CFD simulation of spray dryer by Ansys Fluent

In this project, a spray dryer is simulated in Ansys Fluent. Purchasing this product lets you access CAD and mesh files and simulated files. With the purchase of this product, a training video will be sent to you about the Fluent simulation steps and a full explanation of the options.



In this project, a spray dryer is simulated in Ansys Fluent. A spray dryer is an equipment used to convert liquid feedstock into a dry powder or granules through atomization and evaporation. It consists of a large cylindrical chamber with a conical base, a spray nozzle, a drying chamber, and a cyclone separator. The liquid feedstock is pumped into the spray nozzle, which then sprays the liquid into tiny droplets into the drying chamber. In the drying chamber, hot air is blown into contact with the droplets, which causes the liquid to evaporate, leaving behind dry powder or granules. The hot air temperature is carefully controlled to ensure the product does not overheat or burn.


The dry product is then collected in the cyclone separator, where any remaining fine particles or dust are separated from the product and collected separately. The dried powder or granules can be packaged for sale or further processed. Spray dryers are widely used in the food, chemical, and pharmaceutical industries for drying various products, such as milk powder, coffee, instant noodles, and pharmaceuticals. They offer several advantages, including high production rates, consistent product quality, and the ability to produce powders with specific properties, such as particle size and density.


In this project, hot air with a velocity of 0.5 meters per second and a temperature of 430 Kelvin enters the chamber. Liquid droplets also enter from the lower input, mixed with 298 Kelvin air. The species transport model is activated for modeling the evaporation of active droplets, and a combination of hydrogen, oxygen, and nitrogen species is used. Additionally, the Discrete phase model injects droplets into the chamber. The input water droplet temperature is also 298 Kelvin.

The geometry of this project has been drawn using Space Claim software. The meshing of this geometry has been done using Ansys Meshing software, and the number of elements used for this project is 235920.


After running the simulation, we can observe temperature, velocity, and pressure contours. By tracking the droplets, we also see that out of the 154 injected droplets, 17 have exited the lower output, and 137 have completely evaporated.



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