The Simulation of Fluid Flow with a Vortex Generator 35°

toward the Y-axis to Heat Transfer in Spray Dryer

Pratomo S1, Rani Anggrainy2, Nugroho G Yoga3, Yuga F N Syamsy4, and Oryza F
Hidayat5
1
Department of Mechanical Engineering, Faculty of Engineering, Universitas Negeri Jakarta, Indonesia
a)
Pratomo S : psetyadi@unj.ac.id b)anggrainy.rany507@gmail.com c)ngyoga@unj.ac.id
d)
yugafitrinursyamsy@gmail.com and e)oryzahidayat22.oh@gmail.com

Abstract. The Spray Dryer is a spray drying machine used to change liquid into dry powder. The spray drying machine
works can be defined by the drying process in a cylinder, utilizing air heated in the heater and then flowing through a
blower connected to a vortex generator with an angle of 35° to the Y-axis. The airflow creates a turbulence airflow in the
cylinder, which makes the liquid sprayed through the injector into a dry powder. This machine works by treating the milk
solution particle as a fluid, which flows in a 2-phase stream at different temperatures. This research aims to see the vortex
phenomenon, namely the turbulence intensity, airflow velocity, heat flux, and temperature distribution in a cylinder,
compared with an experiment that used four conditions of temperature inlet. There are 80°C, 90°C, 100°C, and 110°C.
The liquid used in this research is dairy cow's milk mixed with water and maltodextrin, which has a density value of 1056
kg/m3 and a specific heat value of 3930 J/kg K. The cylinder of the machine used has a diameter of 0.5 m with a wall
thickness of 1 x 10-3 m and a height of 2 m with a capacity of 1.27 l/hour with drying time of 80 minutes. The airflow of
this machine into the cylinder has a speed of 16 m/s with a cross-sectional diameter of 9,5 x 10 -2 m and a thickness of 1 x
10-3 m which has a debit of 0.11 m 3/s. In addition, the injector used has a diameter of 2 x 10 -4 m and has a speed of 13,54
m/s with a flow rate of 4,5 x 10 -4 kg/s which has a spray angle of 45°.. Besides that, the results of the analysis show that
the turbulence area of the airflow is in the form of a vortex so that the drying process of heat transfer that occurs between
the product material and the airflow becomes faster.

PRELIMINARY
The drying process is a method that makes foodstuffs more durable without reducing the quality of these
foodstuffs [1]. This drying process is widely used in the industrial sector both large, medium, and small because of
its advantages and benefits for managing foodstuffs [2]. The Spray Dryer machine has a working principle of
spraying the product material into the drying chamber, the purpose is to evaporate the product material into fine
grains that occur due to the forced convection of heat transfer by the flow of hot air with the product materials [3]. In
designing and operating the Spray Dryer machine, several problems are difficult to take into account, including the
most important is the shape of the fluid flow and its effect on the temperature distribution in the drying chamber [4].
The drying process that occurs for too long will make the product material overheat which can make the quality of
the product material less good, on the contrary, if the drying process takes place too quickly it will result in many
product materials failing in the form of deposits or wet product materials [5]. To create a fluid flow that has a good
turbulence intensity in the drying process, the Spray Dryer machine uses a Vortex Generator. A vortex Generator is
a tool that can accelerate the change of fluid flow from laminar flow to turbulent flow [6]. Fluid flow forms are
generally divided into 3 forms, namely laminar, transitional, and turbulence, based on the value of the Reynolds
Number. The Reynolds number in general can be interpreted as a dimensionless number which is the value of the
comparison between the incision force and the viscous force [7]. Computational Fluid Dynamics simulation is
needed on the Spray Dryer machine that can observe the shape of the fluid flow that occurs in the drying chamber
and its effect on the temperature distribution that occurs. Computational Fluid Dynamics is a branch of fluid
mechanics that uses numerical methods and algorithms to solve or analyze related fluid flows [8]. In general, the
stages of the Computational Fluid Dynamics simulation can be broken down into 3 processes, namely pre-
processing, solver, and post-processing [9]. The method used in this fluid flow simulation uses the Eulerian Particle
Tracking method with a Dense Discrete Phase Model [10]. Eulerian Particle Tracking is particle movement by
focusing on the volume control and this method can solve problems in particle movement over continuity equations
under turbulent flow conditions. In this simulation, the heat transfer that occurs between the droplets of the product
material and the fluid flow in the form of hot air flow is convection, more precisely forced convection. Forced
convection is the transfer of heat whose fluid flow is forced to drain a solid surface [11]. Based on the problems
described above, this study aims to determine the shape of fluid flow to the distribution of temperature in the drying
room that occurs in the Spray Dryer machine using Computational Fluid Dynamics simulation through the Ansys
Academic Fluent 2022 software. The simulation results are in the form of a fluid flow that will be formed as a result
of the Vortex Generator which has an angle of 35° to the Y-axis.

