SCALE-UP OF SPRAY DRYERS WITH THE AID OF COMPUTATIONAL FLUID DYNAMICS

Abstract

The scale-up of spray dryer chambers is difficult because of the complexity of gas and spray flow patterns. The principal concerns in designing a spray drying chamber are to ensure sufficient residence time for drying and to avoid particle-wall collisions. Dimensionless groups are of limited use because it is practically impossible to achieve dynamic similarity between small and large chambers. In the past, empirical, rather than theoretically based, rules generated by experience with existing plant have been used in the design and scale-up of spray dryer chambers but these models, because of their empirical nature, are limited in their range of applicability. Computational fluid dynamics (CFD) is potentially a powerful tool to aid spray dryer design allowing much more flexibility in design but because of the difficulties of modelling such complex phenomena, especially the gas turbulence, its predictions cannot, at present, be considered absolutely reliable and experimental validation of the results is required. However, by considering the principles of similarity, it is shown that validations carried out on pilot scale equipment under the correct conditions will prove the accuracy of CFD applied to spray dryers of any size.     

SCALE-UP OF PNEUMATIC CONVEYING DRYERS

Scale-up of pneumatic conveying dryers has until now been largely empirical. A theoretical model is outlined which predicts dryer performance effectively. It depends on some uncertain parameters, notably agglomeration and wall friction, but these can be found more accurately by checking the predictions against results from the small-scale dryer. The model can then be used to scale up to the full size dryer. The required duct length falls as the gas velocity is reduced and the duct diameter increased, subject to satisfactory conveying and dispersion at the feedpoint.     

COMPARISON OF SUPERHEATED STEAM AND AIR OPERATED SPRAY DRYERS USING COMPUTATIONAL FLUID DYNAMICS.

ABSTRACT

In this paper a numerical simulation of a spray dryer using the computational fluid dynamics (CFD) code Fluent is described. This simulation is based on a discrete droplet model and solve the partial differential equations of momentum, heat and mass conservation for both gas and dispersed phase.

The model is used to simulate the behaviour of a pilot scale spray dryer operated with two drying media : superheated steam and air Considering that there is no risk of powder ignition in superheated steam, we choosed a rather high inlet temperature (973 K). For the simulation, drop size spectrum is represented by 6 discrete droplets diameters, fitting to an experimental droplets size distribution and all droplets are injected at the same velocity, equal to the calculated velocity of the liquid sheet at the nozzle orifice.

It is showed that the model can evaluate the most important features of a spray dryer : temperature distribution inside the chamber, velocity of gas, droplets trajectories as well as deposits on the walls. The model predicts a fast down flowing core jet surrounded by a large recirculation zone. Using superheated steam or air as a drying medium shows only slight differences in flow patterns. Except for the recirculation which is tighter in steam.

The general behaviour of droplets in air or steam are quite the same : smallest droplets are entrained by the central core and largest ones are taken into the recirculation zone. In superheated steam, the droplets penetrate to a greater extent in the recirculation zone. Also, they evaporate faster. The contours of gas temperature reflect these differences as these two aspects are strongly coupled. In both air and steam there is a “cool” zone which is narrower in steam than in air. Finally, the panicle deposit problem seems to be more pronounced in air than in steam.

Adding to the inherent interest in using superheated steam as a drying medium, the model predicts attractive behaviour for spray drying with superheated steam. In particular. under the conditions tested with the model, a higher volumetric drying rate is obtained in superheated steam.     

COMPARISON OF SUPERHEATED STEAM AND AIR OPERATED SPRAY DRYERS USING COMPUTATIONAL FLUID DYNAMICS.

In this paper a numerical simulation of a spray dryer using the computational fluid dynamics (CFD) code Fluent is described. This simulation is based on a discrete droplet model and solve the partial differential equations of momentum, heat and mass conservation for both gas and dispersed phase.

The model is used to simulate the behaviour of a pilot scale spray dryer operated with two drying media : superheated steam and air Considering that there is no risk of powder ignition in superheated steam, we choosed a rather high inlet temperature (973 K). For the simulation, drop size spectrum is represented by 6 discrete droplets diameters, fitting to an experimental droplets size distribution and all droplets are injected at the same velocity, equal to the calculated velocity of the liquid sheet at the nozzle orifice.

It is showed that the model can evaluate the most important features of a spray dryer : temperature distribution inside the chamber, velocity of gas, droplets trajectories as well as deposits on the walls. The model predicts a fast down flowing core jet surrounded by a large recirculation zone. Using superheated steam or air as a drying medium shows only slight differences in flow patterns. Except for the recirculation which is tighter in steam.

