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Small Scale Spray Dryer

Hywell machinery specializes in both standard and customizable small scale spray dryer. The small-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 small scale spray dryer is available as standard plants. Furthermore, the small-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. Small 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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Small scale spray dryer Introduction

Small scale spray drying 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 small 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 small scale spray dryer is often named High Speed Centrifugal Spray Dryer Machine, High Speed Centrifugal Spray Dryer, small spray drying machine.Hywell Machinery also have the lab spray dryer that use for lab testing.

Some special materials need to dry again by the vertical fluid bed dryer as batch to batch, or connect vibrating fluid bed dryer as continuous drying to reduce the final moisture, when hywell engineer design the LPG spray drying machine and decide whether to add this second step drying machine base the characteristic of the material.

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.


small spray dryer machine

Small spray dryer machine

small spray dryer

Small spray dryer

small-scale spray drying equipment

Small-scale spray drying equipment


Small Scale Spray Dryers 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 dryer. Passing through the high-speed centrifugal atomizer on the top of the tower of the small-scale 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. If some materials will be environmental pollution, Hywell will design and manufacture the water scrubber for the small-scale spray dryers.

LPG series high speed centrifugal small scale 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 high speed centrifugal small scale 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, there are electrical heaters or steam radiators, gas furnaces, and so on. Which method to choose depends on the customer site conditions. To ensure the drying medium enters the drying chamber with high purity, the heated air should go through the high-temperature high efficiency filter (HEPA-Optional) before entering the drying chamber of the high speed centrifugal small scale spray dryer.


2. Liquid transfer system of the high-speed centrifugal small-scale 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 small scale 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 small-scale spray drying machine

The drying chamber of the small-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 small-scale spray drying machines: The inner wall of small-scale 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 small scale spray drying machine 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 small scale spray drying equipment

Material collecting systems of small-scale spray drying equipment, there are several types. Such as cyclone, cyclone + bag filter, cyclone+ bag filter +water scrubber, and so on. 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 small-scale spray drying equipment

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


Small Spray Dryers Specifications


Model

LPG-5

LPG-10

LPG-15

LPG-25

LPG-50

Maximum moisture   evaporation (Kg)

5

10

15

25

50

Temperature range of inlet air (ºC)

100-280

100-280

100-280

100-280

100-280

Temperature range of outlet air (ºC)

60-130

60-130

60-130

60-130

60-130

Dryer time (S)


1.0 ~ 1.5


1.0 ~ 1.5

1.0 ~ 1.5

1.0 ~ 1.5

1.0 ~ 1.5

Atomization Type

Rotary atomizers

Rotary atomizers

Rotary atomizers

Rotary atomizers

Rotary atomizers

Atomizer Speed(rpm)

24000~30000

24000~30000

18000~24000

18000~24000

18000~22000

Atomizer Disk (mm)

50

80

100

120

120

Heating way

Electricity

Electricity

Steam + electricity

Steam +electricity

Steam +electricity

Drying Chamber Diameter

1000

1200

1600

2000

2300

Dried powder restoring rate (%)

≥95


≥95

≥95

≥95

≥95

Reference machine dimension(m)

1.5x1.1x2.2

2.5x1.5x2.6

3x1.7x2.8

4x2.8x4.2

5x3x5.2

Reference machine weight (Kg)

700

1200

1500

1900

2500

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

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


Heating Method of Small Spray Dryers

For the heating method of the small spray dryer, it can use steam or electrical or burn gas furnace as a heat source. Hywell machine can design the different kinds heating way base the client site situation. LPG-5 just can use electrical heater.


High speed centrifugal spray drying machine

High speed centrifugal spray drying machine

small-scale spray drying machine

Small-scale spray drying machine

small-scale spray dryers

Small-scale spray dryers

Powder recovery unit of small spray drying machine

The collection method of small spray drying machine is usually cyclone collection and bag dust collection. The laboratory spray dryer (LPG-5) uses a single-stage cyclone to receive materials. However, the value of the dried materials is not high and does not pollute the environment. For small spray dryers, two-stage cyclone collection can be used. However, for large-scale spray dryers or 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


Atomizer of the small spray dryer 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. The exhaust gases can be further cleaned by a wet scrubber if required. A spray dryer can also be operated in a closed loop using an inert gas, such as nitrogen, as the drying medium.


How do the Small Spray Dryer Machine Works

The operation of the small spray dryer machine is relatively simple. The hot gases, generated by either steam coils or a combustion furnace. 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 atomised 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 High Speed Centrifugal Spray Dryer Machine

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, that is especially suitable for the 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 high speed centrifugal spray dryer machine , 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 through 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 is more stability.

8. PLC control system, make your research more easier and efficient.


Advantages of High Speed Centrifugal Spray Dryer

1. Product quality and properties can be effectively controlled and maintained through the entire drying operation by the high speed centrifugal spray dryer.

2. high speed centrifugal spray dryer can be thermolabile products/ pharmaceuticals can be dried at atmospheric pressure and low temperature.

3. High speed centrifugal spray dryers 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 construction of high speed centrifugal spray dryer is simplified since the dried material comes in contact with the equipment surfaces in an anhydrous condition.

6. High speed centrifugal spray dryers produces dry powder particles of controllable particle size, shape, form, moisture content, and other specific properties irrespective of dryer capacity and heat sensitivity.

7. High speed centrifugal spray dryer handles a wide range of production rates and provides extensive flexibility in its design that is product specification are readily met through the selection of appropriate spray dryer design and its operation from a wide range of available design.


Disadvantages of high speed centrifugal spray drying machine

1. High speed centrifugal spray drying machine is bulky and also expensive to install.

2. High speed centrifugal spray drying machine is difficult to clean interior of tower and pipe after working.

3. high speed centrifugal spray drying machines have a low thermal efficiency that is a lot of heat is wasted during operation.

4. Solid materials cannot be dried using high speed centrifugal spray drying machine. The high speed centrifugal spray drying machines just can dry the liquid that can be pumpable.

5. Product degradation or fire hazard may result from product deposit on the drying chamber of the high speed centrifugal spray drying machines.

6. High speed centrifugal spray drying machine is an energy-intensive equipment because;

1). Specific heat of evaporation can be supplied in a short time.

2). The temperature difference across the drying chamber is relatively small and

3). An appreciable amount of heat is lost with exhaust air.


Small Industrial Spray Dryers Application

1. Small industrial Spray Dryers 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. Small industrial Spray Dryers for Plastic Resin

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

3. Small industrial Spray Drying Machine for Food Industry

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

4. Small industrial Spray Drying Machine for Food and Plants

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

5. Small  industrial Spray Dryers for Sugars

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


Basic plant of the small spray dryer

• Feed tank

• Liquid pump

• Centrifugal atomizer

• G4 and F7 air inlet filter

• Electrical heater

• Drying chamber

• Cyclone

• Powder container

• Air ducts

• Suction fan

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

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


Options of Small Industrial Spray Dryers

• Insulated feed tank

• An agitator in the feed tank

• Rupture disc

• HEPA filter H13

• Dehumidifier

• Steam heater

• Gas heater, indirect or direct

• Pneumatic hammers

• Bag cloth filter

• Exhaust air water scrubber



Spray Dryer flow chart

Spray Dryer Flow Chart

122

Spray Dryer Flow Chart


Small Industrial Spray Dryers Video


Small Scale Spray Dryer Video

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