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Equipment application:
This equipment is applicable for spray drying of materials such as fresh milk, bean products, egg liquid, agar, fruit juices, medicines and enzyme preparations.
Equipment features:
All surfaces of the equipment that are in contact with materials are made of high-quality stainless steel sheets, which are smooth, glabrous and in conformance with food hygiene conditions. All outer walls are wrapped with patterned stainless steel sheets, with an elegant appearance. The micro powder trapping system is provided on the periphery of the dryer wall, where the trapped micro powder can automatically fall into the tower cone and mix with the granular powder in the tower, which is then discharged outside of the dryer. Due to the short heating time of finished product in the dryer, the degree of destruction of the original components of the dried material is decreased, to ensure the original flavor and nutritive value of the material, and to greatly improve the quality of the powder. This equipment is also equipped with various detecting instruments, so that the operator can grasp and observe the working conditions in the drying process at any time.
The structure of this equipment is a new advanced spray drying equipment.
Operating principle:
The principle of spray drying is: with high-temperature (130-160°C) dry air introduced into the dryer, and by the action of a high-pressure pump, the material is atomized in the tower and comes into contact with the hot air to generate a heat exchange, thus the water in the material is quickly evaporated in few seconds and sent out by exhaust fan. The micro powder carried in the exhaust gas is trapped and recovered in a cloth bag, fell into the cone part of the tower and mixed with the granular powder in the tower, discharged from the outlet at the lower part of the cone to outside of the tower, and sent to a vibrating electric sieve for sieving.
Main structure:
This equipment is designed according to concurrent flow high pressure spray, and is mainly composed of dryer body, bag filter chamber, hot air distribution box, radiator, high pressure pipeline, inlet and exhaust systems and detecting instruments. This equipment is compact and easy to operate.
Control requirements:
Control of powdery particle size
Spray-dried material has large particles, most of which are spherical, and the diameter is about 40-150μm. The particle size of the product is determined by the dry matter content of the material and the size of the spray droplets. Of course, in the process of high-pressure spraying, the size of droplets depends on the structure of the spray nozzle and the size of the nozzle diameter. If the nozzle diameter is small and the spray pressure is high, the particles ejected will be fine, and vice versa.
Control of temperature and negative pressure in dryer
The temperature in the dryer should not be too high, generally controlled at about 85°C. In order to facilitate the evaporation of water during the drying process and to prevent the micro powder from escaping with the exhaust air during the drying process, a negative pressure should be maintained in the dryer (about 20-30mmAq), hence the exhaust air volume must be 30-40% larger than the intake air volume.
Operating procedure of spray drying:
1. Preparation before operation:Preparation before spray drying is necessary for accident prevention and quality assurance.
(1) Carry out a careful and thorough inspection of the drying equipment and its accessories, and check if the operating parts are short of grease, if the drying chamber is clean and sealed, and if the bag is intact.
(2) Check if the high-pressure pump is intact and normal, and if the cooling water is circulating.
(3) Install a proper spray nozzle and check if the nozzle diameter is worn.
(4) Check if all parts are clean and hygienic, and if the high-pressure pipeline is sterilized. Before startup, the hot water stored in the insulation tank at about 90°C should be sucked into the high-pressure pump for 5-10 minutes and be circulated in the pipe of the part that is in contact with the material.
2. Operating points
(1) The quality of spray drying operation has a great impact on the product quality, therefore, it is necessary to strictly implement the process operation procedures and follow the operation sequence. Firstly, open the steam header valve of the heater to allow air to enter slowly (air intake should not be too rush, especially in winter, to avoid sudden thermal expansion and damage to the heater or its components), and a certain pressure should be maintained. Start the inlet fan and allow air to enter the heater into the dryer, then after the temperature inside the dryer rises to 80-85°C start the exhaust fan to keep the temperature rising to 110-115°C. Start the high-pressure pump to spray and control the pressure of high-pressure pump to make it stable between 120-150Kg/cm2. Normal operation can be performed only after the temperature inside the tower, the exhaust temperature and the inlet temperature are stabilized within the required temperature ranges.
(2) In order to ensure a consistent product quality before and after spraying, material must be insulated and continuously stirred in the insulation tank, because a low material temperature will increase the viscosity, causing pressure spraying difficulty and unstable equipment operation, and affecting the solubility of finished powder. However, the temperature should not be too high, otherwise the material will agglomerate in the insulation tank, in particular, material with too high acidity is more liable to agglomerate.
