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Lab Scale Spray Dryer

Hywell machinery specializes in both standard and customizable lab scale spray dryer. The lab-scale spray dryers are targeted for small-scale production as well as R&D work and are widely used by companies and universities. All Hywell lab scale spray dryer is available as standard plants. Furthermore, the lab scale spray dryers can be designed based on a modular concept with a range of optional items. In this way, each individual plant can be custom designed to match our customers’ individual requirements. Lab scale spray dryers are available in many flexible configurations enabling process simulations of larger industrial-size spray dryers.
  • LPG
  • HYWELL
  • 8419399090
  • SUS304/SUS316L/Titanium
  • Food/Pharmaceutical/Chemical
  • Yes
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Lab Scale Spray Dryer Introduction

Lab scale spray dryer is a method for producing a dry powder directly from a solution or slurry.  In a continuous process, the liquid feedstock is dispersed as a mist of fine droplets into a stream of hot drying gas, all within a cylindrical drying chamber.  In aqueous processes, the drying gas is typically air.  Because the kinetics of drying is so rapid, materials are dried in a fraction of a second which helps to make the process viable for thermally sensitive materials such as foods, extracts, and other organic substances.

A lab scale spray dryer is a kind of continuous atmospheric dryer. Use a pneumatic or electric atomization device to make liquid high-speed centrifugal spray as fog droplets, make these fog droplets in contact with the hot air in the drying chamber, and instantaneous drying. This lab scale spray dryers is often named lab high speed centrifugal spray dryer machine, high speed centrifugal spray dryer, Lab spray drying machine

Some special materials need to dry again by the lab fluid bed dryer or lab hot air try oven as batch to batch to reduce the final moisture.

If the liquid is thick and can not be pumped, liquids with high sugar content or heat-sensitive liquids. You can use Hywell company's  High-efficiency vacuum dryer or vacuum shelf dryer.


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Lab scale spray dryer

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Lab spray dryer

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Lab spray drying machine


Lab Spray Dryer Description

The hot air enters the drying room in the spiral form and uniformly after being filtered and heated the air enters the air distributor on the top of the lab spray dryer. Passing through the high-speed centrifugal atomizer on the top of the tower of the lab spray dryer, the material liquid will rotate and be sprayed into the extremely fine mist liquid beads. Through the very short time of contacting the pure heat air, the materials can be dried into the final products in seconds. The final products will be discharged continuously from the bottom of the drying tower or from the cyclones of the small scale spray dryer. The waste gas will be discharged from the blower. Hywell will design the bag filter to collect materials to reach 99.9% materials recollection if some materials are special materials. because the lab spray dryer often just use cyclone to collect powder that recovery rate as 93-95%.

LPG series lab high speed centrifugal spray dryer consists of a liquid transfer system, air filter system and heating system, liquid atomizing, drying tower, air exhausting and material collecting, control system, and so on, the feature for each system as below:

1. Air filtering system and heating system of the lab high speed centrifugal spray dryer

 Before the fresh air enters the heater, it should pass through the Pre & post filter first, and then enter the heater for heating. For the heating method, it is electrical heaters. To ensure the drying medium enters the drying chamber with high purity, the heated air should go through the filter before entering the drying chamber of the lab spray dryers.

2. Liquid transfer system of the lab high-speed centrifugal spray dryers

The liquid delivery system consists of a liquid tank, pump, and so on to ensure the liquid enters the atomizer smoothly.

3. Atomizing system of lab spray drying machine

The atomizing system consists of high-speed centrifugal atomizer with an inverter and so on.

The powder from the high-speed centrifugal atomizer is between 40-120 microns.

4. Drying tower system of lab spray drying machine

The drying chamber of the lab scale spray drying machine consists of the spiral shell, hot air distributor, main tower, and relevant fittings.

The Spiral shell and hot air distributor: the spiral shell and hot air distributor at the top of the tower can regulate air flow rotation angle according to the specific condition to guide the airflow inside the tower effectively and avoid the material sticking to the wall. in the middle, there is the position for installing the atomizer.

Drying tower of lab scale spray drying machines: The inner wall of lab spray drying machines is a SUS mirror sheet, and welded by arc welding. The insulation layer is rock wool

The middle of the tower has a manhole to view and is convenient to clean and maintain the tower. For the tower body cross interface, pipe elbow is arc butt design, reduce dead angle; sealed type.

The main tower of laboratory scale spray dryer is equipped with an air hammer, controlled by the pulse, and hits the main drying tower timely as to avoid the dust sticking to the wall

5. Air exhausting and product collecting system of laboratory scale spray dryer

Material collecting systems of laboratory scale spray dryer, there are several types. Such as cyclone, cyclone + bag filter. The method is depending on the material property itself. For the filtering system for the outlet air, we have a filter on request.

6. Control system of lab scale spray drying equipment

HMI+PLC, each parameter can be displayed on the touch screen of the lab scale spray drying equipment. Every parameter can be controlled and recorded easily. but it also can use buttons to reduce client investment.


Laboratory Spray Dryer Specifications


Model

LPG-5

Maximum moisture   evaporation (Kg)

5

Temperature range of inlet air (ºC)

100-280

Temperature range of outlet air (ºC)

60-130

Dryer time (S)

1.0 ~ 1.5

Atomization Type

Rotary atomizers

Atomizer Speed(rpm)

24000~30000

Atomizer Disk (mm)

50

Heating way

Electricity

Drying Chamber Diameter

1000

Dried powder restoring rate (%)

≥95


Reference machine dimension(m)

1.5x1.1x2.2

Reference machine weight (Kg)

700

1.Hywell   machinery reserves the right to the design without notice

2.All   specifications of laboratory spray dryer are as accurate as is   reasonably possible, but they are not binding.


