Method of monitoring a spray dryer and a spray dryer comprising one or more infrared cameras

Abstract

The spray dryer comprises a spray drying chamber having a substantially cylindrical top section, a conical wall and a narrowed lower section. In the top section, atomizing means is provided. One or more cameras are associated with the drying chamber in order to monitor the process. At least one of the cameras is an infrared camera adapted for measuring the temperature within a predefined area.

Claims

1. A method of monitoring a spray dryer part subject to the formation of deposits thereon during a spray drying process, the method of monitoring comprising: providing a spray drying chamber comprising the spray dryer part, the spray dryer part being at least a spray nozzle, associating one or more cameras with the spray drying chamber, the one or more cameras having a field of view inside the spray drying chamber, and at least one of the one or more cameras being an infrared camera, measuring a temperature of an outer surface of the spray nozzle with the infrared camera, providing a control system, and providing a set value for the temperature of the spray nozzle, wherein a drying gas having a drying gas temperature is fed into the spray drying chamber during the spray drying process, wherein an operating temperature of the spray nozzle relates to the drying gas temperature, wherein the set value for the temperature of the spray nozzle is higher than the operating temperature of the spray nozzle, wherein the outer surface of spray nozzle is exposed to the drying gas within the spray driving chamber, wherein the control system is associated with an alarm triggered when the temperature of the outer surface of the spray nozzle measured by the infrared camera exceeds the set value, wherein the measuring of the temperature of the outer surface of the spray nozzle includes measuring a temperature of deposits of solid material accumulated on the outer surface of the spray nozzle, and wherein the alarm is triggered as a result of the deposits forming on the outer surface of the spray nozzle during the spray drying process and the measured temperature of the deposits exceeding the set value for the spray nozzle.

2. The method according to claim 1, whereby at least two infrared cameras are associated with the spray drying chamber.

3. The method according to claim 1, the spray nozzle is an atomizing nozzle, and the measuring of the temperature of the spray dryer part comprises measuring the temperature of a part of the atomizing nozzle.

4. The method according to claim 1, further comprising monitoring a temperature of a portion of the wall of the spray drying chamber.

5. The method according to claim 1, further comprising monitoring a temperature of a portion of the fluid bed gas distributor plate.

6. The method according to claim 1, wherein the operation of the spray dryer is stopped when the alarm is triggered.

7. The method according to claim 6, further comprising removing the deposits after the spray dryer has been stopped.

8. The method according to claim 1, further comprising supplying a cooling gas to cool the infrared camera.

9. The method according to claim 1, wherein the infrared camera has a field of view of at least 90 degrees.

10. The method according to claim 1, wherein the infrared camera is positioned in the spray drying chamber via a movable and removable camera lance.

11. The method according to claim 9, wherein a visual camera and the infrared camera are combined together in one camera lance.

12. A spray dryer comprising: a spray drying chamber, atomizing means, an inlet for a drying gas, one or more cameras positioned in connection with the spray drying chamber, at least one of the one or more cameras being an infrared camera, and a control system connected to an alarm; wherein the infrared camera measures a temperature of deposits of solid material accumulated on a spray nozzle having an atomizing means wherein the spray dryer is configured to feed the drying gas having a drying gas temperature into the spray drying chamber during a spray drying process, wherein an operating temperature of an outer surface of the spray nozzle relates to the drying gas temperature, wherein the outer surface of spray nozzle is exposed to the drying gas within the spray drying chamber, wherein the control system is configured to activate the alarm when deposits form on the outer surface of the spray nozzle during the spray drying process and the temperature of the deposits on the spray nozzle is determined to have exceeded a set value for the spray dryer part, and wherein the set value for the temperature of the spray nozzle is higher than the operating temperature of the nozzle.

13. The spray dryer according to claim 12, wherein at least two infrared cameras are positioned in the spray drying chamber.

14. The spray dryer according to claim 12, wherein the infrared camera is positioned in the spray drying chamber via a movable and removable camera lance.

15. The spray dryer according to claim 14, wherein a visual camera and the infrared camera are combined together in one camera lance.

16. The spray dryer according to claim 12, wherein the infrared camera is covered by an inspection glass and a protective grid.

