TABLE OF CONTENTS

LIST OF FIGURES.................................................................................................... 10
LIST OF TABLE........................................................................................................ 10
INTRODUCTION...................................................................................................... 12
CHAPTER 1: OVERVIEW....................................................................................... 14
1.1. Overview of Laundry Powder.......................................................................... 14
1.1.1. Concept.................................................................................................... 14
1.1.2. Ingredient Composition........................................................................... 15
a. Surfactant: LAS (Linear Alkylbenzene Sulfonate).................................. 15
b. Builders.................................................................................................... 17
c. Bleaching agent........................................................................................ 18
d. Enzyme.....................................................................................................21
e. Additive.................................................................................................... 22
1.2. Laundry Powder Drying Technologies............................................................ 23
CHAPTER 2: THEORETICAL SPRAY DRYING TECHNOLOGY...................25
2.1. Drying process..................................................................................................25
2.1.1. Definition.................................................................................................25
2.1.2. Objective..................................................................................................25
2.1.3. Principle...................................................................................................26
2.1.4. Types........................................................................................................26
a. Natural Drying..........................................................................................26
Solar drying is the use of solar energy to carry out the drying process.............26
b. Conductive Drying................................................................................... 27
2.1.5. Drying Agent, Drying Principle, Drying Regime....................................28
a. Drying Agent............................................................................................28
b. Drying Method......................................................................................... 29
c. Drying Regime......................................................................................... 29
2.2. Design Option Selection...................................................................................30
2.2.1. Drying equipment: Spray Dryer.............................................................. 30
2.2.2. Drying method......................................................................................... 30
2.2.3. Drying regime..........................................................................................30
2.3. Spray Drying Technology................................................................................ 31
2.3.1. Introduction..............................................................................................31
2.3.2. Mechanism...............................................................................................32
2.4. Main Equipment...............................................................................................33
2.4.1. Spray Nozzle - Centrifugal disc...............................................................33
2.4.2. Drying chamber....................................................................................... 35
2.4.3. Calorifer...................................................................................................36

2
 2.4.4. Cyclone.................................................................................................... 36
2.4.5. Centrifugal Fan........................................................................................ 37
CHAPTER 3: LAUNDRY POWDER MANUFACTURING PROCESS..............38
3.1. Blown Powder Formulation............................................................................. 38
3.2. Powder Properties............................................................................................ 40
3.3. Process Flow Diagram..................................................................................... 41
3.4. Process Description.......................................................................................... 42
CHAPTER 4: CALCULATION OF RAW MATERIALS..................................... 47
4.1. Product Specifications......................................................................................47
4.2. Calculation procedure...................................................................................... 47
CHAPTER 5: MATERIAL BALANCE................................................................... 55
5.1. Process Parameter............................................................................................ 55
5.1.1. Initial Parameters..................................................................................... 55
5.2. Material Balance Calculation........................................................................... 55
5.2.1. The amount of moisture removed from the material (W)........................55
5.2.2. Absolute dry material.............................................................................. 55
5.2.3. The state of ambient air........................................................................... 56
5.2.4. The state of air passing through the calorifer.......................................... 57
5.2.5. The state of air after leaving the dryer.....................................................58
5.2.6. Air Specifications.................................................................................... 59
CHAPTER 6: DESIGN OF SPRAY DRYER...........................................................62
6.1. Atomization Choice..........................................................................................62
6.2. The mean diameter of detergent powder particles after spray drying..............62
6.3. Diameter of spray dryer....................................................................................63
6.4. The cross-section area of the drying chamber..................................................63
6.5. Basic dimension of Dryer.................................................................................64
6.6. Drying time...................................................................................................... 65
6.7. Mechanical design............................................................................................66
6.7.1. Drying chamber....................................................................................... 66
6.7.2. Drying Base............................................................................................. 69
6.7.3. Drying Head.............................................................................................70
6.7.4. Bracket Lug Support................................................................................70
CHAPTER 7: ENERGY BALANCE........................................................................74
7.1. Energy balance calculation...............................................................................74
7.1.1. Heat input into the drying equipment...................................................... 74
7.1.2. Heat output from the drying equipment...................................................74
7.2. Theoretical drying process calculations........................................................... 75
7.2.1. Heat balance equation:.............................................................................75

3
 7.2.2. Common heat consumption for the drying process:................................ 75
7.2.3. Result....................................................................................................... 76
7.3. Heat loss in drying tower:................................................................................ 76
7.3.1. Heat transfer coefficient:......................................................................... 77
7.3.2. Overall heat transfer coefficient from inside to equipment wall 1.......... 77
7.3.3. The overall heat transfer coefficient from the wall to the surrounding
environment 2.................................................................................................... 79
7.3.4. The total thermal resistance of the dryer................................................. 81
7.3.5. Result....................................................................................................... 82
7.4. Actual drying process calculation.................................................................... 83
7.5. Drying agent parameter in the actual drying process.......................................84
CHAPTER 8: DESIGNING AN EFFICIENT CALORIFER................................ 88
8.1. Product specifications:..................................................................................... 88
8.2. Calculation....................................................................................................... 88
8.2.1. Heat transfer area:....................................................................................88
8.2.2. Calculate calorifer size............................................................................ 89
a. Choose calorifer size................................................................................ 89
b. Calculate the area of calorifer.................................................................. 90
c. Calculate the actual velocity of the air traveling in the calorifer............. 91
8.2.3. Calculate the heat transfer coefficient..................................................... 92
CHAPTER 9: EFFICIENT CYCLONE DESIGN.................................................. 96
9.1. Introduction of Cyclone................................................................................... 96
9.1.1. Working mechanism of cyclone.............................................................. 96
9.1.2. Safety considerations for usage............................................................... 97
9.2. Classification of Cyclone................................................................................. 97
9.2.1. Single cyclone..........................................................................................97
9.2.2. Combined cyclone................................................................................... 97
9.2.3. Cluster cyclone........................................................................................ 98
9.2.4. Water film cyclone...................................................................................98
9.3. Types of dust discharge valves for cyclones.................................................... 98
9.4. Calculation of technical parameters of Cyclone using Selection Method....... 99
a. Theoretical minimum captured dust particle diameter:..........................104
b. Theoretical Cutoff Diameter: Dust particle diameter corresponding to
50% collection efficiency...........................................................................104
c. Theoretical Collection efficiency:.......................................................... 105
9.5. Mechanical design of Cyclone....................................................................... 105
9.5.1. Material and Thickness of IIH-11 Cyclone........................................... 105
- Calculated working pressure inside the cyclone:.....................................106
- Welding method:......................................................................................106

4
 - Additional allowance due to chemical corrosion, mechanical corrosion,
and thickness tolerance.............................................................................. 106
- Thickness of body of the cyclone subjected to internal pressure:........... 107
- Stress testing of the cyclone's body based on calculated pressure after
determining the thickness of cyclone’s body:............................................ 108
9.5.2. Mechanical Calculation......................................................................... 108
a. Flange Selection..................................................................................... 108
b. Flange at dust discharge gate (Round)................................................... 109
c. Bracket lug support Selection.................................................................110
CHAPTER 10: EFFICIENT FAN SELECTION AND RESISTANCE
CALCULATION FOR CONSISTENT SPRAY DRYING PERFORMANCE... 113
10.1. Resistance calculation for consistent spray drying performance................. 113
a. The resistance force from the inlet fan to the calorifier......................... 113
b. The resistance force within the calorifier............................................... 114
c. The resistance force from calorifier to the drying chamber................... 115
d. The frictional resistance within the drying chamber.............................. 116
e. The resistance force from drying chamber to the cyclone......................117
f. The resistance force of the pipe from cyclone to the exhaust fan...........117
g. Resistance force within the cyclone....................................................... 118
h. The sudden opening resistance, sudden inlet resistance from the pipe to
the drying chamber.....................................................................................119
10.2. Calculation for choosing efficient fan.......................................................... 120
10.2.1. Push fan placed before the calorifier................................................... 120
10.2.2. Exhaust fan placed after the cyclone................................................... 123
CONCLUSION......................................................................................................... 126
REFERENCES..........................................................................................................127

5
LIST OF FIGURES

Figure 2.1: Small-scale spray drying system from SiccaDania company……...……27

Figure 2.2: Schematic drawing of a spray dryer……………………………………..28
Figure 2.3: Schematic drawing of a spray dried detergent unit…………………..….28
Figure 2.4: The structure of the centrifugal disc and the shape of the groove………29
Figure 2.5: The layout diagram of the drying medium flow and the feed stream in the
spray dryer chamber that uses a centrifugal disc spray mechanism………………….31
Figure 3.1: Formulation of a Concentrated Powder with Phosphates……………….34
Figure 3.2: Mixing Process………………………………………………………..…40

Figure 6.1: Bracket lug support for vertical equipment…………………………...…67

Figure 9.1. Structure of single cyclone…………………………………………..…..91

Figure 9.2. Basic dimension of single cyclone………………………………………97

Figure 9.3: Bracket lug support for vertical equipment………………………..…...107

Figure 10.1: Centrifugal fan……………………………………………………...…115

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LIST OF TABLE
Table 1.1: Physical property of LABSA………………………..……………………12
Table 1.2: Physical property of LAS……………………………….……………...…12
Table 1.3: Physical property of Natri tripolyphosphate (STPP)..................................13
Table 1.4: Physical property of Perborate………………………………...….….…..15
Table 1.5: Physical property of Natri Percarbonate…………………...………..……16
Table 1.6: Physical properties of H2O2………………………………...…….……….17
Table 1.7: Physical properties of SCMC………………………………….…………18
Table 3.1: Laundry Powder Formulation…………………………………………….34
Table 4.1: Weight loss during each stage…………………………………….……....43
Table 4.2: Raw Materials Added During Supplemental blending Stage……………44
Table 4.3: Raw Materials Added During Mixing Stage………………………..……45
Table 4.4: Summary of raw material weights…………………………………...…...49
Table 5.1: Summary for drying agent…………………………………...……..….…56
Table 5.2: Summary for drying material………………………………..…...….……56
Table 6.1 :Design parameters of centrifugal spray disc………………………….…..57
Table 6.2: Design parameters of chamber……………………………………………61
Table 6.3: Material Properties………………………………………………………..62
Table 6.4: Design parameters of drying bottom.……………………………….….…64
Table 6.5: Parameter for the flanges of product outlet pipe……………………….…67
Table 7.1: Summary……………………………………………………………….…81
Table 9.1: Table of technical parameters of one Cyclone IIH-11……………………96
Table 9.2: Design parameters of cyclones.…………………………..……….…….100
Table 9.3: Material Properties of Carbon steel CT3………………………………..100

Table 10.1: Parameters of II.4-70 N010…………………………………………..…119

7
INTRODUCTION
Laundry detergent is an essential product that is used daily by millions of
people around the world. The laundry detergent industry is highly competitive, with a
wide range of products available to consumers, including powders, liquids, and pods.
To remain competitive, manufacturers must continually innovate and improve their
products, focusing on factors such as cleaning efficiency, stain removal, and fragrance.
One critical aspect of laundry detergent production is the spray drying system used to
produce the final product.
Spray drying is a process that involves atomizing liquid detergent into a hot
drying chamber, which causes the droplets to evaporate and form small, dry particles.
The spray drying system is a crucial component of the laundry detergent production
process, as it enables the creation of high-quality, low-moisture products with a long
shelf life. However, the design of a successful spray drying system for laundry
detergent is a complex process, as it requires careful consideration of numerous
factors, such as the properties of the detergent, the characteristics of the dryer, and the
operational parameters of the system. The challenges facing manufacturers in
designing an efficient and effective spray drying system include balancing the need
for high-quality products with the need for cost-effective and energy-efficient
production methods.
In this report, we will provide an overall design for a spray drying system for
laundry detergent with a production capacity of 12,000 tons per year. This design
will include the selection of appropriate equipment, process optimization, and overall
design considerations required to ensure optimal performance of the system.
We also would like to express our sincere gratitude to Asso.Prof Le Thi Kim
Phung, as well as all the faculty members of the department, for their guidance and
support throughout our design project. Their expertise, patience, and willingness to
answer our questions and provide feedback have been crucial to our success in
completing this project to the best of our abilities. We appreciate the time and effort
that they have invested in our education and development, and we are grateful for the
opportunity to have worked with such dedicated and knowledgeable educators.

8
 In this short period of time, and as this is our first attempt at calculating the
system's equipment, errors are inevitable. Therefore, We sincerely hope to receive
further guidance from the teacher as well as feedback from our peers to improve the
quality.
Thank you very much.

9
 CHAPTER 1: OVERVIEW
1.1. Overview of Laundry Powder
1.1.1. Concept
Cleansing agents can be categorized into two main groups. The first group is
the traditional "soap" type, which comprises natural or synthetic fatty acids and
sodium or potassium salts. The second group, synthetic detergents, is denser and was
developed later on, but has increasingly taken over the market.
Laundry powder detergent is one of the most commonly used synthetic
cleansing agents worldwide. It was first produced in 1987 and has since become
widely recognized and used worldwide.
According to the definition, laundry powder detergent is a type of product used
to clean clothes and other fabrics. The main components of laundry powder include
cleansing agents, foaming agents, colorants, fragrances, and other additives. When
laundry powder is added to water in a washing machine, these components dissolve
and combine with the dirt and impurities on clothes to form compounds that are easily
washed away.
The cleansing agents in laundry powder work by reducing the adhesion of dirt
molecules on the fabric and forming small particles that are easily washed away.
Foaming agents help to create suds during the washing process, allowing cleansing
agents to access hard-to-reach areas on clothes. Other additives, such as colorants and
fragrances, help to create pleasant smells and colors for clothes.
Laundry powder is designed to work effectively in water, and therefore,
manufacturers of laundry powder offer products based on the hardness of the water in
the area of use. Hard water has a higher concentration of minerals than soft water, and
if laundry powder is not designed for the water's hardness level, cleansing agents may
not work effectively and may leave residue on clothes after washing.
Therefore, laundry powder is a complex product designed to provide maximum
cleaning efficiency with high safety for clothes and the environment.

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 1.1.2. Ingredient Composition

a. Surfactant: LAS (Linear Alkylbenzene Sulfonate)

A surfactant molecule consists of two parts, a hydrophobic part (insoluble in
water) and a hydrophilic part (soluble in water). These molecules are highly active in
the interfaces between air and water or oil and water.
LAS is considered a fairly good surfactant due to its low cost and versatility in
cleaning products, as it can be used in both liquid and powder household cleaning
products, as well as industrial cleaning products. It has a long-lasting cleaning
performance. Depending on the specific requirements of each cleaning product, LAS
can be included in the formulation along with other surfactants to enhance or decrease
certain cleaning properties.
❖ Property: Due to its strong acidic nature, it reacts completely with bases,
releasing a significant amount of heat. It can cause corrosion of aluminum and
copper, and release toxic SO2 gas with a pungent odor.
❖ Active Matter: The amount of active ingredient in the neutralizing product
(LAS) fluctuates between 40% to 60%, depending on the buffering capacity of
the specific type of sulfuric acid that is being neutralized.
❖ In the specific conditions of the experiment:
- Material: LABSA (Linear Alkyl Benzene Sulphonic Acid).
- LABSA is a type of sulfonic acid. Sulfonic acids are strong acids, so not only
their salts with monovalent cations but also their salts with high-valence
cations or even the free acids themselves are quite soluble in water to form
solutions with all the characteristic properties of detergent solutions. Therefore,
they can be used as detergents in hard water environments (containing Mg2+,
Ca2+ ions) and even in acidic environments.
- LABSA is neutralized with soda to produce LASNa (usually called LAS) - a
very good surfactant, with excellent foaming ability and strong cleaning
properties.

11
 Table 1.1 : Physical property of LABSA

Chemical Structure C18H29SO3H

Average Molecular Weight 326

Composition Pure LABSA: > 98%

H2SO4: ∼ 1%
Non-sulfated substance: ∼ 1%

Appearance Ivory
Gel

Density Temp. (oC) 30 40 50

Linear chain 1050 1045
1040
Branched-chain 1075 1070
1060

Specific Heat Capacity 1.6 kJ/kg.oC

Thermal Conductivity 0.13 W/m.oC

Table 1.2 : Physical property of LAS

Chemical Structure C18H29SO3Na

Average Molecular Weight 348

Appearance Off-white
High Viscosity

Density Changes with AM

Around 1000 kg/m3

Specific Heat Capacity AM % 35 40 45 50

12
 (kJ/kg.oC) cp 3.3 3.2 3.1 3.0

Thermal Conductivity AM % 35 40 45 50
(W/m.oC) λ 0.43 0.40 0.38 0.35

b. Builders
When washing clothes, the problem is often posed by the fact that the washing
water contains a high level of Mg2+ and Ca2+ ions, which can cause surface active
agents to precipitate and reduce the washing efficiency. These ions are mainly present
due to the use of hard water sources, and may also be present due to dirt or sediment
in the fabric during the washing process.
The main function of the builder is to overcome this phenomenon by chelating
with Mg2+ and Ca2+ ions to form new compounds that can dissolve without affecting
the washing process. In addition, the builder also has several other functions:
- To create an alkaline environment for washing.
- To provide a buffer effect to maintain the pH of the washing solution close to
the desired value during the washing process.
- To disperse dirt particles.
❖ Natri Tripolyphosphate (STPP)
Over the past 25 years, STPP has been present in many cleaning products
worldwide as a builder. The reason for this is that STPP has some advantages over
other builders, including
- STPP has good water-softening ability, aiding in wetting and washing fabrics.
- STPP helps control the alkaline environment of the washing water and
disperses dirt during washing. Therefore, it has an anti-redeposition effect.
- STPP has the ability to form a very stable STP-hexahydrate crystal structure,
which affects the appearance quality of the laundry powder.
Table 1.3 : Physical property of Natri tripolyphosphate (STPP)

Chemical Structure Na5P3O10

13
 Molecular Weight 368

Composition P2O5: 57.60%

Na2O: 42.20%

Hydrated molecule STP6H2O

Solubility (100g H2O) 20oC: 12.9g

40oC: 13.7g

Particle size (μm) 50 - 100

Density (kg/m3) 1150

❖ Zeolites
Since the 1970s, the trend of using zeolite as a builder in laundry detergents has
significantly increased, with zeolite A being the most commonly used.
Zeolite A has a crystal structure with many porous cavities. Thanks to this
special feature, the sodium ions contained within its structure have high flexibility and
can easily exchange with ions in hard water, especially calcium.
The main function of zeolite A is to soften washing water by reducing the
concentration of calcium and magnesium. The activity of zeolite A can be enhanced
by adding a small number of water-soluble substances called builders, which are
usually polycarboxylates.
In addition, zeolite A also helps to stabilize the whitening agents in cleaning
products.
Depending on the particle size of zeolite A, it can cause dust, so users should avoid
inhaling it. Since it is insoluble, zeolite A does not absorb moisture and does not cake.
However, the washing performance of products using zeolite A as a builder is
inferior to those containing phosphate because they are not soluble, have poor ability
to treat calcium and magnesium ions and have poor anti-redeposition ability.

14
c. Bleaching agent
Chemical bleaching agents are often used in laundry detergents to improve the
whitening ability of the detergent by removing organic color impurities on the fabric
through chemical reactions. These reactions correspond to oxidation or reduction,
which irreversibly decomposes color-forming systems. This method requires the
decomposition or transformation of color-forming groups and chromophores into
smaller and more soluble particles for easy removal.
❖ Perborate
Perborate has been used as a whitening agent in Europe for a long time. In the
1980s, the use of perborate spread to many other countries such as the United States,
South American countries, and Asia.
Perborate has a formula of NaBO3.4H2O or NaBO2.H2O2.3H2O and contains
about 10% active oxygen. The disadvantage of perborate is that it only works well at
80-100°C. At low humidity, NaBO3.4H2O gradually dehydrates to NaBO3.2H2O at
20°C. At over 90% relative humidity, NaBO3.4H2O will absorb water and become
solid.
Perborate should be stored in a dry environment, away from sunlight, and at a
temperature below 25°C. Materials containing perborate can be made of plastic,
stoneware, or materials coated with resin on the inside.

Table 1.4 : Physical property of Perborate

Chemical Structure NaBO3.4H2O

Molecular Weight 154

Appearance Crystal or powder

White in color, odorless.

Freezing point (oC) 63

Solubility (100g H2O) 40oC: 6.5g

60oC: 29.1g

15
 Hydrate NaBO3.H2O ( trên 40 )

Density (kg/m3) 720 - 800

❖ Percarbonate - Natri Percarbonate (Na2CO3.1.5H2O)

Advantages:
- Good solubility.
- High active oxygen content.
- Multifunctional: source of H2O2 and alkali.
- Non-polluting.
Disadvantages:
- Percarbonate is susceptible to moisture degradation. At temperatures above
25°C, the combination of free moisture in the air can accelerate degradation.
The heat and water vapor released during degradation can also generate
significant amounts of heat and oxygen, and in some special cases, the large
release of water vapor, oxygen and heat can occur together with the formation
of sodium carbonate. If flammable materials such as sawdust, straw, or rags are
present nearby, they can cause a fire.
- Percarbonate should be stored at low temperatures, around below 25°C, and
humidity below 60% RH in containers made of PVC, PE, glass, or stainless
steel.
- Both Sodium perborate and percarbonate cannot be spray-dried and should
only be added after the powder is blown.
Table 1.5 : Physical property of Natri Percarbonate

Chemical Structure Na2CO3.1.5H2O

Molecular Weight 1547

Purity Contains about 16% active oxygen.

Practicle size (µ𝑚) 720

16
 Density (g/l) 850 - 1050

❖ H2O2
Oxygen bleach is added to remove color impurities in LASNa. The presence of
oxygen bleach in laundry detergent not only improves its appearance but also helps to
make the detergent particles fluffy and have better flowability.
H2O2 is easily degraded into H2O and O2, especially when heated, exposed to
light, or catalyzed. Therefore, H2O2 is usually stored by isolating it from light, in a
cool place, and with the addition of inhibitors.

