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Upgrading of Anhydro Spray Drying PlantsF O R E X T R A CA PAC I T Y A N D E N E R GY S AV I N G S
SPX Flow Technology Danmark A/S is an international engineering company with a consistentgoal to provide our customers with the optimalprocessing technology and the highest plantRe-Energizing Your ExistingInvestmentsperformance standards.The dairy and food industries are competing harder than ever before toWe have specialized in supplying the optimaldesign and engineering with respect to production performance, flexibility, energy efficiency andenvironmental protection.sustain and expand their positions in competitive markets. Many dairy andfood manufacturers are looking to modernise their powder production plantin order to provide products with specific functional properties in response toever more demanding market requirements.R E B U I LD I NG AN D MOD E R N I S I NG EXI STI NG PLANTSpray drying technology has made significant advances in recent years tosupport the needs of the dairy and food industries. The latest equipmentoffers a wide range of benefits in terms of throughput, efficiency and powderquality that are essential to maintaining market share and earnings.The cost and lead-time of a new plant may make this option less attractivefor manufacturers looking to minimize capital outlay, maximize return onSPX FLOW, Inc. (NYSE:FLOW) is a leadinginvestment, and secure fast time to market. By partnering with SPX FLOW,manufacturer of innovative flow technologies,however, you can achieve all of the benefits of a new plant faster and at amany of which help define the industry standardin the market segments they serve. From itssignificantly lower cost by rebuilding and modernizing your existing Anhydroheadquarters in Charlotte, North Carolina, itspray drying equipment.operates a sales and support network, centersof manufacturing excellence, and advancedengineering facilities, throughout the world. ItsO P E R AT I O N A L B E N E F I T Scutting-edge flow components and processRebuilding and modernising your existing plant offers a number of decisiveequipment portfolio includes a wide rangebenefits:of pumps, valves, heat exchangers, mixers,homogenisers, separators, filters, UHT, and dryingtechnology that meet many application needs. Lower unit costs through increased powder rate and lower energyconsumptionpremium supplier of customized solutions and A wider range of opportunities through the ability to produce a greatervariety of productscomplete, turn-key packages to meet the most New earnings opportunities with higher quality, premium-priced productsexacting of installation demands. Reduced downtime by installing CIP (Cleaning-In-Place) systemsIts expert engineering capability also makes it aIncorporating many leading brands, SPX FLOW Reduced operational costs through lower maintenance requirementshas a long history of serving the food and Higher efficiency and less waste through automated plant controlbeverage, power and energy, and industrial marketsectors. Its designs and engineered solutionshelp customers drive efficiency and productivity,increase quality and reliability, and meet the latestRebuilding and modernising your existing plant to standards that will secureregulatory demands. In-depth understandingyour competitive position well into the future will more than likely turn outof applications and processes, state-of-the-artto be a solution that is both faster and less expensive than investing in anInnovation Centers, and advanced pilot/testingtechnology further assist in optimizing processesand reducing timescales to reliably meetproduction targets.entirely new plant. You will achieve: Lower capital outlay Minimum production losses through faster implementationTo learn more about SPX FLOW capabilities, Shorter pay-back timeits latest technology innovations and complete Greater return on investmentservice offerings, please visit www.spxflow.com.2FA S T E R R E T U R N O N I N V E S T M E N T