The general behaviour of droplets in air or steam are quite the same : smallest droplets are entrained by the central core and largest ones are taken into the recirculation zone. In superheated steam, the droplets penetrate to a greater extent in the recirculation zone. Also, they evaporate faster. The contours of gas temperature reflect these differences as these two aspects are strongly coupled. In both air and steam there is a “cool” zone which is narrower in steam than in air. Finally, the panicle deposit problem seems to be more pronounced in air than in steam.

Adding to the inherent interest in using superheated steam as a drying medium, the model predicts attractive behaviour for spray drying with superheated steam. In particular. under the conditions tested with the model, a higher volumetric drying rate is obtained in superheated steam.     

USE OF COMPUTATIONAL FLUID DYNAMICS TECHNIQUES TO ASSESS DESIGN ALTERNATIVES FOR THE PLENUM CHAMBER OF A SMALL SPRAY DRYER

The inlet region of a pilot-scale, co-current spray dryer was simulated using the proprietary Computational Fluid Dynamics (CFD) codes, CFX4 and CFX5. Several design alternatives were considered for correcting uneven inlet air distribution, which is known to influence spray dryer performance and airflow patterns. The simulations were used to assess each alternative prior to construction, assuming isothermal and incompressible flow conditions. Experimental measurements were compared with the simulation results for the original and one modified design.

Drying air is supplied to this dryer via an overhead pipe feeding an annular plenum chamber, of diameter 400 mm, surrounding the atomiser. A distributor plate with two concentric rings of 50 holes, each of 5 mm diameter, forms the base of the plenum chamber. A three-dimensional grid was required to model each of the 100 holes separately and to consider the asymmetric flow behaviour. The resulting grid consisted of about 532,000 cells. The CFD simulations proved useful in predicting the trends in flow distributions in each of the designs.     

USE OF COMPUTATIONAL FLUID DYNAMICS TECHNIQUES TO ASSESS DESIGN ALTERNATIVES FOR THE PLENUM CHAMBER OF A SMALL SPRAY DRYER

The inlet region of a pilot-scale, co-current spray dryer was simulated using the proprietary Computational Fluid Dynamics (CFD) codes, CFX4 and CFX5. Several design alternatives were considered for correcting uneven inlet air distribution, which is known to influence spray dryer performance and airflow patterns. The simulations were used to assess each alternative prior to construction, assuming isothermal and incompressible flow conditions. Experimental measurements were compared with the simulation results for the original and one modified design.

Drying air is supplied to this dryer via an overhead pipe feeding an annular plenum chamber, of diameter 400 mm, surrounding the atomiser. A distributor plate with two concentric rings of 50 holes, each of 5 mm diameter, forms the base of the plenum chamber. A three-dimensional grid was required to model each of the 100 holes separately and to consider the asymmetric flow behaviour. The resulting grid consisted of about 532,000 cells. The CFD simulations proved useful in predicting the trends in flow distributions in each of the designs.     

下行床气固两相流动计算流体力学模拟

基于颗粒相动力学理论 ,对层流机制表达的气固两相流体力学模型采用Reynolds平均的方法获得气固两相流的湍流模型描述 .其中 ,气相湍流行为以k -ε模型描述 ;颗粒相的碰撞行为以颗粒流的动力学模型表达 ;而湍流行为以kp 模型描述 .因此建立的k -ε -Θ -kp 模型综合考虑了气相和颗粒相的湍流运动以及颗粒的碰撞行为 .依据此模型建立了三维流体力学求解程序并对下行床气固两相流动行为进行了模型预测 .讨论了恢复系数的选取及壁效应假设 ,从机理上分析并考察了 3种模型的预测能力 .针对内径 1 40mm、高 7m的下行床冷态设备 ,在较宽的操作范围内 ,对比了详细的颗粒浓度和速度径向分布以及轴向参数分布 ,并对下行床的放大行为进行了预测 .     

SIMULATION AND SCALE-UP OF PNEUMATIC CONVEYING AND CASCADING ROTARY DRYERS

ABSTRACT

This paper presents a unified model for simulation of cocurrent and countercurrent dispersion-type dryers. The main industrial applications are to pneumatic conveying (flash) dryers and cascading (direct) rotary dryers. The basic model is a one-dimensional incremental (stepwise) simulation, which has been developed over a number of years Equations for particle motion, heat and mass transfer, heat and mass balances and local gas conditions are solved simultaneously over a small increment along the dryer. All workers have previously had considerable difficulty in obtaining a good fit between simulations and actual results from pilot-plants or large-scale industrial dryers. A new “fitting mode” calculation overcomes this by identifying the parameters which need to be adjusted, concentrating on those which cannot be measured accurately. Excellent agreement has been obtained between the model and experimental data by this method. The paper also presents revised formulations for particle motion and heat transfer in rotary dryers. The model has been incorporated into two computer programs for flash and rotary dryers respectively, and results from the former are shown for a case study.     

