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Furuta 1994
Furuta 1994
Furuta 1994
To cite this article: Takeshi Furuta , Hiromichi Hayashi & Tetsuya Ohashi (1994): SOME CRITERIA OF SPRAY DRYER DESIGN FOR
FOOD LIQUID, Drying Technology: An International Journal, 12:1-2, 151-177
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DRYING TECHNOLOGY, 12(1&2). 151-177 (1994)
ABSTRACT
Spray drying has many applications for a wide variety of dried food
powders. The quality of spray dried food is quite dependent on the
atomization characteristics and the heat and mass transler on drops inside
the spray dryer. This paper deals with some design criteria of the spray
dryer such as the atomizer, the drop trajectory and the heathass transfer
between the drop and the drying air.
151
onions and garlics, and powdered or granulated foods such as fruit juice
and oils and fats. This shows that tile recent advancement of techniques
for drying foods based on food science and food engineering made it
possible to produce high cluality dried food.
Most foods are sensitive to heat. The use of an improper drying
system not only deteriorates their original good taste and flavor in foods,
but also forms an undissolved lu~npor insoluble substance when the food is
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ATOMIZATION
-
Swirl chamber
Orifice
Nozzle
(a) Swirl Chamber (b) Grooved lnsen
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Solution is fed into the center of the disc that rotates at a high
speed, and atomized around the disc by centrifugation. Figures 2 shows
two kinds and operational mechanism of the centrifugal disc atomizer. This
type of the atomizer is advantageous to the high viscous liquid and also
exhibit relatively stable performance under the fluctuation of the feed
liquid. However, since the horizontal trajectory of the drop is wide, the
diameter of the dryer becomes large. Friedman ef al. (1952) obtained the
following dimensionless equation by using rotary'disc atomizer with a
multi-blade disc.
FURUTA, HAYASHI, A N D OHASHI
The mixing characteristics between the swarm of drops and the hot
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air inside the spray tower make great influences on the drying process of
the drclps. For heat sensitive food liquid, the quality of the spray dried
powders are determined by the air temperature distribution and the
tn~jectoryof the drop in the tower. The air flow pattern, temperature and
hunlidily distribulions inside the spray dryer are closely related with the
structure of the tower. The structure and choice of the air distributors and
vanes are summarized by Masters (1972).
One of the ~ n a i rreasons,
~ which make the air dynamics in the spray
tower so complex, is the so-called "pumping effect" near the atomizer. By
comprehensive experiments, King (1958) suggested that the pumping effect
r =O r=R
O ~ i r ( + )
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where ,j is the evaporation rate of water. The heat capacity of the drop
C,, can be calculated by the following equation.
where CW and C, are the specific lieat capacities of water and the solid,
OE water and the dissolved solid,
c ~ , o arid c,, are the initial concentration
and p W 4the density of the pure water, respectively.
The initial and boundary conditions of the moisture concentration
and the temperature of the drop are as follows:
SPRAY DRYER DESIGN FOR FOOD LIQUID
where c, is tlic concen~ratiunof thc dissolvcd solid ill tlle drop. Physically,
x Ineslis the Inass of the dissolved solid inside a spllcre of the radius r.
Being substituted Eq.(8) instead of r in Eq.(5), finite difference procedure
was used to solve the fundamental -drying equations.
A good taste and flavor contained in the spray dried powder are the
most important quality demanded by consumers. The smelling of food is
originated by many kinds of flavor components, which have commonly high
relative volatility with respect to water. Therefore, they can be easily lost
on the spray drying.
160 FURUTA, HAYASHI, AND OHASHI
and Schoeber, 1974; Furuta et a/., 1983) on the basis of the diffusion
equation of the ternary system. A drop is assumed to be dried in an air of
temperature T,, as shown in Fig. 3. In addition to the assumptions made in
the previous section, it is assumed that the concentration of the flavor is
extremely low compared with water and the solid concentration. Then, the
equations of change of water and. the flavor can be formulated as follows:
where D, and D, are the diffusivities of water and the flavor, respectively.
in Eq.(lO) can be estimated by D, and D, as
The cross diffusivity RWQ
follows:
where Hais the modified activity coefficient of the flavor and can be
defined as follows:
SPRAY DRYER DESIGN FOR FOOD LIQUID 161
Pressure nozzle
angle
/
Y '\
Drop
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where % and u, are the velocity of the drop in x and y directions, u, the
downward air velocity, u, the relative velocity of the drop, c, the drag
coefficient, and p, and p, the density of the drop and air, respectively.
Since the drag coefficient c, is a function of the particle Reynolds number
Re, (= D,,p,u,/~,), Eqs.(l4) and (15) should be solved by a numerical
nleillorl, such as the Runye-Kutta method. Some empirical correlations of
c, wit11 Re,, are suggested :
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Figure 5 shows calculated examples of the drop trajectories for a few drop
diameters and sprayed angles a when u, = 0 and p i = 1300. The
discharged velocity of the drop ui is varied from 70 to 140 m/s.