Table 1.6 : Physical properties of H2O2

Chemical structure H2O2
Appearance Liquid
Solubility Infinitely soluble in water

d. Enzyme
Enzymes have become one of the main components added to detergent
formulas in the past decade, for the following reasons:
- The development of concentrated and liquid detergents: enzymes are added in
low proportions but provide high efficiency.
- Changing consumer habits. Previously, people washed clothes just to clean
them. Nowadays, people also care about keeping their clothes looking new for
as long as possible, so the presence of enzymes is highly valued.
- The environmentally friendly nature of enzymes.
Enzymes are very complex nitrogen-containing compounds of proteins that act
as catalysts for various biochemical reactions. Some reactions occur in organic living
bodies, while others occur in non-living systems, such as the conversion of starch into
sugar in the alcoholic beverage industry. Since the 1960s, enzymes used in laundry
detergents have been of great interest, such as:

17
 - Protease: hydrolyzes protein-based stains.
- Lipase: acts on oil and fat stains, and hydrolyzes insoluble glycerides.
- Amylase: hydrolyzes starch-based stains.
- Cellulase: hydrolyzes cellulose-based stains.
Enzymes need a certain amount of time to work and can only function at
temperatures below 55°C; at higher temperatures, they will be degraded. Among these
enzymes, protease is the most focused on.

e. Additive
❖ Soda - Natri carbonate (Na2CO3)
Soda is used in laundry detergent production to:
- Neutralize LABSA to LASNa, and neutralize H2SO4 in LABSA.
- Act as a builder to create an alkaline environment for the hydrolysis of oil,
grease, and sweat stains.
- Soften water (by precipitating with Ca2+, Mg2+ ions to form corresponding
carbonate salts).
In commerce, soda is usually in the form of a white powder, consisting of two
types: light and heavy granules. Soda is hygroscopic and can combine with CO2 to
form NaHCO3 in the form of lumps and crystals.

❖ Natri Sulphate (Na2SO4)

Sodium sulfate is primarily used in laundry detergent as a filler to reduce costs,
but it can affect the durability of the adhesive system. On the other hand, it is a strong
electrolyte that enhances cleaning efficiency.
In commerce, sodium sulfate comes in two types: anhydrous and hydrated. The
hydrated type is used in the production of non-phosphate laundry detergents. Sodium
sulfate cakes at temperatures below 32°C.

❖ SCMC (Carboxymethyl cellulose Natri)

SCMC can disperse well in a slurry mixture in the spray drying method and is
also used in the production of non-phosphate laundry detergent.

18
 SCMC absorbs moisture from the air, so it is prone to caking. Therefore,
SCMC should be stored in a dry and cool environment.
The amount of SCMC used in laundry detergent is usually around 1-2%.
Table 1.7 : Physical properties of SCMC
Chemical structure R-OCH2COONa
Appearance White powder
Density( g/l) 400-700
Particle size( mm) 0.3-0.4

❖ Colorants, Fragrance
Fragrance, and color are usually added to laundry detergent after the mixing
stage. Choosing the appropriate fragrance is very important as it is also one of the
criteria that attract consumers.

1.2. Laundry Powder Drying Technologies

Drying laundry detergent is a crucial step in production as it determines the
quality and cost of the product. The dried laundry detergent must meet the standards
set by the state and the requirements of consumers such as the moisture content of the
finished product, fluffiness, solubility in water, cleaning efficiency, etc.
Given its importance, the choice of drying method must meet production needs.
The selection of the drying method depends on factors such as:
- Drying capacity
- Material properties, including the physical and chemical requirements of the
material being dried
- Plant characteristics: size, space
- Financial conditions of the plant.
With the development of laundry detergent and the improvement of its quality,
production technology has also evolved and improved. Some production technologies
are still in use and are becoming increasingly refined:
- Traditional spray drying method
- Wet agglomeration method

19
 - Combination method
- Crystallization method
Among these, the Spray drying method is more suitable for laundry detergent
production in Vietnam due to the following reasons:
The spray drying method is more suitable for laundry detergent production in
Vietnam due to the following reasons:
- High productivity: short drying time, large drying capacity.
- The quality of the product is better: the dried product is a fine, uniform powder
that is fluffy, easy to dissolve, and does not require grinding. The quality of the
product is less altered compared to the original materials, making it convenient
for use and processing.
- Can dry sensitive materials due to low drying temperature, fast drying time,
and the compressed air used is often air or inert gas.-
- Simple equipment that allows for high and continuous productivity.
- The product comes into contact with the surface of the equipment in a dry
condition, so the choice of corrosion-resistant materials for the equipment is
simpler.
- The range of drying agent temperatures is quite wide, from 150-400°C, but the
efficiency is similar to other types of equipment.
- Easy to mechanize and automate.
- Lower investment costs compared to other production methods such as wet
agglomeration and crystallization."

20
 CHAPTER 2: THEORETICAL SPRAY DRYING TECHNOLOGY

2.1. Drying process

2.1.1. Definition
Drying is the process of using heat energy to evaporate water from a material.
This process can be carried out naturally using natural energy sources such as solar
energy, wind energy (known as natural drying or sun drying).
Using these methods only reduces the need for heat energy, but cannot actively
control the process speed according to technical requirements, resulting in low
productivity. Therefore, in industrial sectors, people often carry out artificial drying
processes (energy sources created by humans).

2.1.2. Objective
- Drying reduces the weight of the material (reduces transportation costs).
- Improves surface bonding and better preservation.
- Limits the growth of microorganisms and biochemical reactions, and shapes.
- Increases the durability of the product, and enhances the sensory properties of
the product.
During the drying process, water is evaporated at any temperature due to
diffusion caused by the difference in moisture content on the surface of the material.
At the same time, there is a difference in the partial pressure of water vapor within the
material at the surface of the material and the surrounding environment to ensure the
requirements for preservation, processing, and transportation."

2.1.3. Principle
Drying is a complex solid-state mass transfer process that involves both
external and internal diffusion within the solid material, as well as heat transfer. It is a
continuous process, meaning that the transfer of moisture within the material

21
progresses from liquid to vapor phase, and the vapor phase is subsequently removed
from the initial material.
The drying rate is influenced by temperature and the humidity of the
surrounding air, so we consider two aspects of the drying process: the static and
dynamic aspects. These aspects refer to the mechanical and kinetic forces involved in
the process.
- Static aspect
Based on the balance of material and energy, we can determine the initial and
final moisture content of the material and the drying agent to determine the
composition of the material, the amount of drying agent, and the amount of heat
required for the drying process.

- Dynamic aspect
The study of the relationship between the moisture content of the material and
the drying time and the process parameters such as the structural characteristics, size
of the drying material, and the hydrodynamic conditions of the drying agent to
determine the appropriate drying regime, drying rate, and drying time.
2.1.4. Types

a. Natural Drying
Solar drying is the use of solar energy to carry out the drying process.
❖ Advantages: Simple, no energy costs.
❖ Disadvantages:
- Difficult to mechanize
- Unable to adjust to the required temperature.
- Low drying intensity,
- Unevenly dried products.
- Occupies a large surface area.
- Slow evaporation rate.
- Takes a long time and is difficult to reduce the moisture content to the
necessary level for preservation.

22
 - Highly dependent on weather conditions (humidity and wind speed).
- Poor hygiene conditions, uneven dryness of products, dependent on weather
and prolonged time, requiring a large surface area.
Due to the low quality of the product, this method is only suitable for regions
where science and technology have not been widely applied to dry low to
medium-economical value products.

b. Conductive Drying
This is a drying method carried out using drying equipment, in which the
drying agent comes into direct or indirect contact with the material to remove
moisture. Depending on the heat transfer method used in drying technology, it can be
divided into:
- Convective Drying: This is a drying method in which the material comes into
direct contact with hot air or flue gas (known as the drying agent).
- Contact Drying: This is a drying method in which the drying agent does not
come into direct contact with the material, but the heat is transferred indirectly
through a barrier.
- Infrared Drying: This is a drying method that uses the energy of infrared
radiation emitted by a heat source to transfer heat to the material being dried.
- High-frequency Electric Field Drying: This is a drying method that uses
high-frequency electric fields to generate heat over the entire length of the
material being dried.
- Freeze Drying: This is a drying method carried out in an environment with a
very low vacuum and temperature, causing the free moisture in the material to
freeze and evaporate directly from the solid state without passing through the
liquid state."
2.1.5. Drying Agent, Drying Principle, Drying Regime

a. Drying Agent
These are substances used to transport the moisture removed from the drying
material.

23
 During the drying process, the drying chamber environment is continuously
supplied with moisture that is released from the material being dried. If this moisture
is not removed promptly, the relative humidity in the drying chamber increases, and at
some point, a balance is reached between the drying material and the environment in
the chamber, and the drying process stops.
❖ Function
- To heat the drying material.
- To remove the moisture from the surface of the material and transport it into
the environment.
- To protect the drying material from damage due to overheating.
In convective drying, the role of the drying agent is particularly important
because it acts as both a heat carrier and a moisture carrier. The drying agents
commonly used are hot air and flue gas, overheated steam, and liquid.
❖ Classification:
- Humid Air
This is the most commonly used drying agent and can be used for most types of
products. Using humid air does not contaminate the product or change its flavor after
drying. However, using humid air as the drying agent requires the installation of an air
heating system (air calorifer, steam or gas, or flue gas). The drying temperature should
not be too high, usually less than 500oC because if the temperature is too high, the
heat exchange equipment must be made of expensive alloy steel or ceramics.
For spray drying equipment, the drying agent used is mainly humid air with
three factors: the relative humidity of the humid air, the temperature of the air before
entering the dryer (t1), and the temperature of the air exiting the dryer (t2). The
temperature of the drying agent after exiting the dryer (t2) is chosen to minimize
energy loss.
- Flue Gas
Flue gas is used as a drying agent and can raise the drying temperature to
1000oC without requiring a heating system. However, it can contaminate the drying
material and cause a smoky odor.
- Overheated Steam

24
 This drying agent is used for products that are prone to ignition or explosion
and can withstand high temperatures.

b. Drying Method
Based on the drying conditions in different cases, there are many drying
methods, such as:
- The drying agent: There are devices that dry using air or devices that dry
using flue gas, devices that dry using methods such as spray drying, and
devices that dry using high-frequency electric fields.
- The working pressure: There are vacuum drying devices and devices that
operate at atmospheric pressure.
- The working method: There is continuous drying and intermittent drying.
- Method of providing heat for the drying process: There are contact dryers,
convective dryers, and radiant dryers.
- Structure of the equipment: There are drying rooms, drying chambers, belt
dryers, rotary dryers, and spray dryers.
- The direction of movement of the drying material and the drying agent:
There are co-current, countercurrent, and cross-current drying methods.

c. Drying Regime
Drying regime refers to the way heat and mass transfer are organized between
the drying agent and the drying material, as well as its parameters to ensure
productivity, product quality, and reasonable operating and energy costs.

2.2. Design Option Selection

2.2.1. Drying equipment: Spray Dryer
2.2.2. Drying method
Counter-current drying method is chosen for detergent powder production due
to its significant advantages in the drying process.
Firstly, the reverse air flow method ensures optimal drying efficiency. In this
process, hot air is supplied from an external heat source and injected from the bottom
of the drying system, while the detergent powder is fed from the top. This creates a

25
counter-current flow, where the hot air transfers heat to the detergent powder,
effectively removing moisture from the powder. This ensures thorough drying and
reduces drying time and energy consumption.
Secondly, the reverse air flow system helps preserve the properties and quality
of the detergent powder. This helps maintain the properties and fragrance of the
detergent powder, ensuring a high-quality final product that meets customer
requirements.
Lastly, the reverse air flow system also offers energy savings and increased
production efficiency. Thanks to its specific design, the reverse air flow method
maximizes the utilization of heat energy from the external heat source and efficiently
transfers heat to the detergent powder. This reduces drying time, saves energy, and
increases production output, leading to cost savings in operation.

2.2.3. Drying regime

The drying regime in the spray dryer includes the following factors: the drying
agent temperature (DAT) entering the drying chamber t1, and the DAT leaving the
drying chamber t2. To maintain the flavor, color, and components in the laundry
powder, the following drying regime is chosen:
- DAT entering the drying chamber: t1 = 170oC
- DAT leaving the drying chamber: t2 = 85oC
- Ambient temperature: t0 = 30oC
- Relative humidity of the environment: φ = 80%
2.3. Spray Drying Technology
2.3.1. Introduction
Spray drying is a well-known method of particle production which comprises
the transformation of a fluid material into dried particles, taking advantage of a
gaseous hot drying medium, with clear advantages for the fabrication of medical
devices. In fact, it is quite common for the production of microspheres and
microcapsules designed for drug delivery systems. This review describes the different
stages of the mechanism of the spray-drying process: atomization, droplet-to-particle
conversion and particle collection. In particular, this work addresses the diversity of

26
available atomizers, the drying kinetics and the importance of the configuration of the
drying chamber, and the efficiency of the collection devices. The final properties of
the dried products are influenced by a variety of factors, namely the spray dryer
design, the feed characteristics and the processing parameters. The impact of those
variables in optimizing both the spray-drying process and the synthesis of dried
particles with desirable characteristics is discussed. The scalability of this
manufacturing process in obtaining dried particles in submicron-to-micron scale
favors a variety of applications within the food, chemical, polymeric, pharmaceutical,
biotechnology and medical industries.

Figure 2.1: Small-scale spray drying system from SiccaDania company

2.3.2. Mechanism
Spray-drying mechanism is based on moisture elimination using a heated
atmosphere to which the feed product is subjected. The process may be described by
three major phases (atomization, droplet-to-particle conversion and particle
collection).

27
 Figure 2.2: Schematic drawing of a spray dryer

As shown in Figure 1, a solution is pumped to an atomizer, breaking up the

liquid feed into a spray of fine droplets. Then, the droplets are ejected into a drying
gas chamber where the moisture vaporization occurs, resulting in the formation of dry
particles. Finally, using an appropriate device, the dried particles are separated from
the drying medium, being then collected in a tank.
A fine dispersed system of material from a solution, emulsion, or suspension
that has been previously concentrated (40-60% moisture) is sprayed to form small
droplets, which fall into a stream of hot air in the same or opposite direction at a
temperature of about 150-400°C in a large drying chamber. As a result, the water
vapor is quickly removed. The product particles are separated from the drying agent
using a separate recovery system.

28
 Figure 2.3: Schematic drawing of a spray dried detergent unit

2.4. Main Equipment

2.4.1. Spray Nozzle - Centrifugal disc
Convert the material (in liquid form) into fine particles (mist) in the drying
chamber. The mist generation process determines the size and distribution of the
liquid droplets in the drying chamber, thereby affecting the heat transfer surface area
and the drying rate.
There are different types of spray nozzles, including mechanical spray nozzles,
air-assisted spray nozzles, and centrifugal discs.
In the process of producing laundry detergent, the spray mechanism is used to
convert the water and solvent mixture into fine powder particles through the drying
process. Currently, in laundry detergent manufacturing plants, the most commonly
used spray mechanism is the rotating disc spray mechanism. This mechanism operates
by using a rotating disc to spray the solution into the drying process, creating a large
number of fine powder particles with uniform size and appropriate moisture content.
With its simple design and flexible use, the rotating disc spray mechanism has become
the top choice in the laundry detergent production process.

Figure 2.4: The structure of the centrifugal disc and the shape of the
groove
❖ Principle

29
 The liquid is pumped into the center of the disc. Under the action of a motor or
compressed air, the disc rotates around the symmetrical axis. Due to the rotation of the
disc and the release of compressed air, the liquid stream collides with the grooves and
is dispersed into fine mist particles with an average diameter of about 8-18 µm, which
then enter the drying chamber. The spray angle is 180 degrees, and the initial
trajectory of the particles is horizontal. When they collide with the wall of the drying
chamber, the particles suddenly change direction, creating a turbulent mist that moves
downward and is then sucked into a cyclone for product recovery by a fan.
The disc rotation speed (mechanical) is about 4000-20000 revolutions per
minute. On the centrifugal disc, there is a narrow disc with different shapes and sizes
depending on the characteristics and productivity of the equipment. The grooves
commonly have circular, oval, or rectangular shapes. The straight radial grooves are
the standard type used for products that require high particle uniformity. The disc with
curved grooves is often used for products that require high density. The number and
size of the grooves determine the productivity of the equipment, and the maximum
productivity achievable with this type of spray mechanism is 200 tons/hour. For
equipment that requires high productivity, two rows of grooves are usually arranged
alternately to increase the number of grooves and the feeding speed.\
2.4.2. Drying chamber
It is the place where the spray-dried sample (in the form of mist) and the drying
medium (hot air) are mixed. The spray dryer chamber can have various shapes, but the
most common one is a vertical cylindrical chamber with a conical bottom. The size of
the drying chamber (height, diameter, etc.) is designed based on the size and trajectory
of the liquid particles, which depend on the type of spray mechanism used.
In this design process, we have chosen a spray dryer chamber that uses a
centrifugal disc spray mechanism.

30
 Figure 2.5: The layout diagram of the drying medium flow and the feed stream
in the spray dryer chamber that uses a centrifugal disc spray mechanism.
Note:
HA: Hot air flow F: Feed stream
OA: Outlet air flow P: Product
The system works according to the principle of co-current flow. The rotating
disc is always placed at the top of the drying chamber, and the spray mist particles are
ejected horizontally. The drying medium enters the chamber through the tangential
inlet and creates a swirling flow that captures the mist particles and moves them
downward in a spiral motion. The radius of the mist particle cluster determines the
diameter of the drying chamber. Since the disc rotates quickly, it acts like a fan that
sucks the drying medium and mist particles upward. Therefore, if the spray disc is
placed too close to the top, it can cause the material being dried to stick to the top of
the drying chamber.

2.4.3. Calorifer
Calorifer is a type of heat exchanger that is commonly used in spray drying
systems. Its main function is to heat the drying medium (usually air) before it enters
the spray dryer chamber. The heated air then absorbs moisture from the feed stream,
and the resulting mist particles are dried as they move through the chamber.
When selecting a calorifer for a spray drying system, several factors must be
taken into consideration. These include the required drying temperature, the flow rate
of the drying medium, and the size of the spray dryer chamber. The calorifer must be

31
able to provide sufficient heat to achieve the desired drying temperature, and it must
also be able to handle the required flow rate of the drying medium. Additionally, the
size of the calorifer should be matched to the size of the spray dryer chamber to ensure
efficient heat transfer and minimize energy consumption.
Overall, the selection of a suitable calorifer is critical to the performance and
efficiency of a spray drying system. Properly designed and optimized calorifiers can
significantly improve the quality and yield of spray-dried products while reducing
energy consumption and operating costs.

2.4.4. Cyclone
A cyclone is a type of dust collector that is commonly used in spray drying
systems to recover the dried product from the exhaust air stream. Its main function is
to separate the fine mist particles from the drying medium and collect them in a
separate container for further processing or packaging.
When selecting a cyclone for a spray drying system, several factors must be
taken into consideration. These include the particle size distribution of the mist
particles, the flow rate of the exhaust air stream, and the desired level of product
recovery efficiency. The cyclone must be able to effectively capture the mist particles
while minimizing the loss of product and maximizing the recovery efficiency.
Additionally, the size and configuration of the cyclone should be matched to
the size and operating conditions of the spray dryer chamber to ensure optimal
performance. The diameter and height of the cyclone, as well as the position of the
inlet and outlet, can significantly impact its efficiency and effectiveness in capturing
the mist particles.
In summary, the selection of a suitable cyclone is critical to the overall
performance and product quality of a spray drying system. Careful consideration of
the particle size distribution, exhaust air flow rate, and desired recovery efficiency can
help ensure optimal cyclone performance and maximize product yield.

32
 2.4.5. Centrifugal Fan
In a drying process, suction fans and exhaust fans play important roles in
controlling airflow and removing moisture from the drying environment. In our
process, we use suction fans and exhaust fans. Both the suction fan and the exhaust
fan should be appropriately sized and positioned to ensure efficient airflow and
optimal drying conditions.
When selecting a fan for a spray drying system, multiple factors must be
considered. These include the required airflow rate, the pressure drop across the
system, and the desired energy efficiency level. The fan must supply enough airflow
to move the mist particles without causing turbulence or pressure drops that could
harm the quality of the dried product. Furthermore, the fan's size and configuration
should match the spray drying system's size and operating conditions to ensure
optimal performance. The fan's diameter, speed, and position, as well as the inlet and
outlet's size, can significantly affect its efficiency and ability to move the mist
particles.
A suction fan is used to create a negative pressure or suction within the drying
system. It pulls air from the surrounding environment into the drying chamber or
through the drying material. The purpose of the suction fan is to enhance the airflow
within the drying system, allowing for efficient evaporation and moisture removal.
An exhaust fan is responsible for expelling moisture-laden air from the drying
system. It creates positive pressure and pushes the moist air out of the drying chamber
or facility. The exhaust fan helps remove the moisture that has been evaporated from
the drying material, maintaining a controlled and desirable drying environment.
To summarize, choosing an appropriate fan is critical for achieving high
performance and energy efficiency in a spray drying system. A well-designed and
optimized fan can provide reliable and efficient airflow, resulting in high-quality
product yield while minimizing energy consumption and operating costs.

CHAPTER 3: LAUNDRY POWDER MANUFACTURING PROCESS

33
3.1. Blown Powder Formulation

Figure 3.1: Formulation of a Concentrated Powder with Phosphates

Based on Table 3.9 (Formulating Detergents and Personal Care Products: A Guide to
Product Development, Louis Ho Tan Tai), we propose detergent formulations for this
problems as follow:

Table 3.1: Laundry Powder Formulation

Ingredients Ratio

LABSA -

NaOH 50% -

H2O2 35% -

NI 6%

TAED 7%

Enzyme -Protease 0.2%

34
 Soap 2%

STPP 23%

Zeolite 5%

Na2CO3 15%

Na2SiO3 6%

Na2SO4 2%

Polymer 2%

Perborate - 13%
monohydrate

SCMC 1.5%

Water balance

FWA 0.3%

Colour, Perfume -

3.2. Powder Properties

The key physical properties of the products are density, particle size
distribution, cake strength-flow properties, and solubility:
The density is typically 250-550 kg/m3 for blown powder. In certain cases,
lower density is caused by a higher slurry water content, higher air temperature, and a
high concentration of film-forming materials. Air is also used at high pressures to
increase the expansion, which is taken with care not to overdo it to protect the fracture
of particles.
Particle size distribution: is about 400-500µ𝑚. Acceptable ends of the
spectrum range from <5% below 100 µ𝑚 to < 2% above 800µ𝑚. The upper limitation

35
is for dustiness of the powder and eventual dispersion when wet. The lower limit is to
control the appearance and dissolution of the powder during the washing process.
Cake strength: is measured by a uniaxial shear test determining flowability
and particle stickiness. Cake strength tends to be an intrinsic function of the
formulation and blown powder moisture.
Solubility: The key factor for solubility tends to be formulation, component
interaction, and process conditions. There are interactions including poor mixing with
acidic ingredients leading to Na2SiO3 insoluble and zeolite insoluble formulations. In
both cases, mixing and pH should be carefully controlled to prevent this situation.