SIMULATION AND SCALE-UP OF PNEUMATIC CONVEYING AND CASCADING ROTARY DRYERS

This paper presents a unified model for simulation of cocurrent and countercurrent dispersion-type dryers. The main industrial applications are to pneumatic conveying (flash) dryers and cascading (direct) rotary dryers. The basic model is a one-dimensional incremental (stepwise) simulation, which has been developed over a number of years Equations for particle motion, heat and mass transfer, heat and mass balances and local gas conditions are solved simultaneously over a small increment along the dryer. All workers have previously had considerable difficulty in obtaining a good fit between simulations and actual results from pilot-plants or large-scale industrial dryers. A new “fitting mode” calculation overcomes this by identifying the parameters which need to be adjusted, concentrating on those which cannot be measured accurately. Excellent agreement has been obtained between the model and experimental data by this method. The paper also presents revised formulations for particle motion and heat transfer in rotary dryers. The model has been incorporated into two computer programs for flash and rotary dryers respectively, and results from the former are shown for a case study.     

CONTROL OF FLUID DYNAMICS WITH ENGINEERED FRACTALS - ADSORPTION PROCESS APPLICATIONS

Engineered fluid transporting fractals can be utilized for a broad range of fluid control applications. These applications include use as alternatives to turbulence, controlled formation of fluid geometry and rapid transition of effective fluid dimension. As applied to adsorption processes, fractals can be used to provide rapid and homogeneous distribution of fluids to form surfaces or rapid distribution and collection of volumes.     

SIMULATION OF A TWO PHASE FLOW BY CFD: ANALYSIS OF THE COMPUTATIONAL METHOD

When using a Computational Fluid Dynamics (CFD) code for the simulation of a two phase system, special attention must be given to the solution procedure. Fluid dynamics in CFD codes are obtained by iterative computations, and criteria must be established to decide the number of iterations needed to obtain a convergent solution under certain defined conditions. In this work, the predicted liquid and gas flow patterns obtained in the simulation of hydrodynamics in bubble columns are analysed throughout the computational process, and the effects of some parameters affecting the computation are studied (dimension of the grid, working conditions, scale-up, relaxation used in the calculations, free surface performance). It was found that each of these parameters affects considerably the solution procedure (though in a different manner) and therefore no general criteria can be established to decide the number of sweeps necessary for a certain simulation. It is concluded that every simulation should be analysed individually each time the conditions are changed. This analysis clearly helps to understand the reliability of CFD predictions in complex systems.     

圆管内含颗粒幂律流体的密相两相湍流

阐述了幂律流体控制方程的特点,研究了幂律流体的稠度系数和流动指数的变化对两相流动的影响.随着流动指数的增加,幂律流体在圆管中心附近的主流速度减小,同时颗粒相速度在圆管中心附近增大,而在管壁附近减小.随着稠度系数的增加,幂律流体和颗粒相的主流速度分布出现了与流动指数带来的影响相似的趋势.对带颗粒的幂律流体的两相流流动与液固两相流流动做了比较,幂律流体两相流的流体速度在管道中心附近的大部分区域比液固两相流的流体速度流动的速度大,而颗粒相的速度分布比较平坦.     

SENSITIVITY ANALYSIS ON THE FLUID DYNAMICS OF A DRAFT TUBE SPOUTED BED WITH BOTTOM PARTICLES FEED

A numerical study was carried out on the parametric sensitivity of the fluid dynamic variables for a draft tube spouted bed (SB) with bottom particles feed. The sensitivities of variables such as the air and particle velocities and voidages in the spout region, as functions of key model parameters, like the spout-annulus air distribution, solids recirculation rates and gas-particle drag coefficient were determined. The model was numerically integrated and sensitivities obtained by the central differences approach. The sensitivities were seen to depend on air inlet flowrates and heights in the bed. For air flowrates close to the minimum spouting velocity the model is very sensitive to all the parameters studied. In most cases, the variables were moderately to highly sensitive to air distribution in the bed. On the other hand, the variables were minimally to moderately sensitive to the drag coefficient and solids recirculation rates. The maps of sensitivity obtained provide useful information for planning of the probe location, hydrodynamic modeling and directing of future work on SB with bottom particles feed.     