(3) Vibrate the cloth bag frequently to facilitate exhausting, and check if there's any powder leakage.
(4) When the temperature becomes steady in the dryer, pay special attention not to make the temperature too high or too low. If any, regulate the inlet temperature, pressure and nozzle flow.
(5) Pay constant attention to whether the atomization is in a good condition and whether the orifice is in a normal state during operation.
(6) Open the access door regularly to shake off the trapped powder sticking to the cloth bag and cone.
(7) During the drying process, open the discharge port regularly to allow a continuous discharge of dry powder. If the dry powder is found to accumulate and bridge at the lower outlet of the cone, the cleaning port should be opened immediately for cleaning.
Common failures in spray drying and the causes
1.The pressure gauge pointer jumps or the pressure is low
(1) Cause: 1) The pointer will be unstable if the material temperature is too high.
2) The valve element and valve seat of the high-pressure pump have poor contacts or burrs, thus the predetermined pressure cannot be achieved, and the pointer of the pressure gauge jumps violently.
(2) Elimination methods: 1) Stabilize the material temperature.
2) Check if the contacts of the valve element and valve seat of the high-pressure pump are in good conditions and fine-grained corundum can be used to grind in case of burrs.
2. Atomization is not in a good condition.
(1) Cause: The nozzle bore or the orifice plate groove is worn during spraying, or blocked by other foreign matters or impurities.
(2) Elimination method: Replace the nozzle or orifice plate, and remove foreign matters or impurities.
3. Material leakage from high-pressure pump
(1) Cause: The fastening parts of the high-pressure pump are not fixed or the piston packing is damaged.
(2) Elimination method: Check the fastening parts of the high-pressure pump, and replace the packing.
4. There are sticky powder or wet powder sticking to wall around the top or upper part of the dryer.
(1) Causes: 1) Uneven hot air distribution, and there is wind vortex on the tower top.
2) The material viscosity is too high to be dispersed.
(2) Elimination methods: 1) Adjust the hot air cylinder and hot air distribution plate to allow hot air to enter the tower vertically in order to reduce vortex.
2) Heat or homogenize the material to allow an even decrease of viscosity.
5. Wet powder occurred around the dryer
(1) Causes: 1) Excessive feed quantity
2) The temperature inside the tower and the exhaust air temperature are too low
3) Failure to heat the dryer adequately before startup.
(2) Elimination method: The above causes are mainly due to the operator's inattention, especially before startup, the tower should be heated adequately to make the tower temperature rise to about 110℃ when open the high pressure valve slowly to feed, during which the feed cannot be too fast to avoid sudden tower temperature drop to bring about wet powder. Therefore, feed should be performed slowly at the beginning, then make it normal when the tower temperature and exhaust temperature are constant.
6. Too low evaporation of the dryer
(1) Cause: It is mainly caused by too low wind velocity or inlet temperature.
(2) Elimination method: Check if the air filter has an excessive resistance or it is blocked by impurities, and if the air heater pipe is unobstructed.
7. High degree of impurity in the product: There are many factors for a high degree of impurity, but process inspection should be carried out from the following aspects.
(1) Degree of impurity in raw material.
(2) Impurities in water.
(3) After the previous work is done, the dryer is not thoroughly cleaned, which results in scorched particles during the drying process that increase product impurities.
(4) The packing in the air filter is uneven, from the gap of which are impurities sucked into the dryer.
Hygienic requirements for spray drying:
1. Insulation tank, high-pressure pump, delivery pipe and other equipment components must be cleaned after work and disinfected before work. In general, the disinfection method is to use boiling water or steam.
2. All tools entering the dryer must be strictly disinfected at the time of powder discharge.
3. When entering the dryer, the operator's clothes, socks, hat and others must be disinfected by ultraviolet rays.
4. When entering the dryer, the operator should take a bath, disinfect his hands with bleaching powder, and additionally put on the clothes disinfected with high-pressure steam.
5. After the filter powder bag is cleaned, disinfect it in water by steam boiling.
Equipment installation
Due to the large volume and many combinations of the equipment, it is manufactured in sections in the factory and shipped to the site for assembly. Our factory is responsible for the following:
1. Designing the equipment layout and process rationally according to the site conditions.
2. Providing relevant technical information or data according to the user's needs.
3. For on-site assembly and commissioning and the training of technical personnel.
Equipment application:
This equipment is applicable for spray drying of materials such as fresh milk, bean products, egg liquid, agar, fruit juices, medicines and enzyme preparations.