The nlotio~iof the drop sprayed by the disc atomizer into the air is in
general three dimensional. Figure 6 illustrates the schematic description of
the motion of the drop, whose velocity components in cylindrical coordinate
are u,, u, and u, in radial, peripheral and vertical downward direction,
respectively. The equations of motion of the drop in each direction are
FURUTA, HAYASHI, A N D OHASHI
Sprayed angle
= 70'
= So'
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D i s . : T \ ; . y ~ ~ ~
atomizer
'-'z
I
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derived as follows:
where u,, is the resultant velocity of the drop relative to uf and r(dq/dd)
and 2u,(dq/dO) are the centrifugal and Coliori's acceleration, respectively.
Tlie initial velocity can be postulated as follows:
where D, is the diameter of the disc and n is the rotational speed. The
FURUTA, HAYASHI, AND OHASHI
, Nozzle
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EXAMPLES OF CALCULATION
The cll;ilnber is divided into small sections (height AZ) for the heat
c . atornized drops have a size distribution which is classified
b ; ~ l i ~ t l ~'I'llc
illto i groups. The drying air flows i111othe section at temperature TI,, and
Icavcs at T,,",,. The flow ratc of the drying air is G,. If the mean residence
tilile Ui and the drying rate .Ii of the i-111 group of the drops are known, the
lleat I,:ilar~cein the small section in Fig. 7 is as fol1ow:
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whcre C,,is the specific humid heat capacity of the air and f, is the total
dry solid Inass of the i-th group of the drop. The sensible heat of the drops
is ricglcctcd in the lieat bala~lceequation. In order to calculate TI,o,,
iteratively I,y Ec1.(22), tlic residence time 0, and the drying rate Ji are
nccess;lry.
Residerice Time Bi: Because the trajectory of the drop can be assumed as
two dimensional, the residence time Oi, which is the time interval required
for tile drop to travel the distance AZ, can be estimated by numerical
calcul;~tionof Eqs.(l4) and (15). Rulige-Kutta method was applied for
ci~lculiitions.
13rvi11cI h t e of Dron Ji: The drying rate of the single drop of maltose slurry
was ensured wit11 the equipment wllich Furuta et al. (1983) used for the
ol' the drying of a single drop. Tllougli tile practical drop size in
resei~rct~
spray dryer is less than 100 pm, the d r y i ~ ~equipn~ent
g was limited to the
cJrol, larger than 1.5 mm diameter. Therefore, it is necessary to convert the
drying rate of such a large drop to that of the practical size of the drop.
Substituting the following new time and space coordinate variables
into Eqs.(4) and (7),
168 FURUTA, HAYASHI, AND OHASHI
It can be concluded from Eqs.(24) - (2G) that the drying rate can be
correlated by a new time variable O/R? for the different diameter of drops.
Figure 8 shows the drying curves of drops of three different initial
diameter. The time course of the moisture content ratio (the ratio of the
moisture content at time 0 to the initial moisture content), wdw,,,, are
correlated well with a single curve by the time variable if hRo is
constant. At the low Reynolds number of particles (Rep), hRo has a
constant value because the Nusselt number is constant at low Reynolds
number. The sprayed drop are small enough to till with this condition.
The drying rate of the practical size of drop can be obtained by the
graphical differentiation of Fig. 8. Figs. 9 and 10 show the effect of the
initial crystal content and the temperature of the air on the drying rate of
the drop. These two figures were used for calculation.
Results of the Simulation: Simulation of the moisture content of maltose
drop and the change of the drying air temperature were performed for the
SPRAY DRYER DESIGN FOR FOOD LIQUID
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wd ( kg-walerlkg-solid 1
( kg-walerlkgsolid
spray dryer of 3.8 m diameter and 16 m height. Table 1 shows the initial
condition of the maltose solution and the distribution of the drop diameter.
The drops were divided into four groups, in each of which the mean
diameter was used for calculations of the drop trajectory and the drying
rate. Calculation steps are as follows:
a) The spray dryer was divided axially at 1 m interval.
b) The mean residence time in the section was calculated by
Eqs.(l4) and (15).
c) The outlet air temperature in the section was postulaled. The
niean temperature of Ttin and T,,, is set to the air temperature
in this section.
d) From Figs. 9 and 10, the drying rate of t11c drop was estimated.
The interpolation was used fur the calculation.
e) TfsOu,
was calculated by Eq.(22) and was compared with the old
one. If the relative deviation of T,,o,, is larger than 1%,go back
to step c), otherwise go to step b).