One-Stage Spray DryerTwo-Stage Spray DryerAi rAi rAi r o u t l e tFe e dAi r o u t l e tFe e dHomogeniserHomogeniserExternal fluid bedPo w d e rPo w d e rAi rPo w e r r a t e : a p p r ox . 9 0 0 k g / h ( 1 , 9 8 4 l b / h )Po w e r r a t e : a p p r ox . 1 , 1 6 0 k g / h ( 2 , 5 5 7 l b / h )S t e a m c o n s u m p t i o n p e r k g w a t e r e v a p o r a t i o n : a p p r ox .S t e a m c o n s u m p t i o n p e r k g w a t e r e v a p o r a t i o n : a p p r ox .2 kg/h (4.4 lb/h)1.8 kg/h (4 lb/h)Three-Stage Spray DryerAi rAi r o u t l e tFe e dHomogeniserIntegratedfluid bedExternal fluid bedPo w d e rAi rPo w e r r a t e : a p p r ox . 1 , 4 0 0 k g / h ( 3 , 0 8 6 l b / h )S t e a m c o n s u m p t i o n p e r k g w a t e r e v a p o r a t i o n : a p p r ox .1.6 kg/h (3.5 lb/h)An h y d r o s p r a y d r y e r3
Upgrade OptionsThere are numerous opportunities for improvements in mostexisting drying plant in order to ensure compliance with newenvironmental regulations, recover heat, increase dryingcapacity, reduce cleaning downtime etc. The best resultdepends, however, on choosing the solution that best meetsyour needs with regard to capacity, product quality, operatingcost, payback time, return on investment etc.BAG F I LT E REnvironmental considerations often dictate the installing ofa bag filter. Today, a bag filter is normally installed after thecyclones in order to reduce costs and collect residual powder,reducing emissions after the filter to 10 mg/Nm3 (see Fig. 1).Fig. 2: Recuperator systemCleaned airI N D I R E C T O I L / G A S A I R H E AT E RAn older steam air heater can be converted into an indirect gasor oil-fired air heater, thus eliminating the need for purchasinga new high-pressure steam boiler. This can also provide anincrease in drying air temperature, resulting in a higher plantcapacity (see Fig. 2).The typical maximum inlet temperature with steam air heateris 190 C (374 F). This can be raised to 220 C (428 F) usingindirect gas air heating, resulting in a plant capacity increase ofFig. 1: Bag filterSeparated materialsome 30%.R E C U P E R ATO R B E T W E E N E X H AU S T A I R A N DI N LET AI RA textile filter ensures exhaust air of a purity that enables theutilisation of a heat recovery system using finned tube heatexchangers in a liquid coupled recuperator system.R E C U P E R ATO R B E T W E E N C O M B U S T I O N A I RAN D I N LET AI RThe combustion air has a purity that enables the utilisation ofa heat recovery system using finned tube heat exchangers in aliquid coupled recuperator system (see Fig. 2).An h y d r o s p r a y b e d d r y e r w i t h a f l u i d b e d4
C O N C E N T R AT E H E AT E RA spiral type heater is frequently used for indirect heating of theconcentrate. The product is heated by means of vacuum steam,thus avoiding the risk of overheating, and achieving long andcontinuous operation time. (see Fig. 3).The installation of a concentrate heater in the feed line closeto the atomiser, for example to heat the concentrate fromapproximately 45 C to 80 C (113 F to 176 F , means threeadvantages: Increase of 8 to 9% in drying capacity Pasteurising heat treatment Reduction of viscosityAi rTo a t o m i s e rFe e dSteamBarometriccondensateoutletFig. 3: Spiral concentrate heaterC L E A N I N G I N P L AC E ( C I P )In addition to raising the efficiency and hygienic standard of adrying plant, an automated CIP system with built-in spray ballsprovides further manpower savings and reduced downtime.An h y d r o s p r a y b e d d r y e r w i t h a f l u i d b e d5