17. The spray dryer according to claim 12, wherein the infrared camera has a view of at least 90 degrees.

18. The spray dryer according to claim 12, wherein the atomizing means is a rotary atomizer.

19. A method of monitoring a spray dryer part subject to the formation of deposits thereon during a spray drying process, the method of monitoring comprising: providing a spray drying chamber comprising the spray dryer part, the spray dryer part being at least a spray nozzle, associating one or more cameras with the spray drying chamber, the one or more cameras having a field of view inside the spray drying chamber, and at least one of the one or more cameras being an infrared camera, measuring a temperature of an outer surface of the spray nozzle with the infrared camera, providing a control system, and providing a set value for the temperature of the spray nozzle, wherein a drying gas having a drying gas temperature is fed into the spray drying chamber during the spray drying process, wherein the set value for the temperature of the spray nozzle is higher than the drying gas temperature, wherein the outer surface of spray nozzle is exposed to the drying gas within the spray drying chamber, wherein the control system is associated with an alarm triggered when the temperature of the outer surface of the spray nozzle measured by the infrared camera exceeds the set value, wherein the measuring of the temperature of the outer surface of the spray nozzle includes measuring a temperature of deposits of solid material accumulated on the outer surface of the spray nozzle, and wherein the alarm is triggered as a result of the deposits forming on the outer surface of the spray nozzle during the spray drying process and the measured temperature of the deposits exceeding the set value for the spray nozzle.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) In the following, the invention will be described in further detail by means of the following description of preferred embodiments and with reference to the drawings, in which

(2) FIG. 1 shows a schematic side view of a spray dryer in one embodiment of the invention;

(3) FIG. 2 shows a schematic side view of a spray dryer in another embodiment of the invention;

(4) FIG. 3 shows a perspective view, on a larger scale, of a detail of the spray dryer shown in FIG. 2.

DETAILED DESCRIPTION OF THE INVENTION

(5) FIG. 1 shows an embodiment of a spray dryer 1 having a spray drying chamber 2 comprising a substantially cylindrical top section 4a, a conical wall 3 and a narrowed lower section 4b. In the top section 4a, atomizing means 9 is provided. An air disperser connected to an air inlet, which may be a straight air inlet, or a radial inlet, or a tangential inlet, is provided in a top section of the spray drying chamber (not shown). The air disperser may for instance have the form described in Applicant's co-pending international application No. WO 2007/071238 or No. PCT/DK2009/050277, or may be designed as any other traditional air disperser as well.

(6) The spray dryer 1 includes, in a manner known per se, feeding means leading to the atomizing means 9. The air disperser may for instance be mounted above or in the ceiling of the drying chamber 2 of the spray dryer 1, or in the top section 4a of the drying chamber 2. Depending on i.a. the size of the drying chamber 2, there may be more than one, e.g. three, such air dispersers mounted in the ceiling of the drying chamber 2.

(7) Drying air entering the air disperser from the air inlet is directed into a downward flow of drying air into the drying chamber, where the drying air is brought into contact with the atomized material emanating from the atomizing means 9. In the embodiment shown, the atomizing means 9 are provided in the form of nozzles 5 directed downwards in the drying chamber 2. In alternative embodiments, the atomizing means 9 may be in the form of a rotary atomizer. As a further alternative, the atomizing means 9 may be provided as one or more nozzles supplied from a nozzle lance system. The nozzle lance may extend through the centre of the air disperser, or outside the air disperser.

(8) In the embodiment shown, the spray dryer 1 furthermore comprises an infrared camera (IR camera) 6 positioned in connection with the drying chamber 2. The IR camera 6 is mounted outside the drying chamber 2 in a camera lance 7. The lance 7 including the camera 6 may also be positioned inside the drying chamber 2. In order to protect the IR camera 6 from the material being spray dried a protective glass 8 is provided. The nozzles 5 are within the field of view of the IR camera 6. Each infrared camera should have a sufficient field of view, which depends on the distance from the camera placement to the area to monitor. For instance a view of at least 15, 30 or 60 degrees, but for monitoring of the nozzles, a 90 degrees view could be preferable if the cameras are placed near to the nozzles. During spray drying, material leaving the nozzles 5 is swirled around in the spray drying chamber 2. Despite efforts to the contrary, deposits may settle on the nozzles 5, such as the non-limiting example deposits 11 shown on the outer surface of one of the nozzles 5, in particular if the material is sticky or viscous. The problem of deposits is particularly pronounced during start-up of the drying process, or in the case of defective nozzles. The temperature of the nozzles 5 may then rise locally, if the deposits are not removed. The deposits become more and more dry, entailing a rise of temperature until they either ignite spontaneously, fall into the drying chamber 2 or on to a fluid bed in the lower section 4, the material being then possibly ignited here. In the embodiment shown in FIG. 1, the IR camera 6 is used to monitor the nozzles 5. This is performed by selecting a predefined area to be monitored. The IR camera 6 is provided with means for allowing adjustment of the predefined area, both in terms of dimensions and position. The temperature is then measured within the predefined area. When a certain temperature level chosen as a set value within that particular predefined area has been detected by the IR camera 6 or related circuitry such as a computer, an alarm is triggered and it is possible to stop the drying and remove the deposits before and actual fire or explosion is set off.

