计算流体力学在顺流喷雾干燥器模拟中的误差源研究

The paper is focused on identifying error sources in computational fluid dynamics(CFD) predictions of a spray drying process. Seven groups of drying and atomisation parameters were selected for analysis and 13 simulation trials were performed. The theoretical results were compared with experimental data and sensitivity of the simulation results to the analysed factors was determined. The following parameters affecting the accuracy of CFD spray modelling were found: gas turbulence model, particle dispersion, atomising air, initial parameters of atomisation and heat losses to the environment. A major difference in the errors committed during modelling of spray drying process for fine and coarse sprays was observed.     

A Sensitivity Study on CFD Modeling of Cocurrent Spray-Drying Process

This article presents CFD modeling of drying process in a cocurrent spray dryer. Initial parameters of discrete and continuous phase were determined experimentally and used in the model. The theoretical results were compared with experimental data and sensitivity of the simulation results to the selected parameters was determined. Results show that the applied gas turbulence model, drying kinetics, effect of atomizing air, and turbulent particle dispersion are crucial parameters that control accuracy of the CFD modeling.     

Conditions for Accurate CFD Modeling of Spray-Drying Process

The paper presents concluding results of extensive experimental and theoretical research on confident CFD modeling of spray drying. An earlier developed experimental method to determine spray-drying kinetics in a lab scale allowed us to find a critical material moisture content and to determine generalized spray-drying curves. The generalized drying curves, identical in shape in the laboratory and pilot plant units, were used in the CFD model of spray drying process. Extensive simulations for spray drying of 10, 30, and 50% of initial solid content of maltodextrin proved high accuracy of the predictions of discrete (particle size distribution, particle moisture content, particle velocity, spray temperature) and continuous-phase parameters (gas temperature and humidity). Maximum error of the predictions of discrete-phase parameters was on the level of 20%, which is probably close to the current capacity of the CFD technique for modeling of spray-drying process. Comparison of experimental measurements and theoretical results shows that incorporation of realistic spray-drying kinetics into the CFD model and correct definition of initial drying and atomization parameters enable reliable simulations of spray-drying process.     

A Sensitivity Study on CFD Modeling of Cocurrent Spray-Drying Process

Abstract

This article presents CFD modeling of drying process in a cocurrent spray dryer. Initial parameters of discrete and continuous phase were determined experimentally and used in the model. The theoretical results were compared with experimental data and sensitivity of the simulation results to the selected parameters was determined. Results show that the applied gas turbulence model, drying kinetics, effect of atomizing air, and turbulent particle dispersion are crucial parameters that control accuracy of the CFD modeling.     

Design study of printer nozzle spray dryer by computational fluid dynamics modeling

Abstract

Milk powder production is one of the most energy-consuming processes in the dairy industry. To reduce production costs and increase spray dryer efficiency, the EU sponsored an international project named ENTHALPY. One of the results of the project was the development of mathematical models and computational fluid dynamics simulation methodology for the milk spray-drying process. This article introduces the methodology of CFD model development and presents simulation results as the basis for further drying tower design optimization. The CFD simulations were performed for a new design of monodisperse multistream atomizer. As a result of the CFD simulation, sets of parameters such as drying efficiency, protein thermal degradation, collision frequency, and wall deposition were obtained.     

MTO催化剂离心喷雾干燥制备过程的数值模拟

采用CFD模型对MTO催化剂喷雾干燥过程进行了非稳态数值模拟,得到了10s内热空气的湿含量、温度、速度、速度向量分布,以及催化剂颗粒的运动轨迹、停留时间和粒径分布.通过与试验结果的对比分析表明,模拟结果可信,模拟离心式喷雾干燥过程可行.     

