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.rany@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 air flow 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 three conditions of temperature inlet. There are 100°C, 105°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°. The simulation results from this research show that
the bigger temperature inlet is used to make a heat flux and temperature distribution in the cylinder more evenly
distributed and constant, making the drying rate fast with good quality products. The simulation results show contour
plots of heat flux and temperature distribution in the cylinder. . Besides that, the results of the analysis show that the
turbulence area of the air flow is in the form of a vortex so that the drying process of heat transfer that occurs between the
product material and the air flow becomes faster.

PRELIMINARY
The drying process is a method that makes foodstuffs more durable without reducing the quality of these
foodstuffs. This drying process is widely used in the industrial sector both in large, medium and small because of its
advantages and benefits for managing foodstuffs [1]. The Spray Dryer machine has a working principle by 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 [2]. In designing
and operating the Spray Dryer machine, there are several problems that 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
[3]. 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 [4]. To create a fluid flow that has a good
turbulence intensity in the drying process, the Spray Dryer machine uses a Vortex Generator. Vortex Generator is
a tool that can accelerate the change of fluid flow from laminar flow to turbulent flow [5]. Fluid flow forms are
generally divided into 3 forms, namely laminar, transitional and turbulents are grouped 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 viscos force [6]. 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 [7]. In
general, the stages of the Computational Fluid Dynamics simulation can be broken down into 3 processes, namely
pre-processing, solver and post-processing. The method used in this fluid flow simulation uses the Eulerian Particle
Tracking method with a Dense Discrete Phase Model [8]. Eulerian Particle Tracking is particle movement by
focusing on 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 [9]. 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.

THEORITICAL REVIEW
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]. In general, the working system of the Spray Dryer machine is the product material to
be dried placed in a reservoir, where the reservoir is connected to the pump, pressure gauge and injector. 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].
2.1 Convection
Convection is the transfer of heat 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 [3].
(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 [9]. The procedure for calculating the forced convection heat transfer starts from looking for the Reynolds,
Prandtl, Nusselt Number 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 viscos force which can be broken
down as follows [6] :

ρ. v . L
ℜ= (2.2)
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 [3] :

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 [3] :

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 [3] :
- 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)

Coefficient of convection heat transfer

(2.7)
 Nu . k
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 [8]. Based on this description, the equation can be stated as follows :

q konv
q̇=
V (2.8)

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

Vortex Generator is a device that can accelerate the flow of fluid from the laminar flow to the turbulent flow
[5]. Using a Vortex Generator will increase the momentum significantly towards fluid flow and can increase the area
of air flow 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 blower are 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 Prantdl
(T,°C) ( ρ , kg/m3) (Cp, J/kg°K) Conductivity Diffusity 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 drying chamber due to the air flow passing through the Vortex Generator. This simulation uses an
Ansys Academic Fluent 2022 software. In this simulation using 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 for simulating the fluid flow that occurs in the inner flow [3]. 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, elements size used is 0,014248 so that 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 limit conditions on each part of the Spray Dryer
machine that is from 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 primary phase to air and discrete phase to
a mixture of water, milk and maltodextrine. 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 drying chamber 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 16,27 W/m°K.
For Inert Particle material, which is a mixture of water, milk and maltodextrine 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 maltodextrine has a mass of 528 gr so that the density value is 1056 kg/m 3 [10]. Furthermore,set the
velocity inlet is 16 m/s and 3 thermal inlet free variables are 100°C, 105°C and 110°C. Furthermore, in the Walls
menu the heat transfer coefficients are set based on temperature free variables, namely 104,32 W/m2°K, 103,59
W/m2°K and 102,84W/m2°K. Then set the ambient temperature to 30°C with wall thickness of 0,001 m. Next set
Heat Generation Rate based on temperature free variables, namely 22.605,06 W/m 3, 22.655,66 W/m3, and 22.605,06
W/m3, 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
Propertie Thermal Expansion (10-6/°C) 17,2
Thermal

Conductivity Thermal (W/m°K) 16,2

s

Spesific 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 100°C, 105°C and 110°C increases when the temperature of the inlet used
increases. It can be seen based on the contours of the color that the three inlet temperature free variables almost have
the same temperature distribution except that the specific values are different. 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 results from Temperature Inlet 100°C, 105°C, and 110°C

