Industrial Drying and Evaporation Systems

We are one of the reputed manufacturers and suppliers of Spray Dryers which is widely used in various industrial process for particle formation as well as drying. Our offered equipment suits for the production of dry solids, agglomerate or granulate particle form from liquid feedstock in one operation. These equipment are extensively used for producing Hemical products, Ceramic materials, Detergents, soaps and surface active agents, Pesticides, herbicides, fungicides, and insecticides; Dyestuffs, pigments; Fertilizers; Mineral flotation concentrates; Inorganic and inorganic chemicals and Food products.

 

Following are the techniques that can be implemented to conduct the feed atomization:

Rotary Disc Atomization

 

In this technique, the liquid is thrown out ward tangentially at high velocities through the high speed rotating force. It helps in forming droplets or mist from the liquid that come in contact with the hot air and become dry solids, granulate or agglomerate particles.

 

Nozzle Atomization

 

In this technique, the feed solution or slurry gets atomized at heavy pressure and passes through a nozzle. The slurry turns into fine droplets and gets dried instantaneously. In atomization systems variegated airflow patterns can be possible. Apart from this, we provide various types of configurations of the equipment such as Open Loop Drying, Multi-Stage Drying and Closed Loop Drying, depending upon the process requirements.

 

Following are some of the components of the Spray Drying System:

• Drying chamber
• Powder recovery system
• Air heater
• Exhaust air cleaning systems
• Process control systems
• Atomizer
• Feed pump
• Air disperser

 

Some unique features of the offered equipment are:

• Operates efficiently in applications such as aseptic pharmaceutical processing and ceramic powder production
• Feed rates range from a few pounds per hour to over 30 tons per hour
• Operation is constant and adaptable to full automatic control
• During the entire run of the dryer powder quality remains consistent
• The equipment can be used for both heat-resistant and heat sensitive products
• The density of the product can be controlled
• Spherical particles can be produced
• Material does not contact metal surfaces until dried which reduces corrosion problems
• The feedstock can be in solution, slurry, paste, gel, suspension or melt form
• As long as they are pumped, the feedstock becomes more abrasive, corrosive, flammable, explosive or toxic
• Customization regarding the capacity is available
• Different types of spray dryers are available to meet various product specifications

We fabricate rotary dryers which are generally used in various industries, especially in the mineral industry. In mineral industry, the equipment is used for drying commodity such as clay, kaolin, gypsum, mineral sand, limestone, potash and silica sand (photo 54). This equipment is suitable for evaporating and drying of wide range of material of variegated sizes and composition. To lift, distribute and transport the material some internal lifters or flights are used. We offer co-current direct-heat rotary dryer which is the most common equipment available in the market. In this equipment, the initial heat transfer level is very high which creates a considerable drop in temperature and prevents over heating of the dryer as well as the material. Apart from this, counter current dryers that we provide are ideal for the material that need to be dried to very low moisture contents. It is further helps for the material in which last traces of moisture are hard to remove.

 

other details of the equipment are mentioned below:

• consist of a relatively long cylindrical shell
• the shell ranges from 0. 6 to 5 m in diameter and from 5 to 30 m long
• it is supported by two riding rings running on a set of rollers (rotation speed up to 25 rpm)
• the shell is slightly inclined from the horizontal and the slope enables material to move from the feed to the discharge end under gravity
• feed rate ranges from less than 1 tonne to 500 tonnes per hour
• the internal flights produce a shower, or cascade, of wet feed material through the hot gas stream
• this promotes evaporation of the moisture and breaks up lumps to produce a more uniformly dried material
• the hot air is introduced either at the feed end such that it moves in the same direction as the material (co-current) or at the discharge end such that it moves in the opposite direction (counter-current)
• while coming in contact with the highest temperature and extremely hot gas stream, the surface moisture of the wet material get evaporated
• as the wet material progresses through the dryer, heat energy is lost to the material it is drying and it leaves the dryer at a comparatively low temperature
• the moisture content can be readily controlled when the final dried product is discharged with the gas stream at its lowest temperature

 

some unique features of the equipment are:

• provides effective drying of materials with high moisture contents
• helps in handling a wide range of sizes of the materials with extended residence times
• the precision design permits highest possible drying temperatures
• drying, cooling or oxidation is possible
• high thermal efficiency

 

application

 

co-current applications :

in co-current direct-heat rotary dryer, the wet slurry comes in contact with the hottest drying gases which is supplied from an external source and the heat transfer is done by convection. This equipment find application in the production process of the following products:

• floatation concentrates
• coal/coke
• clays, phosphates
• suifilter cakes
• minerals, fertilizers
• beet pulp
• germ, stillage
• sludges
• animal feeds

 

We hold expertise in fabricating an extensive variety of fluid bed dryers which is widely used in various industries such as chemical, pharmaceutical and food (dairy) plants. These equipment are sturdily constructed and are precisely engineered for better performance. The other specifications are detailed below:

• the product flows across a perforated bed in the dryer
• hot air is blown up through the perforated bed
• it causes the product to flow in the air stream
• the beds vibrate continuously to move the product through the dryer
• batch type is provided with agitator to keep the product moving through the air stream
• fluid bed dryers may be combined with spray drying, agglomeration, or granulation systems to meet the requirements such as agglomerate or granular form to achieve good instant properties.