36
3.3. Process Flow Diagram

37
3.4. Process Description
3.4.1. Material Preparation
LABSA (Linear alkylbenzene sulfonic acid) is a highly concentrated acidic
surfactant, cômnly used as a surfactant to improve the cleaning performance of the
detergent. Neutralizing LABSA with NaOH (Sodium Hydroxide) is a necessary step to
convert it into its salt form, Sodium Linear Alkyl Benzene Sulfonate (LAS), which is
the most commonly used anionic surfactant in detergent formulations.
Preparing a LABSA to a concentration of 50% is a common practice in laundry
powder production for several reasons:
- LABSA is a high concentrate that minimizes viscous material, minimizes the
reaction time, and makes it easier to handle and mix with other ingredients, such
as sodium carbonate and sodium tripolyphosphate, which are commonly used in
laundry powder formulations.
- It helps to reduce the likelihood of localized overheating during the
neutralization process, which could result in the formation of unwanted
by-products or affect the quality of the final product.
- Dilution of LABSA helps to minimize the impact of its corrosive and toxic
properties on the equipment and environment.
To prepare the LABSA 50% solution, LABSA is first taken from the storage tank
and transferred to a mixing tank. Then, a quantity of water is added to the mixing tank
to form a LABSA solution with a concentration of 50%. The LABSA solution is then
heated and stirred to ensure the complete dissolution of the LABSA in water. After
complete dissolution, the solution is passed through a filtration system to remove any
impurities or solid particles that may be present. The filtered LABSA solution is then
transferred to a holding tank, where it is allowed to settle to allow any remaining
impurities to sink to the bottom of the tank. After settling, the clear LABSA solution is
carefully decanted and transferred to a storage tank. Finally, the LABSA solution is
checked to ensure that its concentration is at 50%. If necessary, water may be added to
adjust the concentration.
3.4.2. Stirring and Scrubbing

38
 LABSA raw materials are subjected to a bleaching process before their
utilization in the production process. This process involves a careful blending of the raw
materials with a 35% hydrogen peroxide (H2O2) solution, which serves to heighten the
raw material's purity. The amount of H2O2 used to bleach LABSA typically falls in the
range of 0.1-0.15%.
3.4.3. Neutralization
Once the bleaching process is complete, LABSA is introduced into a stirred tank,
where a previously prepared solution of NaOH is added to neutralize the LABSA and
create sodium linear alkyl sulfonate (LAS), a highly efficient surfactant known for its
excellent foam generation and strong cleaning capabilities. The neutralization process
calls for around 28% NaOH, meaning that producing LAS from 100kg of LABSA
requires approximately 28-28.5kg of concentrated NaOH solution (40-45%).

Chemical reaction:

+ 𝑁𝑎 →

3.4.4. Crutcher
After the neutralization process, other components such as builders (STP,
zeolite), corrosion inhibitors (sodium silicate), anti-redeposition agents (SCMC,
polymers), fillers (Na2SO4), bleaching agents (TEAD, perborate), and spray-dried
post-adds in powder form are added to the mixing tank in proportions based on the
desired composition of the laundry powder detergent. The mixture is stirred to create a
slurry solution that is suitable for spray drying. Water is also added to the mixture at this
stage to achieve a moisture content of approximately 60%. The mixture is kept at a
temperature of around 80°C. The process of creating the slurry can be done in batches
or continuously, depending on the required production output.
❖ The slurry criteria:

39
 - The uniformity of the components in the slurry must not change between
batches, so accurate dosing is required.
- Ensure uniformity and avoid layering.
Builders play an essential role in creating the desired creamy consistency of the
slurry. Additionally, they aid in the absorption of other surfactants and liquids. When
builders absorb surfactants and are spray-dried, their crystalline structure is maintained,
preventing the loss of surfactant and ensuring even product distribution. This is
important because if the crystalline structure is not maintained, the surfactant may be
lost, resulting in uneven product distribution.

Figure 3.2: Mixing Process

3.4.5. Grinding and Magnetic Filtration

The slurry, after leaving the mixing tank, is transferred into a screw mill for
grinding any large solid particles and crystals that have not completely dissolved.

40
Before entering the spray-drying process, the slurry is passed through a filtration system
to remove any large solid particles such as metal or other impurities. This is done to
prevent clogging and reduce wear and tear on the spray-drying nozzles.
After filtration, the slurry is then transferred into an intermediate storage tank.

3.4.6. Spray Drying

Spray drying is the process of removing moisture from the creamy slurry,
converting it from a 60% moist mixture into a dry powder with a 3-10% moisture
content. The slurry from the intermediate storage tank is pumped using a two-stage
pump system and compressed air into the spray-drying tower. The slurry is then
atomized into fine droplets through high-pressure nozzles at approximately 60 atm.
These droplets are then dried into a powder form by hot air.
The hot air is generated by a combustion chamber, which uses FO oil to
indirectly heat the air to a temperature of around 300°C. The hot air is then blown into
the bottom of the spray-drying tower by a fan, where it rises and contacts the slurry
droplets. The hot air evaporates the moisture from the droplets, leaving behind dry
powder particles of laundry detergent, which fall to the bottom of the tower.
The humidity of the air in the drying chamber greatly affects the structure and
size of the final laundry detergent particles. If the air humidity is too low, the particles
will be very small and may not bind together. Conversely, if the air humidity is too high,
the particles will stick together and become larger, resulting in uneven sizes and
structures. The final laundry detergent particles are collected on a conveyor belt and
transported for further processing.
The hot, dry air from the top of the tower carries the small, light laundry
detergent particles into a dust collection system before being released into the
environment.

3.4.7. Cooling and Classification

The laundry detergent powder, which has a high temperature after the
spray-drying process, is cooled down during transportation on the conveyor belt.

41
 The laundry detergent powder from the conveyor belt is then fed into a vertical
pipe of a vacuum conveying system for particle classification. Inside the pipe, the
vacuum force separates the particles into different sizes, with the suitable-sized particles
being carried upward by the airflow and collected by cyclones. The particles that are too
small to be collected by cyclones are then sent through a bag filter and returned to the
slurry for remanufacturing. The particles that are too large and heavy to be carried
upward by the airflow are dropped onto another conveyor belt, which carries them back
to the mixing tank to be reprocessed into the slurry for another spray-drying process.

3.4.8. Supplemental Blending and Perfumer Spraying

After particle classification, the laundry detergent powder is transferred into
storage tanks where additional ingredients are added. These ingredients include
heat-sensitive materials that cannot be added before the spray-drying process, such as
non-ionic surfactants (NI), optical brighteners, enzymes, foam control agents, and
colorants. These ingredients are added using a weighing system for precise
measurement.
The mixture is then transferred to a rotating drum mixer to ensure the even
distribution of all ingredients, and a fragrance spray is added to give the laundry
detergent powder a pleasant scent.
The final laundry detergent powder has a density of 400-650 g/l.

3.4.9. Packaging
The packaging stage involves filling the laundry detergent powder into bags or
containers made of materials such as plastic, nylon, paper, cardboard, or aluminum foil
to provide a barrier to light, air, and moisture. The bags or containers are formed, filled,
sealed, coded or labeled, and packaged for shipping to retailers or distributors. The
packaging process is crucial for protecting the laundry detergent powder and ensuring
its quality and effectiveness.

42
 CHAPTER 4: CALCULATION OF RAW MATERIALS

4.1. Product Specifications

- Density: 400 (g/l)
- Humidity: 6%
- Productivity: 500kg/h or 3720 tons/ year

4.2. Calculation procedure

Based on a batch size of 100 kg of laundry detergent powder, the computation
yields the dry weight of the final product, which is 94 (kg)
Within the production system, we anticipate losses for each stage as follows:

Table 4.1: Weight loss during each stage

Stage Loss Mass before Stage

Percentage

Agitation and Scrubbing 1%

Neutralizer (***) 1% 𝑚17 =

27.6812
= 27. 9608
1−1%

Mixing (**) 2% 𝑚16 = 27. 6812

Transfer from mixing to storage 0.05% 𝑚15 =

88.8983
= 88. 9428
1−0.05%
tank

Storage tank 0.5% 𝑚14 =

88.4538
= 88. 8983
1−0.5%

The pipeline loss from the 0.05% 𝑚13 =

88.4096
= 88. 4538
1−0.05%
storage tank to the grinding
machine

Grinding 1% 𝑚12 =
87.5255
= 88. 4096
1−1%

43
 Magnetic filtration 1% 𝑚11 =
86.6503
= 87. 5255
1−1%

Transfer from Filtration to Spray 0.05% 𝑚10 =

86.6069
= 86. 6503
1−0.05%
Dryer

Spray Drying 3% 𝑚9 =
84.0087
= 86. 6069
1−3%

The pipeline loss from Dryer to 0.05% 𝑚8 =

83.9667
= 84. 0087
1−0.05%
Sieving

Particle classification 1% 𝑚7 =
83.1271
= 83. 9667
1−1%

Transfer from particle 0.05% 𝑚6 =

83.0855
= 83. 1271
1−0.05%
classification to supplemental
blending

Supplemental blending (*) 1% 𝑚5 = 83. 0855

Sieving 1% 𝑚4 =
94.1411
= 95. 0921
1−1%

The loss from sieving to the 0.05% 𝑚3 =

94.0941
= 94. 1411
1−0,05%
storage tank (before the
perfumer)

Perfumer 0.05% 𝑚2 =
94.0470
= 94. 0941
1−0,05%

Packaging 0.05% 𝑚1 =
94
= 94. 0470
1−0,05%

❖ Supplemental blending detail calculation (*)

- The additives introduced during the supplemental blending stage are in the
following proportions:

Table 4.2: Raw Materials Added During Supplemental blending Stage

44
 NI 6%

TAED 7%

Enzyme 0.2%

FWA 0.3%

Colour Insignificant

- Mass before supplemental blending stage (having additives):

95.0921
𝑚5' = 1−1%
= 96. 0526 (𝑘𝑔)

- Mass of additives = 𝑅𝑎𝑡𝑖𝑜 × 𝑚5'

𝑚𝑁𝐼 = 6% × 96. 0526 = 5. 7632 (𝑘𝑔)

𝑚𝑇𝐴𝐸𝐷 = 7% × 96. 0526 = 6. 7237 (𝑘𝑔)

𝑚𝐸𝑛𝑧𝑦𝑚𝑒 = 0. 2% × 96. 0526 = 0. 1921 (𝑘𝑔)

𝑚𝐹𝑊𝐴 = 0. 3% × 96. 0526 = 0. 2882 (𝑘𝑔)

𝑚𝑡𝑜𝑡𝑎𝑙 𝑎𝑑𝑑𝑖𝑡𝑖𝑣𝑒𝑠 = 12. 9671 (𝑘𝑔)

- Mass before supplemental blending stage (non-additive):

𝑚5 = 96. 0526 − 12. 9671 = 83. 0855 (𝑘𝑔)

❖ Mixing stage detail calculation (**)

- The additional materials introduced during the supplemental blending stage are
in the following proportions:
-
Table 4.3: Raw Materials Added During Mixing Stage

Soap 2%

STPP 23%

45
 Zeolite 5%

Na2CO3 15%

Na2SiO3 6%

Na2SO4 2%

Polymer 2%

Perborate 13%

SCMS 1.5%

- Mass before mixing (having additional material)

88.9428
𝑚16' = 1−2%
= 90.7580

- Mass of additional material = 𝑅𝑎𝑡𝑖𝑜 × 𝑚16'

𝑚𝑆𝑜𝑎𝑝 = 2% × 90. 7580 = 1. 8152 (𝑘𝑔)

𝑚𝑆𝑇𝑃𝑃 = 23% × 90. 7580 = 20. 8743 (𝑘𝑔)

𝑚𝑍𝑒𝑜𝑙𝑖𝑡𝑒 = 5% × 90. 7580 = 4. 5379 (𝑘𝑔)

𝑚𝑁𝑎 𝐶𝑂 = 15% × 90. 7580 = 13. 6137 (𝑘𝑔)

2 3

𝑚𝑁𝑎 𝑆𝑖𝑂 = 6% × 90. 7580 = 5. 4455 (𝑘𝑔)

2 3

𝑚𝑁𝑎 𝑆𝑂 = 2% × 90. 7580 = 1. 8152 (𝑘𝑔)

2 4

𝑚𝑃𝑜𝑙𝑦𝑚𝑒 = 2% × 90. 7580 = 1. 8152 (𝑘𝑔)

𝑚𝑃𝑒𝑟𝑏𝑜𝑟𝑎𝑡𝑒 = 13% × 90. 7580 = 11. 7985 (𝑘𝑔)

𝑚𝑆𝐶𝑀𝐶 = 1. 5% × 90. 7580 = 1. 3614 (𝑘𝑔)

𝑚𝑡𝑜𝑡𝑎𝑙 𝑎𝑑𝑑𝑖𝑡𝑖𝑜𝑛𝑎𝑙 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 = 63. 0768(𝑘𝑔)

- Mass before mixing (non-additional material)

46
 𝑚16 = 90. 7579 − 63. 0768 = 27. 6812 (𝑘𝑔)

❖ Neutralization stage detail calculation (***)

- The neutralization loss is 1%, resulting in a weight of the raw materials
before the neutralization stage of:
27.6812
𝑚17 = 1−1%
= 27. 9608

This means that m17 represents the total weight of NaOH, LABSA, and H2O2:
𝑚17 = 𝑚𝑁𝑎𝑂𝐻 + 𝑚𝐿𝐴𝐵𝑆𝐴 + 𝑚𝐻 𝑂 = 27. 9608(𝑘𝑔)
2 2

- The neutralization reaction:

𝐶𝐻3(𝐶𝐻2)11𝐶6𝐻4𝑆𝑂3𝐻 + 3𝑁𝑎𝑂𝐻 → 𝐶𝐻3(𝐶𝐻2)11𝐶6𝐻4𝑆𝑂3𝑁𝑎 + 3𝐻2𝑂

The ratio of NaOH added is chosen as 28%𝑚𝐿𝐴𝐵𝑆𝐴

The ratio of H2O2 added is chosen as 0.15%𝑚𝐿𝐴𝐵𝑆𝐴

- The input weight of LABSA is:

(100% + 28% + 0. 15%) × 𝑚𝐿𝐴𝐵𝑆𝐴 = 27. 9608

𝑚𝐿𝐴𝐵𝑆𝐴 = 21. 8188 (𝑘𝑔

𝑚𝑁𝑎𝑂𝐻 = 6. 1093 (𝑘𝑔)

𝑚𝐻 𝑂 = 0. 0327 (𝑘𝑔)
2 2

- Since the NaOH solution has a concentration of 50%, the weight of water in
the NaOH solution is:
𝑚𝑐𝑡 6.1093
𝐶𝑁𝑎𝑂𝐻 = 𝑚𝑑𝑑
× 100% = 6.1093+𝑚𝐻 𝑂
× 100% = 50%
2

→ Mass of H2O in NaOH 50% solution: 𝑚𝐻 𝑂 = 6. 1093 (𝑘𝑔)

2

- Given that the H2O2 solution has a concentration of 35%, the weight of
water is:

47
 𝑚𝑐𝑡 0.03273
𝐶𝐻 𝑂 = 𝑚𝑑𝑑
× 100% = 0.0327+𝑚𝐻 𝑂
× 100% = 35%
2 2 2

→ Mass of H2O in H2O2 35% solution: 𝑚𝐻 𝑂 = 0. 0608 (𝑘𝑔)

2

- Preparation of LABSA raw material:

Initially, LABS in solid form. It needs to be added H2O to form a solution with
𝐶𝐿𝐴𝐵𝑆𝐴 = 50% in preparation for the scrubbing stage.
𝑚𝑐𝑡 21.8188
𝐶𝐿𝐴𝐵𝑆𝐴 = 𝑚𝑑𝑑
× 100% = 21.8188+𝑚𝐻 𝑂
× 100% = 50%
2

→ Mass of H2O in LABSA 50% solution: 𝑚𝐻 𝑂 = 21. 8188(𝑘𝑔)

2

- Total mass of H2O:

𝑚𝐻 𝑂 𝑡𝑜𝑡𝑎𝑙= 21.8188 + 6.1093 + 0.0608 =27.9888 (kg)
2

❖ Total mass of ingredients in mixing stage

- M = 𝑚𝑡𝑜𝑡𝑎𝑙 𝑎𝑑𝑑𝑖𝑡𝑖𝑜𝑛𝑎𝑙 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 + 𝑚𝐿𝐴𝐵𝑆𝐴 + 𝑚𝑁𝑎𝑂𝐻 + 𝑚𝐻 𝑂 + 𝑚𝐻 𝑂 𝑡𝑜𝑡𝑎𝑙
2 2 2

= 63.0768 + 21.8188 + 6.1093 + 0.0327 + 27.9888 = 119.0545 (kg)

- Moisture content of ingredient:

𝑚𝑎𝑠𝑠 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟 𝑖𝑛 𝑠𝑎𝑚𝑝𝑙𝑒 27.9888
𝑥= 𝑚𝑎𝑠𝑠 𝑜𝑓 𝑠𝑎𝑚𝑝𝑙𝑒
× 100 = 119.0545
× 100 = 23. 51%

- To achieve a required moisture content input 60% of spray dryer, the total
amount of water required in the raw material is:

𝑚𝐻 𝑂 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑
𝑥= 2

63.0768 + 21.8188 + 6.1093 + 0.0327 +𝑚𝐻 𝑂 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑

× 100 = 60%
2

→ 𝑚𝐻 𝑂 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 = 136. 5563 (𝑘𝑔)

2

48
 Table 4.4: Summary of raw material weights

Material Ratio Mass per Mass per Daily Density Daily

100kg 3720 tons amount (kg/m3) volume of
powder powder (kg) (kg) material
(kg) (m3)

LABSA - 21.8188 811659.14 2618.3 1075 2.436

NaOH 50% - 6.1093 227264.56 733.1 1430 0.513

H2O2 35% - 0.0327 1217.49 3.9 1064.9 0.004

STPP 23% 20.8743 776525.08 2504.9 1150 2.178

Zeolite 5% 4.5379 168809.80 544.5 2000 0.272
Na2CO3 15% 13.6137 506429.40 1633.6 700 2.334
Na2SiO3 6% 5.4455 202571.76 653.5 1520 0.430
Na2SO4 2% 1.8152 67523.92 217.8 1300 0.168
Polymer 2% 1.8152 67523.92 217.8 1100 0.198
Perborate 13% 11.7985 438905.48 1415.8 750 1.888
SCMC 1,5% 1.3614 50642.94 163.4 500 0.327
NI 6% 5.7632 214389.38 691.6 - -
TAED 7% 6.7237 250120.94 806.8 - -

49
 Enzyme 0,20% 0.1921 7146.31 23.1 - -
FWA 0,3% 0.2882 10719.47 34.6 - -

Colour, - - - - - -
Perfumer
Soap 0.242
2% 1.8152 67523.92 217.8 900

Water - 136.5563 5079896.10 16386.8 1000 16.387

Total 240.5610

- The plant annual working days of 310 days

- Amount of material entering the dryer per year = 8466493.5(kg)
- Amount of material entering the dryer per day = 27311.3 (kg)
- Volume of material entering the dryer per day = 27.4 (m3)

50
 CHAPTER 5: MATERIAL BALANCE

5.1. Process Parameter

5.1.1. Initial Parameters
- Initial moisture content of the material to be dried: w1 = 60%.
- The final moisture content of the dried material: w2 = 6%.
- The temperature of the atmosphere air before entering the heater (calorifer): t0 =
30℃
- Relative humidity of the air: φ0 = 0.80

- The amount of material entering spray dryer:

8466493.5
F= 310 * 24
= 1137. 9696 (𝑘𝑔/ℎ)

- The amount of material exiting spray dryer:

𝐹×(1−𝑤1) 1137.9696×(1−0.6)
P= (1−𝑤2)
= (1−0.06)
= 484. 2424 (𝑘𝑔/ℎ)

- Temperature of the drying agent entering the drying device: t1 = 300℃.

- Temperature of the drying agent leaving the drying device: t2 = 90℃.
- Inlet temperature of the material: tvl1 = 30℃.
- Outlet temperature of the material: tvl2 = 80℃.

