Course Number: ChE-302

Course Title: Chemical Engineering Laboratory-II

Experiment Number: 05
Name of the Experiment: Study of Spray Drying

Submitted by:

Submitted to:

Mahe Rukh

Dr. Md. Tanvir Sowgath

Student Number: 1202036

Assistant Professor

Section: A2

Department of Chemical
Engineering

Group Number: 02

Department of Chemical Engineering

BUET

Partners Student Numbers: 1202037

Date of

1202038 Performance:
1202039 31/10/15
1202040 Date of Submission:
7 /11/15

Summary
The purpose of this experiment is to study spray dryers and spray drying procedure. Spray drying
is one of the best drying approaches to convert the fluid materials into solid or semi-solid
particles in a single step. This experiment helped us to understand spray drying technique, the
mechanism of spray drying, working principle of spray dryer, operating variables of spray
drying, types of material handle in spray dryer and advantages and disadvantages of spray dryer
over other types of dryer. We also studied different parts of a spray dryer and their functions.
This process is rapid and labor cost is low. Spray dryers employ atomizer or spray nozzle to
break the bulk of liquid or slurry into controlled drop size. This method of drying is applied in
food, pharmaceuticals and other industries for its unique features.
In this experiment, a solution of 1000.1 g liquor milk with 50.1g milk powder was spray dried
and after the drying process 13g milk powder was recovered. Hence, 26 % milk powder was
recovered and the drying rate was 38g/min. the recovery is not satisfactory. Probable reasons for
low recovery has been explained and modification techniques are also discussed in this report.

Introduction
Spray drying, as the name suggests is a process of drying utilizing spray mechanism. This
process is a largely used industrial operation found in various industries. It is engaged in
producing powders from liquid feedstocks in a single step. The liquid feedstock which can be a
solution, emulsion or suspension is sprayed through a nozzle in a drying chamber where hot air
is flown simultaneously. It can be used for equally heat-resistant and heat sensitive products. In
the spray dryer heated gas mixes with an atomized liquid stream to accomplish evaporation
easily. And dry powder is produced with controlled average particle size at last.
The unit operation of spray dryer includes following steps:

Atomization of liquid stream- by atomization we mean separating something into fine

particles. It is the process of breaking bulk liquids into droplets. Primary functions of
atomization are gaining high surface to mass ratio resulting in high evaporation rates,

production of particles of desired shape, size and density.

Heating of gas/air- Blower is set on the top of the dryer which draws air. Drawn air is
heated using heating coils.
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Mixing of gas/air and atomized stream- This should be done for adequate residence time

for achieving high heat and mass transfer.

Separating and collecting the dried powder from the gas stream.

The unique feature of a spray dryer is the surface area per unit weight generated by atomization
of the liquid feed which enables easy and higher evaporation rate. To see a real life exam, lets
look at milk. The ability to keep cold large quantities of a product like milk is limited. Moreover,
milk has 80-90% water, by spray drying it, one can reduce its bulk weight. Spray drying 100kg
of milk can possibly reduce that weight to 12kg, which offers savings in shipping expenses.
In this experiment, 5% solution of milk and water is fed to the spray dryer through atomizer. The
atomized stream then comes in contact with compressed air and creates mist. The mist comes
into contact with hot air in drying chamber. The temperature of fine droplets increases
instantaneously and solvent vaporizes. Increase in temperature of solvent and subsequent
vaporization counts for the heat transfer in the process. Once solvent vaporizes, it passes into dry
air which can be accounted as mass transfer. As a result, it can be said that spray drying includes
both heat and mass transfer processes. The humid air passes to the atmosphere and dry air and
powder mixture enters cyclone separator from which powder is recovered. In cyclone separator
centrifugal action is used to separate powder from the mixture.
The flow of air to the dryer can be co-current or counter-current to the atomizer direction. In the
latter case, the residence time of the particles in the chamber is greater than the former case. In
our experiment air flew in the counter current direction to the atomizer. Spray drying process
operates in one step which makes it very popular these days as in food industries rapid drying is
required. This process is versatile and particle size can be controlled too. By changing inlet
temperature, hot air flow rate, fluid volume, fluid velocity the quality of final product can be
controlled. This feature made spray drying very widespread in pharmaceutical industries too. But
in this process high maintenance is required while dealing with nozzles used. Nozzles are prone
to clogging and abrasion can also occur at the opening of nozzles. Rotary disc atomizers if used,
there is chance of internal corrosion. Finally, powder may stick to internal chamber contributing
to cleaning cost and low recovery.

