SPRAY DRYERS

Manufacturer of Spray Dryers

SPRAY PROCESS is a Brazilian company dedicated to the manufacture and compromised with the update and technological development to supply to our customers complete Plants Spray Dryers the most varied products of diverse segments of industries: Nourishing, Pharmaceutical, Chemical, Mining, Petrochemical.

Its partners more than accumulate 35 years of experience in the Manufacture of Spray Dryers and in Processes to make possible the Drying, guaranteeing its customers equipment to take care of the highest standards of quality.

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SPRAY PROCESS FABRICAÇÃO E COMÉRCIO DE SECADORES INDUSTRIAIS LTDAEstrada do Itaqui, 711 – Jardim Nova Itapevi - ITAPEVI – SP CEP: 06690-110 - Fone: 11 4142-5731 - Fax: 11 4205-2213
Website: www.sprayprocess.com
E-mail: sprayprocess@sprayprocess.com.br

Rotary Atomizers for Spray Dryers

"Conical Series"

Rotary Atomizers for Spray Dryers

"Standard Series"

TECHNOLOGY IN SPRAY DRYERS

The most important Commercial and Industrial Fair of Food Sector on Latin America -

SPRAY PROCESS participated in

2003 - 2004 - 2005 -2006 -2007 - 2008

-SPRAY PROCESS was on last June in the edition of the fair, which occupied two pavilions in the city of São Paulo. On Anhembi occurred Fispal Technology, and on Expo Center Norte was Fispal Food. These two events become the principal meeting place for Food sector and convergent sectors.
Fispal Technology showed the last news of technological, processing and packing sectors for food industry. Simultaneously, took place the Techno Plus - International Fair of Technology for Pharmaceutical, Chemical and Cosmetic industries, showing two new stands : Plus Lab, with accessories and equipments for laboratories, and Plus Ingredients, with raw materials.

SPRAY DRYER - ROTARY ATOMIZER

VIEW OF OURS SPRAY DRYERS

Basic Introduction to Drying Process

Some items are indispensable to obtain a complete view of ours dryers.
High drying air flow rate leads to a fast dislocation of product in the chamber, with increase of residual humidity.
Low drying air flow rate leads to a long permanence of product in the chamber, which results in a very dry powder.
High air speed leads to a good separation of product in the cyclone.
High speed of atomizer disk results in smaller particles of product.
High concentration of product results in larger particles of product.
Low concentration of product and high speed of atomizer disk result in very small particles of product, making it more difficult to obtain a good cyclonic separation.
With very small and fine particles, the extraction has to be done with manga type filters.
When the air flow rate of the Feed Pump increases and the inletl temperature remains constant, the outlet temperature decreases.
Inlet temperature is equal to air temperature that enters in the drying chamber, which is introduced through the air disperser, by a ventilator/exhaust, and encounters the pulverized product, making the vaporization. The final product (solid) is not submitted to the inlet temperature.The temperature of drying air mixed with the solvent vapors and the dry material, before entering in the cyclone, is denominated outlet temperature. This temperature is not necessarily the temperature of the dry material, which goes relatively cold, according to the residence time in the equipment. Therefore, outlet temperature can be considered the highest temperature that the final product could reach with a slow process of recovery. While the inlet temperature is controlled only by the burner, the outlet temperature is controlled by the following parameters:
- Inlet temperature- Air flow rate.- Air flow rate of Feed Pump.- Concentration of product to dry.
One of the most important points to consider in drying by atomization is the optimum difference At between the inlet temperature and the outlet temperature, which is called .
Increasing the difference At of temperature by raising the amount of product entering in the chamber and keeping the inlet temperature constant, the residual humidity of the final product will raise.
A necessary point which has to be determined to obtain a specific product is the type of air heating utilized. They are called direct and indirect air heating.
Dryer with indirect air heating utilizes the same gases of combustion, of liquid or gas fuels, to heat the drying air. This mixture contacts the product directly.
Dryer with indirect air heating can utilize any thermal source to heat the drying air. In indirect air heating can only enter atmospheric hot air and or previously filtered air.
For a correct performance of drying by spray, the dosage of product has to be uniform (not pulsing) and controlled by microprocessor constantly. The correct gradual variation of dosage makes the equipment to work in continuous periods, without eventual interruptions.

