Criteria for Designing Food Spray Dryers

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SOME CRITERIA OF SPRAY DRYER DESIGN FOR FOOD

LIQUID
a b c
Takeshi Furuta , Hiromichi Hayashi & Tetsuya Ohashi
a
Department of Biotechnology, Tottori University, Minami-4-101, Koyamacho, Tottori, 680,
JAPAN
b
Department of Food Science, College of Bioindustory, Tokyo University of Agriculture 196
Yasaka, Abashiri, Hokkaido, 099-24, JAPAN
c
Production Station, Hayashibara Co., Ltd, 7-7, Amaseminami-machi, Okayama, 700, JAPAN
Version of record first published: 21 May 2007.
To cite this article: Takeshi Furuta , Hiromichi Hayashi & Tetsuya Ohashi (1994): SOME CRITERIA OF SPRAY DRYER DESIGN FOR
FOOD LIQUID, Drying Technology: An International Journal, 12:1-2, 151-177
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DRYING TECHNOLOGY, 12(1&2). 151-177 (1994)
SOME CRITERIA OF SPRAY DRYER DESIGN FOR FOOD LIQUID
Takeshi Furuta, Hiromichi Hayashiq and Tetsuya Ohashis

Downloaded by [Yale University Library] at 04:34 10 March 2013
Department of Biotechnology, Tottori University

Minami-4-101, Koyamacho, Tottori 680 JAPAN
department of Food Science, College of Bioindustory,
Tokyo University of Agriculture
196 Yasaka, Abashiri, Hokkaido 099-24 JAPAN
§Production Station, Hayashibara Co., Ltd.
7-7, Arnaseminami-machi, Okayama 700 JAPAN
Key words and Phrases: spray dryer; drying of drop; atomization;

drop trajectory; flavor retention.
ABSTRACT
Spray drying has many applications for a wide variety of dried food
powders. The quality of spray dried food is quite dependent on the
atomization characteristics and the heat and mass transler on drops inside
the spray dryer. This paper deals with some design criteria of the spray
dryer such as the atomizer, the drop trajectory and the heathass transfer
between the drop and the drying air.
A wide variety of spray dried foods are displayed on the shelves in

supermarkets. These include powdered milk, instant coffee, spice such as
151
Copytight 0 1994 by Marcel Dekkcr. Inc.

IS2 FURUTA, HAYASHI, AND OHASHI
onions and garlics, and powdered or granulated foods such as fruit juice
and oils and fats. This shows that tile recent advancement of techniques
for drying foods based on food science and food engineering made it
possible to produce high cluality dried food.
Most foods are sensitive to heat. The use of an improper drying
system not only deteriorates their original good taste and flavor in foods,
but also forms an undissolved lu~npor insoluble substance when the food is
reconstituted from powder to I~quid. Therefore, it is important to select a

proper drying system based on the physical and chemical properties of
licluid food as a raw material to produce high quality powdered food. Of
course, running and initial cost required for drying, as well as quality, is an
important factor.
'Tliis paper deals with some design procedures of a spriy dryer, such
.as ntoniization of the feed liquid, trajectory of the drop and the heatlrnass
transfer between the drop and tlie hot air stream. Furthermore, a few
calculated examples, which include the spray drying of the maltose slurry
containing-P-maltosecrystals and the estimation of the loss of the flavor on
the spray drying, are presented.
ATOMIZATION
It is technologically common sense that as the surface area of

atomized material increases drying speed will be increased. For instance,
to process solution in a 1 cm3 cube into fine drops of 100 pm or 1 pm
diameter, the surface area must increase 100 or 10,000 times larger than its
original surface area. Spray drying is based on this principle. Liquid is
atomized by high pressure or centrifugal force to the possible degree to
increase its surface area. The fine particles are exposed to air at a high
SPRAY DRYER DESIGN FOR FOOD LIQUID 153
temperature. Usually, atomized liquid is in a diameter of 10 - 200 pm in

spray drying. The drying speed is 5 - 30 seconds, much shorter than other
drying systems such as drum, tray and rotary dryer.
When the material dried contains large amounts of water (e.g., 50 -
60% wet base), the temperature of drops of tlie material dried by this spray
drying dues not exceed 60 - 700C. When tlie inaterial is dried in the
constant rate period, during which the material dried contains large
amounts of water, the temperature of the material dried is said to be equal.

