Operation and Maintenance Tips for Spray Dryers in Dairy Processing
OPERATION AND
MAINTENANCE OF SPRAY
DRYERS FOR MILK POWDER
Dairy Process Engineering (DTE – 221)
Dr. Jahangir Badshah
University Professor-cum-Chief Scientist
Dairy Engineering Department, SGIDT, Patna
(Bihar Animal Sciences University, Patna)
PREPARATIONS REQUIRED
UTILITIES AND SERVICES REQUIRED
ELECTRICITY
WATER
COMPRESSED AIR
STEAM AT REQUIRED PRESSURE FOR AIR INLET
TEMPERATURES OF 180-200° C ( 12 – 15 KGF/CM
2
)
CLEANING & SANITIZATION OF DRYING PLANT
PROPER SETTING OF ATOMIZER, AIR HEATER, FEED PUMP
AND AIR DISPERSING VANES IN DRYING CHAMBER
PROPER LUBRICATION OF ATOMIZER (DISK TYPE) OR
NOZZLES SETTING AND REPLACEMENT OF WORN OUT
NOZZLE HEADS
PROPER FUNCTIONING OF INSTRUMENTS AND QUALITY
CONTROL LAB FOR TESTING MOISTURE CONTENT OF
POWDER
START UP PROCEDURE FOR SPRAY
DRYING PLANTS
CHECK FOR PROPER CONNECTIONS AND CLOSING OF ALL
JOINTS IN CHAMBER AND CYCLONE SEPARATORS
OPEN THE CHAMBER DOOR AND START THE EXHAUST FAN AND
COOLING AIR FAN
START THE SUPPLY FAN AND CLOSE THE CHAMBER DOOR AND AIR
SWEEP DOORS.
ADJUST THE DAMPER IN EXHAUSR FAN TO KEEP SLIGHT VACUUM
OF 7-10 MM HG IN DRYING CHAMBER ON EQUILIBRIUM WITH AIR
VELOCITY OF APPROX. 5 TO 10 m/s.
START THE ROTARY VALVES, VIBRATING DEVICE, AIR CONVEYING
FANS
START THE ATOMIZER, IF CENTRIFUGAL DISK TYPE BEFORE
STARTING POSITIVE DISPLACEMENT LOBED IMPELLER PUMP.
ADMIT STEAM FOR HEATING THE FILTERED AIR AND WHEN THE
OUTLET AIR TEMPERATURE IS RAISED TO 85 TO 100°C, THE FEED
PUMP IS STARTED AND WATER IS FED TO THE ATOMIZER.
CONTROL THE WATER INLET FLOW RATE SO THAT THE AIR INLET
TEMPERATURE IS ADJUSTED TO AROUND 95-100° C.
START UP PROCEDURE FOR SPRAY
DRYING PLANTS
When the outlet air temperature is raised to 190 – 200°c,
switch over to concentrate (45- 50% TS).
Control the mass flow rate of concentrate to adjust outlet air
temperature to 90 -95°c. Higher air outlet air temperature
means low moisture in powder. This is due to low mass flow rate
of concentrate. Increasing flow rate of concentrate means
decrease in outlet air temperature and increase in moisture
content of powder.
The outlet air temperature should be continuously monitored to
control uniform quality of powder either manually or
automatically using servomotor to change the feed rate
automatically.
SHUT DOWN PROCEDURE FOR SPRAY DRYING PLANTS
Change over to water from product. Continuously reduce the feed water to
maintain the air inlet temperature not lower than 120-150° C to avoid soiling
in the chamber.
Close the steam valve of air heater. When the air inlet temperature comes
down to about 120-150°C stop feed pump.
Open the drain cock provided on feed line to the atomizer.
Stop the atomizer.
Open the door and hook it to prevent complete closures of the door.
Stop the air supply fan and cooling fan.
Stop chilled water to the powder cooling chamber.
Allow air sweeping of the chamber.
When all the powder is carried out of the plant, the exhaust fan, conveyor fan
and rotary valves are stopped.
Close the chamber door and dampers on the air ducts.
It is important that when the exhaust fan is started without running supply
fan, the chamber door should be kept opened otherwise it will damage the
chamber lining.
Operational Problems and Remedial measures in spray dryer
Improper spray pattern
Erosion of Pressure Nozzles
Plugged atomizer should be
cleaned.
Reducing the high
concentration of concentrate
which may clog or chock the
nozzles.
Very high pressure or low
pressure in Nozzle atomizer
and very high or low speed in
disk atomizer.
Feed containing high foreign
particles or high concentration
Cavitations due to high feed
temperature and air leakage
Too high atomizer pressure
Operational Problems and Remedial Measures
Incomplete drying and high
moisture content
Low moisture in powder
High Feed rate and low air
outlet temperature. Reduce
feed rate and increase outlet
air temperature.
High air inlet humidity and
incorrect spray pattern
Low pressure or low speed
Increase flow rate to reduce
outlet air temperature.
Fine atomization due to
diluted feed
High pressure or speed.
Operational Problems and Remedial Measures
Burnt powder particles.
Lumpiness in Powder
Dusty air exhaust and
higher stack losses
Deposition on atomizer or
dryer wall
Air temperature too high, adjust it.
Improper and delayed cooling of
powder
Excessive moisture in powder.
Insufficient and slow cooling of
powder.
Too fine atomization.
Increased load on separation.
Insufficient powder separation
High air outlet temperature
Coarse droplets
Incorrect spray pattern
Incomplete drying
Air dispersion vanes wrongly set.
