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Spray Dryer Deposition Problem

09/18/2010 6:52 PM

I have 10mtrs diameter and 20mtrs length huge spray dryer,make:-Apv Anhydro, Denmark.This spray dryer is used for made Horlicks(food drink).The basic problem is when we are run the spray dryer very huge product deposition is happened on dryer chamber.My product property is Hygroscopic product.it catches moisture is very easily.When ever the dryer is running high deposition happened on the chamber walls.We are having CIP(clean in place )system, it means wet cleaning.I problem is to avoid the cleaning and to be introduce the dry cleaning methods.All ready i have dryer cleaning bridge,but it is not axces to all corners in dryer.So please the solve the deposition and implementation of new dry cleaning techniques.

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#1

Re: Executive Utilities

09/18/2010 9:11 PM

My experience was with rotary gas-fired dryers for animal feed products. we had to add loose bars that tumbled within the chambers, The random impacts served to prevent accumulation of product. Maybe you could adapt this to your process.

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#2

Re: Executive Utilities

09/18/2010 10:55 PM

What does the phrase "executive utilities" have to do with any of this?

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#3
In reply to #2

Re: Executive Utilities

09/19/2010 11:40 AM
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#4

Re: Executive Utilities

09/19/2010 1:27 PM

Well it's Horlicks which is supposed to help you sleep.

Most management I've come across seem to be asleep.

So, it's a lumpy executive sleeping aid.

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#5

Re: Spray Dryer Deposition Problem

09/19/2010 11:04 PM

Horlicks hygroscopic? The finished product I have seen is a powder. They might add a flow agent.

How long have you been making this product? When did the problem first show up?

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#6

Re: Spray Dryer Deposition Problem

09/20/2010 1:58 AM

Have you ever looked into an air knife drying system using a high speed, single stage centrifugal blower?

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#7

Re: Spray Dryer Deposition Problem

09/20/2010 3:36 AM

You don't explain the process very well, i.e. Is the problem happening during the introduction of the spray or is it directly after the wet clean?

If it is after the wet clean, i will suggest that you change the operation somewhat and, if possibble of course, to introduce a drying cycle first. This cycle can be hot air which will ensure noting sticks to the wet sides, or use hot water in the cycle. Hot water will take care of your deposition very quickly, and the heat will ensure that the chamber dries off easier.

If the problem is from the sprayers then obviously some of your nozzles are worn out and introduces "coarser" spraying than intended. If you dont have abnormal wear in some nozzles, or less pressure to spray, or less air in the system, for suspension as well as drying (or whatever you use to dry with), it looks as if somebody have "modified" your cleaning program and or your equipment without due consideration to the process it self. No manufacturer will build a drier, of any type, that will lose a lot of product. Something was changed. ( Abnormal wear will also cause any of your symptoms, and product losses)

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#8

Re: Spray Dryer Deposition Problem

09/20/2010 7:44 AM

Have you thought of using super critical CO2 for cleaning?

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#9

Re: Spray Dryer Deposition Problem

09/20/2010 8:15 AM

Often times material deposition on the dryer walls happens at specific points. You don´t say exactly where. My guess is tha your problem has little to do with the fact that the product is hydroscopic, as many spray dried products are highly hygroscopic and spray dryers can be run for weeks and even months non-stop without undue product build up inside. Here are a few things you can check:

At the nozzle elevation check nozzle aligment and spray pattern. Any chance the spray cone hits the dryer wall? Is nozzle pressure sufficient viz a viz spray angle? What about dryer air flow and chamber static pressure? Check that air temperature is high enough and that negative pressure is mantained. Check that air hammers or wall vibrators are installed and operational.

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#10

Re: Spray Dryer Deposition Problem

09/20/2010 12:21 PM

Many factors are involved in making a spray dryer work properly. I suspect that this spray dryer is being misapplied for your process. If it was originally purchased for this application then the process may have changed over the years to the point where the dryer no longer functions as initially designed. If the equipment was purchased used and installed in your facility, then I would say that critical components need to be changed for your unique requirements. First, the amount, and type, of liquid used to slurry your product is critical. If too much liquid, then you won't dry your product properly. Second, the spray nozzles used must be matched to the spray requirements, solids requirements, and heat exchange available. Thirdly, the counterflow (assuming counterflow is used) heated air must be hot enough, dry enough, and velocity just right to effectively evaporate the liquid from the slurry, leaving your dried powder. If you are getting buildup on your dryer walls your spray nozzles may not be correct, or your drying air may be too fast to effectively dry the product and instead pushes it to the walls. Before you make major changes to your system you need to thoroughly evaluate your dryer, hopefully with someone familiar with dryer design, and ensure you have the proper components for your application.

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#12
In reply to #10

Re: Spray Dryer Deposition Problem

09/20/2010 2:19 PM

Hi YesMAM,

I had only a bit of hands-on with a spray dryer long ago, so I didn't feel comfortable offering advice.

However, your idea was the same that came into my mind. Good and informative answer!

Mike

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#13
In reply to #12

Re: Spray Dryer Deposition Problem

09/20/2010 4:22 PM

Thanks. I haven't designed any spray dryers themselves, but am familiar with the requirements and have supplied a lot of dust collection equipment for them over the years.