to wet a bulb temperature of air, which is substantially lower temperature
than inlet air temperature. Therefore, this method is most suitable for
drying heat sensitive foods.
Spray drying can also form a powdered spherical product directly
from liquid. This means that processes such as molding, grinding, and
classification, which a simple drying system requires, can be omitted. The
product is spherical with air entrapped in the particles. The diameter of
the spray dried particle is affected by drying conditions, but similar to the
diameter of drops. Recently, the free flowability and solubility of powder is
i~rlprovedin particulate foods by processing spray dried particles into 300 -
500 vln diameter particles using an instantizer or fluidized bed granulator.
Trying to produce these large-sized particles directly in the spray drying
tower results in rapid decreases in drying speed and efficiency.
For spray drying, usually a raw material is concentrated to increase a
solid content to 20 - 50% before drying. For instance, the solid content of
coffee extract is very low. If it is Eed directly to the dryer without
concentration process, not only heavy drying load may be requires
(increases running cost), but also the apparent bulk density of the product
may be decreased (size of package may increase). In some foods like
soybean milk, when extract is concentrated to 20 - 25% solid content,
atomization is very difficult because the viscosity increases exponentially.
Generally, supplied solid content must be considerably low in foods with
154 FURUTA, HAYASHI, AND OHASHI
components such as albumin, globulin, fish protein that are vulnerable to

heat and easy to change to a highly viscous liquid. The drying cost of these
substallces inevitably increase. Milk contains large amounts of protein
casein, albumin, and globulin, to lesser degree than soybean milk.
Tlierefore, viscosity increases rapidly from about 45% solid content.
Atclmization is quite difcicult I'or higllly viscous liquid, which increases the
drop size. 'I'his causes the adllesion of undried particles to the chamber
wall and scorcl~edpowder due to tocnl ovrrl~eat,wl~ichdeteriorates the

quiility of the product. Solution conti~il~ing
I;~rge:llilounts of sugar that is
c o ~ i c e ~ ~ t r a to
t e dhigh solid content deposits crystals. Sugar crystals exist in
the particles of the spray dried final product, which reduces the solubility of
the product. Therefore, the co~npositionof the food dried must be
carefully considered in setting spray drying conditions.
Solutions can be atomized into 10 - 100 pm diameter by the spray
pressure nozzle and centrifugal disc type, i n 100 - 300 k g / c ~ i land
~ 10,000 -
20,000 rpm, respectively: The processing capacity of a spray dryer lias
gradually raised up to around 7,000 kghr in their evaporation rate. The
concentrate is agglomerated with a diameter of 200 - 300 pfn and sold as
instant foods.
Spray Pressure Nozzle Type
Figure 1 shows the internal structure of spray pressure nozzle. The

solution pressured at 100 - 300 kdcm2 by a high pressure pump flows into
the swirl chamber at nearly a tangent. It circles to form an eddy current in
the center of the chamber. The solution runs along the side of the orifice,
and forms a rotating hyperboloidal thin membrane at the end of the stream
until it is eventually atomized. The degree of atomization depends on the
pressure of the high pressure pumps, and the viscosity, density, and surface
SPRAY DRYER DESIGN FOR FOOD LIQUID
-
Swirl chamber
Orifice
Nozzle
(a) Swirl Chamber (b) Grooved lnsen
Flg. 1 Deslgn Feature of Pressure Noale.
tension of solution. Turner and Moulton (1953) and Ishioka (1964)

obtained the following experimental formulas as:
Rotary Disc Type
Solution is fed into the center of the disc that rotates at a high
speed, and atomized around the disc by centrifugation. Figures 2 shows
two kinds and operational mechanism of the centrifugal disc atomizer. This
type of the atomizer is advantageous to the high viscous liquid and also
exhibit relatively stable performance under the fluctuation of the feed
liquid. However, since the horizontal trajectory of the drop is wide, the
diameter of the dryer becomes large. Friedman ef al. (1952) obtained the
following dimensionless equation by using rotary'disc atomizer with a
multi-blade disc.
FURUTA, HAYASHI, A N D OHASHI
D R Y I N G EQUA'I'ION OF DROI' IN Sl'MY DRYER
The mixing characteristics between the swarm of drops and the hot
air inside the spray tower make great influences on the drying process of
the drclps. For heat sensitive food liquid, the quality of the spray dried
powders are determined by the air temperature distribution and the
tn~jectoryof the drop in the tower. The air flow pattern, temperature and
hunlidily distribulions inside the spray dryer are closely related with the
structure of the tower. The structure and choice of the air distributors and
vanes are summarized by Masters (1972).
One of the ~ n a i rreasons,
~ which make the air dynamics in the spray
tower so complex, is the so-called "pumping effect" near the atomizer. By
comprehensive experiments, King (1958) suggested that the pumping effect
(a) Vane Wheel (b) Steam Swept Wheel
Flg. 2 Spray Mechanism of Rotary Dlsc Atomizer.