SPRAY DRYER EQUIPAMENT SCHEME

Spray Dryer Equipment Scheme

01 – Complete burner

02 – Feed tank
03 – Product filter
04 – Feed pump
05 – Feed set
06 – Complete atomizer
07 – Hot gases generator- direct
08 – Hot air duct
09 – Hot air disperser
10 – Drying chamber roof
11 – Drying chamber with inspection door
12 – Interconnecting ducts
13 – Product recovery cyclone
14 – Aspiration ventilator
15 – Chimney
16 – Vibrators
17 – Control and command panel
18 – Rotary valve
19 – Adjustable Venturi
20 – Gas washer
21 - Washer water storage
22 – Washer bomb
23 - Suporte da talha
24 - Talha do atomizador
25 – Product exit

Optionals

» Gases/effluents washer » Auxiliary atomizer » Indirect air heating» Thermal isolation» Pneumatic transport » Product double exit» Powder cooler » Explosion door » Temperature Marker» Automatization » Replacement parts» Storage chamber» Homogenizer » Instantanizer » Vacuum concentrator» Powder Collector » Etc .

SPRAY DRYERS CO-CURRENT METHOD

Consult drying process schemes.

Click on the figure to obtain the explanation.

SPRAY DRYER COUNTER CURRENT METHOD

Consult drying process schemes.

Click on the figure to obtain the explanation.

COMBINED METOD - TYPE FOUNT

Consult drying process schemes.

Click on the figure to obtain the explanation.

DRYING BY ATOMIZATION - SPRAY DRYER

DRYING BY ATOMIZATION - SPRAY DRYER

Many products utilize drying by atomization system, which maintains the physicals and chemicals characteristics of products, and even can improving these characteristics in some cases. Through a solution, emulsion, suspension or paste, there is a wide variety of products which can be dried by this system in Chemical and Food industries. Milk in powder, juices, instantaneous soups, detergents, are some examples of these products. Drying by atomization is used for preservation of food too. This simple and ultra-fast process can dry solids and soluble solids with the highest quality and with preservation of its essentials characteristics. This process offer advantages on reduction of weight and volume too.The process consists on pulverizing the fluid or fluids mixed into a chamber, which is submitted to a controlled current of hot air. This fluid is atomized into millions of individual droplets by a rotary disk or pulverizing nozzle. By this process, the contact surface area of pulverized product is largely increased, and when it contacts the hot current of drying air inside the chamber, results in a fast vaporization of product solvent, which is normally water, making frigorias in the center of each droplet where the solid is, which dries softly without thermal shock, then turning into powder, which is collected at the end.
See the process in the graphics:

ROTARY DISK ATOMIZERS

5000 liters/hour capacity atomization

SPRAY DRYERS ATOMIZERS

Model DR-15 - SPRAY PROCESS Principal technical characteristics: Using national technology, SPRAY PROCESS developed and released on the market a new atomizer by rotary disk containing last generation technology and modern design to increase atomization quality and production quantity, with more simplicity of cleaning and maintenance.
Technical description of product: In drying process by Spray Dryer with atomization by Rotary Disk, the main objective is having perfect design to control the homogeneity of the product atomization and the safety of the effective work continuity, which are primary conditions in our line of models.The capacity of this atomizer ranges from 50 liters/hour of product to pulverize to 800 liters/hour, with a concentration of 60% of dry material. These atomizers integrate a line of models which ranges from 6 liters/hour to 15.000 liters/hour of capacity of atomization.

ROTARY VALVES FOR SPRAY DRYERS

Rotary Valve, Feed

Model Inox. 80 - SPRA PROCESS Principals Technical Characteristics: Using national technology, SPRAY PROCESS developed a totally mechanized new valve, with until 5 centesimals precision, to supply customers with high standard of demanding.Inox.80 - SPRAY PROCESS can be redesigned for any required capacity.
It is made of rustproof steel AISI 304, 316, 410, 416 or Hastelloy, with jetted finishing, polished or sanitary alimentary degree.This model has capacity of 5.000 cm3 per rotation and 0,5 hp of power.
These valves belongs to a large line of models which capacities ranges from 30 cm3 per rotation, for laboratory tests equipments, to 20.000 cm3 per rotation, or according to the needs of the customer.
They are utilized in Food, Chemical, Pharmaceutical, Mining, Petrochemical industries, etc. SPRAY PROCESS Rotary Valves can feed or dose pneumatic transporters of low and medium pressure, controlling discharges of powders and granulars in Spray Dryers, silos, cyclones, manga type filters, etc., on different temperatures.