THEORETICAL REVIEW
A spray dryer is a machine that functions to produce products in the form of fine grains through a drying
process with the spraying method [2]. The dry spray method is already widely used in the food industry, especially
in powdered food because the drying process is short and easy to package [12]. The resulting product material
becomes more durable because it can improve the energy balance in the product material to minimize disturbances
that will damage the product material [13]. In general, the working system of the Spray Dryer machine is the product
material to be dried and placed in a reservoir, where the reservoir is connected to the pump, pressure gauge, and
injector [14]. This injector is located in the screening room of the Spray Dryer machine because it is arranged so that
the product material in the storage will be sucked in by a pump that will channel it to the injector so that the result of
the injector spray is in the form of wet granules of the product material. The fluid flow is connected to the heater
before entering the drying chamber which aims to create a stream of hot air. The hot air flow is sucked by the blower
into the drying chamber connected with the Vortex Generator. Because of this, a cross hot air flow is created in the
drying chamber which results in heat transfer from the product material to the hot air flow which will make the
formation of fine grains from the product material [3]. The convection heat transfer that occurs can be improved by
increasing the velocity of the fluid flow using a Vortex Generator so that the heat transfer area becomes wider [15].
According to the contact, spray dryers are classified as co-current, counter-current, and mixed flows [16].
2.1 Convection
Convection is heat transfer between solid surfaces bordering the flowing fluid. The type of fluid used can be
liquid or gaseous, the main condition of the convection heat transfer mechanism is the presence of a fluid flow [17] :
(2.1)
q konv =h . A . ( T S −T ∞ )
Explanation :
q konv : The rate of convection heat transfer (W)
h : Coefficient of convection heat transfer (W/m2°K)
A : Surface area (m2)
TS : Temperature of surface (°K)
T∞ : Temperatur of fluid flow (°K)

2.2 Forced Convection

Forced convection is the convection transfer of heat in which the flow of fluid is forced to flow through a solid
surface [11]. The procedure for calculating the forced convection heat transfer starts by looking for the Reynolds,
Prandtl, and Nusselt Numbers to get the coefficient of convection heat transfer values as follows :
2.2.1 Reynolds Number
The Reynolds number is a comparison between the inertial force and the viscous force which can be broken
down as follows [18] :

(2.2)
 ρ. v . L
ℜ=
μ
Explanation :
Re : Reynolds number
ρ : Density (kg/m3)
v : Velocity (m/s)
L : Cylinder Length (m)
μ : Dynamic viscosity (kg/ms)

2.2.2 Prandtl Number

The Prandtl number is a dimensionless number comparing the thickness of the speed limit layer and the
thickness of the thermal limit layer. Can be stated as follows [18] :

μ .C p (2.3)
Pr=
k

Explanation :
Pr : Prandtl number
μ : Dynamic viscosity (kg/ms)
Cp : Specific heat (J/kg°K)
k : Thermal conductivity (W/m°K)
2.2.3 Nusselt Number
The ratio between the amount of heat at convection and the amount of heat at conduction is called the Nusselt
number. The following equation can be expressed by [18] :

q conv h.∆T h.L (2.4)

Nu= = =
q cond k . ∆T / L k

Explanation :
Nu : Nusselt number
h : Coefficient of convection heat transfer (W/m2°K)
L : Wall length (m)
K : Thermal conductivity (W/m°K)
∆T : Temperature Different (°K)

For the nusselt number value in the heat transfer process of convection of flow heat in the pipeline, the
equation is as follows [18] :
- Laminar Flow
1/ 2 1/ 3 (2.5)
Nu=0,664 . ℜ . Pr
- Turbulent Flow

