Spray Drying Apparatus Using Localized Turbulence for Low-Temperature Processing
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Solution Overview
Problem
Conventional spray drying processes are limited by high temperatures, which restrict the types of materials that can be processed and result in material degradation, volatilization losses, and increased costs due to the need for large equipment and energy-intensive operations.
Innovation Solution
The introduction of localized turbulence in the drying fluid flow stream within the spray drying vessel, achieved by injecting pressurized secondary drying fluid at multiple loci, enhances mass transfer and reduces the volume and energy requirements of the drying process, allowing for compact, efficient, and cost-effective production of spray dried products at low temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high elevated temperature drying fluid is used to rapidly evaporate liquid from droplets, then drying speed and productivity are improved, but thermally sensitive materials are degraded and volatilization losses increase
Solution Approach 1:
The invention changes the temperature parameter of the drying fluid from conventional high temperatures (180-200°C) to low temperatures (below 100°C, preferably 20-80°C). This parameter change enables rapid drying of thermally sensitive materials without degradation or volatilization losses, while maintaining high productivity through optimized mass transfer conditions at low temperature
Solution Approach 2:
The invention introduces dynamically generated localized turbulence into the drying fluid flow stream to enhance mass transfer at low temperatures. This dynamic approach compensates for the reduced thermal driving force at low temperatures by creating intense mixing and renewal of the boundary layer around droplets, maintaining high drying rates without thermal damage
2Productivity
If conventional high temperature spray drying is used, then drying efficiency is improved, but equipment size and energy consumption increase
Solution Approach 1:
The invention changes the operating temperature parameter to low temperature (below 100°C), which reduces energy consumption for heating the drying fluid. Combined with dynamically generated localized turbulence that enhances mass transfer, the system achieves high drying efficiency without the high energy costs associated with conventional high temperature operation
Solution Approach 2:
The invention replaces thermal-driven drying efficiency with mechanically-driven turbulence-enhanced mass transfer. Instead of relying on high temperature thermal gradients, the system uses dynamically generated localized turbulence to enhance the mass transfer coefficient, substituting thermal energy with mechanical energy for achieving high drying efficiency
3Object-affected harmful factors
If low temperature drying fluid is used to protect thermally sensitive materials, then material quality is improved, but drying rate and productivity decrease
Solution Approach 1:
The invention introduces dynamically generated localized turbulence to the low temperature drying fluid to dramatically enhance mass transfer rates. This dynamic turbulence creation compensates for the reduced thermal driving force at low temperatures, maintaining high drying rates while preserving thermally sensitive materials through low temperature operation
Solution Approach 2:
The invention changes the temperature parameter to low values (below 100°C) to protect materials, but simultaneously changes the flow regime parameter by introducing dynamically generated localized turbulence. This combination of parameter changes maintains high mass transfer coefficients at low temperatures, achieving both material preservation and high productivity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly increases the efficiency of the spray drying process, enabling the production of high-quality dry powder products with reduced capital and operating costs, while accommodating a wider range of thermally sensitive materials.
Implementation Method 1
The injected wet material in the form of droplets contacts the stream of drying fluid so that the liquid passes from the droplets to the drying fluid stream, producing a spray dried product
Implementation Method 2
injecting pressurized secondary drying fluid into the stream of primary drying fluid in the spray drying contact zone at multiple loci to provide localized turbulence at said multiple loci
Data Source
AI summary
The disclosure relates to ultrahigh efficiency spray drying systems and processes, utilizing induction of localized turbulence in a drying fluid flow stream to produce spray dried product, having particular utility for low temperature spray drying operations. In a specific implementation, a method of processing a spray dryable liquid composition to form a spray dried product includes the steps of: generating a spray of the spray dryable liquid composition; contacting the spray of spray dryable liquid composition in a spray drying contact zone with a stream of primary drying fluid; injecting pressurized secondary drying fluid into the stream of primary drying fluid in the spray drying contact zone at multiple loci thereof to provide localized turbulence at said multiple loci; and recovering the spray dried product from the spray drying contact zone. Systems of the present disclosure are effective in achieving high-rate production of dry powder spray dried products, with substantially reduced capital equipment costs, energy requirements, and operating expenditures.