r =O r=R
O ~ i r ( + )
Flg. 3 Drylng of Drop 111 Alr Stream.
has several important inlluences on the drying process of drops: i) due to

the suction of ihe hot air into the spray core region, the drying rate of
drops in this region is accelerated: ii) there exists a mixing region of the air
i I t ;I certain distance below 111cpressure atomizer, where the cooler and
moist air flowing upward along the tower wall is mixed with the hot air
from upper outside of the spray region and then flows radially inward to
the core region of the spray. This phenomenon is caused by the substantial
axial teinperature gradient.
The simplest situation for predicting the drying rate,of the sprayed
drop is that the moisture in tlle drop is evaporated by supplying heat from
the hot air, as shown in Fig. 3. In this case, the moisture movement inside
the liquid drop should be taken into account, as well as in the surface
boundary film. For liquid food system, a useful approximation is regarding
the liquid phase as a binary system consisting of the dissolved solid and
water, and applying the Fick's diffusion equation to describe the movement
of water. For further simplicity, following assumptions are made:
a) Transfer of water in the liquid phase takes place by the molecular
diffusion and no convective movements are taken into account.
The spherically symmetric diffusion is also assumed.
158 FURUTA, HAYASHI, A N D OHASHI
b) No volume contraction takes place upon mixing. Consequently

the magnitude of shrinkage is equal to the volume of water
evaporated.
c) The temperature is uniform inside the drop.
According to Kerkhof and Schoeber (1974) and Furuta ef of. (1983), the
drying equation of the spherical drop is given as follow:
where D, is the dillusivily of the water.

S i ~ ~ the
c e Diot number inside the drop under the normal drying
condition is lower than that in the gas phase, one can assume that the
temperaturedistribution in the liquid phase is negligible. Thus, the heat
balance gives the following equation for the drop temperature T,,.
where ,j is the evaporation rate of water. The heat capacity of the drop
C,, can be calculated by the following equation.
where CW and C, are the specific lieat capacities of water and the solid,
OE water and the dissolved solid,
c ~ , o arid c,, are the initial concentration
and p W 4the density of the pure water, respectively.
The initial and boundary conditions of the moisture concentration
and the temperature of the drop are as follows:
where v, is the partial specific volume of water.

Since Eqs.(5) and ( G ) , cannot be solved analytically becausc of the
strong dependence of D, on the moisture concentration and the

temperature, a numerical method is necessary to solve the equation.
Because the drop shrinks with the evaporation of water, it is very
complicated to apply the usual finite difference scheme. According to van
der Lijn (1976), this difficulties can be overcume by introducing new
transformed space coordinate described below, in which the boundary of
the drop can be immobilized during drying.
where c, is tlic concen~ratiunof thc dissolvcd solid ill tlle drop. Physically,
x Ineslis the Inass of the dissolved solid inside a spllcre of the radius r.
Being substituted Eq.(8) instead of r in Eq.(5), finite difference procedure
was used to solve the fundamental -drying equations.
FLAVOR LOSS ON SPRAY DRYING
A good taste and flavor contained in the spray dried powder are the
most important quality demanded by consumers. The smelling of food is
originated by many kinds of flavor components, which have commonly high
relative volatility with respect to water. Therefore, they can be easily lost
on the spray drying.
Thijssen et al. (1968) proposed the "selective diffusion theory" to

expIain the mechanism of the flavor loss during drying. The concept is
based on the fact that the rates of the transfer of water and the flavor
component in the liquid food are not equal but depend strongly on the
moisture content of the drying medium.
Matlleniatical formulations of' the selective dil'l'usion concept have
been done by several workers(Chandrasekaran and King, 1972; Kerkhof
and Schoeber, 1974; Furuta et a/., 1983) on the basis of the diffusion
equation of the ternary system. A drop is assumed to be dried in an air of
temperature T,, as shown in Fig. 3. In addition to the assumptions made in
the previous section, it is assumed that the concentration of the flavor is
extremely low compared with water and the solid concentration. Then, the
equations of change of water and. the flavor can be formulated as follows:
where D, and D, are the diffusivities of water and the flavor, respectively.
in Eq.(lO) can be estimated by D, and D, as
The cross diffusivity RWQ
follows:
where Hais the modified activity coefficient of the flavor and can be
defined as follows:
wliere A, is the activity coefficient of the flavor.

