Summary

The main objective of this experiment was to study about the spray dryers and the mechanism of the spray drying process. The experiment was carried with mixed flow spray dryer which contains a two-flow atomizer. A cyclone separator was used for the separation of solid. In our experiment, a solution of known amount of powder milk was spray dried to observe the performance of the spray dryer. In this experiment, 1000.1 gm liquor milk was taken which contains 50 gm milk powder. And after the drying process 12.4 gm milk powder was recovered from the solution. Hence, 24.8% milk powder was recovered. The probable reasons for the poor recovery are highlighted in the discussion.

Experimental Setup
Air water vapor

Feed milk container Exhaust pipe Thermometer Air blower Chamber Temp. Heater Cyclone separator Hot air Drying chamber

Powder milk container Compressor

Air

Figure 2: Schematic diagram of experimental setup of a spray drying system

Observed data
Working pressure, P = 20 psig Inlet temperature, Ti = 150 C Initial outlet temperature of air, To = 78.5 C Final outlet temperature of air, To = 64 C Total time required for drying, t = 38 min = 2280 sec Weight of milk powder, m = 50 gm Weight of water, mw = 950.1 gm Weight of liquid milk, Mt = (mw + ms) = (950.1+50) gm = 1000.1 gm Weight of empty beaker, m1 = 554.1 gm Weight of beaker with recovered milk powder, m2 = 566.5 mg

Calculated data
Weight of solid recovered, MR = (Weight of beaker + recovered milk powder) Weight of empty beaker = m2 m1 = (566.5 554.1) gm = 12.4 gm

Percentage recovery

weight of the solid recovered 100 % weight of the solid intially taken

MR 100 % m
12.4 100 % 50

24.8 %

Drying rate

weight of water Total time of drying

mW t
950.1 gm/sec 2280

0.41671 gm/sec 0.42 gm/sec

Result
Weight of solid recovered, MR = 12.4 gm Percentage recovery of milk powder = 24.8% Drying rate = 0.42 gm/sec

Discussion
From the experiment result the percentages recovery of milk indicates some losses in the system. Probable reason behind such low recovery are stated below 1. Some milk powder may accumulate in the apparatus. 2. Air is exhausted from the cyclone separator which may contain milk powder. 3. A considerable portion of milk was stuck on the separator wall, which also reduced the milk powder recovery. 4. The experiment was done in a very small scale and the dryer had been used for several years. So, the depreciation factor of the pilot plant has caused lower recovery of milk powder. 5. The milk that is supplied has some moisture content but after drying only dry milk powder was obtained. So loss in the weight of milk powder was found. 6. If the paste was not prepared perfectly, then some powder might clot. Clotted powder might create problem while flowing throw pipe and spraying. 7. The feed had been entered the dryer at a quite high flow rate to conduct the drying process quickly, if the rate was lower the drying process would be more efficient 8. Before the experiment there were some water in the nozzle for some operating problem. That is why dried powder may again dissolved in the water. It may be a reason for low percentage recovery.

Process Block Diagram (PBD)

Air

Blower

Heater

Hot air, T=150 Milk powder solution Milk powder=4.9995% Water=95.0005% Air and Water vapor

Spray Dryer

Compressed air P= 20 psig

Air Milk powder Water vapor

Cyclone Separator

Recovered milk powder

Figure 2: Process block diagram of a spray drying system

Process Flow Diagram

Air

Air

Hot air, T=150

Feed Milk powder=4.9995% Water=95.0005% Air and Water vapor Compressed air P= 20 psig

Air

Recovered milk powder

Figure 3: Process flow diagram of a spray drying system

Modification It is essential for both economic and environmental reasons to recover as much powder as possible from the system. Three modifications are available1. Bag filters 2. Wet scrubber 3. Electrostatic precipitator (ESP) Bag filters Bag filters are in general frequently used for dust removal in industrial applications. So as it is used for recovery of particle in spray drying of solid. The flow can be from the outside to the inside of the filter or the other way around, depending on the application. The particles are normally captured on the internal surface of the bag filter. Bag filters are in general not designed for replacement when they are clogged, but some bag filters, like particle removers, can be cleaned, for example by mechanical shaking or by backwashing with compressed air (so called reverse-flow bag filters). Bag filters are mostly surface-type filters.

Made of fabrics (Holds milk powder but removes gases)

Exhaust Air Figure 4: Bag filter Wet scrubber Wet scrubbers are the most economical outlet air cleaner. It can be used in spray drying for higher recovery of solid dust powder. The principle of a wet scrubber is to dissolve any dust powder left in the air stream into either water or the feed stream by spraying the wash stream through the air. This also recovers heat from the exiting air and evaporates some of the water in the feed stream (if used as the wash water).

Water

Exhaust air Liquid milk Figure 5: Scrubber

Electrostatic precipitator An electrostatic precipitator (ESP) or electrostatic air cleaner is a particulate collection device that removes particles from a flowing gas (such as air) using the force of an induced electrostatic charge. Electrostatic precipitators are highly efficient filtration devices that can easily remove fine particulate matter such as dust and smoke from the air stream. In contrast to wet scrubbers which apply energy directly to the flowing fluid medium, an ESP applies energy only to the particulate matter being collected and therefore is very efficient in its consumption of energy (in the form of electricity). Exhaust gas Without particle

Charged collecting plate

Collected particle

Exhaust gas containing particle

Figure 6: Electrostatic precipitator

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