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DRY 2: Dryer Selection

DRY 2: Dryer Selection
     Part 1: Selection Algorithm
         1 INTRODUCTION
             1.1 Statement of purpose
             1.2 How to use this manual
         2 DRYING EQUIPMENT AND ITS CLASSIFICATION
             2.1 Introduction
             2.2 Classification criteria
             2.3 Dryer classification charts
             2.4 Drying equipment types
                 2.4.1 Batch dryers
                 2.4.2 Continuous dryers
                 2.4.3 Equivalent types of equipment
             2.5 Classification tables
             2.6 Flowsheet features and ancillary equipment
                 2.6.1 Type of heater
                 2.6.2 Gas recycle
         3 LITERATURE SURVEY
             3.1 Overview
             3.2 Materials classification
             3.3 Suggested guidelines
         4 FORMULATION OF THE DRYING PROBLEM
             4.1 Introduction
             4.2 Dryer selection decisions
             4.3 Selection strategy
             4.4 Drying in the context of the overall process
             4.5 Problem definition and initial flowsheeting
                 4.5.1 Transition conditions
                 4.5.2 Direct powder production from solution
                 4.5.3 Direct slurry drying
         5 THE SPS DRYER SELECTION ALGORITHM
             5.1 Equipment and application factors
             5.2 Stages in the algorithm
             5.3 Step 1 - Data collection
                 5.3.1 Items to be specified
                 5.3.2 Items to be measured
                 5.3.3 Dryer attributes
             5.4 Step 2 - Fundamental choices
                 5.4.1 Form of feed and product
                 5.4.2 Mode of operation
                 5.4.3 Mode of heating
                 5.4.4 Layer or dispersion dryers
             5.5 Step 3 - Short-list suitable dryer types
             5.6 Step 4 - Dryer sub-types and flowsheet features
             5.7 Step 5 - Evaluation procedure
         6 RULES FOR SELECTION
             6.1 Rules to choose between basic groups of dryers
                 6.1.1 Rule 1. Form of feed
                 6.1.2 Rule 2. Form of product
                 6.1.3 Rule 3. Relationship of feed and product form
                 6.1.4 Rule 4. Feed modification
                 6.1.5 Rule 5. Post-processing of product
                 6.1.6 Rule 6. Upstream process - batch or continuous
                 6.1.7 Rule 7. Downstream process - batch or continuous
                 6.1.8 Rule 8. Dry solids throughput WS
                 6.1.9 Rule 9. Moisture content reduction
                 6.1.10 Rule 10. Requirement for batch integrity
                 6.1.11 Rule 11. Particle size reduction or enlargement
                 6.1.12 Rule 12. Possible use of a two-stage dryer
             6.2 Rules for reformulating input data
                 6.2.1 Rule 13. Interpretation of drying curve and heat and mass balance
                 6.2.2 Rule 14. Basic type of solid
                 6.2.3 Rule 15. Temperature sensitivity of solid
                 6.2.4 Rule 16. Selection of inlet gas temperature and heating medium temperature
                 6.2.5 Rule 17. Particle or agglomerate strength
             6.3 Rules for individual dryer types
                 6.3.1 Rule 18. Overall evaporation rate
                 6.3.2 Rule 19. Acceptable dry solids throughput
                 6.3.3 Rule 20. Particle size and agglomeration
                 6.3.4 Rule 21. Particle size distribution
                 6.3.5 Rule 22. Attrition requirements
                 6.3.6 Rule 23. Handling characteristics of feed and product
                 6.3.7 Rule 24. Particle shape
                 6.3.8 Rule 25. Distribution between surface and internal moisture
                 6.3.9 Rule 26. Outlet moisture content distribution
                 6.3.10 Rule 27. Requirement for turndown
                 6.3.11 Rule 28. Space considerations
                 6.3.12 Rule 29. Other product properties
                 6.3.13 Rule 30. Solids residence time
                 6.3.14 Rule 31. Previous experience
                 6.3.15 Rule 32. Capital cost
                 6.3.16 Rule 33. Requirement for containment of gas
                 6.3.17 Rule 34. Combustibility of solid - fire and explosion hazards
                 6.3.18 Rule 35. Need for solids containment
             6.4 Rules for flowsheet configuration and other non-dryer-specific features
                 6.4.1 Rule 36. Type of solvent - water or organic
                 6.4.2 Rule 37. Choice of basic gas-side flowsheet layout
                 6.4.3 Rule 38. Use of gas recycle
                 6.4.4 Rule 39. Choice of conveying gas
                 6.4.5 Rule 40. Type of heater
                 6.4.6 Rule 41. Energy supply method and temperature