ROTARY VALVES FOR SPRAY DRYERS

SANITARY FEED PUMP

Sanitary Feed Pump (of Flexible Propeller)
Model or Series of Product: Model BDF 15 SPRAY PROCESS This product was developed according to Brazilian market's needs. It has a modern and simple design, which improves its work conditions, cleaning and maintenance, and presents excellent performance with Spray Dryers. Technical Description of Product:
Feed Pump BDF 15 SPRAY PROCESS is of positive dislocation, with constant air flow rate per rotation, obtaining a continuous and proportional flow of the product at the speed of rotation.Air flow rate ranges from 0 (zero) to 400 litres per hour, with 0,5 HP. It has inlet and outlet connections with 1" internal Npt screw; can elevate a water column into a height of 12 m. It is made of AISI 316 rustproof steel, sanitary polished alimentary degree, integrating a large product line with air flow rate ranging from 0 (zero) to 7.000 litres per hour.Furthermore, we offer high pressure propellers of Nitrile, Viton, Neoprene and CLAMP type connections.

This fluid is atomized into millions of individual droplets.

50.000 rpm

DRYING BY ATOMIZATION - SPRAY DRYER

Many products utilize drying by atomization system, which maintains the physicals and chemicals characteristics of products, and even can improving these characteristics in some cases. Through a solution, emulsion, suspension or paste, there is a wide variety of products which can be dried by this system in Chemical and Food industries. Milk in powder, juices, instantaneous soups, detergents, are some examples of these products. Drying by atomization is used for preservation of food too. This simple and ultra-fast process can dry solids and soluble solids with the highest quality and with preservation of its essentials characteristics. This process offer advantages on reduction of weight and volume too.The process consists on pulverizing the fluid or fluids mixed into a chamber, which is submitted to a controlled current of hot air. This fluid is atomized into millions of individual droplets by a rotary disk or pulverizing nozzle. By this process, the contact surface area of pulverized product is largely increased, and when it contacts the hot current of drying air inside the chamber, results in a fast vaporization of product solvent, which is normally water, making frigorias in the center of each droplet where the solid is, which dries softly without thermal shock, then turning into powder, which is collected at the end.

ROTARY ATOMIZER IN ACTION CLIC HERE

Spray Dryers with high pattern of quality.

spray dryer dr 15

spray dryer cone


Production Spray Process produces spray dryer, spray cooler, , spray closed cycle, falling film evaporator, centrifugal decanters, powder pneumatic carriers, coolers, carriers with endless screw and all auxiliary equipment for spray dryers operations.Dryers can be made in suitable measures for each customer. Furthermore, Spray process installs complete projects for any required specification.


APPLICATIONS OF SPRAY DRYING PRODUCT LIST:

Products listed below are suitable for suspended particle processing in systemInvolving atomization. The majority of product listed represent successful spray-drying Operations, but products involved in Spray cooling, and spray concentration are also included.

CHEMICAL INDUSTRY:

Plastics, resinsAB and ABS latexMelamine formaldehyde resinPhenol formaldehyde resinPolyacrylate-em ulsion-typePolyacrylonitrilePolycarbonatePolyethylenePolyvinyl acetatePolyvinyl butyratePolyvinyl chloride emulsion typePolyvinyl chloride suspension typePolyvinyl pyrrolidonePolyvinyl tolueneRubber latexSBR latexUrea formaldehyde resin

CERAMIC MATERIAL:

Aluminium oxideBeryllium oxideCarbidesCarborundumElectro-porcelainEnalmesFloor tile materialFerriteGrinding whell materialGlass powderInsulator materialJron oxideKaolinSilicon dioxideSpark plug materialSteatiteSitanatesTungsten carbideUranium oxideWall tile materialZirconium silicate

DETERGENTS and SURFACEACTIVE AGENTS:

Alkyl-aryt sulphonatesDetergent enzymesDispersing agentsEmulsifying agentsFatty alcohol sulphateHeavy-duty detergentsLight-duty detergents Mono-and dipotassium orthophosphateMono-and disodium orthophosphateNitrilo tri-acetic acid saltsOptical brightenerPhosphatesSaponineSodium lauryl sulphateTetra potassium polyphosphate

PESTICIDES:

Calcium arsenateCooper oxychlorideCuprous oxide2.4 DBA sodium salt2,4.6 TBA sodium saltDDT with filler2.4 dichloro-phenoxyacetic acidMono-methylamine saltDichloro- phenoxypropionic acidDichloro-propionic acid sodiumDimethyl-dipyridyl dichlorideLead arsenateMa n 9 a no-et h yl ene- bis-d it h I oca rbam ateMethyl-chloro- phenoxyacetic acidMenthyl-chloro- phenoxypropionic acidMenthyl-chloro-phenoxybutyric acidSodium saltSodium aluminium fluorideSodium-fluorideSodium methyl arsenateSodium penta-chlorophenolateSulphur colloidalZi nc-et hy I en e- bi s-d ith I oca rbam ateZine diethyl dithiocarbamateZinc dimethyl dithiocarbamate

DYESTUFFS, PIGMENTS:

Basic dyesCeramic coloursChrome-yellowCopper oxideCosmetic coloursDyestuff intermediateFormu lated dyestuffsFood coloursIndigo dyeIn k pigmentsInorganic pigmentsIron oxideKaolimLithoponeMilore blueOrganic pigmentsPaint pigmentsPapers coloursPlastic pigmentsSoluble ande microdisperse textile dyesTitanium dioxideWater coloursZinc chromateZinc potassium chromateZinc tetroxychromate

FERTILIZE:

Nitrogen fertilizersAmmonium saltsUreaPhosphoric acid fertilizersSuperphosphatesPotash fertilizersSewage sludgeTwo component fertilizers (N-P,N-K,P-K)Three component fertilizers (N-P-K)

MINERAL FLOTATIONCONCENTRATES:

Cooper oreCryoliteIron oreLead oreManganese oreMolybdenum oreNickel oreSilver oreTungsten ore

INORGANIC CHEMICALS:

Abrasive gritsAluminium (metallic)Aluminium chlorideAluminium hydroxideAluminium oxideAluminium phosphatesAluminium silicateAluminium sulphateAmmonium chlorideAmmonium molybdateAmmonium nitrateAmmonium phosphateAmmonium sulphateAntimony sulphideArsenic oxideBarium carbonateBarium chlorideBarium HydroxideBarium sulphateBarium titanateBauxite waste liquorBentoniteBeryllium dioxideBismuth aluminateBismuth carbonateBoraxBoric acidBoron phosphateCalcium carbonateCalcium d 1 lorideCalcium hydroxideCalcium d 1 romateCalcium hypochloriteCalcium nitrateCalcium phosphateCalcium silicatesCalcium sulphateCatalystsCementeChorme-iron oxideChromium sulphateCopper chlorideCopper oxideCopper oxychlorideCopper sulphateCopper sulphideCupric oxideCryoliteFeldsparFerric sulphateFerrous sulphateGraphiteGypsumKaolinLead zirconateLime slurryLithoponeLithium chlorideMagnesium aluminium silicateMagnesium carbonateMagnesium chlorideMagnesium hydroxideMagnesium oxideMagnesium phosphatesMagnesium sulphateMagnesium trisilicateMagnesium uranateManganese carbonateManganese chlorideManganese oxideManganese sulphateMolybdenum disulphideNickel carbonateNickel sulphidePotassium acetatePotassium bid 1 romatePotassium carbonatePotassium chloridePotassium chromatePotassium fluoridePotassium metaphosphatePotassium permanganatePotassium phosphatePotassium silicatePowdered metalsSilica gelSilicon dioxideSilicon carbideSodium aluminateSodium aluminium sulphateSodium arsenateSodium bicarbonateSodium bid 1 romateSodium bisuphate and sodium sulphateSodium bisulphideSodium borateSodium carbonateSodium d 1 lorideSodium hypode 1 loriteSodium fluorideSodium formateSodium hydroxideSodium perborateSodium phosphateSodium silicateSodium silicon fluorideSodium sulphateSodium thiosuphateThorium carbonateThorium nitrateTitanium dioxideTitanium tetrachlorideTungsten carbidePotassium nitrateUranium dioxideZinc arsenateZinc carbonateZinc chlorideZinc sulphateZirconates

