A SPRAY DRYING APPARATUS WITH A PLENUM CHAMBER BELOW A PERFORATED BOTTOM OF A SPRAY DRYING CHAMBER

Abstract

A spray drying apparatus has a spray drying chamber; a liquid feed atomizer; a drying gas disperser; a perforated bottom; and a plenum chamber with an outlet below the perforated bottom. At least one guide plate is provided in the plenum chamber to direct gas, which is passing through the perforated bottom into the plenum chamber, towards the bottom of the plenum chamber. The guide plates have lower edges extending on average down to at least half-way between the perforated bottom of the spray drying chamber and the bottom of the plenum chamber.

Claims

1-18. (canceled)

19. A spray drying apparatus comprising a spray drying chamber; a liquid feed atomizer; a drying gas disperser; a perforated bottom; at least one plenum chamber below the perforated bottom; and an outlet of said plenum chamber, wherein said plenum chamber has a perforated ceiling, which is provided by an underside of said perforated bottom, and a bottom, wherein at least one guide plate is provided in the at least one plenum chamber to direct gas, which is passing through the perforated bottom into the plenum chamber, towards the bottom of the plenum chamber, said guide plate having a lower edge and a longitudinal extent extending across an outlet direction towards the outlet, said guide plate through the longitudinal extent thereof extending on average down to at least half-way between the perforated ceiling and the bottom of the plenum chamber.

20. A spray drying apparatus according to claim 19, wherein more such guide plates are provided at mutual distance to extend across said outlet direction, and wherein on average a vertical distance from the bottom of the plenum chamber to the lower edge of a first guide plate is smaller than a corresponding vertical distance from the bottom of the plenum chamber to the lower edge of a second guide plate closer the outlet than the first guide plate.

21. A spray drying chamber according to claim 20, wherein at a side wall a bias guide plate is provided to extend at an acute angle relative to said side wall as seen in a vertical plane perpendicular to the bias guide plate, said acute angle having an apex pointing downwards, a lower edge of said bias plate having a distance from said side wall and the bottom of the plenum chamber.

22. A spray drying apparatus according to claim 19, wherein the bottom of the spray drying chamber and the ceiling comprise a perforated conveyor belt, a supporting structure being provided below the ceiling for supporting the ceiling, including the conveyor belt, the conveyor belt having a direction of travel, and the plenum chamber has a substantially rectangular horizontal cross section with a first dimension extending in a first direction parallel to the direction of travel of the conveyor belt and a second dimension extending in a second direction perpendicular to the direction of travel of the conveyor belt.

23. A spray drying apparatus according to claim 22, wherein the at least one guide plate is a part of said support structure.

24. A spray drying apparatus according to claim 23, wherein the outlet is provided in an outlet side wall extending in the first direction.

25. A spray drying apparatus according to claim 24, wherein the bottom of the plenum chamber is generally trough-shaped and sloping downwards towards the outlet.

26. A spray drying apparatus according to claim 22, wherein the at least one guide plate is extending in the first direction.

27. A spray drying apparatus according to claim 19, wherein the at least one guide plate has a lower edge extending at a distance from the bottom of the plenum chamber substantially throughout the longitudinal extent of the guide plate.

28. A spray drying apparatus according to claim 27, wherein the distance from the lower edge of the guide plate to the bottom of the plenum chamber is substantially uniform throughout the longitudinal extent of the guide plate.

29. A spray drying apparatus according to claim 27, wherein the distance from the lower edge of the guide plate to the bottom of the plenum chamber is enlarged at ends in the longitudinal direction of the guide plate relative to said distance at the longitudinal midpoint of the guide plate.

30. A spray drying apparatus according to claim 27, wherein the distance from the lower edge of the guide plate to the bottom of the plenum chamber is reduced at ends in the longitudinal direction of the guide plate relative to said distance at the longitudinal midpoint of the guide plate.

31. A spray drying apparatus according to claim 19, wherein the at least one guide plate has an up-stream side and a down-stream side relative to the outlet direction and the up-stream side, at least at the lower edge, forms an angle relative to vertical with an upward pointing apex said angle being in the range of 0 to 90°.