5.2. Material Balance Calculation

5.2.1. The amount of moisture removed from the material (W)
𝑊 = 𝐹 − 𝑃 = 653. 7272 (𝑘𝑔/h)

5.2.2. Absolute dry material

100−𝑤2
𝐺𝑘 = 𝑃 × 100
= 483. 9518 (𝑘𝑔/ℎ)

51
 5.2.3. The state of ambient air
Ambient temperature: t0 = 30oC
Relative humidity of air: φ0 = 0.80
Input temperature: t1 = 300oC
Output temperature: t2 = 90oC
Atmosphere pressure:: B = 1 at

- The saturation vapor pressure of steam as a function of temperature

𝑝0 = 0. 0433 (at) (Table I.250/312, [1])

- Absolute humidity of air

φ0×𝑝0
𝑌0 = 0. 622 × 𝐵−φ0×𝑝0
(VII.11/95, [2])

0.8×0.0433
= 0. 622 × 1−0.8×0.0433
= 0. 0223 (𝑘𝑔 𝑚𝑜𝑖𝑠𝑡𝑢𝑟𝑒/𝑘𝑔 𝑑𝑟𝑦 𝑎𝑖𝑟)

- Enthalpy of moist air:

𝐸0 = 𝑐𝑝𝑘 × 𝑡 + (𝑟 + 𝑐𝑝𝑎 × 𝑡) × 𝑌0 (VII.13/95,[2])

= 1. 004 × 30 + (2500 + 1. 842 × 30) × 0. 0223

= 87. 1514 (𝑘𝐽/𝑘𝑔 𝑑𝑟𝑦 𝑎𝑖𝑟)
Note:
+ Specific heat capacity at constant pressure of dry air:
𝑐𝑝𝑘 = 1. 004 (𝑘𝐽/𝑘𝑔𝐾)

+ Specific heat capacity at constant pressure of steam:

𝑐𝑝𝑎 = 1. 842 (𝑘𝐽/𝑘𝑔𝐾)

+ Latent heat of steam:

𝑟 = 2500 (𝑘𝐽/𝑘𝑔)

- Specific volume of moist air:

𝑅×𝑇
𝑣0 = 5 (VII.8/95,[2])
𝑀(𝐵−φ0×𝑝0)×10

52
 287×(30+273) 3
= 5 = 0. 9090 (𝑚 /𝑘𝑔 𝑑𝑟𝑦 𝑎𝑖𝑟)
(1−0.8×0.0433)×10

5.2.4. The state of air passing through the calorifer

- Input air temperature: t1 = 300oC
Due to the fact that the air passing through the heating section undergoes only a
change in temperature but not in humidity, it leads to the conclusion that
𝑌0 = 𝑌1 = 0. 0223 (𝑘𝑔 𝑚𝑜𝑖𝑠𝑡𝑢𝑟𝑒/𝑘𝑔 𝑑𝑟𝑦 𝑎𝑖𝑟)

- The saturation vapor pressure of steam at 300oC:

𝑝1 = 87. 6 (at) (Table I.250/313, [1])

- Relative humidity of air

From (VII.11/95,[2]), we have:
𝑌1×𝐵
φ1 = 𝑝1×(0.622+𝑌1)
× 100

0.0223×1
= 87.6×(0.622+0.0223)
× 100

= 0. 04%

- Enthalpy of air
𝐸1 = 𝑐𝑝𝑘 × 𝑡1 + (𝑟 + 𝑐𝑝𝑎 × 𝑡1) × 𝑌1 (VII.13/95,[2])

= 1. 004 × 300 + (2500 + 1. 842 × 300) × 0. 0223

= 369. 3316 (𝑘𝐽/𝑘𝑔 𝑑𝑟𝑦 𝑎𝑖𝑟)

- Specific volume of moist air

𝑅×𝑇
𝑣1 = 5 (VII.8/95,[2])
𝑀(𝐵−φ1×𝑝1)×10

287×(300+273) 3
= 5 = 1. 7035 (𝑚 /𝑘𝑔 𝑑𝑟𝑦 𝑎𝑖𝑟)
(1−0.04%×87.5)×10

53
 5.2.5. The state of air after leaving the dryer
- Output temperature: t2 = 90oC
In the theoretical drying process, a portion of the heat energy of air is used to
evaporate water in the material, and the water vapor carries that heat back into the air.
Based on this, it is assumed that the enthalpy of the air remains constant
throughout the drying process: 𝐸1 = 𝐸2 = 369. 3316 (𝑘𝐽/𝑘𝑔 𝑑𝑟𝑦 𝑎𝑖𝑟)

- The saturation vapor pressure of steam at 90oC:

𝑝2 = 0. 715 (at) (Table I.250/312, [1])

- Absolute humidity of air

From (VII.13/95,[2]), we have:
𝐸2−𝑐𝑝𝑘×𝑡2 369.3316−1.004×90
𝑌2 = 𝑟 +1.842×𝑡2
= 2500+1.842×90
= 0. 1046 (𝑘𝐽/𝑘𝑔 𝑑𝑟𝑦 𝑎𝑖𝑟)

- Relative humidity of air

𝑌2×𝐵 0.1046×1
φ2 = 𝑝2×(0.622+𝑌2)
× 100 = 0.715×(0.622+0.1046)
× 100 = 20. 14%

- Specific volume of moist air

𝑅×𝑇
𝑣2 = 5 (VII.8/95,[2])
𝑀(𝐵−φ2×𝑝2)×10

287×(90+273) 3
= 5 = 1. 2171 (𝑚 /𝑘𝑔 𝑑𝑟𝑦 𝑎𝑖𝑟)
(1−20.14%×0.715)×10

- The amount of dry air required to evaporate 1kg of moisture in the

material:
1 1
𝑙= 𝑌2−𝑌1
= 0.1046−0.0223
= 12. 1462 (𝑘𝑔 𝑑𝑟𝑦 𝑎𝑖𝑟/𝑘𝑔 𝑚𝑜𝑖𝑠𝑡𝑢𝑟𝑒)

(P.283,[3])
- The amount of dry air required:
𝐿 = 𝑙 × 𝑊 = 12. 1462 × 653. 7272 = 7940. 3332 (𝑘𝑔 𝑑𝑟𝑦 𝑎𝑖𝑟/ℎ)
(P.283,[3])

54
 - At dew point temperature: φ = 1
𝑌2×𝐵
𝑃𝑏ℎ = 0.622+𝑌2
= 0. 1440

From (Table I.251/314,[2]),

𝑜
At 𝑃𝑏ℎ = 0. 1440 → 𝑇𝑠 = 52. 62 𝐶

5.2.6. Air Specifications

3
- Density of air at tave = 195oC: ρ𝑎𝑣𝑒 = 7. 109 (𝑘𝑔/𝑚 )
3
- Density of air at t0: ρ0 = 0. 03036(𝑘𝑔/𝑚 )
3
- Density of air at t1: ρ1 = 0. 6158 (𝑘𝑔/𝑚 )
3
- Density of air at t2: ρ2 = 0. 9718 (𝑘𝑔/𝑚 )

- Volume of air entering the dryer:

𝐿 7940.3332 3
𝑉1 = ρ1
= 0.6158
= 12894. 3378(𝑚 /ℎ)

- Volume of air leaving the dryer:

𝐿 7940.3332 3
𝑉2 = ρ2
= 0.9718
= 8170. 7483 (𝑚 /ℎ)

- Dry air flow rate in a spray dryer:

𝑉1+𝑉2 12894.3378 + 8170.7483 3
𝑉= 2
= 2
= 10532. 5430 (𝑚 /ℎ)

The actual air flow rate in a drying tower includes both the amount of dry air and
the amount of moisture evaporated from the drying material:
𝑊 653.7272 3
𝑉𝑡 = 𝑉 + ρℎ
= 10532. 5430 + 7.109
= 10624. 5007 (𝑚 /ℎ)

55
 Table 5.1: Summary for drying agent

State Temperatur Absolute humidity Y Relative Enthalpy E

e (oC) (kg moisture/kg dry humidity φ (%) (kJ/kg dry
air) air)

0 30 0.0223 80 87.1514

1 300 0.0223 0.04 369.3316

2 90 0.1046 20.14 369.3316

Table 5.2: Summary for drying material

Parameter Unit Value

F kg/h 1137.9696

P kg/h 484.2424

Gk kg/h 483.9518

w1 % 60

w2 % 6

W kg moisture/h 653.7272

l kg dry air/h 12.1462

L kg dry air/h 7940.3332

56
 CHAPTER 6: DESIGN OF SPRAY DRYER

6.1. Atomization Choice

Selecting a centrifugal disc nozzle with the following initial parameters:

Table 6.1 :Design parameters of centrifugal spray disc

Symbol Value

Diameter (mm) Dd 120

Rotation speed (rpm) n 22000

Velocity of slurry into the nozzle (m/s) ν0 1

Surface tension at tvl1 (N/m) σ 0,0669

Density of slurry (kg/m3) ρ 997,6743

3
- Density of slurry: ρ𝑠𝑙𝑢𝑟𝑟𝑦 = 997, 6743 (𝑘𝑔/𝑚 ) (I.2/5,[1])

𝑥𝐿𝐴𝐵𝑆𝐴 𝑥𝑁𝑎𝑂𝐻 𝑥𝐻 𝑂 𝑥𝑆𝑜𝑎𝑝 𝑥𝑆𝑇𝑃𝑃 𝑥𝑍𝑒𝑜𝑙𝑖𝑡𝑒

1/ρ𝑠𝑙𝑢𝑟𝑟𝑦 = ρ𝐿𝐴𝐵𝑆𝐴
+ ρ𝑁𝑎𝑂𝐻
+ 2 2

ρ𝐻 𝑂
+ ρ𝑆𝑜𝑎𝑝
+ ρ𝑆𝑇𝑃𝑃
+ ρ𝑍𝑒𝑜𝑙𝑖𝑡𝑒
2 2

𝑥𝑁𝑎 𝐶𝑂 𝑥𝑁𝑎 𝑆𝑖𝑂 𝑥𝑁𝑎 𝑆𝑂 𝑥𝑃𝑜𝑙𝑦𝑚𝑒𝑟 𝑥𝑃𝑒𝑟𝑏𝑜ả𝑡𝑒 𝑥𝑆𝐶𝑀𝐶 𝑥𝐻 𝑂

+ 2

ρ𝑁𝑎 𝐶𝑂
3
+ 2

ρ𝑁𝑎 𝑆𝑖𝑂
3
+ 2

ρ𝑁𝑎 𝑆𝑂
4
+ ρ𝑃𝑜𝑙𝑦𝑚𝑒𝑟
+ ρ𝑃𝑒𝑟𝑏𝑜𝑟𝑎𝑡𝑒
+ ρ𝑆𝐶𝑀𝐶
+ 2

ρ𝐻 𝑂
2 3 2 3 2 4 2

6.2. The mean diameter of detergent powder particles after spray drying
98.5 2σ
𝑑𝑡𝑏 = 𝑛
× 𝐷𝑑×ρ×𝑔
(13.14/272,[4])

98.5 2×0.0669 −5
= 22000
× −3 = 4. 78 × 10 (𝑚)
120×10 ×997.6743×9.81

While,
Surface tension: σ = 0. 0712 × (1 − 0. 002 × 𝑡𝑣1) = 0. 0669 (N/m)

57
6.3. Diameter of spray dryer
- Spray Radius:
𝑅𝑝 3 1.13 𝑟×µ ×𝑔 0.4
𝑑𝑚𝑎𝑥
= 1. 995 × 10 × 𝑅𝑒 × ( λ ×(𝑡 𝑘−𝑡 ) ) (6.125a/218,[5])
𝑘 1 𝑤

−6
3 1.13 2500×29.7×10 ×9.81 0.4
= 1. 995 × 10 × 16. 3952 ×( −2 )
4.61×10 ×(300−56)

→ 𝑅𝑝 = 1. 45 (𝑚)

While, (I.255/318,[1])
−5 −5
𝑑𝑚𝑎𝑥 = 2𝑑𝑡𝑏 = 2 × 4. 78 × 10 = 9. 56 × 10 (m)

Latent heat of water: r = 2500 (kJ/kg.K)

−6 2
Dynamic viscosity of drying agent at t1=300oC: µ𝑘 = 29. 7 × 10 (𝑁𝑠/𝑚 )
−2 𝑜
Thermal conductivity of drying agent at t1: λ𝑘 = 4. 61 × 10 (𝑊/𝑚. 𝐶)
𝑜
Wet-bulb temperature 𝑡𝑤 = 56 𝐶 ( From Psychrometric chart )

Viscosity of slurry: µ𝑠𝑙𝑢𝑟𝑟𝑦 = 0, 003 (𝑃𝑎. 𝑠)

Reynolds number:
ν×𝑑𝑡𝑏×ρ𝑠𝑙𝑢𝑟𝑟𝑦 −5
1 × 4.78×10 ×997.6743
𝑅𝑒 = µ𝑠𝑙𝑢𝑟𝑟𝑦
= 0.003
= 15. 896

- Diameter of chamber:
𝐷𝑇 ≥ (2. 8 ÷ 3. 4)𝐷𝑝 (P.68,[6])

→ 𝐷𝑇 ≥ 1. 5 × 2 × 𝑅𝑝 = 1. 5 × 2 × 1. 45 = 4. 36 (𝑚)

→ 𝐷𝑇 ≥ 4. 36 𝑚

6.4. The cross-section area of the drying chamber

2
π×𝐷𝑇 3.14×4.5
2
2
𝐹= 4
= 4
= 15. 9 (𝑚 )

58
6.5. Basic dimension of Dryer
- Volume of cylinder portion of chamber:
𝑊 653.7272 3
𝑉' = 𝐴
= 12
= 54. 48 (𝑚 )

While,

𝑊 = 653. 7272 (kg/h)

𝐴: moisture evaporation intensity, (kg/m3.h) taken from Table 13.1 – p. 274, [4]

- Diameter and height of dryer chamber

From (P.221,[5]), We have a ratio of the height to the diameter of drying
chamber is
𝐻𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟
𝐷
= 0. 8 ÷ 1. 1
𝐻𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟
Choose 𝐷
=1

We have:
2
π×𝐷 ×𝐻𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟 2
π×𝐷 ×1×𝐷
𝑉' = 4
= 4
= 54. 5

→ 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟 𝑝𝑜𝑟𝑡𝑖𝑜𝑛 𝑜𝑓 𝑐ℎ𝑎𝑚𝑏𝑒𝑟 𝐷 = 4. 5 𝑚

→ 𝐻𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑐𝑦𝑙𝑖𝑛𝑑𝑒𝑟 𝑝𝑜𝑟𝑡𝑖𝑜𝑛 𝑜𝑓 𝑐ℎ𝑎𝑚𝑏𝑒𝑟 𝐻 = 1 × 𝐷 = 4. 5𝑚

- Total volume of chamber:

ν1+ν2
𝑉𝑇 = 𝐿' × ( 2
) × 𝑡𝑑

8390.8810 1.7131+1.2239 3
= 3600
×( 2
) × 50 0. 6 = 132. 5(𝑚 )

- Volume of conical portion of chamber:

3
𝑉𝑐𝑜𝑛𝑒 = 𝑉𝑇 − 𝑉' = 78 (𝑚 )

The conical portion has 2 diameters. One is column diameter (D = 4.5m)

and the smaller diameter is assumed to be 0.2m (d=0.2m)
3𝑉𝑐𝑜𝑛𝑒 3×78
𝐻𝑐𝑜𝑛𝑒 = 2 2 = 2 2 = 3. 5𝑚
π×(𝐷 +𝐷×𝑑+𝑑 ) π×(4.5 +4.5×0.2+0.2 )

59
 - Cone angle:

We have:
𝐻𝑐𝑜𝑛𝑒 3.5
𝑡𝑎𝑛(β) = 𝐷 𝑑 = 4.5 0.2
2
−2 2
− 2

𝑜
→ β ≃ 58. 5 → α = 31. 5o
→ 𝐶𝑜𝑛𝑒 𝑎𝑛𝑔𝑙𝑒 = 2α = 2 × 31. 5 = 63o

6.6. Drying time

- The drying time is calculated according to the following formula:
𝐻
τ= 𝑤 + 𝑤'
(13.34/277,[4])

- Velocity of drying agent:

0.5×(𝑣𝑘1+𝑣𝑘2)×𝐿
𝑤= π𝐷𝑇
2 (P.276,[4])
3600× 4

0.5 × (1.7131+1.2239)×7940.3332
= 2
3.14×4.5
= 0. 2037 (𝑚/𝑠)
3600× 4

Note:
+ The specific volume of moist air per kg of dry air at t1: vk1
−3
𝑣𝑘1 = 4. 64 × 10 × (0. 622 + 𝑌1)(273 + 𝑡1) (13.33/276,[4])
−3 3
= 4. 64 × 10 × (0. 622 + 0. 0223)(273 + 300) = 1. 7131 (𝑚 /𝑘𝑔)

+ The specific volume of moist air per kg of dry air at t2: vk2
−3
𝑣𝑘2 = 4. 64 × 10 × (0. 622 + 𝑌2)(273 + 𝑡2) (13.33/276,[4])

60
 −3 3
= 4. 64 × 10 × (0. 622 + 0. 1046)(273 + 90) = 1. 2239 (𝑚 /𝑘𝑔)

- Terminal velocity of air in the chamber: w’

2
1 𝑔 × 𝑑𝑡𝑏 × (ρ−ρ𝑘)
𝑤' = 18
× µ𝑘×ρ𝑘

−5 2
1 9.81 ×( 4.93×10 ) × (997.6743−0.75425)
= 18
× −6 = 0, 0511 (𝑚/𝑠)
34.26×10 ×0.75425

𝑡1+𝑡2 𝑜
Note: All parameters is selected at ttb = 2
= 195 𝐶
3
+ Density of air: ρ𝑘 = 0, 75425 (𝑘𝑔/𝑚 )
−6 2
+ Viscosity of air: µ𝑘 = 34, 26 × 10 (𝑚/𝑠 )

- Actual velocity of air flow in chamber

𝑣𝐾 = 𝑤 + 𝑤' = 0. 2548 (𝑚/𝑠)

- Drying time:
4.5
τ= 0.2548
= 17. 66 (𝑠)

6.7. Mechanical design

6.7.1. Drying chamber
Table 6.2: Design parameters of chamber.

Height of cylindrical section 4.5 m

Diameter of chamber 3.5 m

Material Stainless Steel X18H10T

61
 Table 6.3: Material Properties

Density ρ𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 3
7. 9 × 10 (𝑘𝑔/𝑚 )
3 Table
XII.7/313,[2]
Thermal 16. 3 (𝑊/𝑚𝐾)
conductivity of
material λ𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙

(20oC - 100oC)

Tensile Strength σ𝑘 6
540 × 10 (𝑁/𝑚 )
2 Table
XII.4/310,[2]
Yield Strength σ𝑐 6
220 × 10 (𝑁/𝑚 )
2

Welding coefficient 0.95 Table

φℎ(𝐷 ≥ 700𝑚𝑚) XIII.8/362,[2]

Correction factor η 1 Table

XIII.2/356,[2]

- Allowable tensile stress:

σ𝑘
[σ𝑘] = η × η𝑘
(XIII.1/355,[2])
6
540×10 6 2
=1× 2.6
= 208 × 10 (𝑁/𝑚 )

Note:
+ Safety factor according to tensile strength: η𝑘 = 2.6

(Table XIII.3/356,[2])
- Allowable yield stress:
σ𝑐
[σ𝑐] = η × η𝑐
(XIII.1/355,[2])
6
220×10 6 2
=1× 1.5
= 147 × 10 (𝑁/𝑚 )

Note:

62
 + Safety factor according to yield strength: η𝑐 = 1.5

(Table XIII.3/356,[2])
- Thickness:
𝐷𝑇×𝑃
𝑆= 2[σ]φ−𝑝
+ 𝐶 (𝑚) (XIII.8/360,[2])

[σ𝑐] 147×10
6
Due to 𝑃
× φℎ = 4 × 0. 95 > 50, the parameter 𝑝 can be
9.81×10

ignored
𝐷𝑇×𝑃
→ 𝑆= 2[σ]φℎ
+ 𝐶 (𝑚)
4
4.5×9.81×10 −3
= 6 + 1. 18 × 10 = 0, 002764(𝑚)
2×147×10 ×0.95

→ 𝐶ℎ𝑜𝑜𝑠𝑒 𝑆 = 4 𝑚𝑚

- Verifying the thickness of dryer chamber:

[𝐷𝑇+(𝑆−𝐶)]×𝑃0
σ= 2×(𝑆−𝐶)×φℎ
(P.367,[2])
−3
[4.5+(5−1.18)×10 ]×0.2×10
6
6 σ𝑐 6
220×10 6
= −3 = 124. 11 × 10 < 1.2
= 1.2
= 183 × 10
2×(5−1.18)×10 ×0.95

While,
+ Additional quantity: C = C1 + C2 + C3 = 1 + 0 + 0.18 = 1.18 (mm)
Note:
➢ Corrosion allowance factor: C1 = 1 (mm). (Table XII.1/305,[2])
➢ The additional factor due to environmental corrosion is taken into
account. Since there are no solid particles moving at high speed in the
equipment, the parameter C2 can be ignored.
➢ The additional factor due to thickness tolerance is taken into account. For
X18H10T steel, C3 = 0.18 mm. (Table XIII.9/364,[2])
+ Test pressure: P0 = Pth + P1 (Table XIII.5/358,[2])
6 6 2
= 0. 2 × 10 + 0 = 0. 2 × 10 (𝑁/𝑚 )

63
 + Hydraulic test pressure: Pth=0.2 x 106 (N/m2)
+ Hydrostatic pressure of water: P1 = 0
➔ Thickness of the drying chamber is 5 mm.

6.7.2. Drying Base

Table 6.4: Design parameters of drying bottom.

Height of conical section 3.5 m

Large diameter 4.5 m

Small diameter 0.2 m

α 31.5o

Material Stainless Steel X18H10T

[σ𝑐] 147×10
6
Due to 𝑃
× φℎ = 4 × 0. 95 > 50
9.81×10

The minimum thickness of the conical base is

𝐷𝑇 ×𝑃
→ 𝑆' = 2×𝑐𝑜𝑠(β)×[σ]×φℎ
+ 𝐶 (𝑚)
4
4.5×9.81×10 −3
= 6 + 1. 18 × 10 = 0, 004(𝑚)
2×𝑐𝑜𝑠(58.5)×147×10 ×0.95

→ 𝐶ℎ𝑜𝑜𝑠𝑒 𝑆 = 5𝑚𝑚

- Verifying the thickness of dryer bottom:

[𝐷 ×𝑃 1 σ𝑐
𝑇 0
σ = [ 2×𝑐𝑜𝑠(α)×(𝑆−𝐶) + 𝑃0] × φℎ
≤ 1.2
(P.367,[2])
6
4.5×0.2×10 6 1
=[ −3 + 0. 2 × 10 ] × 0.95
2×𝑐𝑜𝑠(31.5)×(5−1.18)×10

6 σ𝑐 220×10
6
6
= 145. 64 × 10 < 1.2
= 1.2
= 183 × 10

→ 𝐶ℎ𝑜𝑜𝑠𝑒 𝑆 = 5 𝑚𝑚

64
 - Choose a flange for the product outlet pipe:

According to Table XIII.27 page 417.[2], the parameters of the flanges with thư
inner diameter of 0.2m and design pressure of 9.81x104 (N/m2) are indicated as follows:

Table 6.5: Parameter for the flanges of product outlet pipe

𝐷𝑦 𝐷𝑛 𝐷 𝐷δ 𝐷1 ℎ 𝑑𝑏 𝑍

(𝑚𝑚) (𝑝𝑖𝑒𝑐𝑒𝑠)
200 219 290 255 232 16 𝑀16 8

6.7.3. Drying Head

Choose a round flat lid. For this type of lid, due to the low load, the
thickness of the lid should be equal to the thickness of the body of the drying
chamber.
→ 𝐶ℎ𝑜𝑜𝑠𝑒 𝑆 = 5 𝑚𝑚

6.7.4. Bracket Lug Support

- The mass of the lid can be calculated as follows:
2
π×𝐷
𝑚𝑙𝑖𝑑 = 𝑡𝑙𝑖𝑑 × 𝑆𝑙𝑖𝑑 × ρ𝑙𝑖𝑑 = 0. 005 × 4
× 7900 = 628. 22 (𝑘𝑔)

- The mass of the chamber can be calculated as follows;

65
 π 2 2
𝑚𝑐ℎ𝑎𝑚𝑏𝑒𝑟 = 4
× (𝐷 − 𝐷𝑖 ) × 𝐻 × ρ𝑐ℎ𝑎𝑚𝑏𝑒𝑟
𝑐ℎ𝑎𝑚𝑏𝑒𝑟

π 2 2
= 4
× (4. 51 − 4. 5 ) × 4. 5 × 7900 = 2515. 67 (𝑘𝑔)

- The mass of conical portion:

𝑚𝑐𝑜𝑛𝑖𝑐𝑎𝑙 𝑠ℎ𝑒𝑙𝑙 = 𝑚𝑐𝑜𝑛𝑖𝑐𝑎𝑙 +𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 − 𝑚 𝑐𝑜𝑛𝑖𝑐𝑎𝑙