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#16
In reply to #12

Re: Spray Dryer Deposition Problem

09/21/2010 4:26 AM

I dont understand the CR4 community, In this post you had JVRJ posting what he believed the problem was, then COFFEEBEAN posted his with some similarities, no recognition to JVRJ, and then eventually YESMAM appears with a little extra explanation of the same post, no recognition to JVRJ, and even MIKERHO added his piece, all derived from JVRJ's post, or so it seems. But no GA's to JVRJ? Are there some cliques on this forum as well?

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#17
In reply to #16

Re: Spray Dryer Deposition Problem

09/21/2010 4:37 AM

It certainly does look like deliberate ignorance of "first facts". However i'm not here long enough to confirm the clique on this forum but why did you not GA him?

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#19
In reply to #16

Re: Spray Dryer Deposition Problem

09/21/2010 10:02 AM

Sealing,

My post was to the OP (original poster), not to JVRJ. I did not reply to JVRJ because he was not the person looking for an answer. Second, JVRJ's response shows that he does not truly understand the problem (as he states in his first line) and, hence, he cannot give a response that addresses the OP's original problem. Third, JVRJ's post indicates he does not understand the operation of a "spray dryer". There is no "wet cleaning" or "dry cleaning" involved in the operation of a "spray dryer". A spray dryer is a large tank with spray nozzles on the top and (usually) countercurrent warm air flow upward through the tank. The desired "powder" is in a slurry of (usually) water or other liquid, pumped through the spray nozzles at the top, and gravity dropped through the tank. The upward warm air evaporates the liquid from the "powder" and passes out the top of the tank to a dust collector, or other dust entrapment device, to extract any residual powder that may be carried in that warm air stream. The "dried" powder then drops into the bottom of the tank where it is removed. There should be no buildup of product on the walls, as OP indicated, and there is no "wet cleaning" or "dry cleaning" required, except in the case of a powder material that will degrade over time. Then, as OP stated, a CIP (clean-in-place) water spray is used to wash any residual material out of cracks, off the walls, etc. However, this material is considered scrap and disgarded. Hence, the desire is to have as little residual material in the tank as possible. OP has a system that is leaving a lot of residual material and is looking for some means of solution. His proposed cleaning methods (wet washing or "dry cleaning") should not be required if the system is properly designed for the product yield he desires. This was the point of my post.

I recognize JVRJ's contribution to the issue, as the same to everyone else's post, and assigning of GA's is based on any particular individuals take on the content of the post. I don't believe JVRJ directly provided a "Good" response to assist the OP. Someone else may differ with my opinion. In addition, my post was intended to assist the OP, not to collect GA's. It is my belief that he needs to review the overall design of the spray dryer rather than approach his problem with a "bandaid" fix. Don't take offense with this, or other posts, as I'm only trying to point out, or clarify to you, my take on this. As to the other contributors to this thread, I don't know them personally and only know of them through this forum. There may be some cliques on this forum between posters, but those, I believe, are generated by similar thinking, common interests, etc., and not to "gang up" on others. The prime interest of everyone here should be, and is, to help someone else that has a problem.

One final thought. I have clearly labelled this post as "Off Topic". Therefore, please no GA's from anyone.

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#21
In reply to #19

Re: Spray Dryer Deposition Problem

09/21/2010 12:12 PM

I concur with you 100% and based on the record or number of GA's JVRJ has, I would expect him to be a brilliant fellow. However, on review of his GA's as listed under his profile (expecting to see a crackerjack) I find his GA's are by and large very nominal in contribution to the topic or knowledge thereof. Look at them for yourself. Oh well, I guess being an anonomous pseudo genius on the web really makes some people feel important. OHHH, did I say anonomous!!!!

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#24
In reply to #19

Re: Spray Dryer Deposition Problem

09/22/2010 3:13 AM

Strangely I agree with what you say, and i only answer here because of your stating , by implication, that i write nonsense here. We'll get to that just now. As for driers, i have experience, including hands on, of a variety of driers and drier types, like fluidised bed, spray drier, manual and old fashioned,as per the OP, and automatic. The one I based my "non understanding" on was the Vometic, a world renowned brand, which you may know. My personal involvement spans drying of soups, instant soups, condiments ( brands kept off the forum) relished the worldover and lately yeast. A prototype for yeast was designed and built by myself 17 years ago. I understood the OP problem to be the fouling on the sides. My opening line asked for more info about the process, as different understandings of operationg procedures can lead to his problem. What you read into the understanding cant be laid at my door, nor can i be castigated for the observation of another poster. Idiots like a lot of these supercritical GUEST'S we find on this forum nowadays are becoming a problem here. The mods should not allow posts from these faceless guys, nor should they be allowed a vote. However, to the reason for the way i post, or what i post. Any poster that expects specialist solutions to his specific problems must be foolish. I believe this forum is to help people along specific guidelines, and not to lay out a physics handbook, or try to impress people with your knowledge. If the advice posted here seems to match your query, then come back and ask that specific posters for more info. THEN you may engage in more indepth advice. Most posters dont come back and report on their solutions any way. Thus this forum have become a "waffle" spot for wannabe engineers and idiotic guests. It seems i have some faceless/nameless followers who only peruse my profile and judge me. GA's, i agree with you are not important, and ive seen GA's being allocated to silly repomses, even to a posters adding info to his own post got GA's. These faceles guests then OT your reponse out of pure malice.