Since the concentration of the flavor is extremely low, the equation
of change of the drop temperature is the same as Eq.(7). The initial and
the boundary conditions of the water are the same as in Eq.(8). For the
flavor, the initial and boundary conditions are as follows:
where k, is tnass transfer coefficient of the flavor vapor. The same

procedure is needed to soIve Eqs.(lO) and (11) as fnentioned in previous
section.
'TRAJECTOItY OF DROP IN DRYING CIIAMBER
The estimation of the trajectories of drops in spray dryer is

important to design the inside of the spray tower. The wrong estimation
must be resulted in the adhesion of undried particles, so that the product
quality is lowered by the thermal degradation of the heat sensitive
substances. Several methods have been proposed to estimate the drop
tn~jcctoryin tlie spray tower. The movement of a drop can be estimated
by solving the kinetic equation of motion, which is derived by the
momentum balance between the drop and the surrounding air. Since the
mass atid size of the drop in the sprily tower cllanges on drying, drying
equation described in previous section should be also taken into account
FURUTA, HAYASHI, AND OHASHl
Pressure nozzle
angle
/
Y '\
Drop
Fig. 4 Two Dimensional Motlon of a Drop.
for t l ~ cc;~lculation. Though several co~nbinationscan be considered

bctwccn the spray nozzle type and the flow pattern of the drying air, two
typical examples are discussed in the following.
Orie L)in~cnsionalDown Stream of Air and Sprayed Cocurrently by a

Prcssurc Nozzle
As shown in Fig. 4, the feed liquid is sprayed cocurrently downward

into the air stream with the sprayed angle a. The coordinate x and y are
defined in the horizontal and vertical downward direction from the exit of
the orifice of the nozzle, respectively. The motion of the drop can be
described by the following two-dimensional simultaneous equation,
where % and u, are the velocity of the drop in x and y directions, u, the
downward air velocity, u, the relative velocity of the drop, c, the drag
coefficient, and p, and p, the density of the drop and air, respectively.
Since the drag coefficient c, is a function of the particle Reynolds number
Re, (= D,,p,u,/~,), Eqs.(l4) and (15) should be solved by a numerical
nleillorl, such as the Runye-Kutta method. Some empirical correlations of
c, wit11 Re,, are suggested :
Kaskas' Correlation 11964)
Ihme el 01's Correlation (1972)
Figure 5 shows calculated examples of the drop trajectories for a few drop
diameters and sprayed angles a when u, = 0 and p i = 1300. The
discharged velocity of the drop ui is varied from 70 to 140 m/s.
Motion or n Drop Sprnyed by the Disc Ato~aizerin One Dimensionnl

Dow~lrvnrdAir Flow
The nlotio~iof the drop sprayed by the disc atomizer into the air is in
general three dimensional. Figure 6 illustrates the schematic description of
the motion of the drop, whose velocity components in cylindrical coordinate
are u,, u, and u, in radial, peripheral and vertical downward direction,
respectively. The equations of motion of the drop in each direction are
Sprayed angle
= 70'
= So'
Fig. 5 Trajectory of Drop from Pressure N o d e in Gravilatlonal Field.

D i s . : T \ ; . y ~ ~ ~
atomizer
'-'z
I
Fig. 6 Motlon of a Drop from Disk Alomizer.
derived as follows:
where u,, is the resultant velocity of the drop relative to uf and r(dq/dd)
and 2u,(dq/dO) are the centrifugal and Coliori's acceleration, respectively.
Tlie initial velocity can be postulated as follows:
where D, is the diameter of the disc and n is the rotational speed. The
FURUTA, HAYASHI, AND OHASHI
, Nozzle
Flg. 7 Oeslgn Model of Spray Tower.
IZu~ige-Kuttamethod can be applied to numerically the siniultaneous

equation, Eqs.(lS) - (20).
dill'cre~~tirtl
EXAMPLES OF CALCULATION
Simulntion of Drying maltose Drup Containing Crystals of P-Msltose
This example provide a simple method to predict the product