CFD study of droplet atomisation using a binary nozzle in fluidised bed coating

An Eulerian–Lagrangian computational fluid dynamics (CFD) model was built to describe two-fluid atomisation in a tapered fluidised bed coater using the air-blast/air-assisted atomiser model. Atomisation was modelled both with and without the inclusion of the solid phase (i.e. gas–liquid and gas–solid–liquid multiphase modelling). In addition, a multi-fluid flow model (Eulerian–Eulerian framework) combined with a population balance model was used as an alternative approach for modelling the spray produced by a two-fluid nozzle. In this approach, the CFD solver couples the population balance equation along with the Navier–Stokes equations for predicting the droplet diameter and mass fraction distribution. Comparison between simulated spray pattern (gas–liquid model) and that experimentally visualised by means of UV illumination was made and a good agreement was obtained. Parametric studies were done in order to investigate the effects of operating conditions on spray cone and liquid mass fraction inside the reactor. Furthermore, comparison of time-averaged fluidised bed behaviour with the inclusion of sprays obtained by both gas–solid–liquid multiphase modelling methods is presented.     

Agglomeration in Spray Drying Installations (The EDECAD Project): Stickiness Measurements and Simulation Results

Spray drying is used for the manufacture of many consumer and industrial products such as instant dairy and food products, laundry detergents, pharmaceuticals, ceramics, and agrochemicals. During spray drying, agglomerates of powder particles are formed that determine the instant properties of the powder. Agglomeration during spray drying is considered to be a difficult process to control. The main cause of this is the complex interaction of the process variables: the atomization process, the mixing of spray and hot air, the drying of suspension droplets, and the collision of particles, which might lead to coalescence or agglomeration. As a consequence, agglomeration during spray drying is operated by trial and error. In an EC-sponsored project, named the EDECAD project and coordinated by NIZO food research, an industrially validated computer model, using CFD technology, to predict agglomeration processes in spray drying machines is developed. A Euler-Lagrange approach with appropriate elementary models for drying, collision, coalescence, and agglomeration of the dispersed phase is used. The main result of the EDECAD project is a so-called design tool, which establishes relations between the configuration of the drying installation (geometry, nozzle selection), process conditions, product composition, and final powder properties. The design tool has been validated on pilot plant scale and industrial scale. This article presents the setup and results of dynamic stickiness tests and some CFD simulation and validation results.     

Agglomeration in Spray Drying Installations (The EDECAD Project): Stickiness Measurements and Simulation Results

Spray drying is used for the manufacture of many consumer and industrial products such as instant dairy and food products, laundry detergents, pharmaceuticals, ceramics, and agrochemicals. During spray drying, agglomerates of powder particles are formed that determine the instant properties of the powder. Agglomeration during spray drying is considered to be a difficult process to control. The main cause of this is the complex interaction of the process variables: the atomization process, the mixing of spray and hot air, the drying of suspension droplets, and the collision of particles, which might lead to coalescence or agglomeration. As a consequence, agglomeration during spray drying is operated by trial and error. In an EC-sponsored project, named the EDECAD project and coordinated by NIZO food research, an industrially validated computer model, using CFD technology, to predict agglomeration processes in spray drying machines is developed. A Euler-Lagrange approach with appropriate elementary models for drying, collision, coalescence, and agglomeration of the dispersed phase is used. The main result of the EDECAD project is a so-called design tool, which establishes relations between the configuration of the drying installation (geometry, nozzle selection), process conditions, product composition, and final powder properties. The design tool has been validated on pilot plant scale and industrial scale. This article presents the setup and results of dynamic stickiness tests and some CFD simulation and validation results.     

喷雾干燥过程工艺参数的模拟计算

对喷雾干燥的计算机模拟计算进行了初步探讨，用FORTRAN语言编制了程序，对喷雾干燥过程进行了总体衡算和微元衡算，使计算快速、准确，而且便于程序与数据管理。结果表明，计算机完全可以替代人工手算。     

Multi-Scale Multiphase Modeling of Transport Phenomena in Spray-Drying Processes

Spray drying is an extensively used technology in process engineering for receiving small particles by rapid moisture evaporation from a spray of droplets. This contribution summarizes achievements and results of the comprehensive scientific research on multi-scale multiphase modeling of transport phenomena in spray-drying processes undertaken by our research group: (1) study of particle formation on the scale of an individual droplet; (2) modeling and simulation of droplet–droplet and particle–particle collisions in a spray; (3) study of gas-spray mixing; (4) 2D and 3D study of spray drying by an innovative multi-scale simulation tool coupled to a commercial CFD software. The proposed multi-scale multiphase model of transport phenomena in a spray-drying process has been developed based on a thorough analysis of previously published experimental and theoretical works. The content of this paper will be useful for both academia and industry; e.g., pharmaceutical, biotechnology, chemical, ceramics, materials, nutrition, and other applications of spray drying.     

