Spray Drying Process Design

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The most important variables in the design of a spray dryer are the evaporation rate and the required particle size distribution of the product. The evaporation rate and the dryer ΔT (inlet air temperature minus the outlet air temperature) dictates the amount of drying air needed, which dictates the sizing and cost of almost all of the system components. The particle size requirement affects the choice of atomization and can also affect the size of the spray dryer.

For a given evaporation rate, the higher the design ΔT, the less process air is required, and the smaller and less costly the spray drying system will be. Many products, though, cannot use high inlet temperatures due to the potential of thermal degradation of the product.

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