Table 2 shows the comparison between the measurement and the
simulation. For the product moisture content, the calculated result is in-
FURUTA, HAYASHI, A N D OHASHI
Diameter of d r y e r : 2 . 2 (m)
Height of d r y e r : 4 (m)
Disk d i a m e t e r : 84 (mm)
Wheel s p e e d : 9000 - 20000 (rpm) '
Air f l o w r a t e : 60 (m3/min)
A i r temperature: T f , j . n = 4 5 3 (K),
T f , c u t = 3 6 3 (K)
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Feed r a t e of l i q u i d : 1 5 ( k g / h r )
The final moisture content in the spray dried powder of HVP (an
amino acid seasoning) was estimated on the basis of the diffusion equation
-
(Eqs.(4) (7)) in combination with the drop trajectory in the dryer
(Tsujimoto ef al., 1986). To obtain the functional relationship between the
moisture diffusivity D, and the moisture content, the drying experiments of
a sit~glcdrop were performed with the same apparatus used by Furuta et
ol. (1983). The formulas of the equation for D, and the activation energy
AE are as follows:
= ex~(al + u2/(43 + w~)) (27)
SPRAY DRYER DESIGN FOR FOOD LIQUID
U
1
0.10 Estimated wdo=0.29
the drop diameter distribution
- ,,,1
u
$'
3
-g
.-
Estimated wd0-0.29 A
lhe mean drop diameter
t h i / I
0 V'VJ
U
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Fig. 11 Estlniation of Product Moisture Content with the lnttial Drop Diameter.
where a's and b's are the fitting parameters. The Arrhenius equation was
assumed to estimate the tenlperature effect. The operational conditions of
the spray dryer are listed in Table 3. In calculation, the air temperature
and the humidity are chosen at constant value, which was calculated by the
heat balance of the dryer. Figure 11 shows the relation between the initial.
di;~n~eter
of the drop and the tnoisture content of the product powder. The
scrlicl line is tile calculated result by taking into account of the distribution
ol' drtq) diameter, while the cl~irin-dottedline is the value calculated by
using the mean diameter of 111edrop. The experimental results are in good
agreenlent with the solid line. This nleans that lor sirnulation it is
ilnpurtnnt to consider tlre distribution of the drop diameter.
A 100 I
0'
C
.-0
-?!
C
aJ uf ~ 1 . 4mls Calculation
(P,= 40.3pm )
0
-
C
0
al
U
10- -
Q
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I I P
- (13) combined with the two dimensional equation of the drop movement.
Simulation was performed on the drop of the mean diameter. All the
physical properties were referred fruln the studies by Kerkhof (1975) and
Furuta ef a/. (1983). The si~nulationof the acetone retention is quite in
good agreement with the experiments as shown in Fig. 12. The feed liquid
in Fig. 12 contains 1% gelatine, because of avoiding the turbulence inside
the drops on atomization. As pointed out by Kieckbusch and King (1980)
and Tsujirnoto er al. (1984), a large loss of the flavor was found in the
vicinity of the pressure nozzle, so that the flavor retention in the product
powder could not be predicted from the result of the single drop
performed by Furuta ef al. (1983). The excess loss of the flavor was
supposed to result from the turbulence generated in the conical sheet of
the feed liquid. To prevent from the excess loss, Tsujimoto ef al. (1984)
recommended to add a small amount of gelatine in the feed liquid, and
Zakarian and King (1982) suggested to mix an oil (e.g. peanut oil) to
emulsify the flavor component into the oil phase.
SPRAY DRYER DESIGN FOR FOOD LIQUID
NOMENCLATURE
D :difi'usivity (m 15)
D,, :cross ~liffusivityof water and flavor (m2/s)
Dl, :drop or article dianictcr (m)
Dp :meal1 11rop diameter (m)
d, :orifice di;lmeter (m1
AE :activatio~~ energy ol dirl'usivity (Jlmol)
F :Inass feed rate (kds)
Go :flow rale of the dry air (kg-dry airls)
y :acceleration. of gravity (m/s2)
Ha :modified activity coefficient (-1
A w :heat of evaporation of water Ins)
h :heat transfer coefficient (J/m .s.K)
Ji :drying rate of the i-th group of the drops (kg/kg-dry solid)
j, :evaporation rate of water (kdrn2.s)
k, :mass transfer coefficient of flavor vapor (kg/mz.s.Pa)
k :mass transfer coefficient of water vapor (kg/mz.s.Pa)
L :length of wet peripheral of the blade (m)
mi :dry solid mass of the i-th group of drops 0%)
N :number of blade (-1
n :rotational speed of disc blade (rpm'
Q :volume feed rate (m3/s)
p :vapor pressure (Pa)
R :radius of drop (m)
r :radial coordinate (m'
Re,, :Reynolds number of drop or particle (-1
Si :inlet section area of insert core (mZ)
u, :relative velocity (m/s>
TI :temperature of air (K or QC)
T, :temperature of drop
' (K or 0C)
u, :x-directional velocity drop (m/s'
u, :y-directional velocity drop (m/s>
uf :velocity of air \mls)
v,,, :partial specific volume of water (m 1%'
w, :lrroisture content (dry basis) (-1
176 FURUTA, HAYASHI, AND OHASHI
AZ :height element
a :spray angle
1' :I'ccd rate per length of wet peripheral of the blade
0 :time
K :crystallinity
p :viscosity
p :c!ensity
p', :density of water
a :surt';lce tension
<subscript>
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a :flavor
b :values at the bulk of air stream
d :drop
f :air
i :values at the interface
I :liquid
s :solid
w :water
0 :initial value
REFERENCES