32. A spray drying apparatus according to claim 19, wherein the at least one guide plate has an up-stream side and a down-stream side relative to the outlet direction and the up-stream side, at least at the lower edge is curved downwards towards the outlet.

33. A spray drying apparatus according to claim 19, wherein the at least one guide plate has an up-stream side and a down-stream side relative to the outlet direction and a substantial thickness, and wherein the lower edge is rounded at the up-stream side.

34. A spray drying apparatus according to claim 19, wherein the spray drying chamber at the perforated bottom has a rectangular cross section and at an upper end thereof has a cross section shaped as a general rectangle with rounded corners, the spray drying chamber having vertical side walls between the bottom end the upper end.

35. A spray drying apparatus according to claim 34, wherein the drying gas disperser has a diameter substantially equal to the length of a minor side of the rectangular cross section of the spray drying chamber.

36. A spray drying apparatus according to claim 34, wherein the drying gas disperser has a diameter smaller than the length of a minor side of the rectangular cross section of the spray drying chamber.

37. A spray drying chamber according to claim 20, wherein at a side wall a bias guide plate is provided to extend at an acute angle relative to said side wall as seen in a vertical plane perpendicular to the bias guide plate, said acute angle having an apex pointing downwards, said angle being in the range of one of: 10° to 70°; 10° to 40°; and 15° to 30°, a lower edge of said bias plate having a distance from said side wall and the bottom of the plenum chamber.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0031] In the following the invention will be explained in further detail by way of non-limiting examples of embodiments, having reference to the schematic drawings, in which

[0032] FIG. 1 shows a prior art spray drying apparatus in which the present invention may be incorporated;

[0033] FIG. 2 is an end view of a prior art type plenum element;

[0034] FIG. 3 is a perspective view of the plenum element in FIG. 2;

[0035] FIG. 4 is a view corresponding to FIG. 3, but showing a plenum element embodying the present invention;

[0036] FIG. 5 is a longitudinal cross section of the plenum element in FIG. 4;

[0037] FIG. 6 is an end view corresponding to FIG. 2, but showing the plenum element of FIG. 4;

[0038] FIG. 7 is a top view of the plenum element of FIG. 4;

[0039] FIG. 8 is a view corresponding to FIG. 5, but showing a variant of the plenum element of the invention;

[0040] FIG. 9 (a)-(e) shows details of variants of the plenum element of FIG. 4;

[0041] FIG. 10 is a perspective view of a drying gas disperser; and

[0042] FIG. 11 is a perspective view of a spray drying chamber wall according to the present invention.

DETAILED DESCRIPTION

[0043] Referring to FIG. 1, a spray drying apparatus indicated generally by 1 is shown, which comprises a spray drying chamber 2, into which a feed stream supplied through conduits 3 is atomized through liquid feed atomizers 4, such as pressure nozzles or rotary atomizers, and brought into contact with a drying gas supplied to the drying chamber through a conduit 5 and annular openings 6 surrounding conduits 3. Furthermore, openings 26 in the ceiling of the chamber 2 are provided for the introduction of supplementary drying gas, supplied through conduit 25. Thus conduits 5 and 25 together with openings 6 and 26 provide a drying gas disperser. By the contact with the drying gas, the atomized feed stream is converted into sticky, partially dried particles, which are collected as a layer 7 on the surface of a perforated conveyor belt 8, forming at least partially a perforated bottom of chamber 2, by suction through a plenum element 10. The perforated conveyor belt 8, or rather the section thereof forming at least partially a perforated bottom of the spray drying chamber, has a direction of travel 8a during operation.

[0044] By the suction, a pressure difference over the perforated conveyor belt of about 20 mm H.sub.2O and a pressure difference over the collected layer, leaving the chamber, of about 10 mm H.sub.2O is established. Thus, the ratio between the pressure difference over the screen means and the pressure difference over the product layer is about 2.0 in the spray drying chamber 2. Below the perforated conveyor belt 8, an optional restriction member 19, comprising a number of perforated plates, is located to cover, together with the perforated conveyor belt 8, the bottom area of spray drying chamber 2. By means of the optional restriction member 19 the total pressure difference over the perforated bottom of the spray drying chamber 2, including the perforated conveyor belt 8 and the optional restriction member 19, may be adjusted.