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Laboratory spray dryer

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Lab scale spray dryer

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Lab spray drying machine


Basic plant of the Laboratory Scale Spray Dryer

Basic plant of the Laboratory Scale Spray Dryer

•      Liquid Feed tank

•      Liquid pump

•      Centrifugal atomizer

•      Air inlet filter

•      Electrical heater

•      Drying chamber

•      Cyclone

•      Powder container

•      Air pipe

•     Exhaust fan

•      Control panel with PLC, touch screen, cables, wiring, and data logging

•      Support structure with stairways, platforms, and railings – all in stainless steel.


Options of Laboratory Scale Spray Dryers

•      Rupture disc

•      Dehumidifier

•      Pneumatic hammers

•      Bag cloth filter

•      Exhaust air water scrubber



Heating Method of Lab Scale Spray Drying Machine

For the heating method of the lab scale spray drying machine, it just can use an electrical as a heat source.


Powder recovery unit of lab spray drying machine

The collection method of the lab spray drying machine is usually a single-stage cyclone to receive materials. However, the value of the dried materials is not high and does not pollute the environment. For the lab spray drying machine, a one-stage cyclone collection can be used. However, for materials that pollute the environment, the material collection system is cyclone dust removal plus bag dust removal system. Specifically designed according to the actual situation of the customer's materials.


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Atomizer of lab spray dryer

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Control panel of lab spray dryer

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Light of lab spray dryer


Atomizer of the Laboratory Spray Drying machine

Proper selection of the feed atomizer is critical and is based on experience but governed by the characteristics of the material to be dried. The two types of atomizers are:

•     High-pressure nozzles

•      Centrifugal atomizers

Any product which is removed from the chamber by the spent drying gases is separated from them by means of a cyclone or a fabric filter dust collector.


How do the Lab High Speed Centrifugal Spray Dryer Machine Works


The operation of the lab's high-speed centrifugal spray dryer machine is relatively simple. The hot air is generated by either electrical heater. A slurry is atomized into the drying chamber in the form of droplets the feed product and the process air are introduced into the top of the drying chamber. Here an instant contact between the atomized feed product and the heated process air takes place and the water evaporates from each droplet. The air and powder are led through the drying chamber to the cyclone for efficient powder separation.


Features of lab high speed centrifugal spray dryer

1. The drying speed is fast, and after the spraying of the liquid materials, the superficial area of the materials is increased greatly. In the hot air flow, 95-98% of water can be evaporated at a moment. The time to complete the drying just needs several seconds, which is especially suitable for heat-sensitive materials.

2. The final products have good uniformity, flow ability & solubility. and the final products are high in purity and good in quality.

3. The production procedures are simple and easy operation and control. The moisture of liquid contents of 40-60% (for special materials, the contents might be up to 90%).can be dried into the powder or particle products once a time.

4. After the drying process by the lab high-speed centrifugal spray dryer, there is no need for smashing and sorting, so as to reduce the operation procedures in the production and to enhance the product purity.

5. The product particle diameters, looseness, and water contents can be adjusted by changing the operation condition within a certain range. It is very convenient to carry out control and management.

6. Stainless steel material, arc corner design

7. Imported electrical components which are more stability.

8. PLC control system of lab high speed centrifugal spray dryer, make your research more easier and efficient.

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Exhaust fan

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Liquid pump

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Upper of lab spray dryer


Advantages of Laboratory Scale Spray Drying Equipment

1. Product quality and properties can be effectively controlled and maintained through the entire drying operation by the laboratory scale spray drying equipment.

2. Laboratory scale spray drying equipment can be thermolabile products/ pharmaceuticals that can be dried at atmospheric pressure and low temperature.

3. Laboratory scale spray drying equipment permits production in continuous operation adaptable to conventional PLC control (Programmable Logic Controller) and it is relatively simple to operate.

4. Feedstock in solution, slurry, emulsion, paste, and melt form can be dried if pumpable.

5. Corrosion problem is minimal and the selection of materials of the construction of laboratory scale spray drying equipment is simplified since the dried material comes in contact with the equipment surfaces in an anhydrous condition.

6. laboratory scale spray drying equipment produces dry powder particles of controllable particle size, shape, form, moisture content, and other specific properties irrespective of dryer capacity and heat sensitivity.

7. laboratory scale spray drying equipment handles a wide range of production rates and provides extensive flexibility in its design that product specifications are readily met through the selection of appropriate spray dryer design and its operation from a wide range of available designs.


Lab spray drying equipment Application

1.    Lab spray drying equipment for Chemical Industry

Sodium fluoride, potassium fluoride, basic dyes and pigments, dye intermediates, compound fertilizers, formaldehyde silicic acid, catalysts, sulfuric acid agents, amino acids, white carbon black, etc.

2.    Lab spray drying equipment for Plastic Resin

AB, ABS emulsion, urea-formaldehyde resin, phenolic resin, glue (urea) formaldehyde resin, polyethylene, polyvinyl chloride, etc.

3.    Lab spray drying equipment for Food Industry

Fat-rich milk powder, gluten, cocoa milk powder, milk replacer powder, hunting blood powder, egg white (yellow), etc.

4.    Lab spray drying equipment for Food and Plants

Oats, chicken juice, coffee, instant tea, seasoning meat, protein, soybean, peanut protein, etc.

5.    Lab spray drying equipment for Sugars

Corn steep liquor, corn starch, glucose, pectin, maltose, potassium sorbate, etc.

6.    Lab spray drying equipment Ceramics

Alumina, tile materials, magnesia, talc, etc.


Lab Spray Drying Machine Video


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