π 2 2 2 3
𝑚𝑐𝑜𝑛𝑖𝑐𝑎𝑙 = ( 3 × ℎ × (𝑅 + 𝑟 + 𝑅𝑟) + 3
π𝑅 ) × ρ

→ 𝑚 𝑐𝑜𝑛𝑖𝑐𝑎𝑙 𝑠ℎ𝑒𝑙𝑙 = 351564. 3 − 349238. 8 = 2325. 5 𝑘𝑔

- The mass of product:

π 2 2 2 3
𝑚𝑝𝑟𝑜𝑑𝑢𝑐𝑡 = ( 3 × ℎ × (𝑅 + 𝑟 + 𝑅𝑟) + 3
π𝑅 ) × ρ𝑝𝑜𝑤𝑑𝑒𝑟

= 17682. 9 𝑘𝑔
- The mass of flange:
π 2 2
𝑚𝑓𝑙𝑎𝑛𝑔𝑒𝑠 − 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 = 4
× (𝐷 − 𝐷𝑦 ) × ℎ × ρ
π 2 2
= 4
× (0. 29 − 0. 2 ) × 0. 016 × 7900 = 4. 3 𝑘𝑔
π 2 2
𝑚𝑓𝑙𝑎𝑛𝑔𝑒𝑠 − 𝑐𝑦𝑐𝑙𝑜𝑛𝑒 = 4
× (𝐷 − 𝐷𝑦 ) × ℎ × ρ

π 2 2
= 4
× (0. 435 − 0. 3 ) × 0. 022 × 7900 = 13. 5 𝑘𝑔
π 2 2
𝑚𝑓𝑙𝑎𝑛𝑔𝑒𝑠 − 𝑐𝑎𝑙𝑜𝑟𝑖𝑓𝑒𝑟 = 4
× (𝐷 − 𝐷𝑦 ) × ℎ × ρ

π 2 2
= 4
× (0. 485 − 0. 35 ) × 0. 022 × 7900 = 11. 53 𝑘𝑔

𝑚𝑡𝑜𝑡𝑎𝑙 𝑓𝑙𝑎𝑛𝑔𝑒𝑠 = 𝑚𝑓𝑙𝑎𝑛𝑔𝑒𝑠 − 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 + 𝑚𝑓𝑙𝑎𝑛𝑔𝑒𝑠 − 𝑐𝑦𝑐𝑙𝑜𝑛𝑒 + 𝑚𝑓𝑙𝑎𝑛𝑔𝑒𝑠 − 𝑐𝑎𝑙𝑜𝑟𝑖𝑓𝑒𝑟 = 29. 33 𝑘𝑔

- The total mass of the column can be determined as follows:

𝑚𝑡𝑜𝑡𝑎𝑙 = 𝑚𝑓𝑙𝑎𝑛𝑔𝑒𝑠 + 𝑚𝑙𝑖𝑑 + 𝑚𝑐𝑜𝑛𝑖𝑐𝑎𝑙 𝑠ℎ𝑒𝑙𝑙 + 𝑚𝑝𝑜𝑤𝑑𝑒𝑟 + 𝑚𝑐ℎ𝑎𝑚𝑏𝑒𝑟 = 23181. 5 𝑘𝑔

- Total load
𝐺 = 𝑚𝑡𝑜𝑡𝑎𝑙 × 𝑔 = 23181. 5 × 9. 81 = 227411 𝑁

Given that there are 4 basket lug support, thus the weight for each stand is
determined as:

66
 227441
4
= 56852. 7 (𝑁)

Thus, for the safety of the spray dryer, the weight for each stand can be
determined to be 60000 N (according to Table XIII.35, page 438 [2]). The design of the

support is illustrated in

Figure 6.1: Bracket lug support for vertical equipment

Some parameters for the design of the support are summerized in Table 6.6:

Design parameters for the support stands

G.10- F.10-4 q.10-6 L B B1 H S l a d meach

4
m2 N/m2 support
mm
N kg

6.0 451 1.33 230 200 205 350 12 100 25 34 13.2

Table 6.5: Summary data of basic parameters of one dryer design (for size)
Parameters Symbols Unit Value

Total volume of VT m3 132.5

chamber
Cylindrical volume V’ m3 54.5
Conial volume Vcone m3 78

67
Column diameter D m 4.5

Small diameter of d m 0.2

cone
Height of cylinder H m 4.5
Height of cone Hcone m 3.5
Cone angle 2α degree 630
Drying time τ s 17.66

Thickness of Schamber mm 5
chamber
Thickness of Sbase mm 5
Conical base
Thickness of Lid Slid mm 5

68
 CHAPTER 7: ENERGY BALANCE

7.1. Energy balance calculation

Inlet temperature of the material: tvl1 = 30℃.
Outlet temperature of the material: tvl2
𝑜
tvl2 = 𝑡2 − (5 ÷ 10 𝐶) = 90 − 10 = 80℃

- Specific heat capacity of material: 𝑐𝑣𝑙 (𝑘𝐽/𝑘𝑔. 𝐾)

𝑐𝑣𝑙 = 𝑐𝑘 × (1 − 𝑤2) + 𝑐𝑛 × 𝑤2 (I.44/152,[1])

= 1. 26 × (1 − 6%) + 4. 2 × 6% = 1. 4363 (𝑘𝐽/𝑘𝑔. 𝐾)

Note:
+ 𝑐𝑣𝑙 = 𝑐𝑣𝑙1 = 𝑐𝑣𝑙2 ( 𝑈𝑛𝑐ℎ𝑎𝑛𝑔𝑒𝑑 𝑏𝑒𝑓𝑜𝑟𝑒 𝑎𝑛𝑑 𝑎𝑓𝑡𝑒𝑟 𝑑𝑟𝑦𝑖𝑛𝑔)

+ Specific heat capacity of water: 𝑐𝑛 = 4. 2 (𝑘𝐽/𝑘𝑔𝐾)

+ Specific heat capacity of absolute dry material: 𝑐𝑘 = 1. 26 (𝑘𝐽/𝑘𝑔𝐾)

(Table I.145/163,[1])

7.1.1. Heat input into the drying equipment

- Heat input from the drying agent: 𝐿. 𝐸0 (J/s) where 𝐸0 is the enthalpy of the air

before entering the heating calorifier (J/kg kkk).

- Heat input received from the supplied calorifier by the drying agent:
𝐿. (𝐸1 − 𝐸0).

- Heat input from the material :[(𝐹 − 𝑊) × 𝑐𝑣𝑙 + 𝑊 × 𝑐𝑛] × 𝑡𝑣𝑙1.

7.1.2. Heat output from the drying equipment

- Heat loss carried away by the exhaust air: 𝐿 × 𝐸2 (J/s) where 𝐸2 is the enthalpy

of the air after leaving the drying chamber (J/kg kkk).

- Heat carried away by the dried material: 𝐺2 × 𝑐𝑣𝑙 × 𝑡𝑣𝑙2.

69
 - Heat loss to the surrounding environment: 𝑄𝑚.

7.2. Theoretical drying process calculations

7.2.1. Heat balance equation:
• 𝐿 × 𝐸0 + 𝐿 × (𝐸1 − 𝐸0) + [(𝐹 − 𝑊) × 𝑐𝑣𝑙 + 𝑊 × 𝑐𝑛) × 𝑡𝑣𝑙1]

= 𝐿 × 𝐸2 + 𝑃 × 𝑐𝑣𝑙 × 𝑡𝑣𝑙2 + 𝑄𝑚

Since 𝐹 − 𝑊 = 𝑃

⇔ 𝐿 × (𝐸1 − 𝐸0) = 𝐿 × (𝐸2 − 𝐸0) + 𝑃 × 𝑐𝑣𝑙 × 𝑡𝑣𝑙2 − 𝑃 × 𝑐𝑣𝑙 × 𝑡𝑣𝑙1

− 𝑊 × 𝑐𝑛 × 𝑡𝑣𝑙1 + 𝑄𝑚

7.2.2. Common heat consumption for the drying process:

𝑄 = 𝐿 × (𝐸1 − 𝐸0) = 𝐿 × (𝐸2 − 𝐸0) + 𝑃 × 𝑐𝑣𝑙 × (𝑡𝑣𝑙2 − 𝑡𝑣𝑙1) − 𝑊 × 𝑐𝑛 × 𝑡𝑣𝑙1 + 𝑄𝑚

Let:
𝑄𝑣𝑙 = 𝑃 × 𝑐𝑣𝑙 × (𝑡𝑣𝑙2 − 𝑡𝑣𝑙1) called the heat required to heat the drying material

⇔ 𝑄 = 𝐿 × (𝐸1 − 𝐸0) = 𝐿 × (𝐸2 − 𝐸0) + 𝑄𝑣𝑙 − 𝑊 × 𝑐𝑛 × 𝑡𝑣𝑙1 + 𝑄𝑚

Dividing both sides of the equation by W, we have specific heat consumption

(heat required to evaporate 1 kg of moisture):
𝑞 = 𝑙 × (𝐸1 − 𝐸0) = 𝑙 × (𝐸2 − 𝐸0) + 𝑞𝑣𝑙 − 𝑐𝑛 × 𝑡𝑣𝑙1 + 𝑞𝑚

While,
+ 𝐿 × (𝐸2 − 𝐸0) is the heat required to evaporate 1 kg of moisture.
𝑄𝑣𝑙
+ 𝑞𝑣𝑙 = 𝑊
is the specific heat consumption to heat the drying material from tvl1

to tvl2.
𝑄𝑣𝑙 𝑃 × 𝑐𝑣𝑙× (𝑡𝑣𝑙2−𝑡𝑣𝑙1)
𝑞𝑣𝑙 = 𝑊
= 𝑊

484.2424 × 1.4363 ×(80−30)

= 653.7272
= 53. 2 (𝑘𝐽/𝑘𝑔 𝑚𝑜𝑖𝑠𝑡𝑢𝑟𝑒)

70
 + 𝑐𝑛 × 𝑡𝑣𝑙1: is the heat content of 1 kg of moisture in the incoming material

Cn×tvl1 = 4.18 × 30 = 125.4 (kJ/kg moisture)

𝑄𝑚
+ 𝑞𝑚 = 𝑊
: is the specific heat loss to the surrounding environment.

7.2.3. Result
Let △ = 𝑐𝑛 × 𝑡𝑣𝑙1 − 𝑞𝑚 − 𝑞𝑣𝑙: it represents the additional heat input for the

actual drying process.

- Specific heat consumption:
q = l×(I1 – I0) = l×(I2 – I0) + △

For the theoretical drying process: △ = 0

- Common heat consumption:
𝑄 = 𝐿(𝐸2 − 𝐸0) (7-11/103,[7])

=7940. 3332 × (369. 3316 − 87. 1514) = 2240605. 124 (𝑘𝐽)

- Specific heat consumption:

𝑄 2240605,124
𝑞= 𝑊
= 653,7272
= 3427. 4314 (𝑘𝐽/𝑘𝑔 𝑚𝑜𝑖𝑠𝑡𝑢𝑟𝑒)

7.3. Heat loss in drying tower:

𝐾×𝐹×∆𝑡𝑙𝑛
𝑞𝑚𝑡 = 𝑊
(7.41/142,[4])

Note:
+ The surface area around the drying machine: F
+ Mean temperature difference between the drying agent and the
surrounding environment: ∆𝑡𝑙𝑛
2
+ Heat transfer coefficient: K (𝑊/𝑚 . độ)

71
 7.3.1. Heat transfer coefficient:
1
𝐾=
1 δ 1
α1
+∑ λ + α
2

(7.42/142,[4])
With:

δ
∑ λ : Total thermal resistance of the dryer.

α1: The overall heat transfer coefficient from inside to the equipment wall.

α2: The overall heat transfer coefficient from the wall to the surrounding

environments.

7.3.2. Overall heat transfer coefficient from inside to equipment wall α1

, ,,
α1 = 𝑘 × (α 1 + α 1)

Note:
+ The convection heat transfer coefficient from the drying agent to the dryer's wall:
, 2
α 1 (𝑊/𝑚 độ)

+ Natural convection heat transfer coefficient from the drying agent to the
,, 2
equipment wall: α 1 (𝑊/𝑚 độ)

+ Rough coefficient: k = 1.25

,
a. Calculation α 1:

- Average temperature of the air in the dryer

𝑡1+𝑡2 300+90 𝑜
𝑡𝑡𝑏 = 2
= 2
= 195 𝐶

- Determine the flow regime of the drying agent:

Reynolds number:

72
 ω × 𝐷𝑇 × ρ ω × 𝐷𝑇
𝑅𝑒 = µ
= µ
(V.36/13,[2])
0.8118 × 4.50
= −6 = 33461. 8872
34.26 × 10

4 4 𝐻
𝑊𝑒 ℎ𝑎𝑣𝑒: 5 × 10 > 𝑅𝑒 > 2 × 10 , 𝐷
= 1. 25

→ ε1 = 1. 392

- Nusselt number:
0.8
𝑁𝑢 = 0. 018 × 𝑅𝑒 × ε1 (V.42/16,[2])
0.8
= 0. 018 × 33461. 8872 × 1. 392 = 104. 3643
Note:
+ DT: Diameter of drying tower, D = 4.50m.
+ ω: Air velocity, ω = ν𝑘 = 0. 2548 (𝑚/𝑠)
−6 2
+ µ: Viscosity of air at t = 195oC, µ = 34. 26 × 10 (𝑚/𝑠 )

𝑜
- At 195oC, λ = 0. 0375 (𝑊/𝑚. 𝐶)
𝑁𝑢 × λ
α'1 = 𝐷𝑇
(P.17,[2])

104.3643× 0.0375 2
= 4.5
= 0. 870 (𝑊/𝑚 . độ)

● Calculation α''1:

- Gratkov number:
3 3
𝑔 × 𝐷 𝑇× β ×∆𝑡 𝑔×𝐷 × ∆𝑡
𝐺𝑟 = µ
= 2
𝑇
(V.39/13,[2])
µ × 𝑇2

3
9.81 × 4.5 × (300−90) 9
= −6 2 = 440. 6 × 10
(34.26 × 10 ) × (273+90)

Note:
2
+ Gravity acceleration: 𝑔 = 9. 81 𝑚/𝑠
+ Coefficient of volumetric expansion: β
+ Temperature difference between the inlet and outlet drying agent: ∆𝑡
−6 2
+ Viscosity of air: µ = 34. 26 × 10 (𝑚/𝑠 )

73
b. Calculation α''1:

- Nusselt number:
0.25
𝑁𝑢 = 0. 47 × 𝐺𝑟 (V.78/24,[2])
9 0.25
= 0. 47 × (440. 6 × 10 ) = 382. 92

𝑜
- At 195oC, λ = 0. 0375 (𝑊/𝑚. 𝐶)
𝑁𝑢 × λ
α''1 = 𝐷𝑇
(P.17,[2])

382.92× 0.0375 2
= 4.5
= 3. 1910 (𝑊/𝑚 . độ)

c. Calculation α2:

α1 = 𝑘 × (α'1 + α''1)
2
= 1. 25 × (0. 87 + 3. 1910) = 5. 0759 (𝑊/𝑚 . độ)

7.3.3. The overall heat transfer coefficient from the wall to the
surrounding environment α2.

α2 = α'2 + α''2

Note:
+ External heat transfer coefficient of a natural convection dryer: α'2

+ Radiative heat transfer coefficient: α''2

a. Calculation α'2:

The heat transfer coefficient from the exterior of the equipment to the
surrounding environment.

74
 𝑜
Assuming that the temperature of the air in the plant is 𝑡𝑘 = 28 𝐶 and the

temperature of the protective steel layer on the exterior surface of the equipment is
𝑜
𝑡𝑛 = 60 𝐶.
𝑡𝑘 + 𝑡𝑛 28+60 𝑜
𝑡𝑡𝑏 = 2
= 2
= 44 𝐶

- At 44oC, we have:
Thermal conductivity of drying agent: λ = 0, 0278 (𝑊/𝑚. độ)
−6 2
Viscosity of air: µ = 17, 356 × 10 (𝑚 /𝑠)

- Gratkov number:
3 3
𝑔 × 𝐷 𝑇× β ×∆𝑡 𝑔×𝐷 × ∆𝑡
𝐺𝑟 = µ
= 2
𝑇
(V.39/13,[2)
µ × 𝑇2

3
9.81 × 4.5 × (60−28) 9
= −6 2 = 315. 5 × 10
(34.26 × 10 ) × (273+28)

- Nusselt number:
0.25
𝑁𝑢 = 0. 47 × 𝐺𝑟 (V.78/24,[2])
9 0.25
= 0. 47 × (315. 5 × 10 ) = 352. 2456

𝑜
- At 44oC, λ = 0. 0278 (𝑊/𝑚. 𝐶)
𝑁𝑢 × λ
α'2 = 𝐷𝑇
(P.17,[2])

352.2456 × 0.0278 2
= 4.5
= 2. 18(𝑊/𝑚 . độ)

b. Calculation α''2:
1
𝑇 4 2
𝑇 4
[( 100 ) −( 100 )]
α''2 = ε𝑛 × 𝐶0 × 𝑇1−𝑇2
(V.135/41,[2])
333 4 301 4
[( 100 ) −( 100 ) ] 2
= 0. 85 × 5. 7 × 333−301
= 6, 19 (𝑊/𝑚 . độ)

75
 Note:
+ Blackness of an object: ε𝑛 = 0. 85 (𝐼𝑛 𝑡ℎ𝑒 𝑐𝑎𝑠𝑒 𝑜𝑓 𝑎 𝑠𝑡𝑒𝑒𝑙 𝑠𝑦𝑠𝑡𝑒𝑚)

+ Absolute blackbody emissivity: 𝐶0 = 5. 7

𝑜
+ Outer surface temperature in contact with air: 𝑇1 = 60 + 273 = 333 𝐶
𝑜
+ Air temperature: 𝑇2 = 28 + 273 = 301 𝐶

c. Calculation α2:
2
α2 = α'2 + α''2 = 2. 18 + 6. 19 = 8. 37 (𝑊/𝑚 . độ)

7.3.4. The total thermal resistance of the dryer

❖ Insulation layer:
- Material: Glass wool.
2
- Thermal conductivity: λ𝑖𝑛𝑠𝑢𝑙𝑎𝑡𝑖𝑜𝑛 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 = 0. 0372 (𝑊/𝑚 . độ)

- Thickness of insulation material: 𝑏2 (𝑚)

❖ Equipment:
- Material: Stainless Steel X18H10T
- Thickness is 𝑏1 = 5 𝑚𝑚
2
- λ1 = 16. 3 (𝑊/𝑚 . độ)

❖ Corrosion allowance layer:

- Material: Stainless Steel X18H10T
- Thickness is 𝑏3 = 1 𝑚𝑚
2
- λ1 = 16. 3 (𝑊/𝑚 . độ)

❖ Heat transfer rate within the tower due to heat supply:

- 𝑞 = π × 𝐷𝑇 × α1 × (𝑡𝑡𝑏 − 𝑡2)

= 3. 14 × 4. 5 × 5. 0759 × (195 − 90) = 7534. 6771 (𝑊/𝑚)

76
 λ2
- 𝑞= 𝑏2
× π × 𝐷𝑡𝑏 × (𝑡𝑤2 − 𝑡𝑤3)

0.0372
⇔ 7534. 6771 = 𝑏2
× 3. 14 × (4. 51 + 2𝑏2) × (195 − 90)

⇒ 𝑏2 = 0, 0074 𝑚

Note:
+ 𝑡𝑤1, 𝑡𝑤2: Inside and outside temperature of equipment’s wall,
𝑜
𝑡𝑤1 ∼ 𝑡𝑤2 = 195 𝐶

+ 𝑡𝑤3, 𝑡𝑤4: Inside and outside temperature of protect layer,

𝑡𝑤4 ∼ 𝑡𝑤3 = 90𝐶

+ 𝐷𝑡𝑏: Mean diameter of equipment ( include insulation layer )

𝐷𝑡𝑏 = 𝐷𝑇 + 2 × (𝑏1 + 𝑏2 + 𝑏3)

= 4. 5 + 2 × (0. 005 + 𝑏2 + 0. 001) = 4. 512 + 2𝑏2 (𝑚)

= 4. 512 + 2 × 0. 0074 = 4. 52468 (𝑚)

7.3.5. Result
- Overall heat transfer coefficient from the equipment to the environment is
1
𝐾= 1 1 𝑏1+𝑏3 𝑏
α1
+α + λ1
+ λ2
2 2

1
= 1 1 0.005+0.001 0.0074 = 1. 9383
5.0759
+ 8.37
+ 16.3
+ 0.0372

- Average temperature difference between the environment inside the

equipment and the surrounding environment:
𝑜
∆𝑡1 = 𝑡1 − 𝑡𝑘 = 300 − 28 = 272 𝐶
𝑜
∆𝑡2 = 𝑡𝑡𝑏 − 𝑡𝑘 = 195 − 28 = 167 𝐶
∆𝑡1−∆𝑡2 272−167 𝑜
∆𝑡𝑙𝑛 = ∆𝑡1 = 272 = 215, 25 𝐶
𝑙𝑛( ∆𝑡 ) 𝑙𝑛( 167
)
2

- Surface area for heat exchange with the surrounding environment:

77
 2
π×𝐷 𝑡𝑏
𝐹 = π × 𝐷𝑡𝑏 × 𝐻 + 4
2
3.14×(4.5268) 2
= 3. 14 × 4. 5268 × 4. 5 + 4
= 80. 0901 (𝑚 )

- Heat loss to the environment per 1 kg of moisture:

𝑄𝑚𝑡 = 𝐾 × 𝐹 × ∆𝑡𝑙𝑛

= 1. 9383 × 80. 0901 × 215. 25 = 33414. 25 (𝑘𝐽/ℎ)

𝑄𝑚𝑡 33459.44
𝑞𝑚𝑡 = 𝑊
= 653.7272
= 51. 11(𝑘𝐽/𝑘𝑔 𝑚𝑜𝑖𝑠𝑡𝑢𝑟𝑒)

7.4. Actual drying process calculation

𝑜
- Specific capacity of material: 𝑐𝑣𝑙 = 1. 4363 (𝑘𝐽/𝑘𝑔 𝐾)

- The overall heat transfer coefficient from inside to the equipment wall
2
α1 = 5. 0759 (𝑊/𝑚 . độ)

- The overall heat transfer coefficient from the wall to the surrounding
2
environment α2 = 8. 37 (𝑊/𝑚 . độ)

- Actual supplementary heat input:

∆ = 𝑐𝑛 × 𝑡𝑣𝑙1 − 𝑞𝑚𝑡 − 𝑞𝑣𝑙

= 4. 2 × 30 − 53. 2 − 224. 0605 =− 151. 2605 (𝑘𝐽/𝑘𝑔 𝑚𝑜𝑖𝑠𝑡𝑢𝑟𝑒) < 0

⇒ 𝐸2 < 𝐸1

Based on the above data, as delta is less than zero, the drying process requires
additional heat input due to the need to compensate for the heat lost to the environment
and the heat taken away by the drying material. Therefore, the actual drying process
will differ from the theoretical drying process, specifically in that the amount of heat
required for the actual drying process will be higher than that required for the
theoretical drying process.

