Shanghai Xinzhuang Instrument Co., Ltd. can leverage commercial CFD software to analyze the temperature, velocity, humidity fields, and the flight trajectory of materials within a spray drying tower. This allows for a comprehensive understanding of gas medium behavior, including changes in humidity and temperature. To better capture the drying characteristics of droplets, it is essential to integrate custom user programs, particularly advanced drying models. Moreover, due to the turbulent nature of gas flow inside the drying tower, selecting an appropriate turbulence model significantly affects simulation accuracy—especially when using a rotary air inlet system, where turbulence effects are more pronounced. Recent transient simulations of spray drying have revealed that the flow field inside the tower evolves over time, leading to irregular droplet movement. As a result, even with identical initial conditions, different drying outcomes may occur. Although some residual solvent is acceptable, droplets might still return to high-temperature regions during their flight, a phenomenon that requires further investigation.
Simulation and detailed analysis of small-scale spray dryers have also been conducted. A newly developed small spray dryer uses cryogenic dehumidification to generate low-temperature, low-humidity air, combined with a specialized atomization system to enable continuous production of ice powder and dried material. Supercritical fluid spray drying is an emerging technology that has shown promising results in producing protein liposome powders. Comparisons between supercritical and subcritical spray drying techniques reveal differences in particle size distribution and morphology. Studies on sugar and chicken protein drying using supercritical methods show that the resulting particles range from 1 to 60 μm, with spherical shapes and smooth surfaces. However, supercritical fluids have limited compatibility with water, making direct use challenging. They often require entrainment with other solvents, which makes their integration with traditional spray drying an area worth exploring. While foreign researchers have studied this technique, no similar reports have emerged in China yet.
With the advancement of computer technology, solving complex mathematical models has become more efficient. Internationally, computational fluid dynamics (CFD) has been widely applied to simulate the entire spray drying process, yielding significant results. Research efforts have focused on model development, calibration, new drying tower designs, horizontal and centrifugal spray drying, as well as large-scale industrial pressure spray drying.
Shanghai Xinzhuang has an industry-recognized team of experts and top-tier technical professionals. We are committed to delivering the highest quality products and services to earn our customers' trust. Every product and every step of the process receives our full dedication and attention.
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