CFD simulations of droplet and particle agglomeration in an industrial counter-current spray dryer

Abstract

In this study, CFD simulations of particle and droplet agglomeration in an industrial counter-current spray dryer are presented. For this purpose, a modified form of the stochastic collision agglomeration model is proposed. This model takes into account droplet–droplet collision as well as wet and dry particle interaction. These events are coupled with heat, mass and momentum transfer. A comprehensive moisture evaporation model based on the concept of characteristic drying curve (CDC) was applied to predict the drying kinetics of the detergent slurry. Due to high instability in air flow inside the drying chamber, simulations were carried out under transient condition. A comparison between time-averaged simulation results and measurements, which were performed on an industrial spray drying installation, shows a good agreement. This finding proves the correctness of the developed agglomeration and drying models. The presented methodology of CFD simulations of agglomeration can be used to design or optimise spray-drying installations and to predict the final particle size distribution of the product.