Equipment features:
All surfaces of the equipment that are in contact with materials are made of high-quality stainless steel sheets, which are smooth, glabrous and in conformance with food hygiene conditions. All outer walls are wrapped with patterned stainless steel sheets, with an elegant appearance. The micro powder trapping system is provided on the periphery of the dryer wall, where the trapped micro powder can automatically fall into the tower cone and mix with the granular powder in the tower, which is then discharged outside of the dryer. Due to the short heating time of finished product in the dryer, the degree of destruction of the original components of the dried material is decreased, to ensure the original flavor and nutritive value of the material, and to greatly improve the quality of the powder. This equipment is also equipped with various detecting instruments, so that the operator can grasp and observe the working conditions in the drying process at any time.
The structure of this equipment is a new advanced spray drying equipment.
Operating principle:
The principle of spray drying is: with high-temperature (130-160°C) dry air introduced into the dryer, and by the action of a high-pressure pump, the material is atomized in the tower and comes into contact with the hot air to generate a heat exchange, thus the water in the material is quickly evaporated in few seconds and sent out by exhaust fan. The micro powder carried in the exhaust gas is trapped and recovered in a cloth bag, fell into the cone part of the tower and mixed with the granular powder in the tower, discharged from the outlet at the lower part of the cone to outside of the tower, and sent to a vibrating electric sieve for sieving.
Main structure:
This equipment is designed according to concurrent flow high pressure spray, and is mainly composed of dryer body, bag filter chamber, hot air distribution box, radiator, high pressure pipeline, inlet and exhaust systems and detecting instruments. This equipment is compact and easy to operate.
Control requirements:
Control of powdery particle size
Spray-dried material has large particles, most of which are spherical, and the diameter is about 40-150μm. The particle size of the product is determined by the dry matter content of the material and the size of the spray droplets. Of course, in the process of high-pressure spraying, the size of droplets depends on the structure of the spray nozzle and the size of the nozzle diameter. If the nozzle diameter is small and the spray pressure is high, the particles ejected will be fine, and vice versa.
Control of temperature and negative pressure in dryer
The temperature in the dryer should not be too high, generally controlled at about 85°C. In order to facilitate the evaporation of water during the drying process and to prevent the micro powder from escaping with the exhaust air during the drying process, a negative pressure should be maintained in the dryer (about 20-30mmAq), hence the exhaust air volume must be 30-40% larger than the intake air volume.
Operating procedure of spray drying:
1. Preparation before operation:Preparation before spray drying is necessary for accident prevention and quality assurance.
(1) Carry out a careful and thorough inspection of the drying equipment and its accessories, and check if the operating parts are short of grease, if the drying chamber is clean and sealed, and if the bag is intact.
(2) Check if the high-pressure pump is intact and normal, and if the cooling water is circulating.
(3) Install a proper spray nozzle and check if the nozzle diameter is worn.
(4) Check if all parts are clean and hygienic, and if the high-pressure pipeline is sterilized. Before startup, the hot water stored in the insulation tank at about 90°C should be sucked into the high-pressure pump for 5-10 minutes and be circulated in the pipe of the part that is in contact with the material.
2. Operating points
(1) The quality of spray drying operation has a great impact on the product quality, therefore, it is necessary to strictly implement the process operation procedures and follow the operation sequence. Firstly, open the steam header valve of the heater to allow air to enter slowly (air intake should not be too rush, especially in winter, to avoid sudden thermal expansion and damage to the heater or its components), and a certain pressure should be maintained. Start the inlet fan and allow air to enter the heater into the dryer, then after the temperature inside the dryer rises to 80-85°C start the exhaust fan to keep the temperature rising to 110-115°C. Start the high-pressure pump to spray and control the pressure of high-pressure pump to make it stable between 120-150Kg/cm2. Normal operation can be performed only after the temperature inside the tower, the exhaust temperature and the inlet temperature are stabilized within the required temperature ranges.
(2) In order to ensure a consistent product quality before and after spraying, material must be insulated and continuously stirred in the insulation tank, because a low material temperature will increase the viscosity, causing pressure spraying difficulty and unstable equipment operation, and affecting the solubility of finished powder. However, the temperature should not be too high, otherwise the material will agglomerate in the insulation tank, in particular, material with too high acidity is more liable to agglomerate.