Table 4.1 Temperature Distribution

T1/Inlet T2 T3 T4 T5
100°C 70 66 77 59
105°C 72 68 79 60
110°C 75 70 81 62
 Graph of Temperature Distrubution
90

80

70

60
Temperature (°C)

50

40

30

20

10

0
1 2 3 4

Point of Temperature

100 105 110

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 drying chamber 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 a air velocity value of 16 m/s to 19,5 m/s after passing through 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 results from Temperature Inlet 100°C, 105°C, and 110°C

4.3 Turbalance 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 3 inlet temperature free variables. From the results of 3 simulations
on inlet temperature-free variables of 100 °C, 105 ° 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 3 simulations can be the same because the speed of the
incoming air flow and also the position of the injector is 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 that it has an area of
0,19625 m2. It can be known that the overall area of air flow turbulence that occurs in the drying chamber is 196,25
m2.
 Figure 4. 4 Turbulance Intensity results from Temperature Inlet 100°C, 105°C, and 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 100°C a heat transfer
coefficient value is 69,6 W/m 2°K, an inlet temperature is 105°C a heat transfer coefficient value is 56,3 W/m 2°K and
an inlet temperature is 110°C a heat transfer coefficient value is 41,4 W/m 2°K.

Figure 4. 5 Coefficient of Convection Heat Transfer results from Temperature Inlet 100°C, 105°C, and 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 35° and its effect to temperature distribution in the drying chamber using the Ansys
Academic Fluent 2022 software, it can be concluded as follows :
1. The temperature distribution in the drying chamber shows the same and stable contour color of the 3 variable
inlet temperatures used, namely 100°C, 105°C and 110°C.
2. The type of air flow 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.
 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. This happens because the value of the density of the incoming air will drop as the temperature
increases.

ACKNOWLEDGMENT
I would like to thanks to Mr. Pratomo Setyadi that already dedicated his time to help me on this research. Thanks to
Riza who did experiments and Mr. Nugroho Gama Yoga who validate the jobs on this research. Hopefully this
research can contribute to the fluid research.

REFERENCES

[1] L. Qomariyah, D. H. Prajitno, F. Firmansyah, and L. Alawiyah, “STUDI HIDRODINAMIKA

PADA FLAME SPRAY DRYER (FSD) DENGAN MENGGUNAKAN COMPUTATIONAL
FLUID DYNAMIC (CFD),” 2021.
[2] S. Huda, “EFEK EVAPORASI DAN SUHU PENGERINGAN SPRAYDRYING TERHADAP KARAKTERISTIK
FISIK DAN KIMIA WHEY BUBUK,” Jurnal Teknologi Hasil Pertanian, vol. 13, no. 2, p. 84, Aug. 2020, doi:
10.20961/jthp.v13i2.42716.
[3] P. Setyadi, N. Gama Yoga, M. Rizqi, and F. N. Amsir, “The simulation of fluid flow and heat transfer in a fluidized
bed spray dryer with a vortex generator 30 ° toward the Y axis,” 2021.
[4] N. Suarnadwipa and D. Hendra, “Pengeringan jamur dengan dehumidifier,” 2008.
[5] S. S. Hariyadi and W. Aries Widodo, “Efek Penggunaan Vortex Generator Terhadap Karakteristik Aliran pada
Airfoil NACA 43018,” 2015.
[6] M. Irsyad, “KARAKTERISTIK KOEFISIEN PERPINDAHAN PANAS KONVEKSI,” 2017.
[7] S. Maulana, “PEMANFAATAN COMPUTATIONAL FLUID DYNAMICS (CFD) DALAM STRATEGI
PENELITIAN SIMULASI MODEL PADA TEKNOLOGI PENGHAWAAN RUANG,” 2016.
[8] A. Fulamdana and I. Mukhaimin, “SIMULASI KARAKTERISTIK,” 2016.
[9] A. Walujodjati and ) Abstrak, “Perpindahan Panas Konveksi Paksa,” 2016.
[10] Debora M. Katz, Physics for Scientist and Engineering : Foundations and Connections with Modern Physics.
Boston: Cengange Learning, 2017.