s2
50. v =
s
1.495 x 105 m 2
18(
)
s

51.

v s=0.45

m
s

52. The operating velocity would be twice the settling velocity to provide turbulence
and maximum contact time between droplets and air:
53.

v a =2 v s

54.

v a =2(0.45

55.

v a =0.9

m
)
s

m
s

m
56. v a 1.0 s
57. Use operating velocity of 1.0 m/s.
58.

59. 5.

Chamber Dimensions

60. The calculations for chamber dimensions are based on Mass Transfer
Operations by Suryanarayana, Pages 575-576.

61.
62. a. Column Area
63. The column area is based on the mass flow rate of the drying air and its
operating velocity. The column must provide enough space for a given mass flow
rate of drying air to circulate and remove most moisture from the droplets as
possible. Thus, the equation given below is used:
64.

A c=

m da
va

65. Where:

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66. Ac = Column area
67. m = mass flowrate of d.a.

68.

da = Specific Volume of dry air

69.

v a = Operating velocity

70.

5,023 kg
1hr
3
hr
1.1587 m
3,600 s
kg
A c=
1m
s

71.

A c =1.62 m2

72. For safety purposes, we assume 15% safety,

73.

A c =1.151.62 m2

74.

A c =1.86 m2

75.

A c =2 m2

76. Use Column Area of 2 m2.

77.

78. b. Column Diameter

79. The cylindrical column diameter (Dc) is based on the computed column area
which is computed using the equation:

4 Ac

80.

Dc=

81.

42 m2
Dc =

82.

D c =1.60 m

83.

Dc 2 m

84. Use Column Diameter of 2 m.

85.

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86. c. Volume of Drying Chamber

87. The total volume of the drying chamber, like the column area is based on the
mass flow rate of the entering drying air along with the specific volume of the air;
which indicates the volume of air that can be occupied by the moisture removed,
and the air residence time (T) in the chamber. The chamber volume must provide
enough residence time for the air to be scattered around the chamber providing
efficient drying of the droplets. The volume is computed using the equation:
88.

V T =m daT

89. To compute for the volume of the drying chamber, we need first to determine the
residence time of the drying air needed to complete the drying. The residence
time of the air is calculated based on Mass Transfer Operations by
Suryanarayana, Page 576:
90.

T =2 0 x

91. Where:
92. T = residence time of drying air in seconds
93. x = initial moisture content
94.
95. x = 0.32 (from material balance, p.215)
96.

T =2 0 0.32

97.

T =11.31 sec

98.

T 12 sec

99. Computing for the volume of the chamber:

100.

5,023 kg
1 hr
hr
1.1587 m3
3,600 s
VT=
12 sec
kg
101.

102.
103.

V T 20 m3
Use Volume of 20 m3.

V T =19.40 m3

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104.

105.

d. Height of the Drying Chamber

106.

The height of the drying chamber is determined by calculating the height

of the cylindrical and the conical section of the chamber. For the height of the
cylindrical portion, well be using a ratio of H=2D:
107.

H cyl =2 D c

108.

H cyl =22 m

109.

H cyl =4 m

110.
111.
112.

For the height of the conical portion, the conical volume is first determined

by subtracting the chamber total volume to the volume of the cylindrical portion of
the drying chamber which is translated into this equation:

D c 2 H cyl
4

113.

V cone =V T

114.

( 2 m)24 m
V cone =20 m
4

115.

V cone =7.43 m3

116.

The height of the conical portion is then computed using the equation:

3 V cone

117.

H cone =

118.

H cone =

119.

H cone =1.77 m

120.

H cone 2 m

121.

Dc

37.43 m3
(2 m)2

For the angle of the conical section ():

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( )

122. tan 2 =

123.

2
m

2
tan =
2 2m

124.

=5 3.13 0

125.

()

The height of the drying chamber is:

126.

H T =H cyl + H cone

127.

H T =4 m+2 m

128.