FLUID1ZED BED SPRAY GRANULATION AND FILM COATING A NEW METHOD FOR THE INVESTIGATION OF THE COATING PROCESS ON A SINGLE SPHERE

The coating and granulation of solid particles in a fluidized bed is a process which converts pumpable and atomizable liquids (solutions, slurries, melts) into granular solids in one step through drying. Although this process has been applied in industry for several years, there is still a lack of understanding the physical fundamentals and the mechanisms by which spherical granules are formed. Hence a new method was developed which allows the direct observation of the subsequent particle-forming mechanisms such as droplet deposition, spreading, wetting and drying. The authors will present a laboratory scale apparatus in which a single freely suspended particle can be coated under well defined and constant coating and drying conditions. With this device, particle-growth-rate and the development of particle morphology were measured and investigated under various experimental conditions.     

FLUID1ZED BED SPRAY GRANULATION AND FILM COATING A NEW METHOD FOR THE INVESTIGATION OF THE COATING PROCESS ON A SINGLE SPHERE

ABSTRACT

The coating and granulation of solid particles in a fluidized bed is a process which converts pumpable and atomizable liquids (solutions, slurries, melts) into granular solids in one step through drying. Although this process has been applied in industry for several years, there is still a lack of understanding the physical fundamentals and the mechanisms by which spherical granules are formed. Hence a new method was developed which allows the direct observation of the subsequent particle-forming mechanisms such as droplet deposition, spreading, wetting and drying. The authors will present a laboratory scale apparatus in which a single freely suspended particle can be coated under well defined and constant coating and drying conditions. With this device, particle-growth-rate and the development of particle morphology were measured and investigated under various experimental conditions.     

FLOW OF A NON-NEWTONIAN FLUID WITH HEAT TRANSFER ABOVE A ROTATING DISK CONSIDERING THE ION SLIP

The steady flow and heat transfer of a conducting non-Newtonian fluid due to the rotation of an infinite nonconducting disk in the presence of an axial uniform steady magnetic field are studied considering the ion slip. The governing nonlinear equations are solved numerically using finite differences, and the solution shows that the ion slip and the non-Newtonian fluid characteristics give some interesting results.     

FLOW OF A NON-NEWTONIAN FLUID WITH HEAT TRANSFER ABOVE A ROTATING DISK CONSIDERING THE ION SLIP

The steady flow and heat transfer of a conducting non-Newtonian fluid due to the rotation of an infinite nonconducting disk in the presence of an axial uniform steady magnetic field are studied considering the ion slip. The governing nonlinear equations are solved numerically using finite differences, and the solution shows that the ion slip and the non-Newtonian fluid characteristics give some interesting results.     

MASS TRANSFER WITH HETEROGENEOUS CHEMICAL REACTION OF THE FIRST ORDER IN FALKNER-SKAN FLOW OF A POWER-LAW FLUID

Mass transfer with a heterogeneous chemical reaction of the first order in a Falkner-Skan flow of non-Newtonian power-law fluid is investigated. This problem is solved by the method of Laplace transform following the approach suggested by Apelblat (1980). The solution is obtained in a closed analytical form.     

MASS TRANSFER WITH HETEROGENEOUS CHEMICAL REACTION OF THE FIRST ORDER IN FALKNER-SKAN FLOW OF A POWER-LAW FLUID

ABSTRACT

Mass transfer with a heterogeneous chemical reaction of the first order in a Falkner-Skan flow of non-Newtonian power-law fluid is investigated. This problem is solved by the method of Laplace transform following the approach suggested by Apelblat (1980 Apelblat , A. ( 1980 ). Chem. Eng. J. , 19 , 19 – 37 . [CSA] [CROSSREF]  [Google Scholar]). The solution is obtained in a closed analytical form.     

A PSEUDO-THREE-DIMENSIONAL TWO-PHASE TURBULENT FLUID MECHANICAL MODEL FOR THE PREDICTION OF LIQUID FLOW PATTERNS WITH A FREE SURFACE IN A SHALLOW CHANNEL

A closed-loop analysis is presented for a turbulent multiphase fluid mechanical model of flow along a shallow channel, which is capable of accurately predicting free surface elevations at any point within the computational domain. It is shown that simulations based on a finite difference method and the mixing length hypothesis, effectively account for turbulent effects, with good agreement between theoretical predictions and recently performed experiments. The proposed model has many applications in everyday engineering.