Unlock Peak Performance: How Optimized Airflow Reduced Deposits by 22%
Downtime Reduction
-100%
Time between CIPs was increased by 100%.
Optimized Output
+7%
Peak capacity of spray dryer increased by 7%.
Minimized Product Loss
-40%
Scorched particle concentration was reduced by 40%.
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Challenge
Optimizing a spray dryer suffering from line-stopping particle deposits. The Spray Dryer’s original configuration led to the need for frequent Clean-in-Place (CIP) procedures, reduced product quality and product loss due to scorched particles and reduced peak capacity. It was suspected that the root cause was a poor air disperser configuration, however, the client could not perform an optimization based on physical trial and error due to the risk and cost involved.
Approach
Using our virtual spray dryer testing, we simulated the spray dryer in its current configuration. By comparing the predicted deposit risk with the observed deposits, we ensured that the model had good accuracy. Based on the analysis of the reference simulations, we quickly identified three potential design modifications. These were tested, and the most cost-effective solution—which included guide vanes in the air disperser—was implemented.
Result
The air disperser uniformity was significantly increased, and the swirl level was adjusted to maximize the capacity of the chamber. This led to a 22% reduction in the peak deposit risk, a 40% reduction of scorched particles and the elimination of CIP requirements.
Interesting Facts or Post-Project Impacts
Simulation of a spray drying process involving drying air, effect of atomizer rotation on air flow, drying behavior of injected particles, and monitoring of fluid properties throughout the system has been simulated by Aerotak. The simulation technique can be applied for evaluating spray dryer designs of various sizes and configurations for improving performance and final product quality. The simulation allows for estimating wall deposition of semi-dried product, proving a valuable tool in prediction of product overheating, degrading, and risk of explosion. The simplicity, effectiveness, and efficiency of the setup enables the CFD tool to be applied in all stages of the design and construction phase to ensure reliable performance of the final dryer.
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