Just as in evaporators is spray drying also water evaporation. This is relative easier then with evaporators, but there is a wide range of spray dryers.
There are so many different types of spray dryers, we only design and fabricate a small part of this. Often we deliver spray dryers for food, feed, pharmaceutical or (light) chemical purposes and most of them are the conventional spray dryers. Only in the conventional spray dryers there are so much possibilities that it becomes complex again. Depending products, space, energy and of course on our customers needs we design complete spray drying plants.
As Sanco Processing we fabricate complete spray drying plants, small or large. Simple to most advanced. One phase up to three phase spray drying. At one phase we dry only in the drying chamber and with three phase drying is being done in drying chamber, internal (static) fluidbed and external (vibrating) fluidized bed. The spraying can be done with a wheel atomizer or with high pressure nozzle. Gas is often used for our indirect air heaters (fuel oil, steam also). We design according the most latest standards for hygiene, air filtration, emission, heat recovery and energy saving.
Belt drying is used for products with a very high fat content, sticky and thermoplastic . As Sanco Processing we are very experienced with belt drying.
Sanco Processing delivers turn key projects for e.g. lactose drying. Our static fluidbed dryers are very sanitary with an agitator in the pre dryer.
Also we design very small spray dryers for use as pilot plant or small scale (batch) drying. 10 kg/h water evaporation with wheel or nozzle atomizing are solutions.
Various steps of air filtration in primary or secondary air are being used by us. Normally we filter the incoming air G4 and F7, later E11 or H13 when needed.
Our indirect air heaters in a range of 1.000 up to 100.000 kg/h are often heated with a gas burner, fuel oil is also used.
For spray drying temperatures of 200 °C are normal, but we also design air heaters for 400 °C.
Steam coils with condensate cooling are also much used and designed by us.
The fluidbeds we make are of a very hygienic design with a complete welded fine hole sheet. We are making the fluidbeds with different sections for drying and cooling. Of course with CIP cleaning.
Also our design of cyclones is complete sanitary with only round edges. Equipped with inspection openings and CIP cleaning (pop in pop out nozzles).
Our nozzle system is often part of the feed line of a spray dryer, mostly between evaporator and spray dryer. The system contains buffer tanks, homogenizer and high pressure pump, concentrate heating, high pressure piping and high pressure unit on top of the spray dryer. The high pressure lances with swirls and orifices can be cleaned separate.
For secondary air we design complete stainless steel boxes where we include ventilators and blowers, heating and cooling coils, air filtration on such a way that cleaning and maintenance is easy .
Air absorption of primary and secondary air is very popular at spray drying. Together with our partners we often install them for drying the air. The removal of moisture from the incoming air results in higher air temperatures, sometimes this is wanted otherwise cooling is needed.
Dust emission is very important, we design and deliver bagfilters for spray dryers, complete from stainless steel and CIP cleanable.
The possibilities for heat recovery at spray drying are various and very interesting. Spray drying is expensive in energy, and energy what can be re used is a saving. Outlet air from the spray dryer and fluegas from our indirect airheater are connected through a water circulation system which gives this energy back to the incoming air to preheat this. The saving is often big.
In spray drying there is a reasonable chance for a fire or worse an explosion. For this we deliver complete prevention, relief or suppression systems.e.
Together with partners we deliver CO detection systems by measuring (clean) incoming air and outlet air and complete automated fire extinguish systems, fail safe. This can be a combination within a CIP system or water supply system.
The suppression systems by means of pressure detectors and suppression bottles (with powder or hot water) and the relief systems by placing bursting discs on dryer chamber and bagfilter for example. Safety first.