                 6.4.7 Rule 42. Operating cost and cost of energy source
             6.5 Additional comments and general notes
                 6.5.1 Rule 43. Choice of outlet moisture content
                 6.5.2 Rule 44. State of solids
                 6.5.3 Rule 45. Estimated cycle time
                 6.5.4 Rule 46. Combinational heating mode
                 6.5.5 Rule 47. System pressure
                 6.5.6 Rule 48. Location
                 6.5.7 Rule 49. Gas cleaning system
                 6.5.8 Rule 50. Proven nature of dryer
                 6.5.9 Rule 51. Sticky-point experimental data
             6.6 Rules to distinguish between dryer subtypes
                 6.6.1 Rule 52. Gas flow pattern
                 6.6.2 Rule 53. Equilibrium moisture content data
                 6.6.3 Rule 54. Fluidised bed dryers
                 6.6.4 Rule 55. Pneumatic conveying dryers
                 6.6.5 Rule 56. Cascading rotary dryers
                 6.6.6 Rule 57. Indirect rotary dryers
                 6.6.7 Rule 58. Horizontal agitated dryers
                 6.6.8 Rule 59. Spray dryers
                 6.6.9 Rule 60. Through-circulation dryers
                 6.6.10 Rule 61. Film-drum dryers
         7 SMALL-SCALE TESTS
             7.1 Role of user laboratory tests
             7.2 Batch simulation and scale-up
             7.3 Details of testing methods
                 7.3.1 Physical properties
                 7.3.2 Handling properties
                 7.3.3 Thermal sensitivity
                 7.3.4 Environmental factors
                 7.3.5 Drying characteristics
             7.4 Laboratory simulation of selected layer dryers
                 7.4.1 Continuous rotating shelf dryer
                 7.4.2 Continuous vacuum plate dryer
                 7.4.3 Horizontal and vertical agitated dryers
                 7.4.4 Continuous rotary-louvre dryer
             7.5 Laboratory simulation of dispersion dryers
         8 APPROXIMATE SIZING AND COSTING METHODS
             8.1 Introduction
             8.2 Calculation of characteristic area of dryer
                 8.2.1 Dispersion and through-circulation dryers
                 8.2.2 Worked example
                 8.2.3 Contact dryers
                 8.2.4 Worked example
                 8.2.5 Convective cross-circulation dryers
                 8.2.6 Worked example
                 8.2.7 Other heating methods and dryer types
             8.3 Calculation of dryer dimensions
                 8.3.1 Calculation of width and length for single beds
                 8.3.2 Worked example
                 8.3.3 Calculation of horizontal and vertical dimensions for multi-layer beds
                 8.3.4 Worked example
                 8.3.5 Length calculation for dispersion dryers
                 8.3.6 Worked example
                 8.3.7 Mechanically agitated and indirect rotary dryers
                 8.3.8 Worked example
                 8.3.9 Multiple dryers
             8.4 Cost criteria
                 8.4.1 Capital cost
                 8.4.2 Cost data from users
                 8.4.3 Simple formulae for cost estimation
                 8.4.4 Worked example for capital cost
                 8.4.5 Scaling factors for historical cost data
                 8.4.6 Operating cost
                 8.4.7 Value of product
                 8.4.8 Worked example for energy cost and production value
             8.5 Delivery
         9 WORKED EXAMPLES
             9.1 Principal worked example
                 9.1.1 Base case
                 9.1.2 High throughput example
                 9.1.3 High outlet moisture content example
                 9.1.4 Low inlet moisture content example
             9.2 Industrial case studies
                 9.2.1 Example 1 - organic peroxide
                 9.2.2 Example 2 - salt dryer
                 9.2.3 Example 3 - organic crystals
                 9.2.4 Example 4 - organic solid
                 9.2.5 Example 5 - drying of organo-tin compounds
             9.3 Other standard test cases
                 9.3.1 Slurry
                 9.3.2 Paper
                 9.3.3 Artefact
                 9.3.4 Pharmaceutical
             9.4 Additional cases
                 9.4.1 Inorganic paste
                 9.4.2 Sewage sludge
                 9.4.3 Soap flakes
                 9.4.4 Synthetic detergent
                 9.4.5 Cereal drying
                 9.4.6 Other examples
         10 IMPLEMENTATION IN THE EXPERT SYSTEM DRYSEL
         11 CONCLUSIONS AND RECOMMENDATIONS
         12 REFERENCES
         13 NOMENCLATURE
         14 APPENDIX 1. CHECKLIST OF DATA REQUIRED FOR DRYER SELECTION
         15 APPENDIX 2. RESULTS FORM FOR SELECTION PROCEDURE
         16 APPENDIX 3. DRYING KINETICS DATA FOR MAIN WORKED EXAMPLE
     Terms and Conditions of Use