Numerical Study of Two-Stage Horizontal Spray Dryers Using Computational Fluid Dynamics

This article presents the findings of a numerical simulation model of the spray-drying process in a two-stage horizontal chamber design with the aid of a computational fluid dynamic (CFD) model. The model describes heat, mass, and momentum transfer between two phases; namely, a continuous gas phase and a discrete phase of droplets (or particles), using the finite volume method. In this study, a new two-dimensional horizontal spray dryer (HSD) geometry is considered as a pilot study into the spray-drying process in this novel chamber configuration. The tested model is able to predict some important features of the spray-drying process, such as air flow patterns indicating recirculation zones and particle trajectory plots. Some performance parameters for spray drying, such as the rate of evaporation, average volumetric heat and mass transfer rates, etc., are calculated and discussed. This two-stage drying process especially applicable for the horizontal spray dryer (HSD) model is investigated and modeled. The bottom wall of the HSD is assumed to be a shallow fluid bed used for second stage drying. In this article, the fluid bed drying conditions are changed and compared. The drying within the fluid bed itself is not modeled in this study, however. It is shown that the particle residence time is higher when the fluid bed is included. The drying performance of this two-stage horizontal spray dryer is expected to be better than that of a single-stage dryer.     

Comparative study of droplet drying models for CFD modelling

CFD simulation is used to study wall deposition and agglomeration phenomena commonly encountered in industrial spray dryers. This paper initially provides a comparison of two drying kinetics models: Characteristic Drying Curve (CDC) and Reaction Engineering Approach (REA). Comparisons are made with experimental data with application to carbohydrate droplet drying obtained from past workers. These models were then extrapolated to actual drying conditions to assess their performance. The REA model predicts the progressive reduction in drying rate better than the CDC model for the carbohydrate droplets. A modified CDC model incorporating a convex falling rate produced better agreement than the conventional linear falling rate model. Further analysis showed that the REA model can be extended to simulate the particle surface moisture which may affect the agglomeration process. The proposed concept was compared with reported simulation results from a diffusion model which showed reasonable fit with data.     

An analysis of a pulse combustion drying system

The paper presents a theoretical and experimental analysis of a pulse combustion spray drying system. Measurements of the velocity flow field inside the drying chamber and extensive tests on drying and water evaporation were carried out for various feed rates and operating parameters of the pulse combustor. Each test included the analysis of temperature distribution in the dryer, evaporation level and sprayed material structure. LDA and PDA techniques were employed to determine the character of pulsating flow in the chamber, amount of water evaporated and to perform a profound analysis of spray structure. Experimental results show an intensive and efficient drying process. An attempt was made to perform theoretical predictions of velocity and temperature distribution in the drying chamber. The CFD technique was used to calculate time-dependent flow in the chamber. Results show vanishing velocity, pressure and temperature oscillations along the length of the drying chamber. Temperature oscillations decline faster than oscillations of pressure and velocity. Satisfactory agreement between calculations and experimental results was found in certain regions of the drying chamber. Discrepancies might be caused by simplification of the system geometry and flow pattern which were assumed to perform calculations in reasonable time.     

Numerical Study of Two-Stage Horizontal Spray Dryers Using Computational Fluid Dynamics

This article presents the findings of a numerical simulation model of the spray-drying process in a two-stage horizontal chamber design with the aid of a computational fluid dynamic (CFD) model. The model describes heat, mass, and momentum transfer between two phases; namely, a continuous gas phase and a discrete phase of droplets (or particles), using the finite volume method. In this study, a new two-dimensional horizontal spray dryer (HSD) geometry is considered as a pilot study into the spray-drying process in this novel chamber configuration. The tested model is able to predict some important features of the spray-drying process, such as air flow patterns indicating recirculation zones and particle trajectory plots. Some performance parameters for spray drying, such as the rate of evaporation, average volumetric heat and mass transfer rates, etc., are calculated and discussed. This two-stage drying process especially applicable for the horizontal spray dryer (HSD) model is investigated and modeled. The bottom wall of the HSD is assumed to be a shallow fluid bed used for second stage drying. In this article, the fluid bed drying conditions are changed and compared. The drying within the fluid bed itself is not modeled in this study, however. It is shown that the particle residence time is higher when the fluid bed is included. The drying performance of this two-stage horizontal spray dryer is expected to be better than that of a single-stage dryer.     