(3) Vibrate the cloth bag frequently to facilitate exhausting, and check if there's any powder leakage.
(4) When the temperature becomes steady in the dryer, pay special attention not to make the temperature too high or too low. If any, regulate the inlet temperature, pressure and nozzle flow.
(5) Pay constant attention to whether the atomization is in a good condition and whether the orifice is in a normal state during operation.
(6) Open the access door regularly to shake off the trapped powder sticking to the cloth bag and cone.
(7) During the drying process, open the discharge port regularly to allow a continuous discharge of dry powder. If the dry powder is found to accumulate and bridge at the lower outlet of the cone, the cleaning port should be opened immediately for cleaning.
Common failures in spray drying and the causes
1.The pressure gauge pointer jumps or the pressure is low
(1) Cause: 1) The pointer will be unstable if the material temperature is too high.
2) The valve element and valve seat of the high-pressure pump have poor contacts or burrs, thus the predetermined pressure cannot be achieved, and the pointer of the pressure gauge jumps violently.
(2) Elimination methods: 1) Stabilize the material temperature.
2) Check if the contacts of the valve element and valve seat of the high-pressure pump are in good conditions and fine-grained corundum can be used to grind in case of burrs.
2. Atomization is not in a good condition.
(1) Cause: The nozzle bore or the orifice plate groove is worn during spraying, or blocked by other foreign matters or impurities.
(2) Elimination method: Replace the nozzle or orifice plate, and remove foreign matters or impurities.
3. Material leakage from high-pressure pump
(1) Cause: The fastening parts of the high-pressure pump are not fixed or the piston packing is damaged.
(2) Elimination method: Check the fastening parts of the high-pressure pump, and replace the packing.
4. There are sticky powder or wet powder sticking to wall around the top or upper part of the dryer.
(1) Causes: 1) Uneven hot air distribution, and there is wind vortex on the tower top.
2) The material viscosity is too high to be dispersed.
(2) Elimination methods: 1) Adjust the hot air cylinder and hot air distribution plate to allow hot air to enter the tower vertically in order to reduce vortex.
2) Heat or homogenize the material to allow an even decrease of viscosity.
5. Wet powder occurred around the dryer
(1) Causes: 1) Excessive feed quantity
2) The temperature inside the tower and the exhaust air temperature are too low
3) Failure to heat the dryer adequately before startup.
(2) Elimination method: The above causes are mainly due to the operator's inattention, especially before startup, the tower should be heated adequately to make the tower temperature rise to about 110℃ when open the high pressure valve slowly to feed, during which the feed cannot be too fast to avoid sudden tower temperature drop to bring about wet powder. Therefore, feed should be performed slowly at the beginning, then make it normal when the tower temperature and exhaust temperature are constant.
6. Too low evaporation of the dryer
(1) Cause: It is mainly caused by too low wind velocity or inlet temperature.
(2) Elimination method: Check if the air filter has an excessive resistance or it is blocked by impurities, and if the air heater pipe is unobstructed.
7. High degree of impurity in the product: There are many factors for a high degree of impurity, but process inspection should be carried out from the following aspects.
(1) Degree of impurity in raw material.
(2) Impurities in water.
(3) After the previous work is done, the dryer is not thoroughly cleaned, which results in scorched particles during the drying process that increase product impurities.
(4) The packing in the air filter is uneven, from the gap of which are impurities sucked into the dryer.
Hygienic requirements for spray drying:
1. Insulation tank, high-pressure pump, delivery pipe and other equipment components must be cleaned after work and disinfected before work. In general, the disinfection method is to use boiling water or steam.
2. All tools entering the dryer must be strictly disinfected at the time of powder discharge.
3. When entering the dryer, the operator's clothes, socks, hat and others must be disinfected by ultraviolet rays.
4. When entering the dryer, the operator should take a bath, disinfect his hands with bleaching powder, and additionally put on the clothes disinfected with high-pressure steam.
5. After the filter powder bag is cleaned, disinfect it in water by steam boiling.
Equipment installation
Due to the large volume and many combinations of the equipment, it is manufactured in sections in the factory and shipped to the site for assembly. Our factory is responsible for the following:
1. Designing the equipment layout and process rationally according to the site conditions.
2. Providing relevant technical information or data according to the user's needs.
3. For on-site assembly and commissioning and the training of technical personnel.