Experimental work
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Apparatus

Spray Dryer
o Drying Chamber
o Air blower
o Atomizer
o Air heater
Feed tank
Temperature gauge
Pressure gauge
Beaker
Milk-water solution
Stop watch
Thermometer
Cyclone separator
Dry air

Experimental Set up

Figure-01: Schematic diagram of experimental setup of a spray drying system

Figure 02: Two fluid nozzle

Figure-03: Cyclone Separator

Experimental Procedure

About 50g milk powder was taken in a beaker by weighing

950gm of water was added to the beaker and mixed to prepare 5% solution
The spray dryer was started by by turning the hot air blower on. The heater was adjusted

according to requirements.
The operating atomizer pressure was set to 20 psi.
The milk powder was separated in a cyclone separator and was collected in a bottle.
Weight of recovered powder was measured and by comparing to initial weight percentage
of recovery was calculated.

Process Block Diagram

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Air

Blower

Heater

Water
Hot air
Air
Spray
Mixer
Milk
Powder

Dryer
Milk
Solution (5%)

Compressor

Compressed
air

Air
Milk Powder

Exhaust air
Cyclone
Separator

Product Milk Powder

Figure-04: Process block diagram of a spray drying system

Process Flow Diagram

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Blower

Feed container

Air

Water

Milk

Heater
Feed

Mixing unit

solution
Hot air

Flow controller

Spray dryer
Exhaust air

Compressed air
Dried milk & air

Pressure controller
Air

Cyclone
Separator
Recovered milk powder
Compressor
Figure-05: Process flow diagram of a spray drying system

Observed Data
Weight measured
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Weight of milk powder taken, w1 = 50 g

Weight of water, w2 = 950 g
So, wt % of prepared milk solution = 5%
Weight of the container, wc = 561.6 g
Weight of container + recovered milk powder, wc+m = 574.6 g
Temperature measured
Initial inlet temperature of air,TIi = 150C
Initial outlet temperature of air, TIo = 80C
Final inlet temperature of air, TFi = 150C
Final outlet temperature of air, TFo = 66.5C
Pressure measured (P)
Working pressure of atomizing air = 20 psia
Time measured
Required time for drying the solution, t = 25 minutes

Calculation
Data calculation:
Weight of liquor milk = W1 + W2
= (50.1+950.) g
= 1000.1 g
Weight of milk powder recovered, = (Weight of beaker with recovered milk-Weight of empty
beaker)
Wp= Wc+m-Wc
= (574.6-561.6) g
=13 g

Percentage of milk powder recovered = (Weight of milk powder recovered)/(Weight of milk

powder initially taken)100 %
= (13/50.1)100 %
= 26 %
Weight of water W2= 950 g
Total time required for drying, t = 25.0 min
= (2560) sec
= 1500 sec
Drying rate = (Weight of water, Mw)/( Total time required for drying ,t)
= 950/25
= 38 g min-1

Result
Percentage recovery of milk powder = 26 %
The drying rate = 38 g/min

Discussions
The percentage of recovery was 26% and drying rate is 38g/min. from the values we can easily
tell that the recovery of powder is not satisfactory. The possible reasons of this low recovery are
enlisted below:

Some dried milk may accumulate in the apparatus

The flow of feed was controlled manually which resulted in low recovery
Dry milk powder is assumed to pass to the atmosphere with exhaust air which resulted in

loss.
In spray dryer heat transfer mode is convection and so it shows low thermal efficiency.