Case Story: Skim Milk Production - Before and AfterP R O D U CT : S K I M M I L KDATA B E F O R E U P G R A D I N GDATA A F T E R U P G R A D I N GF E E D T E M P E R AT U R E4 0 C ( 10 4 F )4 0 C ( 10 4 F )I N L E T T E M P E R AT U R E180 C (356 F)180 C (356 F)O U T L E T T E M P E R AT U R E95 C (203 F83 C (181 F)A M O U N T O F A I R O U T TO C H A M B E R3 3 , 2 9 0 k g / h ( 73 , 3 9 2 l b / h )3 5 , 970 k g / h ( 79 , 3 0 0 l b / h )SOLI DS I N FE E D45%48%M O I S T U R E I N P OW D E R3.5%3.5%P OW D E R R AT E8 0 0 k g / h ( 1 ,76 3 l b / h )1,000 kg/h (2,204 lb/h)A skim milk manufacturer decided to upgrade a two-stageS I G N I F I CA N T C O S T - B E N E F I T S A N D N E W2CSD77 spray dryer into a three-stage 3CSD77 unit. TheOPPORTU N ITI E Supgrade included:The described upgrade resulted in the following enhancements: Mew integrated fluid bed Powder rate increase of 37% from 800 kg/h to 1,100 kg/h New complete air system for the fluid bed(1,763 lb/h to 2,204 lb/h). Capacity increase of suction fan by approximately 10% Energy saving if approximately 0.15 kW per kg finished Modification of the cyclones to achieve greater quantity of air Fines return systempowder Enhanced powder quality due to a significantly lower outlettemperature The opportunity to produce agglomerated powder due to thefines return systemOriginal Two-Stage Spray DryerUpgrated Three-Stage Spray DryerAi rAi rAi r o u t l e tAi routletFe e dHomogeniserFe e dHomogeniserIntegratedfluid bedExternal fluid bedExternal fluid bedPo w d e rAi r6Po w d e rAi r
Case Story: Skim Milk Production - Before and AfterDepending on your existing equipment and specificThe combination of spray dryer and fluid bed drying results inrequirements, you can choose between a number of modificationhigher capacity, lower outlet temperatures, and a more flexibleoptions for adding stages and other features. These include:drying process. Equipping of a one-stage conical spray dryer with anA fluid bed system offers the opportunity of an on-lineintegrated fluid bed at the base of the existing dryer chamber,lecithination process for the production of lecithinated wholeand/or an external fluid bed for final drying and/or coolingmilk powder. In addition, other ingredients can be sprayed into Extension of two-stage spray dryer to three stages by addingan extra fluid bedthe powder layer in the fluid bed in order to achieve large andstable agglomerates. Reserving of the external fluid bed for cooling in order toensure sufficient cooling of powders with high fat content.Integratedfluid bedO n e - s t a g e C o n i c a l S p r a y D r y e r, C S DTw o - s t a g e C o n i c a l S p r a y D r y e r, 2 C S D(with internal fluid bed)Integratedfluid bedExternal fluid bedExternal fluid bedTw o - s t a g e C o n i c a l S p r a y D r y e r, 2 C S DTh r e e - s t a g e C o n i c a l S p r a y D r y e r, 3 C S D(with external fluid bed)(with internal and external fluid beds)7
Upgrading ofAnhydro SprayDrying PlantsGlobal locationsUSAA PACS PX F LOWS PX F LOW C H I N AGetzville, NY 14068Shanghai 2000052USAPeoples Republic of ChinaP: 1 716 692 3000 or 800 828 7391P: 86 21 2208 5888F: 1 716 692 6416E: anhydro.china@spxflow.comE: anhydro.americas@spxflow.comBased in Charlotte, North Carolina, SPX FLOW, Inc. (NYSE: FLOW) is a multi-industry manufacturing leader. For more information,please visit www.spxflow.comS P X F LOW T E C H N O LO GY DA N M A R K A / SOestmarken 72860 SoeborgDenmarkP: 45 7027 8222F: 45 7027 8223E: ft.dk.soeborg@spxflow.comSPX FLOW, Inc. reserves the right to incorporate our latest design and material changes without notice or obligation.Design features, materials of construction and dimensional data, as described in this bulletin, are provided for your information only and should not be relied upon unless confirmedin writing. Please contact your local sales representative for product availability in your region. For more information visit www.spxflow.com.The green “ ” and “ ” are trademarks of SPX FLOW, Inc.ANH-120-GBVERSION 02/2017COPYRIGHT 2018 SPX FLOW, Inc.ISSUED 1/2018
Anhydro spray bed dryer with a fluid bed. 5 Anhydro spray bed dryer with a fluid bed CONCENTRATE HEATER A spiral type heater is frequently used for indirect heating of the concentrate. The product is heated by means of vacuum steam, thus avoiding the risk of overheating, and achieving long and