Thank You
ejazbadshah@gmail.com
This guide covers the essential operations and maintenance procedures for spray dryers used in the production of milk powder. It includes preparation requirements, start-up procedures, and shutdown steps for ensuring optimal performance and quality control. Key aspects such as utilities, services, setting of equipment, and temperature control are highlighted to facilitate efficient processing. Proper maintenance, cleaning, and monitoring are essential for the smooth functioning of spray drying plants.
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Presentation Transcript
OPERATION AND MAINTENANCE OF SPRAY DRYERS FOR MILK POWDER Dairy Process Engineering (DTE 221) Dr. Jahangir Badshah University Professor-cum-Chief Scientist Dairy Engineering Department, SGIDT, Patna (Bihar Animal Sciences University, Patna)
PREPARATIONS REQUIRED UTILITIESAND SERVICES REQUIRED ELECTRICITY WATER COMPRESSEDAIR STEAM AT REQUIRED TEMPERATURES OF 180-200 C ( 12 15 KGF/CM2) CLEANING & SANITIZATION OF DRYING PLANT PROPER SETTING OF ATOMIZER, AIR HEATER, FEED PUMP ANDAIR DISPERSINGVANES IN DRYING CHAMBER PROPER LUBRICATION OF ATOMIZER (DISK TYPE) OR NOZZLES SETTING AND REPLACEMENT OF WORN OUT NOZZLE HEADS PROPER FUNCTIONING OF INSTRUMENTS AND QUALITY CONTROL LAB FOR TESTING MOISTURE CONTENT OF POWDER PRESSURE FOR AIR INLET
START UP PROCEDURE FOR SPRAY DRYING PLANTS CHECK FOR PROPER CONNECTIONS AND CLOSING OF ALL JOINTS IN CHAMBERAND CYCLONE SEPARATORS OPEN THE CHAMBER DOOR AND START THE EXHAUST FAN AND COOLINGAIR FAN START THE SUPPLY FAN AND CLOSE THE CHAMBER DOOR AND AIR SWEEP DOORS. ADJUST THE DAMPER IN EXHAUSR FAN TO KEEP SLIGHT VACUUM OF 7-10 MM HG IN DRYING CHAMBER ON EQUILIBRIUM WITH AIR VELOCITY OFAPPROX.5TO 10 m/s. START THE ROTARY VALVES, VIBRATING DEVICE, AIR CONVEYING FANS START THE ATOMIZER, IF CENTRIFUGAL DISK TYPE BEFORE STARTING POSITIVE DISPLACEMENT LOBED IMPELLER PUMP. ADMIT STEAM FOR HEATING THE FILTERED AIR AND WHEN THE OUTLET AIR TEMPERATURE IS RAISED TO 85 TO 100 C, THE FEED PUMP IS STARTEDANDWATER IS FEDTOTHEATOMIZER. CONTROL THE WATER INLET FLOW RATE SO THAT THE AIR INLET TEMPERATURE ISADJUSTEDTOAROUND 95-100 C.
START UP PROCEDURE FOR SPRAY DRYING PLANTS When the outlet air temperature is raised to 190 200 c, switch over to concentrate (45- 50%TS). Control the mass flow rate of concentrate to adjust outlet air temperature to 90 -95 c. Higher air outlet air temperature means low moisture in powder.This is due to low mass flow rate of concentrate. Increasing flow rate of concentrate means decrease in outlet air temperature and increase in moisture content of powder. The outlet air temperature should be continuously monitored to control uniform quality of automatically using servomotor to change the feed rate automatically. powder either manually or
SHUT DOWN PROCEDURE FOR SPRAY DRYING PLANTS Change over to water from product. Continuously reduce the feed water to maintain the air inlet temperature not lower than 120-150 C to avoid soiling in the chamber. Close the steam valve of air heater. When the air inlet temperature comes down to about 120-150 C stop feed pump. Open the drain cock provided on feed line to the atomizer. Stop the atomizer. Open the door and hook it to prevent complete closures of the door. Stop the air supply fan and cooling fan. Stop chilled water to the powder cooling chamber. Allow air sweeping of the chamber. When all the powder is carried out of the plant,the exhaust fan,conveyor fan and rotary valves are stopped. Close the chamber door and dampers on the air ducts.
Operational Problems and Remedial measures in spray dryer Improper spray pattern Plugged cleaned. Reducing concentration which may clog or chock the nozzles. Very high pressure pressure in Nozzle atomizer and very high or low speed in disk atomizer. Feed containing high foreign particles or high concentration Cavitations due to high feed temperature and air leakage Too high atomizer pressure atomizer should be the of concentrate high or low Erosion of Pressure Nozzles
Operational Problems and Remedial Measures Incomplete drying and high moisture content High Feed rate and low air outlet temperature. Reduce feed rate and increase outlet air temperature. High air inlet humidity and incorrect spray pattern Low pressure or low speed Low moisture in powder Increase flow rate to reduce outlet air temperature. Fine atomization diluted feed High pressure or speed. due to
Operational Problems and Remedial Measures Air temperature too high,adjust it. Improper and delayed cooling of powder Excessive moisture in powder. Insufficient and slow cooling of powder. Too fine atomization. Increased load on separation. Insufficient powder separation High air outlet temperature Coarse droplets Incorrect spray pattern Incomplete drying Air dispersion vanes wrongly set. Burnt powder particles. Lumpiness in Powder Dusty higher stack losses air exhaust and Deposition on atomizer or dryer wall
Thank You ejazbadshah@gmail.com