Much of the material has been developed by SPS over a number of years, (The use of small scale tests in the selection of dryers: C G Moyers and C G J Baker) has also been incorporated. It also draws on material from Crystallization Manual CR III.1 on how crystallization and downstream processing interact. A revised version to reflect changes incorporated in the algorithm during the conversion of the associated DRYSEL expert system to Windows.

 

Volume DRY II Part 1 Dryer selection algorithm.

This is a detailed description of the process of dryer selection and of the new SPS selection procedure. After an initial introduction, the principal types of dryers are briefly listed and classified in Chapter 2. The classification is more detailed than that in Manual Volume I and is based on the underlying scientific principles which affect selection; thus apparently similar dryers such as tray and rotary units are divided into conduction, cross-circulated, through-circulated and dispersion types. A literature survey (Chapter 3) reviews the scanty material previously published on dryer selection.

Drying is then set in the context of the overall flowsheet in Chapter 4, noting interactions with particle formation and dewatering processes. The SPS selection algorithm is then described in Chapter 5. It has five steps: data collection; basic choice of categories; short-listing of dryer types; refinements and subtypes; and evaluation. The search procedure has a tree structure which is equipment-based. However, material-based considerations are equally important and the complete set of selection rules, organised on this basis, are listed and explained in Chapter 6.

Appropriate small-scale tests for determining solids properties and drying characteristics are described in Chapter 7. Rough sizing and costing procedures are given in Chapter 8 to allow a quantitative comparison between dryers, using a new SPS method based on gas flow through convective dryers or heat transfer area in contact dryers. A number of worked examples are also included as Chapter 9 to illustrate the algorithm in operation.

An appendix gives a checklist of the data needed in order to run the algorithm in an easy-to-use form, together with a results form for hand calculation.


Volume DRY II Part 2 Dryer manufacturers database.

This is a quick reference guide to SPS dryer manufacturers and their products, produced as a result of a suggestion of the Drying Panel. Each manufacturer supplies a brief two-page guide giving the types of dryer they manufacture, practical test facilities and contact names and addresses. Manufacturers are responsible for updating their own entries as necessary. The on-line version on CD-ROM will be updated every six months if required, but it is not planned to reissue paper versions regularly. Other Panels are now producing similar databases and the overall compilation may be issued in the Mini-Manual series.


Volume DRY II Part 3 DRYSEL User Guide.

This is the printed User Guide to the DRYSEL expert system software (DOS version) which implements the design algorithm in DRY II.1.