CFD Simulation of a Counter-current Spray Drying Tower with Stochastic Treatment of Particle-wall Collision

In this study, a steady state, three-dimensional, multiphase CFD modeling of a pilot-plant counter-current spray drying tower is carried out to study the drying of detergent slurry and to predict spray-dried detergent powder characteristics. The coupling between the two phases is achieved using the Eulerian-Lagrangian approach. The continuous phase turbulence is modeled using the Reynolds stress transport model. The droplet drying kinetics is studied using a semi-empirical droplet/particle drying model. Emphasis is given on the modeling of particle-wall interaction by considering only the rebound effect and specifying the coefficient of restitution as a function of impact angle with wall surface roughness taken into account using a stochastic approach, as well as a function of moisture content. This influences the post-wall collision trajectories of particles, residence time distribution and the overall exchange of heat and mass transfer. The model predictions agree well with the measured outlet values of powder average temperature, moisture content and exhaust air temperature considering the complexity of the process and the measurements accuracy

Influence of wall friction on flow regimes and scale-up of counter-current swirl spray dryers

The structure of the vortex flow in swirl spray dryers is investigated after having fouled the walls with deposits typical of detergent manufacture. The range of Re and swirl intensity Ω characteristic of industry are studied using three counter-current units of varying scale and design. The friction with the deposits increases the flow turbulence kinetic energy and causes a drastic attenuation of the swirl and as a result, the vortex breaks down in the chamber forming recirculation regions (i.e. areas of reverse flow). Three flow regimes (1) no recirculation, (2) central and (3) annular recirculation have been identified depending on the swirl intensity. New control and scale up strategies are proposed for swirl dryers based in predicting the decay and the flow regime using the unit geometry (i.e. initial swirl intensity Ωi) and experimental decay rates function of the coverage and thickness of deposits. The impact in design and numerical modelling must be stressed. Adequate prediction of the swirl is vital to study fouling and recirculation, which surely play an important part in the dispersion and aggregation of the solid phase. Current models have no means to replicate these phenomena, and yet, in this case neglecting the deposits and assuming smooth walls would result in (a) over-prediction of swirl velocity up to 40-186% (b) under-prediction of turbulent kinetic energy up to 67-85% and (c) failure to recognise recirculation areas

An experimental investigation of the swirling flow in a tall-form counter current spray dryer

This work studies the air flow in a large swirl counter-current dryer using sonic anemometry. Air velocity and turbulence fields are reported at isothermal conditions and in the absence of particles. In a tall-form unit the structure of the flow is largely influenced by the design of the exit. A contraction originates a central jet and suppresses the formation of recirculation zones despite the vortex acquires a high swirl intensity Ω (i.e. 1<Ω<2). Access to a full scale tower has permitted to: (a) identify asymmetries owed to the design of inlet and exhaust ducts, (b) present the first detailed turbulence data in production units, characterized by a highly anisotropic field and the axial decay of the turbulence kinetic energy, (c) study the flow stability, identifying the precession of the vortex core and oscillations at a constant Strouhal number and (d) study the impact that a rough wall has in the strength of the swirl. This work presents the first clear evidence of significant friction in spray dryers. The swirl intensity Ω decays exponentially in the dryer at a rate between 0.08 and 0.09, much higher than expected in pipe flow and independent of Re in the range 105-2.2{dot operator}105. Production dryers have a large characteristic wall roughness due the presence of deposits, which explains the stronger friction and the discrepancies found in the past between data at full scale or clean laboratory or pilot scale units. It is essential to address this phenomenon in current numerical models, which are validated on laboratory or pilot scale facilities and ignore the role of deposits, thus causing an overprediction of the tangential velocity above 30-40%