ORGANIC CHEMICAL:

Aluminium stearate or triformateAmino-naphthol-sulphonic acid para-Aminosacvlic acidAmino acidAscorbic acidAmmonium di-nitro-ortho cresolBarbituric acid derivateBarium ricinoleateCalcium acetateCalcium butyrateCalcium gluconateCalcium caseinateCalcium lactateCalcium propionateCalcium saccharatesCalcium stearateCarboxymethyl celluloseChloramineChlorohexidine gluconateChloromycetine succinate-calcium saltChlorophyllCholine saltsCitric acidDicyandiamideDicydohexylphthalateDiethyldiphenylurea2,4-dichlorophenoxy-acetic acid sodiumDodecylbenzenesulphonate sodium saltEDTA saltGlutamic acidGlyoxalLactoseLysineMaleic acidMethyl acrylic acidMethyl arsenic acid-disodium sulphateMono-carbonic acidMono-ethanol aminosuphateMonochloroacetic acid sodium saltOxalic acidPara-Nitro phenolPantholtenatesPerfumesPotassium acetaldehyde sulphoxylatePotassium acetatePotassium isopropylxanthogenatePotassium phthalatePotassium bicarbonatePotassium sorbateQuinoline sulphonateSodium acetateSodium benzene sulphonateSodium benzoateSodium di-oxalateSodium dimethyl dithiocarbamateSodium monochloroacetateSodium salicylateStearic acidTartaricacidThiocarbamatesThionineUreaWaxesXanthatesZinc stearate

FOOD INDUSTRY:

Milk produdsBaby foodyButter (high fat produds)ButtermilkCaseinCaseinatesChesseCocoamilk with sugarCoffee whitenerCreamFat-fjlled milkFat-fjlled wheyHidrolysed milk productsIce cream mixMalted milkMilk replacerMixed milk productsSkim milkWheyWhey mother liquorWhey permeateWhey proteinWhole milk

EGG PRODUCTS:

Egg whiteEgg yolkWhole egg

FOOD PRODUCTS AND PLANT EXTRACT:

Artichoke extractsBeef brothBouillonCake mixesCamomile teaCereals, pre-cookedChicken brothChlorophyllCocoa mixturesCoffee-extractsCoffee-substitute extractDecaffeinated coffee extractFat flour mixturesFish proteinsFlavouringsFood colouringGarlicHip-extractLactoseLiquorice extractMalt extractMeat pureeMilk-coffee mixturePimentoPlant proteinProtein HydorlysateRennetSoup mixesTea extractWhiteners (coffeetea)

FRUIT VEGETABLES:

ApricotsAsparagusBananaBeansBeetrootCarrotCitrus fruits with fillerMangoesOnionPeachesSoft fruitsTomato

CARBOHYFRATES AND SIMILAR PRODUCTS:

Baking compoundsCorn steep liquorCorn syrupGlucoseGum ArabicMaize glutenPectinSorbitol sorboseStard 1 esSugar / gelatin mixturesSweetenersTotal sugarWheatflourWheat glutenWort

BIOCHEMICAL INDUSTRY:

Phannaceutical productsAntibiotics and mouldsBacitracinPenicilinStreptomycinSulphatiazole (selected)EnzymesHonnonesLysinePhannaceutical gumsSeraSporesTabletting constituentsVaccinesVitamins

YEAST PRODUCTS:

Brewers yeastFodder yeastSingle-cell protein (SCP)Yeast extractYeast hydrolysates

INDUSTRIES UTILIZING CHEMICALS FROM TIMBER:

Tanninsil Tannins from barkMimosa extradOak extradTannins from woodQuebracho extradChestnut extradTannins from fruitsDividivi extradMyrobalan extradTannins (synthetic)
CELLULOSE:Sulphite waste liquorLignosulphonates

OFFAL AND FISH INDUSTRIES:

Slaughterhouse produdsAnimal proteinBloodBone glueExcretaGelatinGlandsTissuesFISH

PRODUCTS:

Fish flour, meal, pulp, hidrolFish stickwater (solubles)Whale stickater stickwater