moisture content by the spray drying of maltose solution containing some
crystals of P-maltose.
Heat Balance for S ~ r a vChamber: Let's consider a circular spray chamber,
in which a pressure atomizer is set at the top center of the tower, as shown
in Fig. 7. The drying hot air is supplied to the chamber from the ceiling,
and flows axially downward through the tower. For simplicity of
calcula~ions,following assumptions are made:
a) The air flows through the chamber in plug flow.
b) The shrinkage of drop is negligible on drying.
c) The heat loss from the chamber can be negligible.
The cll;ilnber is divided into small sections (height AZ) for the heat
c . atornized drops have a size distribution which is classified
b ; ~ l i ~ t l ~'I'llc
illto i groups. The drying air flows i111othe section at temperature TI,, and
Icavcs at T,,",,. The flow ratc of the drying air is G,. If the mean residence
tilile Ui and the drying rate .Ii of the i-111 group of the drops are known, the
lleat I,:ilar~cein the small section in Fig. 7 is as fol1ow:
whcre C,,is the specific humid heat capacity of the air and f, is the total
dry solid Inass of the i-th group of the drop. The sensible heat of the drops
is ricglcctcd in the lieat bala~lceequation. In order to calculate TI,o,,
iteratively I,y Ec1.(22), tlic residence time 0, and the drying rate Ji are
nccess;lry.
Residerice Time Bi: Because the trajectory of the drop can be assumed as
two dimensional, the residence time Oi, which is the time interval required
for tile drop to travel the distance AZ, can be estimated by numerical
calcul;~tionof Eqs.(l4) and (15). Rulige-Kutta method was applied for
ci~lculiitions.
13rvi11cI h t e of Dron Ji: The drying rate of the single drop of maltose slurry
was ensured wit11 the equipment wllich Furuta et al. (1983) used for the
ol' the drying of a single drop. Tllougli tile practical drop size in
resei~rct~
spray dryer is less than 100 pm, the d r y i ~ ~equipn~ent
g was limited to the
cJrol, larger than 1.5 mm diameter. Therefore, it is necessary to convert the
drying rate of such a large drop to that of the practical size of the drop.
Substituting the following new time and space coordinate variables
into Eqs.(4) and (7),
one can re-arrange these equations as follows:

T l ~ cdrying rate Ji can be calculated as:
It can be concluded from Eqs.(24) - (2G) that the drying rate can be
correlated by a new time variable O/R? for the different diameter of drops.
Figure 8 shows the drying curves of drops of three different initial
diameter. The time course of the moisture content ratio (the ratio of the
moisture content at time 0 to the initial moisture content), wdw,,,, are
correlated well with a single curve by the time variable if hRo is
constant. At the low Reynolds number of particles (Rep), hRo has a
constant value because the Nusselt number is constant at low Reynolds
number. The sprayed drop are small enough to till with this condition.
The drying rate of the practical size of drop can be obtained by the
graphical differentiation of Fig. 8. Figs. 9 and 10 show the effect of the
initial crystal content and the temperature of the air on the drying rate of
the drop. These two figures were used for calculation.
Results of the Simulation: Simulation of the moisture content of maltose
drop and the change of the drying air temperature were performed for the
Fig. 8 Drying Curve of Drop by Reduced Time Variable.
wd ( kg-walerlkg-solid 1
Flg. 9 Effect of Crystalllnily on Drylng Rate.

( kg-walerlkgsolid
Fig. 10 Effect of Temperature on Drylng Rate.
Table 1 Condillons of Spray Drops.
Initial condition of sprayed drop: wd,O = 0.515, K~ = 0.43

Feed rate of maltose slurry: 2000 (g-dry solid/sec)
Product moisture content of drop: 0.262
Distribution of sprayed drop diameter:
mean diameter (pm) weight fraction ( - )
254 0.523
178 0.337
127 0.120
89.5 0.020
Table 2 Cornparlson between Experlmenls and Calculation of Drylng Drops

In Spray Dryer.
Vertical Evaporation Rate (g/s) ~oisture Tf Tf

Position 89.5 127 178 254 Cantent Estimated Measured
(m) tw) (-1 ( 'CI ("3
0 0 0 0 0.515
0.457 0.828 0.213 0.089 0.495
0.092 0.894 1.957 0.510 0.449
0.017 0.329 1.174 1.264 0.410
0.267 0.708 1.013 0.384
.0.431 0.922 1.495 0.347

0.308 0.493 0.916 0.325
0.404 0.645 0.310
0.382 0.516 , 0.298
0.673 0.852 0.298
spray dryer of 3.8 m diameter and 16 m height. Table 1 shows the initial
condition of the maltose solution and the distribution of the drop diameter.
The drops were divided into four groups, in each of which the mean
diameter was used for calculations of the drop trajectory and the drying
rate. Calculation steps are as follows:
a) The spray dryer was divided axially at 1 m interval.
b) The mean residence time in the section was calculated by
Eqs.(l4) and (15).
c) The outlet air temperature in the section was postulaled. The
niean temperature of Ttin and T,,, is set to the air temperature
in this section.
d) From Figs. 9 and 10, the drying rate of t11c drop was estimated.
The interpolation was used fur the calculation.
e) TfsOu,
was calculated by Eq.(22) and was compared with the old
one. If the relative deviation of T,,o,, is larger than 1%,go back
to step c), otherwise go to step b).
Table 2 shows the comparison between the measurement and the
simulation. For the product moisture content, the calculated result is in-
Table 3 Operatlonal Conditions of Spray Dryer.
Diameter of d r y e r : 2 . 2 (m)
Height of d r y e r : 4 (m)
Disk d i a m e t e r : 84 (mm)
Wheel s p e e d : 9000 - 20000 (rpm) '
Air f l o w r a t e : 60 (m3/min)
A i r temperature: T f , j . n = 4 5 3 (K),
T f , c u t = 3 6 3 (K)
Feed r a t e of l i q u i d : 1 5 ( k g / h r )
good ilgrcernent with the measurement. However, the air temperature is