[0045] From the chamber 2, the collected layer 7 is transferred to a drying chamber 11, by means of the perforated conveyor belt 8, in which chamber 11, layer 7 is e.g. subjected to further drying by means of a hot drying gas, introduced in chamber 11 through a conduit 12 and withdrawn by suction through a second plenum element 13, located below chamber 11. In plenum element 13 a further perforated plate 14 is located below the perforated conveyor belt 8, in the immediate vicinity thereof. From drying chamber 11, the product layer 7 is transferred to a cooling chamber 15 by means of the perforated conveyor belt 8, in which chamber 15 it is e.g. brought into contact with dehumidified, cooled air, supplied through conduit 16 and withdrawn through a third plenum element 17, located below the perforated conveyor belt 8, beneath chamber 15. After cooling, the product leaves chamber 15 and the perforated conveyor belt 8 as shown schematically to the right in the FIG. 1.

[0046] FIGS. 2 and 3 show an example of a prior art type plenum element 30′ usable as e.g. the plenum element 10 shown in FIG. 1. The plenum element 30′ defines a plenum chamber 31 with a bottom 32 that is generally trough-shaped and slopes downwards towards an outlet 33. The bottom 32 is in the example provided by three plane sections 32a, 32b and 32c. The outlet 33 is provided in an outlet side wall 34 of the plenum chamber 31. Opposite the outlet side wall 34, a minor, substantially vertical, end side wall 35 is provided. The outlet side wall 34 and the end side wall 35 are parallel and are connected by longitudinal side walls 36 whereby the plenum chamber has a substantially rectangular horizontal cross section with a first dimension extending in a first direction 37 and a second dimension extending in a second direction 38. Opposite the bottom 32 a supporting structure is provided comprising bias slats 39, and cross slats 40 extending between the longitudinal side walls 36, below the bias slats 39 to support the latter. The bias slats 39 provides a support for a perforated ceiling of the plenum chamber 31 provided by the perforated bottom of the spray drying chamber 2. In the shown example the plenum element 30′ is intended to be installed below the spray drying chamber 2 so that the first direction 37 is parallel to the direction of travel 8a of the perforated conveyor belt 8 and the second direction 38 is perpendicular to the direction of travel 8a.

[0047] It should be noted that though a single plenum element 10 is shown in FIG. 1 it is possible to provide several plenum elements 30′ in a side-by-side relationship along the direction of travel 8a. In such case the outlets 33 may be connected with a common conduit for guiding the drying gas, that has passed the plenum chambers, to a filter.

[0048] Referring now to FIGS. 4 to 7 a plenum element 30 embodying the present invention is disclosed. The plenum element 30 is to a large degree identical to the plenum element 30′ described above and in the following similar elements are designated by the same numbers.

[0049] Thus, the embodiment of the plenum element 30, shown in FIGS. 4 to 7, is identical to the plenum element 30′ except for the fact that cross slats 40′ has been substituted by guide plates 40. It is noted that in a top view as shown in FIG. 7 the plenum element 30 and plenum element 30′ will look identical.

[0050] According to the present invention guide plates 40a, 40b, 40c are provided to direct gas, which has passed through the perforated ceiling into the plenum chamber 31, towards the bottom 32 of the plenum chamber, as indicated by arrows 42 in FIG. 5, before said gas passed below a lower edge 41 of the respective guide plates 40a, 40b, 40c for said gas to flow along the bottom 32 towards the outlet 33 in an outlet direction 43.

[0051] In the present embodiment the guide plates 40a, 40b, 40c each has a longitudinal extent extending in the first direction 37, i.e. across the second direction 38 which constitutes a general outlet direction 43 towards the outlet 33. The lower edges 41 of the guide plates 40a, 40b, 40c extend, in the present embodiment, through their respective longitudinal extent parallel to the bottom 32 of the plenum chamber 31, and in the present embodiment the guide plates 40a, 40b, 40c extend, as indicated in FIG. 5, more than half-way down between the perforated ceiling, that will be supported by the bias slats 39, and the bottom 32 of the plenum chamber 31.

