A Three-Dimensional Simulation of a Spray Dryer Fitted with a Rotary Atomizer

Abstract

Spray dryers fitted with rotary atomizers are commonly used in diverse industries to produce engineered powders on a large scale. Scale-up of such units is still largely empirical and based on prior experience and know-how. In the present study, a three-dimensional spray dryer with rotary atomizer is investigated numerically with a commercial CFD code. Continuous-phase, i.e., air, conservation equations are formulated in the Eulerian model while the droplet or particle equations are set up in the Lagrangian model. Two-way coupling between the continuous and dispersed phases is taken into account in the governing equations. The stochastic approach is used to predict the particle trajectories. The RNG k − ϵ turbulence model was used. Typical results, viz. air velocity, temperature, humidity profiles, and particle trajectories are presented and discussed. Compared with the pressure nozzle spray dryer, more volume of drying chamber is used effectively by the rotating disc type spray dryer. It is found that evaporation and drying take place mainly in the region and in the vicinity of first contact between air and spray. A parametric study is presented and, where appropriate, comparison is made with experimental data obtained with the simulated spray dryer.