clui~edil'l'crerrt with the experiment. This means the air in the spray dryer
flows it] the ititerri~cdiatestate between the plug fluw and the perfect
nrixirtg.
Estimation of ~roduct'sMoisture Content by Spray Drying
The final moisture content in the spray dried powder of HVP (an
amino acid seasoning) was estimated on the basis of the diffusion equation
-
(Eqs.(4) (7)) in combination with the drop trajectory in the dryer
(Tsujimoto ef al., 1986). To obtain the functional relationship between the
moisture diffusivity D, and the moisture content, the drying experiments of
a sit~glcdrop were performed with the same apparatus used by Furuta et
ol. (1983). The formulas of the equation for D, and the activation energy
AE are as follows:
= ex~(al + u2/(43 + w~)) (27)
U
1
0.10 Estimated wdo=0.29
the drop diameter distribution
- ,,,1
u
$'
3
-g
.-
Estimated wd0-0.29 A
lhe mean drop diameter
t h i / I
0 V'VJ
U
50 100 150 200

Initial drop diameter (urn)
Fig. 11 Estlniation of Product Moisture Content with the lnttial Drop Diameter.
where a's and b's are the fitting parameters. The Arrhenius equation was
assumed to estimate the tenlperature effect. The operational conditions of
the spray dryer are listed in Table 3. In calculation, the air temperature
and the humidity are chosen at constant value, which was calculated by the
heat balance of the dryer. Figure 11 shows the relation between the initial.
di;~n~eter
of the drop and the tnoisture content of the product powder. The
scrlicl line is tile calculated result by taking into account of the distribution
ol' drtq) diameter, while the cl~irin-dottedline is the value calculated by
using the mean diameter of 111edrop. The experimental results are in good
agreenlent with the solid line. This nleans that lor sirnulation it is
ilnpurtnnt to consider tlre distribution of the drop diameter.
Sit11ul:ilion or Acctcrtie Relenlic~nin Spray Ilryer
Tsujirnoto et al. (1984) calculated the retention of acetone in the

spray dryer. The simulation was based on the diffusion equation of Eqs.(9)
A 100 I
0'
C
.-0
-?!
C
aJ uf ~ 1 . 4mls Calculation
(P,= 40.3pm )
0
-
C
0
al
U
10- -
Q
I I P
0.1 0.3 0.5

lrlitial moisture content of drop (-1
Flg. 12 Esllmallon of Acetone Retention In Relation to the Initial

Concentration.
- (13) combined with the two dimensional equation of the drop movement.
Simulation was performed on the drop of the mean diameter. All the
physical properties were referred fruln the studies by Kerkhof (1975) and
Furuta ef a/. (1983). The si~nulationof the acetone retention is quite in
good agreement with the experiments as shown in Fig. 12. The feed liquid
in Fig. 12 contains 1% gelatine, because of avoiding the turbulence inside
the drops on atomization. As pointed out by Kieckbusch and King (1980)
and Tsujirnoto er al. (1984), a large loss of the flavor was found in the
vicinity of the pressure nozzle, so that the flavor retention in the product
powder could not be predicted from the result of the single drop
performed by Furuta ef al. (1983). The excess loss of the flavor was
supposed to result from the turbulence generated in the conical sheet of
the feed liquid. To prevent from the excess loss, Tsujimoto ef al. (1984)
recommended to add a small amount of gelatine in the feed liquid, and
Zakarian and King (1982) suggested to mix an oil (e.g. peanut oil) to
emulsify the flavor component into the oil phase.
NOMENCLATURE
A, :activity coefficient of flavor (-1