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#26
In reply to #24

Re: Spray Dryer Deposition Problem

09/23/2010 9:08 AM

jvrj, et al,

My apologies if I did not correctly interpret your posting. Mea culpa. In rereading I do see your point of view and, based on your followup (to which I am replying) do note your dryer experience and the interests of the OP. Again, I apologize for any perceived slights. Let's hope OP reads these and follows a good path towards solving his system problems. And thanks for your contributions to this discussion. As for your profile, I have no interest in reviewing that, or anyone's, to assess their capabilities or experiences. We all do what we want to do and contributing, or not contributing, is a personal choice. Likewise, "granting" GA's to any particular poster is a personal choice of the grantor, based on their own perceptions and nothing more.

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#27
In reply to #26

Re: Spray Dryer Deposition Problem

09/27/2010 2:04 AM

Thanks YESMAM, I appreciate your coming back here, which illustrates the type of poster you are and, believe me, there are some very petty posters here. Youre right, a lot of OP's just disappear with no feedback.

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#22
In reply to #16

Re: Spray Dryer Deposition Problem

09/21/2010 5:19 PM

Please lighten up.

This is a forum and not a contest.

Yes, a person may not be recognized as a good answer.

I have posted many an response that I thought, was either a "Slam Dunk" or perhaps brilliant.

Then the Crickets chirp. (No response or worse)

We are what we are.

We are the mishmash and the remainders of the day. We cover many fields and discipline's. The big constant is that we wish to share knowledge and learn as much as we can. At least we give a dam.

I will learn as much as I can, for that is fun; That is till my head explodes

If you wish to discuss clique's. I can refer you to my cat. Now there is an attitude.

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#25
In reply to #22

Re: Spray Dryer Deposition Problem

09/22/2010 3:47 AM

Well said, Icarus, i guess thats the gist of JVRJ's reponse to Yesmam. This time yesmam did not read JVRJ post correctly, before going for first lines statements.

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#11

Re: Spray Dryer Deposition Problem

09/20/2010 1:24 PM

YesMAM is absolutely right. Among the points made you need to do some serious troubleshooting involving trained people. Given a dryer as big as yours production losses must be staggering. As far as new dry cleaning techniques there is none. The painful old fashion way prevails today: dryer shutdown with attendant losses and broom stick with telescopic handle.

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#14

Re: Spray Dryer Deposition Problem

09/21/2010 4:01 AM

CR4 Admin: Deleted Post

Spam: This post was deleted because it contained advertising outside the Commercial Space forum. Please review Section 14 of the CR4 Site FAQ about advertising.

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#15

Re: Spray Dryer Deposition Problem

09/21/2010 4:04 AM

CR4 Admin: Deleted Post

Spam: This post was deleted because it contained advertising outside the Commercial Space forum. Please review Section 14 of the CR4 Site FAQ about advertising.

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#18
In reply to #15

Re: Spray Dryer Deposition Problem

09/21/2010 8:31 AM

Que the Monty Python team Vikings

Spam, Spam, Spam, Spam, Spam, Spam, Spam, Spam.

Lovely Spam, Lovely Spam,

Lovely Spam, Lovely Spam,

I like Spam, I'm going to have Spam, egg, Spam, beans, Spam, sausage, Spam, Spam and Spam!

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#23
In reply to #18

Re: Spray Dryer Deposition Problem

09/21/2010 5:25 PM

What the world needs is more Monty Python.

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#20

Re: Spray Dryer Deposition Problem

09/21/2010 11:19 AM

Guest,

At this point you´re probably lost by the argumentative spin this thread is taking while getting no further practical advice. At the same time you haven´t come back with follow up comments. So I will say one final word. You will not easily solve the deposition unless a dozen or more variables are adressed by a knowledgable operator, some of which have been touched upon by previous posters. In the spray drying business dryer shutdowns and wet cleaning are dirty words. But when faced with such situations you´d better have procedures that will minimize product losses and turn around time. A dryer your size will probably collect up to 1 ton or more of powder buildup and once you get it wet there´s no turning back; it could take up to 3 days to get back on stream. Sometimes you can get away with dry cleaning only. Thus my broom with telescopic handle solution mentioned earlier. In any case, you should first try to recover as much dry product as possible before going wet as it can be used for dry rework by sieving and back blending. As to wet cleaning, I´d imagine that you have a liquid recovery loop from the dryer cone back to the evaporator, either by dedicated line or liquid tote.

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#28

Re: Spray Dryer Deposition Problem

11/28/2018 8:07 PM

This is exactly the kind of problem our company helps to solve. If you would like some support, please visit us at https://www.envirostarllc.com and we'd be happy to talk through a strategy to reduce / eliminate your losses.

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