 

some salient features of the equipment are:

• to increase capacity or reduce bed area, the indirect heat transfer surfaces can be added
• due to reduced vapor pressure, heat sensitive materials can also be dried at temperatures lower than the boiling point
• enhanced heat and mass transfer is provided through close contact and mixing with the fluidizing gas
• closed cycle fluid bed systems are available to handle toxic products, oxygen sensitive products, or flammable solvent wet materials in which inert gases can be recycled

 

our offered equipment used to meet the following applications:

• fertilizers
• foodstuffs in powder or agglomerated form
• chemicals
• polymers and resins
• agglomerated products
• inorganic and organic chemicals

We offer to our clients a range of flash dryers that are available in various specifications. These are widely used fr drying of powders, granules and crystalline material. Furthermore, the wet material is incorporated into the system that contains a stream of hot air fetched through a drying duct. Moreover, utmost care is taken, so as to make sure that the true surface water gets evaporated from the feed. The feed materials can be processed easily with the help of the flash dryers used. In addition to this, our range of flash dryers is widely used in various application areas that are as follows:

• agrochemicals
• ceramics
• food and feed products
• pharmaceuticals
• pigments and dyestuffs
• waste products

spin flash dryer

our clients can avail from us a wide range of spin flash dryers which is immensely used for the industrial process such as drying of wet cake, slurry, paste and others which are normally difficult to dry in other dryers. Through a variable speed drive the material is fed in to the vertical drying chamber. There it is heated by air and gets disintegrated by a specially designed disintegrator, at the same time. Depending upon specific application, the heating air can be direct or indirect. At the last stage, the dry powder is collected through bag filter or cyclone separator or with an assemblage of both.

our offered equipment is used to produce some of the following products:

• amino acids
• dyes & dye intermediates
• pigments
• starch
• gluten

 

some of the salient features our flash dryers offered by us are as follows:

• dries many thermoplastic and hygroscopic products that are problematic in other designs
• produces free flowing powders in agglomerated or granulated form
  high drying efficiency and low energy costs
• produces powders having a very low content of small particles (dustless)
• direct drying with no initial diluting
• ideal for heat sensitive products as particle temperatures are kept low throughout the drying process
• drying is completed at low outlet drying temperatures, giving high energy utilization efficiencies
• available in gmp design
• continuous processing with short drying time
• pressure shock-resistant chamber for safe drying of organic products
• low operator overheads and minimum maintenance costs

Atomization Systems
We offer a gamut of atomization systems to suit various industrial drying applications
 
Rotary Atomizers
 
The rotary atomizer have wide applications in industrial drying, the main advantages are:
 

• Large quantities of material can be handled.
• Highly viscous concentrates can be handled easily .
• Various wheel designs can be designed for different powder characteristics .
• Crystalline products can be handled
• Higher solids content in the feed is possible, therefore better economy

Pressure Nozzles

Pressure spray nozzles are used for atomization of the material to be dried. The advantages of pressure nozzles can be summarized as follows:
 

• High powder bulk density could be achieved.
• Free flowing powders can be produced especially in whole milk powder.
• Comparatively lesser deposits in the drying chamber.
• Bigger sized particles can be produced .

Rotary Valves

In Pneumatic conveying systems many times ambient air is used thus providing a dual advantage, namely both conveying and cooling of the powder. In order to get the full benefit of the cooling effect a locking between the chamber outlet and the duct is recommended to prevent warm moist air from entering the conveying system. The locking is usually done by means of a rotary valve.

Hot air generator (hag)

direct fired hot air generator

in direct fired hags, the combustion chamber is enclosed in a concentric shell with suitable (refractory) lining. The fresh air from dynamically and statically balanced blower is fed to the chamber tangentially. The air envelopes the combustion chamber and absorbs the radiant heat from its surface and then mixes with completed combustion gases in a conical chamber.
the hot air, thus generated is let out from hot air generator at controlled temperature to the process. Such heating systems have very high thermal efficiency with proper insulation.

indirect fired hot air generator

the combustion is completed within the chamber. Hot gases, after complete combustion are then passed through tube heat exchanger, comprising of second & third pass.
fresh air from atmosphere is fed onto the surface of combustion chamber through a statically & dynamically balance blower. The shape of passage ensures to form an envelope on the combustion chamber to extract maximum heat, thus higher heat transfer efficiency. The air continues to pass through outer surface of heat exchanger, gaining heat & is collected at the other end of hot air generator. The generation of hot air is within minutes of its start.