C,, :specific heat capacity of humid air (JIK kg-dry air)
C,, :heat capacity of drop (J/K)
C, . :specific heat capacity (JIK-kg)
c :mass concentration (kg/m3>
c, :drag coefficient (-1
D, :blade diameter if"'
D :difi'usivity (m 15)
D,, :cross ~liffusivityof water and flavor (m2/s)
Dl, :drop or article dianictcr (m)
Dp :meal1 11rop diameter (m)
d, :orifice di;lmeter (m1
AE :activatio~~ energy ol dirl'usivity (Jlmol)
F :Inass feed rate (kds)
Go :flow rale of the dry air (kg-dry airls)
y :acceleration. of gravity (m/s2)
Ha :modified activity coefficient (-1
A w :heat of evaporation of water Ins)
h :heat transfer coefficient (J/m .s.K)
Ji :drying rate of the i-th group of the drops (kg/kg-dry solid)
j, :evaporation rate of water (kdrn2.s)
k, :mass transfer coefficient of flavor vapor (kg/mz.s.Pa)
k :mass transfer coefficient of water vapor (kg/mz.s.Pa)
L :length of wet peripheral of the blade (m)
mi :dry solid mass of the i-th group of drops 0%)
N :number of blade (-1
n :rotational speed of disc blade (rpm'
Q :volume feed rate (m3/s)
p :vapor pressure (Pa)
R :radius of drop (m)
r :radial coordinate (m'
Re,, :Reynolds number of drop or particle (-1
Si :inlet section area of insert core (mZ)
u, :relative velocity (m/s>
TI :temperature of air (K or QC)
T, :temperature of drop
' (K or 0C)
u, :x-directional velocity drop (m/s'
u, :y-directional velocity drop (m/s>
uf :velocity of air \mls)
v,,, :partial specific volume of water (m 1%'
w, :lrroisture content (dry basis) (-1
AZ :height element
a :spray angle
1' :I'ccd rate per length of wet peripheral of the blade
0 :time
K :crystallinity
p :viscosity
p :c!ensity
p', :density of water
a :surt';lce tension
<subscript>
a :flavor
b :values at the bulk of air stream
d :drop
f :air
i :values at the interface
I :liquid
s :solid
w :water
0 :initial value
REFERENCES
1. Turner G.M. and Moulton,'R.W., 1953, Drop-Size Distributions from

Spray Nozzles, Chern. Eng. Progr., 49, pp.185-196.
2. Isl~iokil,Y., 1964, Effect of Spraying Conditions on Drop-sizes of
Coricentrated Milk, Kagaku Kogaku (in 'Japanese), 28, pp.52-58.
3. Friedrn;ln, S.J., Gluckert, F.A. and Marsllall, Jr. W.R., 1952, Centrifugal
Disk Atomization, Chem. Eng. Progr., 48, pp.181-19 1.
4. M;rsters, K., 1972, Spray Drying, Leonard Hill Books, London, 668 p.
5. King, C.J., 1988, Spray Drying of Food Liquids and -Volatiles Retention,
pp.147-162, in S. Bruin (ed.), Precancentration and Drying of Food
Materials, Elsevier, Amsterdam.
6. King, C.J., Kieckbusch, T.G. and Greenwald, C.G.,1954, Food-Quality
Factors in Spray Drying, pp.71-120, in A.S. Mujundar (ed) Advances in
Drying vo1.3, Hemispl~erePubl. Co., New York.
7. Kerkhof P.J.A.M. and Schueber, W.J.A.I.I., 1974, Theoretical Modelling
of the Drying Behaviour of Droplets in Spray Dryers, pp349-398, in A.
Spicer (ed) Advances ill Preconcentration and Dehydration of Foods,
Applied Scientific Publisher Ltd., Londou.
8. Furuta, T., Tsujimoto, S., Okazaki, M. and Toei, R., 1983, Effect of
Drying on Retention of Ethanol in Maltodextrin Solution During Drying
of ;I SingIe Droplet, J. Drying Technol., 2, pp.311-327.
9. 1-ijr~,van der, 1976, Simulation of Heat and Mass Transfer in Spray

D~yir~g, PhD Thesis, Agricultural University of Wageningen,
Ncll~crl;~nds, 87 p.
10. 'l'l~ijssen I-I.A.C.nncl Rulkens, W.H., 1968, Retention of Aroma in
1)1-yi11g 1:ood Liquid, De Illgc~~ieur, 80 (C1145-56).
I I. I<cr.kliot'I'.J.A;M., 1975, A Qualltitativc Skucly ol' the Efl'ect of Process
V;~l.iaOlcson tllc Ilcle~~tioti of' Volatile 'l'racc Co~rlponentsin Drying,
I'l~l) 'l'llcsis, .Eindllovc~lUrliversity of' 'l'ccl~~~ology,
Netherlands, 138 p.
12. Knsktls, A., 1964, Diplomarbeit, Technishe Universitat, Berlin, (obtained
I'ro111Reference 7).
13. Ill~l~e, F., Schmidt-Traub, H. and Brauer, H., 1972 Theoretische
Url~ersuchunguber die U~nstrijrnungund den Stroffubergang an Kugeln,