Note:

78
 + 𝑞𝑣𝑙: The specific heat input required to heat the drying material from tvl1 to

tvl2 per 1 kg moisture.

𝑄𝑣𝑙 𝑃 × 𝑐𝑣𝑙× (𝑡𝑣𝑙2−𝑡𝑣𝑙1)
𝑞𝑣𝑙 = 𝑊
= 𝑊

484.2424 × 1.4363 ×(80−30)

= 653.7272
= 53. 2 (𝑘𝐽/𝑘𝑔 𝑚𝑜𝑖𝑠𝑡𝑢𝑟𝑒)

+ Assuming the heat loss to the environment is 10% of the total heat
amount:
𝑞𝑚𝑡 = 10% × 𝐿 × (𝐸2 − 𝐸0)

= 0. 1 × 7940. 3332 × (369. 3316 − 87. 1514)

= 224060. 5124 (𝐽/𝑘𝑔) = 224. 0605 (𝑘𝐽/𝑘𝑔)

7.5. Drying agent parameter in the actual drying process

- The specific heat capacity of the drying agent before drying:
𝐶𝑑𝑥(𝑌1) = 𝐶𝑝𝑘 + 𝐶𝑝𝑎 × 𝑌1 (P.138/[4])

= 1. 004 + 1. 842 × 0. 0223 = 1. 0451 (𝑘𝐽/𝑘𝑔 𝑑𝑟𝑦 𝑎𝑖𝑟)

Note:
+ Specific heat capacity at constant pressure of dry air:
𝑐𝑝𝑘 = 1. 004 (𝑘𝐽/𝑘𝑔𝐾)

+ Specific heat capacity at constant pressure of steam:

𝑐𝑝𝑎 = 1. 842 (𝑘𝐽/𝑘𝑔𝐾)

+ Latent heat of steam:

𝑟 = 2500 (𝑘𝐽/𝑘𝑔)

- The moisture content Y2 of the drying agent after the actual drying process:
𝑖2 = 2500 + 1. 842 × 𝑡2

= 2500 + 1. 842 × 90 = 2665. 78

𝐶𝑑𝑥(𝑌1)×(𝑡1−𝑡2)
𝑌2 = 𝑌1 + 𝑖2−∆

79
 1.0451×(300−90)
= 0. 0223 + 2665.78−(−151.2605)
= 0. 1002 (𝑘𝑔 𝑚𝑜𝑖𝑠𝑡𝑢𝑟𝑒/𝑘𝑔 𝑑𝑟𝑦 𝑎𝑖𝑟)

- Enthalpy of moist air:

𝐸2 = 𝑐𝑝𝑘 × 𝑡2 + 𝑌2 × 𝑖2

= 1. 004 × 90 + 0. 1002 × 2665. 78 = 357. 5471(𝑘𝐽/𝑘𝑔 𝑑𝑟𝑦 𝑎𝑖𝑟)

- Relative humidity of air:

𝑌2 × 𝐵 0.1002×1
φ2 = (0.622+𝑌2)×𝑃2
= (0.622+0.1002)×0.715
= 0, 1941 = 19. 41%

- The amount of dry air required to evaporate 1 kg of moisture in the

material:
1
𝑙' = 𝑌2−𝑌1
(P.283,[3])

1
= 0.1002−0.0223
= 12. 8354 (𝑘𝑔 𝑑𝑟𝑦 𝑎𝑖𝑟/𝑘𝑔 𝑚𝑜𝑖𝑠𝑡𝑢𝑟𝑒)

- The amount of dry air required:

𝐿' = 𝑙' × 𝑊 (P.283,[3])
= 12. 8354 × 653. 7272 = 8390. 8810 (𝑘𝑔 𝑑𝑟𝑦 𝑎𝑖𝑟/ℎ)

- Specific volume of moist air:

𝑅×𝑇
𝑣2 = 5 (VII.8/95,[2])
𝑀(𝐵−φ2×𝑝2)×10

287×(90+273) 3
= 5 = 1. 210 (𝑚 /𝑘𝑔 𝑑𝑟𝑦 𝑎𝑖𝑟)
(1−19.41%×0.715)×10

- The heat energy consumption for the actual drying process:

𝑞 = 𝑙' × (𝐸1 − 𝐸0)

= 12. 8354 × (369. 3316 − 87. 1514) = 3621. 4014(𝑘𝐽/𝑘𝑔 𝑚𝑜𝑖𝑠𝑡𝑢𝑟𝑒)

- Useful heat energy:

80
 𝑞1 = 𝑖2 − 𝑐𝑛 × 𝑡𝑣𝑙1 = 2665. 78 − 4. 2 × 30 = 2539, 78 (𝑘𝐽/𝑘𝑔 𝑚𝑜𝑖𝑠𝑡𝑢𝑟𝑒)

- Heat loss carried away by the drying agent:

𝑞2 = 𝑙' × 𝐶𝑑𝑥(𝑌1) × (𝑡2 − 𝑡0)

= 12. 8354 × 1. 0451 × (90 − 30)

= 804. 8687 (𝑘𝐽/𝑘𝑔 𝑚𝑜𝑖𝑠𝑡𝑢𝑟𝑒)

- Total heat loss:

𝑞' = 𝑞1 + 𝑞2 + 𝑞𝑣 + 𝑞𝑚𝑡

= 2539. 78 + 804. 8687 + 53. 2 + 224. 0605

= 3621. 9092 (𝑘𝐽/𝑘𝑔 𝑚𝑜𝑖𝑠𝑡𝑢𝑟𝑒)
In principle, the heat energy consumption Q and the total useful heat energy and
heat loss must be equal. However, due to various reasons, rounding errors may occur
during the calculation process, resulting in discrepancies.

- The absolute error:

∆𝑞 = |𝑞 − 𝑞'| = |3621. 49014 − 3621. 9092| = 0. 419
- The relative error:
∆𝑞 0.419
ε= 𝑞
× 100 = 3621.9092
× 100 = 0. 01%

⇒ Based on the above results, it can be concluded that the selected parameters
are entirely appropriate.
Table 7.1: Summary

Parameter Symbol Value Unit

1 Amount of dry air required in L' 8390.8810 𝑘𝑔 𝑑𝑟𝑦 𝑎𝑖𝑟/ℎ

actual drying process

2 The heat energy consumption for q 3621.9092 𝑘𝐽/𝑘𝑔 𝑚𝑜𝑖𝑠𝑡 𝑎𝑖𝑟

the actual drying process

81
 Parameter Symbol Value Unit

3 Actual heat input ∆ 151.2605 𝑘𝐽/𝑘𝑔 𝑚𝑜𝑖𝑠𝑡 𝑎𝑖𝑟

4 Useful heat energy q1 2539.78 𝑘𝐽/𝑘𝑔 𝑚𝑜𝑖𝑠𝑡 𝑎𝑖𝑟

5 Heat loss carried away by the q2 804.8687 𝑘𝐽/𝑘𝑔 𝑚𝑜𝑖𝑠𝑡 𝑎𝑖𝑟

drying agent

6 The specific heat input required to qvl 53.2 𝑘𝐽/𝑘𝑔 𝑚𝑜𝑖𝑠𝑡 𝑎𝑖𝑟
heat the drying material from tvl1
to tvl2 per 1 kg moisture.

7 The heat loss to the environment qmt 224.0605 𝑘𝐽/𝑘𝑔 𝑚𝑜𝑖𝑠𝑡 𝑎𝑖𝑟

8 Total heat loss q' 3621.9092 𝑘𝐽/𝑘𝑔 𝑚𝑜𝑖𝑠𝑡 𝑎𝑖𝑟

9 Calculation error ∆𝑞 0.419 𝑘𝐽/𝑘𝑔 𝑚𝑜𝑖𝑠𝑡 𝑎𝑖𝑟

10 Overall error ε 0.01 %

82
 CHAPTER 8: DESIGNING AN EFFICIENT CALORIFER

8.1. Product specifications:

Calorifer used in dryers come in many types. Here, we choose the gas-steam type
calorifer, which is a heat transfer device consisting of a bundle of finned tubes. The
condensed steam flows inside the tube, while the air moves outside the tube. The
temperature of the air entering the calorifer is equal to the temperature of the
atmosphere air t1’ = t0 = 30°C. The temperature of the air exiting the calorifer is equal to
the temperature entering the dryer t2’ = 300°C.

8.2. Calculation
8.2.1. Heat transfer area:
Choosing the heat transfer medium to flow inside the tube as saturated steam
under pressure p = 5 at. We have: Q = k×F×△t, W
With: + k: heat transfer coefficient, W/m2.°C
+ △t: average temperature difference, °C
+ F: heat transfer surface area, m2
𝑄
- Heat transfer surface area: F = 𝑘×∆𝑡
, m2

- The amount of heat required to evaporate W kg of moisture:

Q = L×(E1−E0)
= 7940.3332×(369.3316−87. 1514) = 2240604.8104 (kJ/Kg)
- The actual heat energy supplied by the calorifer:
𝑄 2240604.8104
Qactual = η
= 0.9
= 2489560.9005 (kJ/Kg)

(η is the heat supply efficient with η = 90%)

- The amount of steam required to supply to the calorifer:
𝑄𝑎𝑐𝑡𝑢𝑎𝑙
Qactual = Gsteam (ih1−ih2) => Gsteam = 𝑖ℎ1−𝑖ℎ2

With p= 5 at, we have the following physical parameters:

Tsaturated = 151.1°C
I’’ = 2754 kJ/kg
I’ = 637.7 kJ/kg

83
 With dryness x = 0.9 thì ih1 = x × I” + (1 - x) × I’= 0.9 × 2754 + 0.1× 637.7 =
2542.37 (kJ/kg)

Steam comes out of the calorifer when water is trapped at high pressure p p = 5
at so ih2 = I’ = 637.7 kJ/kg

- Therefore, the amount of steam is required for calorifer:

2489560,9005 𝑘𝑔 𝑘𝑔
Gsteam = (2542.37−637.7)
= 1307.0825 ( ℎ
) = 0.3631 ( 𝑠
)

- Next, calculate the average temperature difference △t

Saturated steam pressure p = 5 at => tsteam=151.10C

+△t1 = 151.1 – 30 = 121.10C

+△t2 = 300 – 151.1 = 148.90C

△𝑡1 − △𝑡2 121.1−148.9

=> ∆𝑡 = △𝑡1 = 121.1 = 134. 5216 0C
𝑙𝑛 △𝑡2
𝑙𝑛 148.9

- Calculate heat transfer coefficient k

1
K= 1 1 𝐹𝑡𝑟
α𝑡
+ α1 × 𝐹𝑛
+Σ𝑟

While:

+ Fn: the entire outer surface of the tube, including the helical surface, is counted
as a length unit of the tube, m2.

+ F1: the inner surface of the tube is counted as one length unit of the tube, m2.

+ Σ r: total thermal resistance of the wall and insulation layers.

8.2.2. Calculate calorifer size

a. Choose calorifer size

84
 Consider cooper as the material of heat transfer tube, which is finned to increase
the coefficient of thermal conductivity, with a coefficient of thermal conductivity:
λ = 385 W/m.0C (Table I.123/T125, [1]).

- The outside diameter of tube Dout = 0.04 (m)

- The inside diameter of tube Din = 0.03 (m)
𝐷𝑜𝑢𝑡−𝐷𝑖𝑛
- The thickness of tube δ = 2
= 0. 005 (m)

- The length of tube l = 1 m

- The diameter of fin Df = 1.4× Dout = 1.4 × 0.04 = 0.056 (m)
𝐷𝑓 −𝐷𝑜𝑢𝑡
- The fin height Hg = 2
= 0. 008 (m)

- The common step of tube f1 = (1.2÷1.5)Dout.

- Choose f1 = 1.25Dou t= 1.25 × 0.04 = 0.05 (m)

𝐷𝑜𝑢𝑡
The step of fin f2 follows : 3 < 2
< 4.8

Choose Dout/f2 = 4 so f2 = 0.04/ 4 = 0.01(m)

1 1
- The number of fins in one tube : m = 𝑓2
= 0.01
= 100

- The fin thickness δ’ = 0,002 (m)

- Total length of fins on tube: lf = m×δ’ = 100 × 0.002 = 0.2 (m)
- The tube length with no fins : L1 = l – lf =1.0 - 0.28 = 0.72 (m)

b. Calculate the area of calorifer

- The area around the tube excluding fins

F1 = ⫪×Dout×L1= 3.14×0.04×1.12=0.14 (m2)

- The vertical area of ​the total number of fins per tube

F1’=⫪× Dout×lf = 3.14 × 0.04 × 0.28=0.035 (m2)

- The upper and lower surface area of ​the total number of veins per tube

F2’=2×(⫪/4)×(Df2–Dout2)×m=2×(3.14/4)×(0.0562–0.042)×140 = 0.338 (m2)

85
 - The total surface area of ​all fins on 1 tube

F2 = F1’ + F2’= 0.035 + 0.338 = 0.373 (m2)

- The total surface area of ​a tube (including fins)

Fn = F1 + F2 – F1’ = 0.14+0.373-0.035 = 0.478 (m2)

- The total internal surface area of ​the pipe

Ftr = ⫪×(Dng - 2δ)×l= 3.14 × (0.04 - 2×0.005)×1.0=0.132 (m2)

- Total heat resistance of the wall : Σ𝑟 = 1.2987x10-5 (kgW/m2.0C)

c. Calculate the actual velocity of the air traveling in the calorifer

Choose the number of rows of calorifer to be n1 = 11 tubes, lined up.

- The width of calorifer

R = f1×(n1-1) + Df×n1 + 2lh (m)

=>R= 0.05×(11-1) + 0.056×11= 1.012 (m)

- The cross section of calorifer

Ffree = F - Fblock , (m2)

Ffinned =Dg × l×n1= 0.056×1.4×16= 0.784 9 (m2)

F pipe =Dout ×L1×n1= 0.04×1,12×10=0.448 (m2)

F = Ffinned + F pipe = 0.784+ 0.448= 1.232 (m2)

F = ×l= 1.012×1.4= 1.4168 (m2)

=> Ffree = 1.4168 -1.232 = 0.1848 (m2)

- The amount of air required for drying: L’= 2232.48

- The initial air temperature: to= 30oC-
- The air temperature after exiting calorifer: t2= 300oC
- The specific volume of air:

1 1
V300oC = ρ300
= 0.615
= 1.6260 (m3/kg)

86
 1 1
V30oC = ρ30
= 1.69
= 0.8554 (m3/kg)

𝑉300𝑜𝐶+𝑉30𝑜𝐶 1.626+0.8554
Vmean= 2
= 2
= 1.2407 (m3/kg)

- The volume flow of dry air before entering calorifer:

V’= L’×Vmean = 8390.8810×1.2407 = 10410.5661 (m3/h)

- The velocity of the air:

𝑉' 1041.,5661
ωair= 𝐹𝑓𝑟𝑒𝑒
= 0.1848×3600
= 15.6484 (m/s)

8.2.3. Calculate the heat transfer coefficient

Choose the velocity of the air traveling in the calorifer Wair = 40 (m/s)

a. Calculate the heat supply coefficient of saturated steam to the inner tube wall α1

4 𝑟
α1 = 2.04A 𝐻𝑥∆𝑟
(W/m2.độ) (CT V.101/T28, [2])

With:

+ A: The coefficient depends on the condenser film temperature.

+ △t1: The difference between the condenser temperature (saturation temperature)
and the wall side temperature exposed to the condensate, choose △t1=1.840C.
Therefore, the temperature at the heat transfer tube wall is tpipe = 1500C.
+ H: the tube height , H = 1.4m
+ The average temperature tm= 0.5 ×(tpipe + tsaturated)

=> tm = 0.5 ×(150+151.1)=150.550C so A= 196.5 (Table T29, [2])

With the temperature tm = 150.550C then we have the physical parameters:

λ = 68.69 ×102 W/m2K;

ρf = ρ’= 915.16 kg/m3;

ρh=ρ”=2.699 kg/m3;

87
 v=0.2019 m2/s;

r=2117 (J/kg).

Substituting the data in the above formula we have:

4 3
2117× 10
α1 = 2.04×196.5× 1.4×1.84
= 12069 (W/m2.độ)

b. Calculate the heat supply coefficient outside the tube α2

The heat supply coefficient is calculated by the formula:

𝑁𝑢×λ
α2 = 𝑓2

- Calculate Nu (for the case of flow across the outer area of the finned tubes)

𝐷𝑜𝑢𝑡 −0.54 𝐻𝑔 −0.14 𝑛 0.4

Nu = C×( 𝑓2
) ×( 𝑓2
) × 𝑅𝑒 × 𝑃𝑟 (CT V.57/20.[2])

With:

- Dout: the outer diameter of pipe; Dout = 0.04(m)

- f2: the step of fin ; f2 = 0.01 (m)
- Hg: the height of fin ; Hg = 0.008(m)
- C, n:thequantities that depend on the arrangement of the tubes. Choose the pipe
arrangement to be aligned, so we have: C = 0.116 ; n = 0.72
● Reynolds

The air flow rate through calorifer: wair­ = 40 m/s

𝑡1+𝑡2 300+30
The average temperature towards the air: tmean = 2
= 2
= 165 0C

From ttb = 165 0C then we have the physical parameters of the air : Search table
I.255 page 318 in “Sổ tay quá trình và thiết bị tập 1” book

µ=24.7×10-6(Ns/m2);

a = 3.3215×10-5 (m2/s)

88
 λ=3.19×10-2 (W/m. 0C);

n=22.8725×10-6(m2/s);

Pr= 0.6885

Substituting the data in we have:

𝑊𝑎𝑖𝑟×𝑓2 40×0.01
Re = 𝑣
= −6 = 13033. 5614
30.68×10

0.04 −0.54 0.008 −0.14 0.72 0.4

Nu = 0.166×( 0.01 ) ×( 0.01
) × 13033. 5614 × 0. 68175 = 44.5870

● Heat supply coefficient α2

−2
𝑁𝑢×λ 44.5870×3.674×10
α2 = 𝑓2
= 0.01
= 163.8126

=> Heat supply coefficient: αt = 100 (Graph V.17b/P.20, [2])

1
=> Heat transfer coefficient: K = 1 1 0.132 −5 = 99.6426 (W/m2. 0C)
100
+ 12069
× 0.478
+1.2987×10

➢ Heat transfer surface

2489560.9005×1000
F= 99.6426×134.5216×3600
= 51.5921

➢ The number of heat transfer tubes in calorifer

51.5921
n= 0.478
= 151

Choose n = 160 tubes

The number of rows of calorifer

160
n2 = 10
= 16

The length calorifer

L = f1×(n2­­-1)+Dg× n2 + 2lđ =0,048×16+0,056×16+0,02= 1,684 (m)

➢ The height of calorifer

89
 H = H’+Hch

With:

- H’: the height of tube

- H1: the height of barrier layer , choose H1= 0,15(m)

=> H = 1,0+0,15 = 1,55 (m)

The size of calorifer (D1 × R × C) = (0,04×1,844×0,116)

90
 CHAPTER 9: EFFICIENT CYCLONE DESIGN

9.1. Introduction of Cyclone

Figure 9.1. Structure of single cyclone

9.1.1. Working mechanism of cyclone

- Inlet: The gas or liquid stream containing particles enters the cyclone through an
inlet tangentially, creating a swirling motion inside the cyclone.
- Swirling motion: As the gas or liquid stream enters the cyclone, it starts to spin
rapidly due to the tangential entry. This swirling motion creates a centrifugal
force that pushes the particles towards the outer walls of the cyclone.
- Particle separation: The centrifugal force causes the heavier particles to move
towards the outer walls of the cyclone. These particles then slide down the walls
and collect at the bottom of the cyclone.
- Clean gas or liquid exit: The cleaned gas or liquid, with a reduced concentration
of particles, continues its upward spiral motion toward the center of the cyclone.
At the top of the cyclone, there is an outlet for the clean gas or liquid to exit.

91
 - Particle collection: The particles that have been separated and collected at the
bottom of the cyclone can be periodically removed through a discharge valve or
a collection chamber.

9.1.2. Safety considerations for usage

To ensure the normal operation of cyclones, the following conditions must be
met:
A) When using a group of cyclones with a common bunker, the occurrence of
flow reversal must be avoided as gas flows from one cyclone to another. Therefore, the
cyclones in the group must have equal resistance. The gas must enter and exit in a way
that ensures even distribution among the cyclones.
B) When installing a group of cyclones, the air ducts of each cyclone must be
welded onto the main duct from the outside.
C) The dust removal system must be sealed. If the dust removal system is not
sealed, dust will be released when the cyclone operates at high pressure, and air will be
drawn in when the cyclone operates at low pressure, resulting in a significant decrease
in cleanliness. The conical section of the cyclone must not be used to store dust. Dust
can only be removed from the bunker through a hydraulic valve. A gate valve or ball
valve can be used for intermittent dust removal, and a butterfly valve can be used for
continuous dust removal. Hydraulic valves must not be installed on the cyclone outlets.
The cleaning efficiency depends on the cohesive properties and concentration of
dust in the air. The operating mode of the cyclone affects the cleaning efficiency.
Therefore, for systems operating under varying gas flow conditions, an adjustment
device is necessary to allow for certain cyclones to be turned off when necessary.
9.2. Classification of Cyclone
There are 4 types of cyclone system such as single cyclone, combination cyclone,
cluster cyclone, and water film cyclone.
9.2.1. Single cyclone
9.2.2. Combined cyclone
- Connecting two cyclones of the same type in series.
- Connecting cyclones of the same type in parallel or multiple.

