Spray drying is the process of converting a mixture in its liquid form to a powder. The moisture content is removed from the liquid solutions and it is known as an emulsion. It is sprayed through a nozzle into a chamber that has hot air blown into it. A droplet of the solution is released through the nozzle the moisture content of each droplet is removed, turning the liquid to powder form.
Dry patterns are used for nozzle testing and the measurement is providing maximum output resulting in better resolution. The drop size is referred to the size of the individual drops that compromises a nozzle’s spray pattern. Dry patterns provide a range of liquid drop sizes there are several factors which affect the drop size.
The spray patterns have liquid properties and a high degree of atomization is used for producing very small drop size. In the process of spray drying, the mixture can be turned into a dried powder. It results in a single step resulting in not only profit maximization.
Different stages of spray drying
The spray dryers are considered important in many industrial drying operations. The spray drying process begins with atomization and a nozzle or rotary atomizer turns the liquid feedstock into small liquid droplets. It also includes desired qualities for the final product like particle size and viscosity.
The next step is the drying process. As the droplets exit the nozzle, it needs to be dried to form a powder that can be packed easily and transported. The powder drying process is carried out using air that has been heated with natural gas. The final moisture of the powder is controlled by fine-tuning the temperature of the hot air.
The last process is known as the recovery process and it just takes a few seconds to recover the powder from the exhaust gas, by way of a cyclone or big filter.
List of details of spray pattern characteristics
Spray Angle: The range gets determined by the spray patterns, the number of nozzles and the nozzle. It is ranging from 0° to 175°.
Operating Pressure: The moisture need defines the operating pressure and flow rate. The nozzle operating should be placed close to the dust source and it is best suited for enclosed areas.
Surface Wetting: The nozzle is used to increase the surface wetting and any impact can also increase surface wetting. The drops are traveling through the turbulent air before they hit the material.
The spray dryers are used in a wide range of processes associated with food, detergent, minerals, pharmaceutical and other product processing. The modeling of the physical process is governed by the performance of dryers. The key issue in dryer operation is flow stability, i.e. the need to avoid highly unsteady flows. The flows lead to significant wall deposition of partially dried product which sticks to the wall, resulting in the buildup of crust. It results in significant cost and production loss.