[0052] In the embodiment shown in FIGS. 4 to 7 three guide plates 40a, 40b, 40c are provided which are plane and vertical and mutually placed generally equidistantly and in parallel. However, it should be noted that at another number of guide plates may be used, such as one, two, four, five, six or even more depending, inter alia, on the actual size of the plenum chamber. Further variations are possible such as the guide plates being non-parallel, non-plane, not equidistantly spaced, etc.

[0053] In the present embodiment the guide plates 40a, 40b, 40c are part of the supporting structure and support the bias slats 39. However, it is also possible that the guide plates do not form part of the supporting structure.

[0054] Inter alia it is foreseen that the guide plates may be movable or removable for cleaning of the plenum chamber 31.

[0055] In operation the guide plates 40a, 40b, 40c will, as mentioned, direct gas that has passed through the perforated ceiling supported by the bias slats 39 towards the bottom 32 of the plenum chamber 31 to create a gas flow along the bottom 32 towards the outlet 33. The guide plates 40a, 40b, 40c may be dimensioned to create a gap between the respective lower edges 41 and the bottom 32 to promote a flow pattern across the bottom whereby the speed of the flow is at least 1 m/s or more e.g. in the range of 2 to 20 m/s, at least across the majority of the bottom 32. The flow across the bottom 32 may prevent particles or powder, that has penetrated the perforated ceiling and entered the plenum chamber 31, like the gas, from settling in the plenum chamber 31 and instead being carried along with the gas out the outlet 33 to be finally captured in a filter, not shown.

[0056] The actual need for speed of flow for a given apparatus may depend on different parameters, such as the nature of the material to be processed; the nature of the perforated bottom of the spray drying chamber 2, i.e. the perforated ceiling of the plenum chamber 31; etc.

[0057] The sizes of the gaps largely influence the speed of the flow across the bottom and to create a flow pattern with a generally even speed of the flow the gap between the lower edge 41 of a given guide plate 40a, 40b, 40c should be larger the closer the guide plate is to the outlet 33. Accordingly, the gap, i.e. the vertical distance, between the lower edge of guide plate 40c and the bottom 32 is larger than the gap between the lower edge of the guide plate 40b and the bottom 32 which in turn is larger than the gap between the lower edge of the guide plate 40c and the bottom 32. Hereby a relatively even flow pattern in respect of speed may be created while avoiding pressure build-up due to narrow gaps.

[0058] In an alternative embodiment the vertical distances between the bottom 32 and two or more of the guide plates 40a, 40b, 40c are generally equal.

[0059] As mentioned, in the present embodiment the lower edges 41 of the guide plates 40a, 40b, 40c extend in parallel to the bottom 32. It is however possible to provide gaps that are e.g. more narrow at the longitudinal side walls 36 than in the middle of the plenum chamber 31, i.e. at areas at the longitudinal midpoint of respective guide plates, to promote the speed of the flow at the longitudinal side walls 36 relative to the flow at the middle of the plenum chamber 31, or vice versa.

[0060] It should be noted that some of the gas may by-pass the guide plates 40a, 40b, 40c by flowing above the guide plates 40a, 4b, 4c between the bias slats 39, but the intended effect of the present invention will not be jeopardized as long as a sufficient amount of gas flows beneath the guide plates 40a, 40b, 40c.

[0061] FIG. 8 shows a variant of the embodiment shown in FIGS. 4 to 7. In this variant a bias guide plate 44 has been added in the plenum chamber 31. The bias guide plate 44 is, in the present embodiment, extending in the second direction 38, like the guide plates 40a, 40b, 40c, but it is biased or angled relative to the vertical end side wall 35 at an angle α. A gap is present between a lower edge 44a of the bias guide plate 44 and the end side wall 35 and the bottom 32, respectively. The angle α may be in the range of 10° to 70°, especially of 10° to 40°, and particularly of 15° to 30°. The bias guide plate 44 entails that gas, that has passed into the plenum chamber 31 through the ceiling above the bias guide plate 44 will be guided towards the corner between the end side wall 35 and the bottom 32 before that gas is directed along the bottom 32 towards the outlet 33, thereby providing a flow of gas across the area of the bottom 32 most remote from the outlet 33. It should be noted that in case the end side wall 35 is not vertical, but extends somewhat outwardly from the bottom 32 relative to the plenum chamber 31, the angle α in the above ranges will still be found between the end side wall 35 and the bias guide plate 44, the latter extending correspondingly closer to vertical, or even vertically.