H T =6 m

129.

Radius of theChamber
Conical Height

Height of the drying chamber is 6 m.

130.

131.

6.

Wall Thickness

132.

Wall thickness can be estimated using the formula:

Dc +100
1000

133.

t min=

134.

12
1 ft
m3.2808 ft
2
+100
1m

t min =

135.

t min=0.18 4.54 mm

136.

Use 4.6 mm thickness.

137.

7.

138.

Insulation Thickness

From energy balance,

139.

Q = 13,729.8 kJ/batch = 13,013.3 BTU/batch

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140. The operating temperature of the steam at the boiler is 200C and
the temperature of the surrounding is assumed to be at 25 C,
141.

T = 175C = 347F

142.
Using Equation 10.8 from page 294 Unit Operation of Chemical
Engineering, 6th ed, by McCabe, Smith, and Harriott,
143.
144.
145.
146.

Q
T
=k
A
x
Arranging the equation,

Q=( 2 rL ) k

T
x

Where x is the thickness of layer of insulation,

147.

13,013.3

148.
149.

BTU batch 3600 sec

x
x
=
batch 12 sec
1 hr

2 ( 19.69 ft )

BTU
)(347)
( 6.562 ft )(0.35 ft hrF
x

x=0.013 ft =0. 15 3.9 mm

Use 4 mm insulation thickness.

150.
151.

8.

Power Consumption of Rotary Atomizer

152.

The power consumption of the atomizer is computed based on the feed

rate of the solution that is atomized, the rotational speed of the atomizer and the
atomizer size in terms of radius, which is expressed using this equation:
153.

P=1.02 x 108F( Nr d )2

154.

Where:

155.

F = Feed rate of solution in lb/min

156.

N = Rotational speed in rpm

157.

rd= Radius of rotary atomizer in ft

158.

P=power in hp

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2
20000 rev
0.3 ft
min
159. P=1.02 x 108 17.2 lb (
)
min
2

160.

P=1.58 hp

161.

P 1.6 hp

162.
The power requirement of the atomizer is 1.6 hp, use a standard 2 hp
motor (Silla, pg. 240).
163.

164.

9.

Power Consumption of Centrifugal Fan

165.

The power consumption of the centrifugal fan is computed using the

mechanical-energy-balance equation (Geankoplis, Pg. 150). This equation was

used since it gives the power consumption with respect to the pressure head,
velocity head, and mass flowrate of the drying air. To solve for the power
consumption, we first assume that the flow is incompressible. The average
density of the flowing gas will be used in the mechanical-energy-balance
equation. The density at the suction of the fan (Point 1), is:

kg air
1 kg mol
kg mol 22.414 m3

)(

166.

1= 29

167.

1=0.940 kg /m3

168.

741.7
)(
)( 273.2
366
760 )

The molecular weight of 29 for air, the volume of 22.414 m 3/kg mol at

101.3 kPa, and 273.2 K were obtained from Appendix A.1. The other densities
are:
169.
170.

2=0.867 kg/m3 at 150

3

3=1.024 kg/m at 81

171.
172.
173.

Getting the average density:

av =

0.940+0.867+1.024
3

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174. av =0.944 kg/m

175.
Since the centrifugal fan has a suction pressure of 741.7 mmHg and a
pressure increase of 3%, then the developed pressure head is:
176.

N
p2 p 1 [ ( 1.012 ) (741.7 )741.7 ] mmHg
m2
=
1.01325 105
av
760 mmHg/ atm
atm

177.
178.

180.
181.
182.
183.
184.

1
0.944 kg /m3

p2 p 1
J
=1,257.02
av
kg
The developed velocity head for v1 = 0, and operating velocity of 1 m/s is:
2

179.

