Spray Dryer CFD Simulation
The spray dryer is used to dry liquids and convert them to dry solid powders. These spray dryers are widely used in the food, pharmaceutical, ceramic and other industries, and these dryers can deliver the final products to the desired moisture content and size. The resulting powder is removed from the chamber by separating systems such as cyclone and bag filter from hot air.
This product includes a CFD simulation and training files using ANSYS Fluent software.
There are some free products to check the service quality.
Spray Dryer Mechanism
The feed solution (slurry, paste, etc.) is first conveyed to the atomizer via a tank by means of a pump; the atomizer disperses the liquid solution as spray or liquid droplets into the dryer main compartment . On the other hand, hot air, which raises by a burner or steam heater, blows into the chamber by a fan. At this point, the liquid phase of the spray contact with hot air, so that the moisture within the droplets evaporates within a short time, leaving the powdered dry particles with the hot air out of the chamber.
Problem Description for Spray Dryer CFD Simulation
For this simulation, we use two types of continuous and discrete phases. In fact, the hot air flow, which is responsible for evaporating the moisture contained in the solution, enters the spray dryer chamber as a continuous phase and flows into the chamber (Eulerian). While a solution containing water and solid particles (Lagrangian) injects into the chamber as discrete phase. In fact, the main purpose of this simulation is to investigate the behavior of particles that flow as discrete phase in a continuous flow.
Assumption for Spray Dryer CFD Simulation
There are several assumptions to solve this problem:
The problem is STEADY.
We take the effect of the earth’s gravity into account for the spray dryer modeling, so that its value is 9.81 m.s-2.
We assume the incompressible flow, so the solution is pressure-based.
The Design Modeler software design the 3-D geometry of the Spray Dryer. The drying chamber consists of two cylindrical and conical sections. The device injects Inlet hot air and feed solution from the upper part of the chamber and the powder from the conical bottom.
In the present modeling, we use unstructured mesh. The total element number is 84047. In the inlet and outlet zones we use more accurate grid.
All files, including Geometry, Mesh, Case & Data, are available in Simulation File. By the way, Training File presents how to solve the problem and extract all desired results.
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