CFD Modeling of Air Flow on Wall Deposition in Different Spray Dryer Geometries

Wall deposition is one of the most conventional problems in the spray drying process. The operation of a spray dryer is affected by the wall deposition fluxes inside the equipment. In this study, computational fluid dynamic (CFD) simulation was used to investigate the effect of spray dryer geometry on wall deposition. A CFD model was developed for different geometries of spray dryer with a conical (case A) or a parabolic (cases B and C) bottom. The results implied that the parabolic geometry resulted in a lower deposition rate on the spray dryer walls. A comparison of results using the P-values (F-test) of the air velocity, in the conical and parabolic geometries, showed that there was a significant difference in air stability between them. The flow field in conical geometry case A was significantly more unstable, and parabolic geometry case C produced the most uniform airflow patterns. Moreover, the higher wall shear stress in case C, with lower values of the vorticity, would result in less wall deposition.     

Reduction of a model for single droplet drying and application to CFD of skim milk spray drying

In this work, a novel methodology for the development of a high-accuracy computational fluid dynamics (CFD) model for the spray-drying process is described. Starting point is an own spatially resolving model of droplet/particle drying, which was developed and validated on the basis of a series of single droplet drying (SDD) experiments. This sophisticated model is transformed to a much simpler version: the characteristic drying curve approach, after running the full SDD model in a wide range of operating conditions. Then, the obtained reduced model is implemented into the CFD solver. The CFD spray-drying model takes into account the hydrodynamics of the continuous phase, particle drying kinetics, changes in the particle diameter, and the heat loss from the drying chamber to the environment. Validation of the entire procedure is provided by data obtained from drying experiments performed in a co-current laboratory spray tower. High accuracy of the developed CFD model of skim milk spray drying has been found for both phases, for the mean outlet temperature of the continuous phase (air) and for the change in average particle moisture content along the spray tower (discrete phase).     

Effect of Maltodextrin Addition during Spray Drying of Tomato Pulp in Dehumidified Air: I. Drying Kinetics and Product Recovery

This work investigates the effect of maltodextrin addition on the drying kinetics and the stickiness during spray drying of tomato pulp in dehumidified air. A pilot-scale spray dryer was employed for the spray-drying process. The modification made to the original design consisted in connecting the spray dryer inlet air intake to an absorption air dryer. Twenty-seven different experiments were conducted varying the dextrose equivalent (DE) of the maltodextrin, the ratio (tomato pulp solids)/(maltodextrin solids), and the inlet air temperature. Data for the residue remaining on the walls were gathered. Furthermore, the effect of maltodextrin addition on the drying kinetics and the stickiness of the product was investigated using a numerical simulation of the spray-drying process modeled with the computational fluid dynamics (CFD) code Fluent. The code was used to determine the droplet moisture content and temperature profiles during the spray-drying experiments conducted in this work. The stickiness was determined by comparing the droplet temperature with its surface layer glass transition temperature (T_g ). The T_g was determined using a weighted mean rule based on the moisture content profiles calculated by the CFD code and the experimental data of T_g , which were obtained for the different tomato pulp and maltodextrin samples and fitted to the Gordon and Taylor model.     

DRYING KINETICS AND PARTICLE RESIDENCE TIME IN SPRAY DRYING

A unique experimental equipment for extensive trials on the spray drying kinetics and particles residence time involving “in situ” analysis of the properties of continuous and dispersed phases was designed, built, and tested. Advanced experimental techniques (including laser techniques) to determine current parameters of spray drying process (temperature, humidity, moisture content) and current structure of spray (particle size distribution, particle velocities, etc.) were employed. Full scale spray drying tests of baker's yeast and maltodextrin enabled identification of the effect of process parameters on drying kinetics and spray residence time in the tower. Quantitative relationship describing spray drying kinetics as a function of atomization ratio and drying agent temperature were determined. The experimental results proved that spray residence time was controlled by atomization ratio and airflow rate. Drying kinetics in spray drying process is presented for the first time in the literature.