92
 9.2.3. Cluster cyclone
9.2.4. Water film cyclone
Cyclones are also classified into two types: high efficiency cyclones and high capacity
cyclones.
9.2.5 High efficiency cyclone
9.2.6 High capacity cyclone
9.3. Types of dust discharge valves for cyclones

a) Simple manual slide gate b) Rotary valve

c) Discharge screw feeder d) Automatic flap valve

93
9.4. Calculation of technical parameters of Cyclone using Selection Method
Conditions of the air entering the cyclone is the air after leaving the dryer:

- t2 = 90oC
3
From Table I.255/ p.318, [1], we have density ρ𝑎𝑖𝑟 = 0. 972 (𝑘𝑔/𝑚 )

- Specific volume of moist air: (VII.8/ p.94,[2])

𝑅×𝑇 287×(90+273) 3
𝑣2 = 5 = 5 = 1. 22 (𝑚 /𝑘𝑔 𝑑𝑟𝑦 𝑎𝑖𝑟)
𝑀(𝐵−φ2𝑝2)×10 (1−20.14%×0.715)×10

Where:

R = 8314 J/kmol.K - gas constant

T (K): temperature of inlet air of cyclone

M = 29 kg/kmol - molar weight of air

φ2(%): relative humidity of air

B (atm): atmospheric pressure

p2 (atm): saturated vapor pressure

- Total volumetric flow rate of inlet air into cyclones:

𝐿' 8390.8810 3 3
𝑉𝑖 = ρ𝑎𝑖𝑟
= 0.972
= 8632. 6(𝑚 /ℎ) = 2. 398 (𝑚 /𝑠𝑒𝑐)

Where: L’ is actual amount of dry air required (kg dry air/ h)

3
ρ𝑎𝑖𝑟 = 0. 972 is density of inlet air into the cyclone (𝑘𝑔/𝑚 )

- Average conventional speed on the cross-sectional area of cylindrical

portion of the cyclone : 2. 2 < ω𝑞 < 2. 5 (𝑚/𝑠) in order to prevent possible blockage

due to dust accumulation

2∆𝑃𝑐𝑦𝑐𝑙𝑜𝑛𝑒 2×545.0
ω𝑞 = ρ𝑎𝑖𝑟×ξ
= 0.972×180
= 2. 50 (𝑚/𝑠) (III.48/p.522, [1])

Choose ξ = 180 (𝑇𝑦𝑝𝑒 𝐼𝐼𝐻 − 11 𝑠𝑖𝑛𝑔𝑙𝑒 𝑐𝑦𝑐𝑙𝑜𝑛𝑒)

94
ξ: resistance coefficient of single or combined cyclone, refer to (Table III.10/p.528, [1])

- Resistance of the cyclone:

∆𝑃𝑐𝑦𝑐𝑙𝑜𝑛𝑒
Let ∆𝑃𝑐𝑦𝑐𝑙𝑜𝑛𝑒 be the resistance of the cyclone, 540 < ρ𝑎𝑖𝑟
< 740,(III.48/p.522, [1])

∆𝑃𝑐𝑦𝑐𝑙𝑜𝑛𝑒
We choose ρ𝑎𝑖𝑟
= 560. 7

2
Then ∆𝑃𝑐𝑦𝑐𝑙𝑜𝑛𝑒 = ρ𝑎𝑖𝑟×560. 7 = 0. 972×560. 7 = 545. 0 (𝑁/𝑚 )

- Normal operating condition of cyclone system required:

∆𝑃𝑐𝑦𝑐𝑙𝑜𝑛𝑒
( ρ𝑎𝑖𝑟×𝑔
= 35 ÷ 75𝑚)

∆𝑃𝑐𝑦𝑐𝑙𝑜𝑛𝑒 545.0
ρ𝑎𝑖𝑟×𝑔
= 0.972×9.81
= 57. 16 𝑚 (satisfied)

- Diameter of cyclone:

𝑉𝑖 2.398
𝐷= 0.785×ω𝑞×𝑁
= 0.785×2.50×2
= 781. 64 (𝑚𝑚)

Where:

N: number of cyclones in the system

ω𝑞 = 2. 50 (𝑚/𝑠): conventional speed on the cross-sectional area of

cylindrical portion of the cyclone

Then, we choose D=800 (mm)

Based on diameter and productivity, we choose 2 single cyclones IIH-11 as

single cyclone group with each diameter of 800 mm and technical parameters as below
(Table III.4/ p.524,[1])

95
 Table 9.1 Table of technical parameters of one Cyclone IIH-11

1 Inner diameter of cyclone (mm) 𝐷𝑖 = 40 − 800 𝑚𝑚 800

2 Inlet gate height (inner dimension) (mm) 𝑎 = 0. 48 𝐷 384

Height of the center tube with flange ℎ1 = 1. 56 𝐷

3 1248
(mm)

4 Height of cylindrical section (mm) ℎ2 = 2. 08 𝐷 1664

5 Height of conical section (mm) ℎ3 = 2. 0 𝐷 1600

Height of the external portion of the ℎ4 = 0. 3 𝐷

6 240
center tube (mm)

7 Total height (mm) 𝐻 = 4. 38 𝐷 3504

8 Outer diameter of the outlet pipe (mm) 𝑑1 = 450 450

Inner diameter of the dust discharge gate 𝑑2 = 0. 35 𝐷

9 280
(mm)

10 Width of the inlet gate (mm) 𝑏 = 0. 2 𝐷 160

11 Length of the inlet pipe (mm) 𝑙 = 0. 6 𝐷 480

Distance from the end of the cyclone to ℎ5 = 57

12 57
the flange face (mm)

96
 Inclined angle between the lid and the ° °
13 α = 11 α = 11
inlet pipe

14 Resistance coefficient of cyclone ξ = 180 ξ = 180

Figure 9.2. Basic dimension of single cyclone

- Speed of inlet exhaust gas into each cyclone ( > 15 m/s, usually 18-20 m/s) :
𝑉𝑖 2.398
ω𝑖 = 𝑎×𝑏×𝑁
= 0.384×0.16×2
= 19. 51 (𝑚/𝑠)

Where:

N: number of cyclones in the system

a (m): Inlet gate height (inner dimension)

b (m): Width of the inlet gate

3
𝑉𝑖(𝑚 /𝑠𝑒𝑐): Total volumetric flow rate of inlet air into cyclone

- Diameter of inlet pipe of cyclone system:

4×𝑉𝑖 4×2.398
𝑄𝑡 = 1000 × 𝑁×ω𝑖×π
= 1000 × 2×19.51 ×π
= 279. 73 (𝑚𝑚),

(III.27/ p.519, [1])

97
 Where:

N: number of cyclones in the system

ω𝑖 = 19. 51 (𝑚/𝑠) is speed of inlet exhaust gas

3
𝑉𝑖 = 2. 398 (𝑚 /𝑠) is total volumetric flow rate of inlet air into cyclones

Then choose 𝑄𝑡 = 300 (𝑚𝑚)

- Diameter of outlet pipe of cyclone system:

Speed of outlet gas from each cyclone (usually 4-8 m/s), choose ω𝑜 = 7. 6 𝑚/𝑠

4×𝑉𝑖 4×2.398𝑖
𝑑1 = 1000 × 𝑁×ω𝑜×π
= 1000 × 2×7.6×π
= 448. 2 , (III.25/ p.519, [1])

Where: N: number of cyclones in the system

ω𝑜 = 7. 6 (𝑚/𝑠) is speed of inlet exhaust gas
3
𝑉𝑖 = 2. 398 (𝑚 /𝑠) is total volumetric flow rate of inlet air into cyclones

Then choose 𝑑1 = 450 (𝑚𝑚)

- Number of turns of the gas inside the cyclone:

1 ℎ3 1 1600
𝑛= 𝑎
× (ℎ2 + 2
)= 384
× (1664 + 2
) = 6. 42

Then choose n = 7 (turns)

Where: a (mm): Inlet gate height (inner dimension)
ℎ2(mm): Height of cylindrical section

ℎ3(mm): Height of conical section

- Retention time of dust particles in each cyclone:

𝑛 7
τ = π × 𝐷𝑖 × ω𝑖
= π × 0. 8 × 19.51
= 0. 902(𝑠)

Where: 𝐷𝑖 = 0. 8 (𝑚) is inner diameter of cyclone

𝑛 = 7 is number of turns
ω𝑖 = 19. 51 (𝑚/𝑠) is speed of inlet exhaust gas

98
 - Theoretical Collection Efficiency
Dynamic viscosity of inlet air at T=90oC
387 273+𝑇 3/2 −6 387 273+90 3/2
µ = µ0◦𝐶 × 387+𝑇
( 273
) = 17. 29 × 10 × 387+90
( 273
)
−6
= 21. 51 × 10 (𝑘𝑔/𝑚. 𝑠)
−6
Where: µ0◦𝐶 = 17. 29 × 10 (kg/m.s) is dynamic viscosity of air at 1atm, 0૦C

a. Theoretical minimum captured dust particle diameter:

−6
µ×𝑏 (21.51×10 ) × 0.16 −5
𝐷𝑝 = 3 × π×𝑛×ω𝑖×(ρ𝑝−ρ𝑔)
=3× π × 7 × 19.51 × (400−0.972)
= 1. 345 × 10 (𝑚)

−6
Where: µ = 21. 51 × 10 (𝑘𝑔/𝑚. 𝑠) is dynamic viscosity of inlet air at
T=90oC
𝑏 = 0. 16 (𝑚) is width of the inlet gate
𝑛 = 7 is number of turns
ω𝑖 = 19. 51 (𝑚/𝑠) is speed of inlet exhaust gas
3
ρ𝑝= 400 (𝑘𝑔/𝑚 ) is density of dust
3
ρ𝑔 = 0. 972 (𝑘𝑔/𝑚 ) is density of inlet air into the cyclone

b. Theoretical Cutoff Diameter: Dust particle diameter corresponding to 50%

collection efficiency
−6
µ×𝑏 (21.51×10 ) × 0.16 −6
𝐷𝑝50 = 3 × 2π × 𝑛 × ω𝑖× (ρ𝑝−ρ𝑔)
=3× 2π × 7 × 19.51 × (400−0.972)
= 9. 511 × 10 (𝑚)

−6
Where: µ = 21. 51 × 10 (𝑘𝑔/𝑚. 𝑠) is dynamic viscosity of inlet air at
T=90oC
𝑏 = 0. 16 (𝑚) is width of the inlet gate
𝑛 = 7 is number of turns
ω𝑖 = 19. 51 (𝑚/𝑠) is speed of inlet exhaust gas
3
ρ𝑝= 400 (𝑘𝑔/𝑚 ) is density of dust

99
 3
ρ𝑔 = 0. 972 (𝑘𝑔/𝑚 ) is density of inlet air into the cyclone

c. Theoretical Collection efficiency:

1 1
η= 2 = −6 −5 2 = 66. 66 (%)
1+(𝐷𝑝50/𝐷𝑝) 1+[(9.511×10 )/(1.345×10 )]

Where: 𝐷𝑝: Minimum captured dust particle diameter

𝐷𝑝50: Particle diameter corresponding to 50% collection efficiency

9.5. Mechanical design of Cyclone

9.5.1. Material and Thickness of IIH-11 Cyclone
Table 9.2: Design parameters of cyclones.

Height of cylindrical portion 1664 mm

Height of conical portion 1600 mm

Material Carbon steel CT3

Table 9.3: Material Properties of Carbon steel CT3

Density ρ𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 7850 (𝑘𝑔/𝑚 )

3

Thermal conductivity of 50. 0 (𝑊/𝑚𝐾) Table XII.7/313,[2]

material λ𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙

(20oC - 100oC)

Tensile Strength σ𝑘 6
380 × 10 (𝑁/𝑚 )
2

Table XII.4/310,[2]
Yield Strength σ𝑐 6
240 × 10 (𝑁/𝑚 )
2

Welding coefficient φ𝑤( 0.95 (double-sided Table XIII.8/362,[2]

𝐷 ≥ 700𝑚𝑚) joint weld)

Correction factor η 1 Table XIII.2/356,[2]

100
 Safety factor η𝑘 2.6
Table XIII.3/356,[2]
Safety factor η𝑐 1.5

- Allowable tensile stress:

σ𝑘 380×10
6
6 2
[σ𝑘] = η × η𝑘
=1× 2.6
= 146. 2 × 10 (𝑁/𝑚 ) (XIII.1/355,[2)

Safety factor according to tensile strength: η𝑘 = 2.6 (Table XIII.3/356,[2])

- Allowable yield stress:

σ𝑐 240×10
6
6 2
[σ𝑐] = η × η𝑐
=1× 1.5
= 160 × 10 (𝑁/𝑚 ) (XIII.1/355,[2])

Safety factor according to yield strength: η𝑐 = 1.5 (Table XIII.3/356,[2])

6 2 6 2
Because [σ𝑘] = 146. 2 × 10 (𝑁/𝑚 ) < [σ𝑐] = 160 × 10 (𝑁/𝑚 )
6 2
Then choose [σ𝑘] = 146. 2 × 10 (𝑁/𝑚 ) for the following calculation.

a. Thickness of the body of the Cyclone subjected to internal pressure (Welding

method):
- Calculated working pressure inside the cyclone:
5 2
𝑃𝑐𝑦𝑐𝑙𝑜𝑛𝑒 = 𝑃𝑒𝑛𝑣𝑖𝑟𝑜𝑛𝑚𝑒𝑛𝑡(𝑜𝑓 𝑎𝑖𝑟) = 1 𝑎𝑡𝑚 = 1. 013 × 10 𝑁/𝑚

- Welding method:
6 2
Welding is used for devices working at low pressure (< 1. 6 × 10 𝑁/𝑚 ) and
6 2
medium pressure (1. 6 ÷ 10) × 10 𝑁/𝑚
5 2 6 2
𝑃𝑐𝑦𝑐𝑙𝑜𝑛𝑒 = 1. 013 × 10 (𝑁/𝑚 ) < 𝑃𝑙𝑖𝑚𝑖𝑡 = 10 × 10 𝑁/𝑚 (satisfied)

- Additional allowance due to chemical corrosion, mechanical corrosion, and

thickness tolerance
𝐶 = 𝐶1 + 𝐶2 + 𝐶3 , 𝑚 ,(XIII.17/363,[2])

101
 Where: 𝐶1(m): Additional allowance due to chemical corrosion

𝐶2(m): Additional allowance due to mechanical corrosion

𝐶3(m): Additional allowance due to thickness tolerance

+ Carbon steel CT3 is classified as durable material (0.05÷0.1 mm/yr), 𝐶1 = 1𝑚𝑚

(working time from 15÷20 years)

+ Since there are no solid particles moving at high speed in the equipment, the
parameter C2 can be ignored.
+ With carbon steel CT3 material (thin-rolled steel) has
3
ρ𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 = 7850 (𝑘𝑔/𝑚 ), parameter 𝐶3 = 0. 12 𝑚𝑚
−3 −3
+ 𝐶 = 𝐶1 + 𝐶2 + 𝐶3 = 10 × (1 + 0 + 0. 12) = 1. 12 × 10 (𝑚)

- Thickness of body of the cyclone subjected to internal pressure:

𝐷𝑖×𝑃𝑐𝑦𝑐𝑙𝑜𝑛𝑒
𝑆= 2[σ𝑘]×φ𝑤−𝑃𝑐𝑦𝑐𝑙𝑜𝑛𝑒
+ 𝐶 (𝑚) (XIII.8/360,[2])

Where: 𝐷𝑖 = 0. 8 (m): Inner diameter of cyclone

6 2
[σ𝑘] = 146. 2 × 10 (𝑁/𝑚 ) : Allowable tensile stress of Carbon

steel CT3 material

5
𝑃𝑐𝑦𝑐𝑙𝑜𝑛𝑒 = 1. 013 × 10 (N/m2): Pressure inside the cyclone

φ𝑤 = 0. 95: Welding coefficient

−3
𝐶 = 1. 12 × 10 (m): Additional allowance due to chemical
corrosion, mechanical corrosion, and thickness tolerance
𝐷𝑖×𝑃𝑐𝑦𝑐𝑙𝑜𝑛𝑒 0.8×(1.013×10 )
5
−3
𝑆= 2[σ𝑘]×φ𝑤−𝑃𝑐𝑦𝑐𝑙𝑜𝑛𝑒
+𝐶= 6 5 + 1. 12 × 10
2×(146.2×10 )×(0.95)−(1.013×10 )

−3
= 1. 412 × 10 (𝑚) = 1. 412 (𝑚𝑚)

Then, choose Thickness of body of the cyclone is S = 2 (mm)

102
 - Stress testing of the cyclone's body based on calculated pressure after
determining the thickness of cyclone’s body:
[𝐷𝑖+(𝑆−𝐶)]×𝑃𝑐𝑦𝑐𝑙𝑜𝑛𝑒
σ= 2×(𝑆−𝐶)×φ𝑤
(XIII.26/p.367,[2])
−3
[0.8+(0.002−1.12×10 )]×1.013×10
5
7 σ𝑐 6
240×10 8
= −3 = 4. 852 × 10 < 1.2
= 1.2
= 2 × 10
2×(0.002−1.12×10 )×0.95

(satisfied)

Where: 𝐷𝑖 = 0. 8 (m): Inner diameter of cyclone

5
𝑃𝑐𝑦𝑐𝑙𝑜𝑛𝑒 = 1. 013 × 10 (N/m2): Pressure inside the cyclone

φ𝑤 = 0. 95: Welding coefficient

−3
𝐶 = 1. 12 × 10 (m): Additional allowance due to chemical
corrosion, mechanical corrosion, and thickness tolerance

𝑆 = 0. 002 (m): Thickness of body of the cyclone

9.5.2. Mechanical Calculation

a. Flange Selection
● Flange at inlet gate (Rectangular)

Inlet gate (a x b = 388 mm x 164 mm)

● Flange at outlet gate (Round) (Ferrous material)

Outlet gate (𝑑1 = 450 𝑚𝑚)

103
 P Dy D Db D1 Do Bolt h flange
(N/m2) (mm) (mm) (mm) (mm) (mm)
db Z(qty) h
(mm)

10x106 450 570 530 500 461 M16 20 20

(Table XIII.27/p.418,[2])

● Gasket selection:

Dy (mm) (0.1-6.4) x106 (N/m2)

D2 (mm) D4 (mm)

450 497 477

(Table XIII.31/p.433,[2])

b. Flange at dust discharge gate (Round)

● Inlet pipeline (𝑄𝑡 = 300 𝑚𝑚)

104
 P (N/m2) Dy Do D D1 Db Bolt h flange
(mm) (mm) (mm) (mm) (mm)
db Z(qty) h
(mm)

0.25x106 300 325 435 365 395 M20 12 22

(Table XIII.26/p.415,[2])

● Gasket selection: (Table XIII.30/p.4325,[2])

Dy (mm) (0.25-1.0) x106 (N/m2)

D2 (mm) D4 (mm)

300 356 336

c. Bracket lug support Selection

3
- Weight of Shell made of Carbon steel CT3 ρ𝐶𝑇3 𝑠𝑡𝑒𝑒𝑙 = 7850 (𝑘𝑔/𝑚 )

- The mass of the lid can be calculated as follows:

2
1 π×𝐷𝑖
𝑚𝑙𝑖𝑑 = 𝑡𝑙𝑖𝑑 × 4
𝑆𝑙𝑖𝑑 × ρ𝐶𝑇3 𝑠𝑡𝑒𝑒𝑙 = 0. 002 × 16
× 7850 = 1. 97 (𝑘𝑔)

- The mass of 1 cyclone shell can be calculated as follows;

π 2 2
𝑚𝑐𝑦𝑙𝑖𝑛𝑑𝑟𝑖𝑐𝑎𝑙 𝑠ℎ𝑒𝑙𝑙 = 4
× (𝐷 − 𝐷𝑖 ) × 𝐻𝑐𝑦𝑙𝑖𝑛𝑑𝑟𝑖𝑐𝑎𝑙 × ρ𝐶𝑇3 𝑠𝑡𝑒𝑒𝑙
𝑐𝑦𝑙𝑖𝑛𝑑𝑟𝑖𝑐𝑎𝑙

π 2 2
= 4
× (0. 804 − 0. 8 ) × 1. 664 × 7850 = 65. 82 (𝑘𝑔)

𝑚𝑐𝑜𝑛𝑖𝑐𝑎𝑙 𝑠ℎ𝑒𝑙𝑙 = 𝑚𝑐𝑜𝑛𝑖𝑐𝑎𝑙 +𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 − 𝑚 𝑐𝑜𝑛𝑖𝑐𝑎𝑙

π 2 2
𝑚𝑐𝑜𝑛𝑖𝑐𝑎𝑙 = [ 3 × 𝐻𝑐𝑜𝑛𝑖𝑐𝑎𝑙 × (𝑅 + 𝑟 + 𝑅𝑟)] × ρ𝐶𝑇3 𝑠𝑡𝑒𝑒𝑙

→ 𝑚 𝑐𝑜𝑛𝑖𝑐𝑎𝑙 𝑠ℎ𝑒𝑙𝑙 = 3141. 6 − 3098. 8 = 42. 77 𝑘𝑔

𝑚𝑠ℎ𝑒𝑙𝑙 = 𝑚𝑐𝑦𝑙𝑖𝑛𝑑𝑟𝑖𝑐𝑎𝑙 𝑠ℎ𝑒𝑙𝑙 + 𝑚𝑐𝑜𝑛𝑖𝑐𝑎𝑙 𝑠ℎ𝑒𝑙𝑙 = 65. 82 + 42. 77 + 1. 97 = 110. 56 𝑘𝑔

105
 3
- Weight of detergent powder ρ𝑝𝑜𝑤𝑑𝑒𝑟 = 400 (𝑘𝑔/𝑚 )

- The mass of product:

π 2 2
𝑚𝑝𝑟𝑜𝑑𝑢𝑐𝑡 = [ 3 × 𝐻𝑐𝑜𝑛𝑖𝑐𝑎𝑙 × (𝑅 + 𝑟 + 𝑅𝑟)] × ρ𝑝𝑜𝑤𝑑𝑒𝑟

π 2 2
= [ 3 × 0. 16 × (0. 4 + 0. 14 + 0. 4 × 0. 14)] × 400 = 15. 79 𝑘𝑔
3
- Weight of flanges ρ𝐶𝑇3 𝑠𝑡𝑒𝑒𝑙 = 7850 (𝑘𝑔/𝑚 )

- The mass of flange

π 2 2
𝑚𝑓𝑙𝑎𝑛𝑔𝑒𝑠 − 𝑜𝑢𝑡𝑙𝑒𝑡 = 4
× (𝐷 − 𝐷𝑦 ) × ℎ × ρ𝐶𝑇3 𝑠𝑡𝑒𝑒𝑙

π 2 2
= [ 4 × (0. 57 − 0. 45 ) × 0. 02] × 7850 = 15. 09𝑘𝑔

𝑚𝑓𝑙𝑎𝑛𝑔𝑒𝑠 − 𝑖𝑛𝑙𝑒𝑡 = [(𝑎' × 𝑏') − (𝑎 × 𝑏)] × ℎ × ρ𝐶𝑇3 𝑠𝑡𝑒𝑒𝑙

= [(0. 468 × 0. 224) − (0. 388 × 0. 164)] × 0. 022 × 7850 = 7. 12 𝑘𝑔

π 2 2
𝑚𝑓𝑙𝑎𝑛𝑔𝑒𝑠 − 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 = 4
× (𝐷 − 𝐷𝑦 ) × ℎ × ρ𝐶𝑇3 𝑠𝑡𝑒𝑒𝑙
π 2 2
= 4
× (0. 435 − 0. 3 ) × 0. 022 × 7850 = 13. 46 𝑘𝑔