Nu=0,023 . ℜ
4 /5
. Pr
1/ 3 (2.6)

2.2.4 Coefficient of convection heat transfer

Nu . k (2.7)
h=
D

Explanation :
h : Coefficient of convection heat transfer (W/m2°K)
Nu : Nusselt number
k : Thermal conductivity (W/m°K)
D : Diameter of cylinder (m)
2.3 Heat Generation Rate
Heat Generation Rate is the spatial distribution of reactor energy. It can be said that the Heat Generation Rate
is the influence of heat from the outer boundary layer on the drying chamber based on the volume of the drying
chamber [10]. Based on this description, the equation can be stated as follows :

q konv (2.8)
q̇=
V

Explanation :
q̇ : Heat generation rate (W/m3)
q konv : The rate of convection heat transfer (W)
V : Volume of the cylinder (m3)

q konv =ṁ .C p . (T S−T ∞ ) (2.9)

Explanation :
q konv : The rate of convection heat transfer (W)
ṁ : Flow rate (kg/s)
Cp : Spesific heat of fluida (J/kg°K)
TS : Temperature of fluid (°K)
T∞ : Temperature of ambient (°K)

2.4 Vortex Generator

A vortex generator is a device that can accelerate the flow of fluid from the laminar flow to the turbulent flow
[6]. Using a Vortex Generator will increase the momentum significantly towards fluid flow and can increase the area
of airflow turbulence that occurs in the drying chamber. The Vortex Generator is needed on the Spray Dryer
machine to speed up the drying process without compromising the quality of the product material to be consumed.
This Vortex Generator is placed after the heater and the blower is right on the bottom side of the drying chamber.
Table 2.1 Properties of Air at 1 atm Pressure
Temp. Density Spesific Heat Thermal Thermal Dynamic Kinematic Prandtl
(T,°C) ( ρ , kg/m3) (Cp, J/kg°K) Conductivity Diffusivity Viscosity Viscosity Number
(k, W/m°K) (α, m2/s) ( μ, kg/ms) (v, m2/s) (Pr)
70 1,098 1007 0,02881 2,780 x 10-5 2,052 x 10-5 1,995 x 10-5 0,7177
-5 -5 -5
80 0,9994 1008 0,02953 2,931 x 10 2,096 x 10 2,097 x 10 0,7154
-5 -5 -5
90 0,9718 1008 0,03024 3,086 x 10 2,139 x 10 2,201 x10 0,7132
100 0,9458 1009 0,03095 3,243 x 10-5 2,181 x 10-5 2,306 x 10-5 0,7111
120 0,8977 1011 0,03235 3,565 x 10-5 2,264 x 10-5 2,522 x 10-5 0,7073

COMPUTATIONAL FLUID DYNAMICS (CFD)