[0062] FIGS. 9(a) to 9(e) show, in enlarged detail, different variants of the lower part of a guide plate, such as guide plate 40a. It should be noted that though guide plate 40a is used as an example, the variants might be applied to any of the guide plates 40a, 40b, 40c.

[0063] FIG. 9(a) shows an enlarged detail of the guide plate 40a and the bottom 32. It Is noted that the guide plate 40a is plane and vertical and a gap or vertical distance 45 exists between the lower edge 41 and the bottom 32.

[0064] To stream-line the flow in the plenum chamber 31 it is possible to e.g. amendment the geometrical properties around the gap 45.

[0065] In a first variant, shown in FIG. 9(b) the entire guide plate 140 is tilted at an angle β relative to vertical. Thus the area at the lower edge 141, together with the rest of the guide plate, especially at an up-stream side 140a thereof relative to the outlet direction 43, forms an angle β relative to vertical with an upward pointing apex said angle β being in the range of 0 to 90°, especially closer to 0 than to 90°.

[0066] In a second variant shown in FIG. 9(c) the area at the lower edge 241 is angled relative to the rest of the guide plate 240 to provide for the area at the lower edge 241 forming an angle β relative to vertical with an upward pointing apex, said angle being, as indicated, in the range of 0 to 90°.

[0067] In a third variant shown in FIG. 9(d) the area of the guide plate 340 at the lower edge 341 is curved to provide an angle β, as indicated, in the range of 0 to 90°, especially closer to 90° than to 0.

[0068] In a forth variant shown in FIG. 9(e) the guide plate 440 has an up-stream side 440a and a down-stream side 440b relative to the outlet direction 43 and a substantial thickness (t), and the lower edge 441 is rounded at the up-stream side. Thereby, line in the third variant, the area of the up-stream side 440a of the guide plate 440 at the lower edge 441 is curved to provide an angle β, as indicated, in the range of 0 to 90°, especially close to 90°.

[0069] Referring to FIGS. 10 and 11 a drying gas disperser 50 and a circumferential spray drying chamber wall 51 are shown.

[0070] The spray drying chamber wall 51 has according to the present invention has a rectangular cross section at a bottom end 52 and at an upper end 53 the spray drying chamber wall 51 has a cross section shaped as a general rectangle with rounded corners 54, the spray drying chamber wall having generally plane, vertical side wall portions 55 between the bottom end 52 the upper end 53. The rectangular cross section has a major side length 56 and a minor side length 57, and the major side length is intended to be parallel with the direction of travel 8a of the conveyor belt 8 when the spray drying chamber wall 51 is implemented in a spray drying apparatus 1 of the type shown in FIG. 1. It is also possible that the cross section of the spray drying chamber wall 51 at the bottom end 52 is quadratic.

[0071] By means of the embodiment of the circumferential spray drying chamber wall 51 according to the present invention, a problem observed at drying chambers having side walls that converge conically in an upwards direction, namely that for some operating conditions, particles or powder can form a layer of deposits on an inner surface of the chamber walls, may be reduced or avoided. As also indicated in the opening part of the present description, in some of these cases, the amount of powder deposit on the wall is so high, that powder lumps fall down on the conveyor belt causing dried particles or powder to fall through the conveyor belt and powder lumps that are not dried to appear in the product.

[0072] The drying gas disperser 50 is of a kind disclosed in Danish patent application No. DK PA 2018 70454, to which reference is made for detailed description of the construction of the drying gas disperser 50. The drying gas disperser 50 comprises a supply duct section 58 which has a diameter D, and an inlet duct section 59.

[0073] In the present example, the drying gas disperser 50 may be mounted on top of the spray drying chamber wall 51 whereby an intermediate ceiling element (not shown) is interposed between the upper end 53 of the spray drying chamber wall 51 and the supply duct section 58 of the drying gas disperser 50.

[0074] The diameter D of the supply duct section 58 may be substantially equal to the minor side length 57 of the spray drying chamber wall 51. In the alternative the diameter D of the supply duct section 58 may be smaller than the minor side length 57 of the spray drying chamber wall 51.