Heat is lost in the discharged air.

A good amount of particles had been attached within the walls of spray dryer and also at
cyclone separator.
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Feed may have entered the dryer at high flow rate which reduced contact period between

droplets and dry air and thus affected evaporation process.

The pressure of the atomizing air and the working pressure of spray dryer should have
been maintained at constant value. If the atomizing air pressure were higher, the feed
would have been broken into finer particles, resulting in efficient drying.

Modifications
To make drying more efficient in spray drying process the following measures can be taken.
Such as

Allowing lengthier contact time.

Using bigger separator.
Lower flow rate feed.
Increasing atomizing pressure.
Ensuring better insulation.
Using a dryer with smoother wall, and using smooth pipes with fewer bends.
Replacing spray nozzle with rotary atomizer can increase contact area between

drying air and feed ensuring more mass transfer.

If flowing area of drying agent can be increased, more vaporization will occur.

Some instrument can be used for better result. Such asBag filter

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Figure-06: Bag Filter

Bag filters work very simply; air is pulled through the filter drawn by the exhaust fan powder
collects on the bags while air is allowed to pass through the filter medium. A compressed air
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jet frees the powder from the bag and drops into a hopper and out of the system. It reduces
particle degradation and it is useful for low density powders.
Wet scrubber:

Figure-07: Wet Scrubber

Dust collectors that use liquid are commonly known as wet scrubbers. In these systems, the
scrubbing liquid (usually water) comes into contact with a gas stream containing dust
particles. The greater the contact of the gas and liquid streams, the higher the dust removal
efficiency. It ensures high efficiency and low maintenance cost. Higher level of
instrumentation is usually required for density and level control.

Electrostatic precipitators (ESP)

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An ESP is an emission control unit largely used in various industries e.g. power/electric, cement,
chemical, metal, paper. in many industrial plants, particular matter created in the industrial
process is carried as dust in the hot exhaust gases. These gases pass through an electrostatic
precipitator which removes most of the dust. Cleaned gas then gets out of the precipitator and
passes to the atmosphere. Precipitators usually accumulate 99.9% or more of the dust from the
gas stream.
Precipitators function electrostatically by charging the dust particles of the gas stream. The
charged particles are then attracted to and deposited on plates or other collection devices. When
enough dust has been collected, the collectors are shaken to remove the dust. The dust is then
removed by a conveyor system for discarding or reusing.

References
Books
1.Foust et al: Principles of Unit Operations, 2nd ed, John Wiley & sons, New York (1994)
2.Masters, K.: Spray Drying Handbook, 4th ed., George Godwin, London, (1985)
3. McCabe, W.L., Smith, J.C. Harriot, P.: Unit Operation of Chemical Engineering, 6th ed.,
Mcgraw-Hill, Singapure, (2001)
Websites
https://www.academia.edu/3192734/Spray_Drying_as_an_Appropriate_Technology_for_
the_Food_and_Pharmaceutical_Industries
http://www.eurotherm.com/industries/life-sciences/applications/spray-drying/
https://www.neundorfer.com/knowledge_base/electrostatic_precipitators.aspx
https://www.corrosionpedia.com/definition/120/atomization
http://www.fortitechpremixes.com/formulation/what-is-spray-drying/
http://www.spraydrysys.com/spray-dryers/spray-dryers.htm

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Nomenclature
Symbol

Significance

Unit

Temperature

Weight

Time

second

Marking Scheme: Normal Report

Name: Mahe Rukh
Student number: 1202036
Section and marks allocated

Marks
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Summary (1)
Introduction (1)
Experimental Work (1.5)
Observed Data (1)
Calculated Data (1)
Sample Calculation (1)
Graphs (1)
Results and Discussion (1)
References and Nomenclature (0.5)
Writing Quality and Style (1)
Total (10)

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