(9) The set value, i.e. temperature that is required to trigger the alarm, depends on the type of material handled in the spray dryer 1. The drying gas temperature for chemical or ceramic products is considerably higher than for dairy, pharmaceutical or food products. The operating temperature of the nozzles 5 and chamber 2 will relate to the drying temperature, so the temperature that triggers the alarm will then be higher. For example for aluminium oxide, the drying gas inlet temperature interval is between 300-500° C., while the drying gas inlet temperature interval for whole milk is 175-240° C. and for enzymes, the drying gas inlet temperature interval is 140-180° C. A relevant nozzle temperature that triggers the alarm will then be set accordingly. As an alternative it is the temperature difference between two areas within the drying chamber 2 that triggers the alarm. The monitoring may thus be carried out with respect to deposits of solid material, and the set value for the temperature is the temperature of the deposits. The operation of the spray dryer may be stopped when the alarm is triggered, and the deposits removed. This prevents excessive heating and the break-out of fire. Following the removal of the deposits and possibly further cleaning procedures, the operation of the spray dryer may be re-started.

(10) In FIG. 2 further features have been added to the features present in FIG. 1. Four more cameras, of which some may be IR cameras and others ordinary TV cameras, have been added. Two of the cameras are pointing at or have a free view of the nozzles 5. These cameras register if the temperature of the nozzles rises above an acceptable level as described in the above. Two additional cameras 6 have been mounted on each side of the drying chamber 2. This may be for monitoring the temperature of the wall 3 or for monitoring several nozzles 5 with one camera 6. Deposits may build up on the wall 3 of the spray dryer 1 as well, the predefined area to be monitored by these cameras being chosen according to for instance a programmed surveillance pattern. The cameras 6 on the side may be either IR cameras 6 or a mix of IR cameras 6 and ordinary TV cameras.

(11) Instead of measuring when the temperature exceeds a certain level, the IR camera 6 or related circuitry may also detect if the temperature difference between the drying chamber 2 and the nozzles 5 exceed or move below a certain level. The cameras 6 on the side may detect the temperature on the walls of the drying chamber 2, thus indicating a normal operational temperature, or the temperature of potential deposits, while the cameras monitoring the nozzles 5 detect the temperature of the nozzles 5. The temperatures may then be compared in a computer, monitoring the whole process.

(12) The IR camera mounted at the lower section 4 monitors the temperature below a fluid bed gas distributor plate 10 of the fluid bed. If the temperature in an area of the fluid bed gas distributor plate 10 rises above a certain level or the temperature difference becomes greater than a certain value, this may indicate that a lump of the material to be dried has fallen onto the fluid bed gas distributor plate 10 and the lump is too heavy to fluidise. This lump may ignite spontaneously if not detected and removed.

(13) Temperature differences may be measured and/or monitored by one IR camera alone or be calculated based on input from several IR cameras.

(14) In general the more nozzles 5 and greater area to monitor, the more IR cameras 6 are required.

(15) FIG. 3 is a close up view of the camera in a mounted position. A 19 M pixel IR-camera of a commercially available type may be used. The lance 7 is suitable for insertion into the drying chamber. The lance 7 furthermore contains the wiring and electronics 12 of the camera 6 and means for connecting the camera 6 with a monitoring station such as a computer. The lance 7 makes it easy to move, remove and replace cameras.

(16) One or more cameras 6, e.g. an IR and a normal camera, may be mounted in one lance 7. The combination of an ordinary TV camera and an IR camera makes it possible to combine information from the process. Furthermore, other surveillance or monitoring means are conceivable, such as the use of fibre optics.

(17) At the end of the lance 7 an inspection glass 8 is provided. A protective grid 13 is furthermore provided. It should be understood that by “glass” is meant a material suitable for IR-use as well as for safety demands for the product to be dried.

(18) A cooling air may be supplied to the camera 6 due to the hot environment in which it is placed. The cooling air may be provided transversely to the camera's point of view. Further, the temperature of the camera 6 itself may be monitored as well.

(19) The wiring and electronics 12 connects the IR camera 6 with matching software. The matching software easily makes it possible to define an area of the spray dying chamber 2 to monitor. The area may be displayed on a screen. This area may be increased or decreased at will. An average temperature may be displayed. An alarm function may be activated whenever the average temperature exceeds a set value for the specified area. Further, an operator at the screen may visualize the temperature at any point of the picture by simply moving the curser to the actual point he would like to view.

(20) When referring to a camera there is meant at least one instance of a camera, which may both be an ordinary TV camera, an IR camera or a combination thereof.

(21) The invention should not be regarded as being limited to the embodiment shown and described in the above but various modifications and combinations of features may be carried out without departing from the scope of the following claims.