The Computational Fluid Dynamics simulation conducted in this study aims to determine the temperature
distribution in the silo due to the airflow passing through the Vortex Generator. This simulation uses an Ansys
Academic Fluent 2022 software. This simulation uses a multiphase model of Eulerian with Dense Discrete Phase
Model. The meshing method used is Tetrahedrons because it has the advantage of being able to adjust to the shape
of the cylinder and simulating the fluid flow that occurs in the inner flow [19]. The simulation steps can be described
as follows :
3.1 Pre Processor
At this stage, the first thing that is done is Input Geometry. After success, then the next step is Extract Volume,
and then after that Suppress for Physics Solid. Furthermore, the meshing, element size used is 0,014248 so the
number of Nodes is 100.553 and Elements is 511.882. The Meshing Method used is Tetrahedrons because it
corresponds to this simulation model, namely the Dense Discrete Phase Model. After success, the next step is
Named Selection. At this stage, the process carried out is to provide limited conditions on each part of the Spray
Dryer machine that is from the Inlet, Outlet, and Walls. After that, set up the limit conditions and parameter values
to be used, first on the General menu is to set a gravity value of 9,8 m/s 2 and type Solver. Next, in the Multiphase
menu, select Eulerian with Dense Discrete Phase Model, in the Phase sub menu set up the primary phase to air and
the discrete phase to a mixture of water, milk, and maltodextrin. After that set Energy ON and on the Viscous menu
that is used, namely k-epsilon with realizable conditions and standard wall functions. After that, set Injection
Properties using an injector cone type with a diameter of 0,2 mm, a spray angle of 45°, a speed of 13,54 m/s, and a
flow rate of 0,00045 kg/s with a position of 0,15 m above the bottom surface of the cylinder. After that, the silo
material set is Stainless Steel 304 with a density value of 8030 kg/m 3, specific heat 502,48 J kg°K, and thermal
conductivity of 16,27 W/m°K. For Inert Particle material, which is a mixture of water, milk and maltodextrin has a
specific heat value of 3930 J/kg°K obtained from the book Physics for Scientist and Engineering: Foundations and
Connections with Modern Physics by Debora M. Katz, the density value is obtained from direct measurements at
500 ml of a mixture of water, milk, and maltodextrin has a mass of 528 gr so that the density value is 1056 kg/m 3
[20]. Furthermore, set the velocity inlet is 16 m/s and four temperature inlet free variables are 80°C, 90°C, 100°C,
and 110°C. Furthermore, in the Walls menu, the heat transfer coefficients are set based on temperature inlet-free
variables, namely 107,6 W/m2°K, 105,9 W/m2°K, 104,32 W/m2°K, and 102,84W/m2°K. Then set the ambient
temperature to 30°C with a wall thickness of 0,001 m. Next set Heat Generation Rate based on temperature inlet free
variables, namely 22.492,73 W/m3, 22.548,34 W/m3, 22.605,06 W/m3 and 22.695,68 W/m3. Finally, the Initialization
set for the air and particle temperature set is 30°C.
3.2 Solver
In this simulation, the solver model used is Type Pressure-Based with Velocity Formulation Absolute and
Time Transient.
3.3 Post Processor
The simulation results are in the form of contouring the distribution of temperatures in the cylinder, the shape
of the fluid flow, the contour of turbulence intensity, and the contour value of the convection coefficient.
 Table 3.1 Material Properties

Material SS-304
Elastic Modulus (GPa) 193
Mechanical Properties Tensile Strength (MPa) 515
Yield Strength (MPa) 205
Hardness (HRB) 88
Thermal Expansion (10-6/°C) 17,2
Conductivity Thermal (W/m°K) 16,2
Thermal Properties
Specific Heat (J/kg°K) 500
Melting Point (K) 1700

Figure 3.1 Input Geometry Figure 3.2 Extract Volume

Figure 3.3 Meshing Figure 3.4 Named Selection

Figure 3.5 Solver

Figure 3.6 2D Mesin Spray Dryer

 RESULT AND DISCUSSIONS
4.1 Temperature Distribution in Drying Chamber
Based on the simulation results, it can be said that the temperature distribution in the drying chamber with
variable free inlet temperatures of 80°C, 90°C, 100°C, and 110°C increases when the temperature of the inlet used
increases. It can be seen based on the contours of the analysis results that if the inlet temperature rises, the
temperature distribution in the drying chamber will be even better. The temperature distribution that occurs in the
drying chamber can be said to be evenly distributed which will speed up the drying process with good product
quality results.

Figure 4.1 Temperature Distribution result from Temperature Inlet (a). 80°C (b). 90°C (c). 100°C and (d).
110°C

Table 4.1 Temperature Distribution

T1/Inlet T2 T3 T4 T5
80°C 62 60 70 53
90°C 66 63 74 57
100°C 70 66 77 59
110°C 75 70 81 62
 Graph of Distrubution of Temperature
120

100

80
Temperature (°C)

60

40

20

0
1 2 3 4 5

Point of Temperature

80 90 100 110
Figure 4.2 Graph of Temperature Distribution

4.2 Air Flow in Drying Chamber

Based on the simulation results, it can be said that the value of the air velocity after the Vortex Generator has
increased and the form of fluid flow that occurs in the silo is turbulent flow and forms a vortex flow. To get these
values in the simulation results, use Streamline at airspeed. The simulation results show a change in the air velocity
value after passing through the Vortex Generator, which is 3,5 m/s which before entering the Vortex Generator has
an air velocity value of 16 m/s to 19,5 m/s passing the Vortex Generator. Another purpose of the Vortex Generator
is to accelerate the change from laminar to turbulent flow. The simulation results show that the flow formed after
passing through the Vortex Generator is a turbulent flow.
 Figure 4.3 Fluid Path result from Temperature Inlet (a). 80°C (b). 90°C (c). 100°C and (d). 110°C