𝑚𝑡𝑜𝑡𝑎𝑙 𝑓𝑙𝑎𝑛𝑔𝑒𝑠 = 𝑚𝑓𝑙𝑎𝑛𝑔𝑒𝑠 − 𝑜𝑢𝑡𝑙𝑒𝑡 + 𝑚𝑓𝑙𝑎𝑛𝑔𝑒𝑠 − 𝑖𝑛𝑙𝑒𝑡 + 𝑚𝑓𝑙𝑎𝑛𝑔𝑒𝑠 − 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 = 35. 67 𝑘𝑔

- The total mass can be determined as follows:

𝑚𝑡𝑜𝑡𝑎𝑙 = 𝑚𝑠ℎ𝑒𝑙𝑙 + 𝑚𝑝𝑟𝑜𝑑𝑢𝑐𝑡 + 𝑚𝑡𝑜𝑡𝑎𝑙 𝑓𝑙𝑎𝑛𝑔𝑒𝑠 = 110. 56 + 15. 79 + 35. 67 = 162. 02 𝑘𝑔

- Total load
𝐺 = 𝑚𝑡𝑜𝑡𝑎𝑙 × 𝑔 = 162. 02 × 9. 81 = 1589. 4 𝑁

Given that there are 2 basket lug support, thus the weight for each stand is
determined as:

1589.4 𝑁
2
= 794. 7 (𝑁)

106
 Thus, for the safety of the cyclone, the weight for each stand can be determined
to be 1000 N (according to Table XIII.35, page 438 [2]). The design of the support is
illustrated in

Figure 9.3: Bracket lug support for vertical equipment

Some parameters for the design of the support are summarized in Table 9.4:

Design parameters for the support stands

G.10- F.10-4 q.10-6 L B B1 H S l a d meach

4
m2 N/m2 support
mm
N kg

0.1 42.5 0.24 80 55 70 125 4 30 15 14 0.53

107
 CHAPTER 10: EFFICIENT FAN SELECTION AND RESISTANCE
CALCULATION FOR CONSISTENT SPRAY DRYING PERFORMANCE

10.1. Resistance calculation for consistent spray drying performance

Determining the resistance of the drying system is an important step in the
process of designing a drying device. Based on the results of this calculation, we can
design or select a suitable fan for the drying system.

a. The resistance force from the inlet fan to the calorifier

2
𝐿1 𝑤1
∆𝑝1 = λ1 × 𝑑1
× ρ1 × 2

Choose an air duct with a length of 𝐿1 = 1. 5𝑚 and a diameter of

𝑑1 = 0. 3472𝑚

- The cross-sectional area of the pipe:

2 2
π𝑑 π×0.3472 2
𝐹' = 4
= 4
= 0. 0947𝑚

At the temperature of 30oC, referring to table I.255 on page 318 [1], we have:
3 −6 2
ρ1 = 1. 165𝑘𝑔/𝑚 𝑣1 = 16. 00 × 10 𝑚 /𝑠

- The velocity of the air flow blowing inside the pipe:

𝐿' 8390.8810
ω1 = 3600×ρ1×𝐹1
= 3600×1.165×0.0947
= 21. 1315(𝑚/𝑠)

- Reynolds number:
ω1 𝑑1 21.1315×0.3472
𝑅𝑒 = 𝑣1
= −6 = 458553. 0171 > 4000
16.00×10

→ Turbulent flow regime.

Choose material of the pipe is painted sheet steel which has surface roughness
−4
ε = 1 × 10 𝑚 (Table II.5, [381,1]).
The swirling motion is divided into three regions:
- The smooth hydraulic region: the Reynolds number limit is determined by the
following formula:

108
 8

𝑅𝑒𝑛𝑙 = 6 × ( )
𝑑
ε
7
= 112753. 2314

- The rough hydraulic region: The value of the Reynolds number at which the
rough region appear is:
9

𝑅𝑒𝑛 = 220 × ( )𝑑
ε
8
= 3545026. 822

𝑅𝑒𝑛𝑙 < 𝑅𝑒 < 𝑅𝑒𝑛 → The friction coefficient is calculated by the following formula:

100 0.25
(
λ = 0. 1 × 1. 46 ×
ε
𝑑
+ 𝑅𝑒 ) = 0. 0159
2
⇒ ∆𝑝1 = 17. 8638 𝑁/𝑚 ( )

b. The resistance force within the calorifier

2
𝑤2
∆𝑝2 = ξ × 𝑝𝑘 × 2

Where:
𝑤2 is the air velocity within the calorifier.

ξ is the local resistance coefficient.

3
(
𝑝𝑘 is the air density at the temperature being calculated 𝑘𝑔/𝑚 . )
The initial temperature of the air is 30oC when it enters the calorifier and is
heated to 300oC.

- The average temperature of the gas stream within the calorifier:

30+300 ◦
𝑡𝑎𝑣𝑔 = 2
= 165 𝐶
◦
- At the average temperature 165 𝐶, we have the physical properties of air:
−6
𝑣 = 30. 69 × 10 (𝑚2/𝑠)
3
ρ = 0. 806(𝑘𝑔/𝑚 )

F2= R× Lc = 1.012× 1.652= 1.6718 (m2)

- The air velocity within the calorifier is:

109
 𝐿'
𝑤2 = 3600×ρ2×𝐹2
= 1. 7298(𝑚/𝑠)

Π3 is the circumference of the cross-sectional area of the calorifier:

Π3= 2× (H× Lc)= 2×(1.55+1.652)= 6.404

4𝐹2
𝑑2 = Π2
= 1. 0442𝑚

- Reynolds number:
𝑤2×𝑑2
𝑅𝑒 = 𝑣
= 58856. 1694

Due to the parallel arrangement of pipes:

−0.23
ξ = (6 + 9𝑚) × ( )
𝑠
𝑑𝑔
× 𝑅𝑒
−0.26

Where:
s is the distance between two pipe axes in the direction perpendicular to the flow
(in the width of the flow).
𝐷𝑛𝑔 0.04
𝑠 = 𝐷𝑛𝑔 + 𝑓1 + 2
= 0. 04 + 0. 05 + 2
= 0. 11(𝑚)

0.11 −0.23
→ ξ = (6 + 9 × 10) × ( 0.056) × 58856. 1694
−0.26
= 4. 7281
2
⇒ ∆𝑝2 = 5. 7014(𝑁/𝑚 )

c. The resistance force from calorifier to the drying chamber

2
𝐿3 𝑤3
∆𝑝3 = λ3 × 𝑑3
× ρ3 × 2

Choose a pipe with a length of 𝐿3 = 2𝑚 and a diameter of 𝑑3 = 0. 3472𝑚.

2
π𝑑3 π×0.3472
2
2
𝐹3 = 4
= 4
= 0. 0947𝑚

- Temperature of air leaving calorifier is 300 degree celsius, so:

3
ρ3 = 0. 615𝑘𝑔/𝑚
−6 2
𝑣3 = 48. 33 × 10 𝑚 /𝑠

110
 - The air velocity within the duct is:
𝐿' 8390.8810
ω3 = 3600×ρ3×𝐹3
= 3600×0.615×0.0947
= 40. 0203(𝑚/𝑠)

- Reynolds number:
𝑤3 𝑑3 40.0203×0.3472
𝑅𝑒 = 𝑣3
= −6 = 287503. 3356 > 4000
48.33×10

Choose a turbulent flow regime.

The friction coefficient is calculated by the following formula:
6.81 0.9⎤ 0.9
−4
1
λ
=− 2𝑙𝑔⎡⎢
⎣
ε
𝑑3×3.7
+ ( ) 𝑅𝑒 ⎥ =−
⎦
2𝑙𝑔⎡⎢ 0.3472×3.7 +
⎣
10
( 6.81
287503.3356 ) ⎤
⎥
⎦
→ λ = 0. 017
2
⇒ ∆𝑝3 = 48. 2496 𝑁/𝑚 ( )

d. The frictional resistance within the drying chamber

2
𝐻4 𝑤4
∆𝑝4 = λ4 × 𝑑4
× ρ4 × 2

Corresponding to the average temperature within the drying chamber is 195

degree celsius, we have:
3 −6 2
ρ4 = 0. 959𝑘𝑔/𝑚 𝑣4 = 22. 115 × 10 𝑚 /𝑠

The air velocity within the drying chamber is:

4𝐿' 4×8390.8810
𝑤4 = 2 = 2 = 0. 1528(𝑚/𝑠)
3600π×ρ4×𝑑4 3600π×0.959×4.5

- Reynolds number:
𝑤4 𝑑4 0.1528×4.5
𝑅𝑒 = 𝑣4
= −6 = 31095. 4693
22.115×10

- The friction coefficient:

16 16
λ= 0.2 = 0.2 = 2. 0211
𝑅𝑒 31095.4693

2
⇒ ∆𝑝4 = 0. 0402(𝑁/𝑚 )

111
e. The resistance force from drying chamber to the cyclone
2
𝐿5 𝑤5
∆𝑝5 = λ5 × 𝑑5
× ρ5 × 2

Choose length of the pipe from drying chamber to the cyclone 𝐿6 = 2𝑚 and a

diameter of pipe is 𝑑6 = 0. 3𝑚.

The air flow rate within the pipe is the same as the air flow rate after leaving the
cyclone. Air flow in cyclone:
𝐿' 8390.8810 3 3
𝑉= ρ𝑎𝑖𝑟
= 0.972
= 8632. 6(𝑚 /ℎ) = 2. 398 (𝑚 /𝑠𝑒𝑐)

- The cross-sectional area of the pipe:

2 2
π𝑑 π×0.3 2
𝐹' = 4
= 4
= 0. 0707𝑚

- The air velocity within the drying chamber is:

2
𝑤5 =
𝑉
𝐹'
= 33. 9248 𝑚/𝑠 ( )
Corresponding to the air temperature after leaving the drying chamber at 90
degree celsius, we have:
3 −6 2
ρ6 = 0. 972𝑘𝑔/𝑚 𝑣6 = 22. 1 × 10 𝑚 /𝑠

- Reynolds number:
𝑤5 𝑑5 33.9248×0.3
𝑅𝑒 = 𝑣5
= −6 = 460517. 1083 > 4000
22.1×10

- The friction coefficient is calculated by the following formula:

6.81 0.9⎤ 0.9
−4
1
λ
=− 2𝑙𝑔⎡⎢
⎣
ε
𝑑5×3.7
+ ( ) 𝑅𝑒 ⎥ =−
⎦
2𝑙𝑔⎡⎢ 0.3×3.7 +
⎣
10
( 6.81
460517.1083) ⎤
⎥
⎦
⇒ λ = 0. 0167
2
⇒ ∆𝑝5 = 62. 2609 𝑁/𝑚 ( )
f. The resistance force of the pipe from cyclone to the exhaust fan
2
𝐿6 𝑤6
∆𝑝6 = λ6 × 𝑑6
× ρ6 × 2

112
 Choose 𝐿6 = 2. 5𝑚 is the length of the pipe from cyclone to the suction fan and

diameter of pipe is 𝑑6 = 0. 45𝑚.

The air flow rate within the pipe is the same as the air flow rate after leaving the
cyclone. Air flow in cyclone:
𝐿' 8390.8810 3 3
𝑉= ρ𝑎𝑖𝑟
= 0.972
= 8632. 6(𝑚 /ℎ) = 2. 398 (𝑚 /𝑠𝑒𝑐)

- The cross-sectional area of the pipe:

2 2
π𝑑 π×0.45 2
𝐹' = 4
= 4
= 0. 1590𝑚

- The air velocity within the drying chamber is:

2
𝑤6 =
𝑉
𝐹'
= 15. 0777 𝑚/𝑠 ( )
Corresponding to the air temperature after leaving the drying chamber at 90
degree celsius, we have:
3 −6 2
ρ6 = 0. 972𝑘𝑔/𝑚 𝑣6 = 22. 1 × 10 𝑚 /𝑠

- Reynolds number:
𝑤6 𝑑6 15.0777×0.45
𝑅𝑒 = 𝑣6
= −6 = 307011. 4056 > 4000
22.1×10

- The friction coefficient is calculated by the following formula:

6.81 0.9⎤ 0.9
−4
1
λ
=− 2𝑙𝑔⎡⎢
⎣
ε
𝑑6×3.7
+ ( ) 𝑅𝑒 ⎥ =−
⎦
2𝑙𝑔⎡⎢ 0.45×3.7 +
⎣
10
( 6.81
307011.4056) ⎤
⎥
⎦
⇒ λ = 0. 0164
2
⇒ ∆𝑝6 = 7. 2942 𝑁/𝑚 ( )

g. Resistance force within the cyclone

Assume ∆𝑝7 is the resistance force of the cyclone, then we have:
∆𝑝
540 < ρ𝑘
< 750

∆𝑝7 2
Choose ρ90
= 560.7, so ∆𝑝7 = 560. 7 × 0. 972 = 545. 0004 𝑁/𝑚 ( )

113
h. The sudden opening resistance, sudden inlet resistance from the pipe to the
drying chamber
● Inlet:
- The cross-sectional area of the pipe:
2 2
π𝑑 π×0.3472 2
𝐹= 4
= 4
= 0. 0947𝑚

- The cross-sectional area of the drying chamber:

2
𝐹1 = 15. 9𝑚
𝐹 0.0947
We have: 𝐹1
= 15.9
= 0. 006

Using table page 387, 388, [1]:

Sudden opening resistance case: ξ = 0. 9886
Sudden inlet resistance case: ξ = 0. 6
Temperature of air leaving calorifier is 300 degree celsius, so:
3 −6 2
ρ8 = 0. 615𝑘𝑔/𝑚 𝑣8 = 48. 33 × 10 𝑚 /𝑠
4𝐿' 4×8390.8810
ω8 = 2 = 2 = 40. 0295(𝑚/𝑠)
3600π×ρ8×𝑑8 3600π×0.615×0.3472

2
2
→ ∆𝑝8 = Σξ × ρ ×
ω
2
= 782. 7445 𝑁/𝑚 ( )
● Outlet:
- The cross-sectional area of the pipe:
2 2
π𝑑 π×0.45 2
𝐹= 4
= 4
= 0. 1590𝑚

- The cross-sectional area of the cyclone:

2
π×(2×0.8) 2
𝐹2 = 4
= 2. 0106𝑚
𝐹 0.1810
We have: 𝐹2
= 0.4803
= 0. 08

Using table page 387, 388, [1]:

Sudden opening resistance case: ξ = 0. 848
Sudden inlet resistance case: ξ = 0. 29
Corresponding to the air temperature after leaving the drying chamber at 90
degree celsius, we have:

114
 3 −6 2
ρ9 = 0. 972𝑘𝑔/𝑚 𝑣9 = 22. 1 × 10 𝑚 /𝑠
4𝐿' 4×8390.8810
ω8 = 2 = 2 = 15. 0773(𝑚/𝑠)
3600π×ρ9×𝑑9 3600π×0.972×0.45

2
2
→ ∆𝑝9 = Σξ × ρ ×
ω
2
= 125. 7262 𝑁/𝑚 ( )
So the total pressure drop of the entire system is:
14
2
∆𝑃 = ∑ ∆𝑃𝑛 = 1594. 8808 𝑁/𝑚 ( )
𝑛=1

10.2. Calculation for choosing efficient fan

Figure 10.1: Centrifugal fan

Centrifugal fans are widely used in various industries for ventilation, air
movement, and air handling applications. They are designed to generate a high volume
of airflow at a relatively low pressure. In our drying system, we need to use a fan to
create dynamic pressure to move air into the system and partly overcome the drag force
of the pipe. We use two types of fans:
- An inlet fan to push air into the calorifier.
- An exhaust fan to extract exhaust gasses from the cyclone and discharge them
outside.

10.2.1. Push fan placed before the calorifier

- The airflow rate pushed in is:

115
 3 3
𝑄 = 𝑉 × 𝐿' = 0. 9090 × 8390. 8810 = 7627. 3108𝑚 /ℎ = 2. 1187 𝑚 /𝑠

- Where:
- V is the specific volume of outdoor air (m3/kg dry air).
- L' is the actual drying agent flow rate (kg dry air/h).

Overall working pressure:

273+𝑡 2
𝐻 = 𝐻𝑝 × 293
×
760
𝐵
×
ρ'
ρ
= 852. 0108 𝑁/𝑚 ( )
Where:

2
- 𝐻𝑝 is the total system pressure drop (𝑁/𝑚 )

2
𝐻𝑝 =
∆𝑃
2
= 797. 4404 𝑁/𝑚 ( )
- 𝑡0 is the initial temperature, 𝑡 =30°C.

- B is the atmospheric pressure at the workplace, B = 735.6 mmHg.

- ρ is the density of air at standard conditions, ρ = 1.165 kg/m3.
- ρ' is the density of air at working conditions, ρ' = 1.165 kg/m3.

2 3
From calculation, with 𝐻 = 852. 0108 𝑁/𝑚 ( ) and 𝐿' = 8390. 8810𝑚 /ℎ,
based on the characteristic curve of the centrifugal fan, we choose fan II.4-70 N010
(P.485, [1])

116
 - Power of the fan:
𝑄𝑑×𝐻×𝑔×ρ
𝑁= 1000×η𝑞×η𝑡𝑟
(II.239a/T463.[1])

Where:
+ ƞq =0.8 is efficiency of the fan.
+ ƞtr =0.95 is belt drive efficiency.
2.1187×852.0905×9.81×1.165
So, 𝑁 = 1000×0.8×0.95
= 27. 1454(𝑘𝑊)

Power factor reserve: With N >5 choose k = 1.1 (Table II.48/T464.[1])

Rated power of electric motor: 𝑁𝑚 = 𝑘 × 𝑁 = 1. 1 × 27. 1454 = 29. 8599(𝑘𝑊)

(II.240/T464.[1])

117
 10.2.2. Exhaust fan placed after the cyclone

a. The airflow rate pushed in is:

3 3
𝑄 = 𝑣2 × 𝐿' = 1. 22 × 8390. 8810 = 10236. 87482𝑚 /ℎ = 2. 8436 𝑚 /𝑠

Where:
- V is the specific volume of outdoor air (m3/kg dry air).
- L' is the actual drying agent flow rate (kg dry air/h).

Overall working pressure:

273+𝑡 2
𝐻 = 𝐻𝑝 × 293
×
760
𝐵
×
ρ'
ρ (
= 851. 6271 𝑁/𝑚 )
Where:

2
- 𝐻𝑝 is the total system pressure drop (𝑁/𝑚 )

2
𝐻𝑝 =
∆𝑃
2 (
= 797. 4404 𝑁/𝑚 )
- 𝑡0 is the temperature of air after leaving drying chamber, 𝑡0 = 90°C.

- B is the atmospheric pressure at the workplace, B = 735.6 mmHg.

- ρ is the density of air at standard conditions, ρ =1.165 kg/m3.
- ρ' is the density of air at working conditions, ρ' = 0.972 kg/m3.

2
From calculation, with 𝐻 = 851. 6271 𝑁/𝑚 ( ) and 𝐿' = 8390. 8810( 𝑚3/ℎ),
based on the characteristic curve of the centrifugal fan, we choose fan II.4-70 N010
(P.485, [1])

118
Power of the fan:
𝑄𝑑×𝐻×𝑔×ρ
𝑁= 1000×η𝑞×η𝑡𝑟
(II.239a/T463.[1])

Where:
+ ƞq =0.8 is efficiency of the fan.
+ ƞtr =0.95 is belt drive efficiency.
2.8436×851.6271×9.81×0.972
So, 𝑁 = 1000×0.8×0.95
= 30. 3836(𝑘𝑊)

Power factor reserve: With N >5 choose k = 1.1 (Table II.48/T464.[1])

Rated power of electric motor: 𝑁𝑚 = 𝑘 × 𝑁 = 1. 1 × 30. 3836 = 33. 4220(𝑘𝑊)

According to table II.52 page 484 [1]:

Table 10.1 Parameters of II.4-70 N010

No. Dimension (mm)

119
 A B B1 B2 G E N P K H

N010 650 1018 784 700 768 888 433 650 1130 1057

No. Dimension (mm) Number Weight Standard belt

of holes (kg)

D D1 d1 d2 n1 n2 D0 O Number Type
of of
grooves belts

N010 1020 1060 12×20 12×20 16 20 522 315 190 7 B

120
CONCLUSION
In conclusion, this report has presented the design of a spray drying system for
laundry detergent powder, including the calculations and selection of the drying tower,
calorifer, cyclone, and centrifugal fan.
The design process involved careful consideration of various factors such as
drying efficiency, heat transfer requirements, particle separation, and air handling.
Through calculations and analysis, the appropriate sizing and specifications for each
component were determined to achieve optimal performance and desired drying
outcomes.
The selection of the drying tower took into account factors such as tower height,
diameter, and airflow patterns to ensure effective drying and particle residence time.
The calorifer was chosen based on its capacity to provide the required heat energy
efficiently and maintain stable temperature conditions within the drying system.
Furthermore, the cyclone separator was selected to efficiently separate the dried
powder from the exhaust air stream, ensuring product quality and minimizing
emissions. The centrifugal fan was carefully chosen to provide the necessary air
circulation and pressure requirements for the system, facilitating the proper flow of air
and particles throughout the process.
Overall, this design report has successfully outlined the calculations and
selection processes involved in designing a spray drying system for laundry detergent
powder. The chosen components, including the drying tower, calorifier, cyclone, and
centrifugal fan, have been carefully considered to ensure optimal performance, energy
efficiency, and product quality. The designed system holds promise for efficient and
effective drying of laundry detergent powder, contributing to the overall success and
productivity of the manufacturing process.

121
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khoa học kĩ thuật, Hà Nội, 2005.
[2] Nguyễn Bin , Sổ tay quá trình và thiết bị trong công nghệ hóa chất tập 2 ,nhà xuất
bản khoa học kĩ thuật, Hà Nội, 2005.
[3] Vũ Bá Minh, Quá trình và thiết bị công nghệ hoá học và thực phẩm truyền khối tập 3,
nhà xuất bản Đại học quốc gia TP. Hồ Chí Minh, 2018.
[4] Trần Văn Phú, Tính toán và thiết kế hệ thống sấy , nhà xuất bản khoa học kĩ thuật Hà
Nội, 2002.
[5] Nguyễn Văn Lụa, Quá trình và thiết bị công nghệ hoá học thực phẩm - Tập 7 Kỹ thuật
Sấy vật liệu.
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122