Drop trajectory predictions and their importance in the design of spray dryers

Abstract

A knowledge of the trajectories of atomized droplets in both the nozzle zone (where the droplets are rapidly decelerating from their initial high velocity) and in the free-entrainment zone (where the droplets are conveyed by the drying gas) is required for the design of spray dryers, since it governs the evaporative capacity and thermal efficiency of the chamber, while affecting the moisture content and general quality of the product through the control of the drying time. The trajectories of droplets in three-dimensional motion were determined theoretically in both zones. In the case of two-fluid pneumatic atomizers, the characteristics of the jet of atomizing fluid were found to be important in both the zones. Predictions of droplet trajectories were tested in an experimental circular cocurrent spray-drying chamber with a conical bottom, in which the drying air was introduced tangentially near the top. Water was used as the feed material. A study was made of the effects of liquid feed rate and temperature, drying air flowrate and temperature, and of nozzle position on the thermal efficiency and evaporative capacity of the chamber. The results were interpreted in the light of the droplet trajectories predicted.