)(

v2 ( 1)
=
2
2

v 22
J
=0.5
2
kg
Writing the mechanical-energy-balance equation:

v 21 p1
v 22 p2
z 1 g+ + W s=z 2 g+ + + F
2
2
Setting z1=0, v1=0, and F=0, and solving for Ws:

W s=

p2 p1 v 22
J
+ =1,257.020.5=1,256.52
av
2
kg

185.
Substituting into eq. 3.3-2 of Geankoplis, Pg. 145, and with an efficiency
of 80% for the fan, we compute for the brake kW:

W s m
1000

186.

brake kW=

187.

kg
1,256.52 J /

s
1.40 kg /

brake kW=

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188. brake kW=1.57 kW
189.
Solving now for the electric power input, using 90% efficiency of electric
motor, substituting into eq. 3.3-5 of Geankoplis, Pg. 145:
190.

electric power input ( kW )=

brake kW 7.33 kW
=
=1.75 kW 2.34 hp
e
0.90

191.
The power requirement of the centrifugal fan is 2.34 hp, use a
standard 2.5 hp motor (Silla, pg. 240).

192.
193.
194.
195.
196.
197.

DESIGN SPECIFICATION

198.

199.

SPRAY DRYER DATA SHEET

200.

201.

Mode of
Operation
203.
Number
of Units
205.
Total
Drying Time

202.
204.
206.
208.

207.

225.

Feed

Drying
Air

Operating Data

Compound

211.
Inlet
Temperature
214.
Outlet
Temperature
217.
Initial
Moisture Content
220.
Final
Moisture Content
223.
Final Particle
Mean Diameter
226.
Inlet
temperature

Batch
1
60 min/ batch
209.
Moist
Diphenolic Acid
212.

130C

215.

50C

218.

32 % w/w

221.

10 % w/w

224.

100m

227.

150C

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229.
Outlet
Temperature
232.

Inlet Humidity

235.

237.
238.
239.
242.
245.

Atomizer Type

Outlet
Humidity

230.

80.9C

233.
0.01 kg
water/ kg d.a.
236.
0.0305 kg
water/ kg d.a.

Technical Data
Atomizer

240.

Proposed

241.
244.

243.
FS1.5
rotary atomizer

Maximum Feed
246.
0.52 t/hr
Rate
248.
Rotational
249.
20,000 rpm
Speed
251.
Diameter
252.
90 mm
254.
Drying Chamber
255.
Capacity
256.
7.8 kg/min
258.
Drying Air
259.
5,023 kg d.
Requirement
a. /hr
261.
Operating Air
262.
1.0 m/s
Velocity
264.
Column Area
265.
2 m2
267.
Column
268.
2m
Diameter
270.
Column Total
271.
20 m3
Volume
273.
Column Total
274.
6m
Height
276.
Cylinder Height
277.
4m
279.
Conical Bottom
280.
2m
Height
282.
Conical Bottom
283.
53.13O
Angle
285.
Wall Thickness
286.
4.6 mm
288.
Miscellaneous
289.
Insulation Type
290.
Calcium
and Thickness
silicate 4 mm
292.
Power
Requirement of
293.
2 hp
Atomizer
295.
Power
Requirement of
296.
2.5 hp
Centrifugal Fan

Existing
High
speed
centrifugal
atomizer

247.
250.
253.

18,000
rpm
120mm

257.
260.

263.

266.
269.
272.
275.
278.
281.
284.

3m
3.2 m
55O

287.

291.

294.

2.95 hp

297.

2.1 hp

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298. Material
s of
Construction

299.

301.
302.
304.

Supplier
Supplier
Address
306.
Cost

Stainles
s Steel

Existing Equipment
303.
305.

308.
309.
Fan
311.
Dryer
Exhaust Control
313.
Air Heater
315.

300.

Stainless
Steel 304

TOPTION GROUP CO., LIMITED

5-21501 ROOM, Hecheng, Taibai South
Road, Yanta District, Xi'an, China
307.
Php 3,200,000

Auxiliaries
310.
312.
314.

Centrifugal Fan
Bag Filter
Steam-heated Coils