4.3 Turbulence Intensity in Drying Chamber

Based on the simulation results, it can be said that the magnitude of the intensity value of turbulence that
occurs in the drying chamber is the same as the four temperature inlet-free variables. From the results of four
simulations on temperature inlet free variables of 80°C, 90°C, 100°C, and 110°C the same magnitude of turbulence
intensity value was obtained, which was 196%. This value is obtained from looking at the Contour Turbulent
Intensity in the simulation results. The turbulence intensity value in the four simulations can be the same because the
speed of the incoming airflow and also the position of the injector are the same which is different only the inlet
temperature is the same which makes the turbulence intensity value the same.
In addition to the value of turbulence intensity in the drying chamber, there is also a value area where fluid
flow turbulence occurs. In the results of the analysis, it can be seen that air turbulence occurs as high as 1 meter
from the bottom surface of the drying chamber. The diameter of the drying room is 0,5 m so it has an area of
0,19625 m2. It can be known that the overall area of airflow turbulence that occurs in the drying chamber is 196,25
m2.
 Figure 4.4 Turbulence Intensity result from Temperature Inlet (a). 80°C (b). 90°C (c). 100°C and (d). 110°C

4.4 Coefficient of Convection Heat Transfer

Based on the simulation results, it can be said that the value of the heat transfer coefficient will decrease as the
temperature of the incoming inlet increases. This happens because the value of the density of the incoming air will
drop as the temperature increases. This value is obtained from the simulation results in the form of Contour which
shows how much the value of the heat transfer coefficient occurs. At an inlet temperature is 80°C a heat transfer
coefficient value is 93,2 W/m2°K, an inlet temperature is 90°C a heat transfer coefficient value is 79,5 W/m 2°K, an
inlet temperature is 100°C a heat transfer coefficient value is 65,9 W/m 2°K and an inlet temperature is 110°C a heat
transfer coefficient value is 52,6 W/m2°K.

Figure 4.5 Coefficient of Convection Heat Transfer results from Temperature Inlet (a). 80°C (b). 90°C (c).
100°C and (d). 110°C

CONCLUSION
Based on the results of simulations that have been carried out in this study, namely a simulation of fluid flow
with a Vortex Generator at 35° and its effect on temperature distribution in the drying chamber using the Ansys
Academic Fluent 2022 software, it can be concluded as follows :
1. Based on the contour of the result analysis that the temperature distribution in the drying chamber shows more
even and better when the temperature of the inlet used increases.
2. The type of airflow that occurs inside the drying chamber is a turbulent flow and takes the form of a vortex after
passing through the Vortex Generator.
 3. The airflow speed increased after passing through the Vortex Generator by 3.5 m/s, which before entering the
Vortex Generator has an air velocity value of 16 m/s to 19,5 m/s passing the Vortex Generator.
4. The magnitude of the turbulence intensity value that occurs in the drying chamber is optimal, which is 196%
which will speed up the drying process.
5. The large area of turbulence that occurred in the drying chamber amounted to 196,25 m 2. The area turbulence air
occurs as high as 1 m from the bottom surface of the drying chamber.
6. There is a decrease in the value of the convection heat transfer coefficient when the temperature of the used inlet
increases. At an inlet temperature is 80°C a heat transfer coefficient value is 93,2 W/m 2°K, an inlet temperature
is 90°C a heat transfer coefficient value is 79,5 W/m 2°K, an inlet temperature is 100°C a heat transfer coefficient
value is 65,9 W/m2°K, and an inlet temperature is 110°C a heat transfer coefficient value is 52,6 W/m 2°K. This
happens because the value of the density of the incoming air will drop as the temperature increases.

ACKNOWLEDGMENT
I would like to thank Yuga and Riza who helped with the simulation and experiment, Mr. Nugroho Gama Yoga who
contributed to the calculation, and Mrs. Rani who do the proofreading. Hopefully, this research can contribute to the
fluid research.

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