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INTEGRATION OF NEW FLUID BED AND NEW AIR FLOW IN EXISTING SPRAY DRYER

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To demonstrate that the energy and operating efficiency of existing spray-dryers can be improved by integrating a vibrating fluid bed, modification of air and product flow in the dryer. This technique reduces energy consumption by allowing higher air inlet temperatures, extension of product runs (decreased fouling), reduction of product waste and increased flexibility in setting of process conditions.
For two different infant food formulations the actual energy consumption during drying has been reduced by some 10%; which is in fact somewhat less than expected.
On the other hand, there are major benefits in reduced product accumulation in the dryer, resulting in less fouling and reduction of cleaning intervals. The effect of this has been :
- reduction of product losses (of secondary quality),
- a consequenlty additional energy reduction (approx. 5%),
- and a more efficient operating schedule.
The existing spray-dryer is of a type frequently used, particularly in the dairy industry. The air flow is co-current at relatively high inlet and outlet temperatures. Through the modification of air flow and the integration of a fluid-bed, a more optimal drying effect can be achieved.
From preliminary research and field experience it appeared however that critical parameters apply with regard to air flow, temperature and humidity, especially for thermoplastic and thermosensitive products, such as infant food formulae. Undesired stickiness and long residence times of the product in the dryer should be avoided.
In the modified dryer more optimal drying conditions can be created through better adjustment of air flow patterns, air temperatures and product features (such as thermoplastic behaviour). The relatively large sizing of the already existing drying chamber, with a cylindrical super and conical substructure, were advantageous in this respect.
Because of the impossibility of full pilot-scale simulation (because of overall sizing, air flow pattern and temperature effects) the ultimate process conditions and resulting efficiencies can only be determined after the projects'realisation, i.e. in the testing and measuring phase.

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VERENIGDE COOPERATIEVE MELKINDUSTRIE (COBERCO)
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