Chcn~.Ing. Tech., 44, pp.306-313.
14. 'l'sujinloto, S., Nishikawa, N., F u r ~ ~ iT., a , Okazaki, M. and Toei, R.,
19H4, Volatile Lass in Spray Drying, pp.397-402, in R. Toei and A.S.
Mujundar (ed) Drying '85, Hemisphere Publ. Co., New Yark.
15. Tsujimoto, S., Tachibana, T., Ohkubo,,Y. and Furuta, T., 1986,
Es~i~ni~tion of Drying Characteristics in Spray Drying. Proceedings of
World Congress I11 of Chemical Engineering, Tokyo, pp.592-595.
16. Kicckbusclr, T.G. and King, C.J.,1980, Volatiles Loss during
Alociiization in Spray Drying, A.1.Ch.E Journal, 26, pp.718-725.
17. Z;~kilria~i,'J.A. i~ndKing, C.J., 1982, Vol;ltile Loss in the Nozzle Zone
durillg Spri~yDrying or E~nulsions.Ind. Eng. Chern. Process Des. Dev.,
21, j)l>.lU7-113.

Criteria for Designing Food Spray Dryers

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This article was downloaded by: [Yale University Library]

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Drying Technology: An International Journal

SOME CRITERIA OF SPRAY DRYER DESIGN FOR FOOD

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SOME CRITERIA OF SPRAY DRYER DESIGN FOR FOOD LIQUID

Takeshi Furuta, Hiromichi Hayashiq and Tetsuya Ohashis

Department of Biotechnology, Tottori University

Key words and Phrases: spray dryer; drying of drop; atomization;

A wide variety of spray dried foods are displayed on the shelves in

Copytight 0 1994 by Marcel Dekkcr. Inc.

reconstituted from powder to I~quid. Therefore, it is important to select a

It is technologically common sense that as the surface area of

temperature. Usually, atomized liquid is in a diameter of 10 - 200 pm in

amounts of water, the temperature of the material dried is said to be equal.

components such as albumin, globulin, fish protein that are vulnerable to

wall and scorcl~edpowder due to tocnl ovrrl~eat,wl~ichdeteriorates the

Spray Pressure Nozzle Type

Figure 1 shows the internal structure of spray pressure nozzle. The

Flg. 1 Deslgn Feature of Pressure Noale.

tension of solution. Turner and Moulton (1953) and Ishioka (1964)

Rotary Disc Type

D R Y I N G EQUA'I'ION OF DROI' IN Sl'MY DRYER

(a) Vane Wheel (b) Steam Swept Wheel

Flg. 2 Spray Mechanism of Rotary Dlsc Atomizer.

Flg. 3 Drylng of Drop 111 Alr Stream.

has several important inlluences on the drying process of drops: i) due to

b) No volume contraction takes place upon mixing. Consequently

where D, is the dillusivily of the water.

where v, is the partial specific volume of water.

strong dependence of D, on the moisture concentration and the

FLAVOR LOSS ON SPRAY DRYING

Thijssen et al. (1968) proposed the "selective diffusion theory" to

wliere A, is the activity coefficient of the flavor.

where k, is tnass transfer coefficient of the flavor vapor. The same

'TRAJECTOItY OF DROP IN DRYING CIIAMBER

The estimation of the trajectories of drops in spray dryer is

Fig. 4 Two Dimensional Motlon of a Drop.

for t l ~ cc;~lculation. Though several co~nbinationscan be considered

Orie L)in~cnsionalDown Stream of Air and Sprayed Cocurrently by a

As shown in Fig. 4, the feed liquid is sprayed cocurrently downward

Kaskas' Correlation 11964)

Ihme el 01's Correlation (1972)

Motion or n Drop Sprnyed by the Disc Ato~aizerin One Dimensionnl

Fig. 5 Trajectory of Drop from Pressure N o d e in Gravilatlonal Field.

Fig. 6 Motlon of a Drop from Disk Alomizer.

Flg. 7 Oeslgn Model of Spray Tower.

IZu~ige-Kuttamethod can be applied to numerically the siniultaneous

Simulntion of Drying maltose Drup Containing Crystals of P-Msltose

This example provide a simple method to predict the product

one can re-arrange these equations as follows:

T l ~ cdrying rate Ji can be calculated as:

Fig. 8 Drying Curve of Drop by Reduced Time Variable.

Flg. 9 Effect of Crystalllnily on Drylng Rate.

Fig. 10 Effect of Temperature on Drylng Rate.

Table 1 Condillons of Spray Drops.

Initial condition of sprayed drop: wd,O = 0.515, K~ = 0.43

Table 2 Cornparlson between Experlmenls and Calculation of Drylng Drops

Vertical Evaporation Rate (g/s) ~oisture Tf Tf

.0.431 0.922 1.495 0.347