SUS316 20000kg/H YPG Pressure Spray Dryer Machine

Product Description

YPG Series Pressure spray dryer

 

General description

 

YPG series pressure-spray granulating and drying machines can spray-granulate size mixture with high content of solid under pressure and dry it into globular grain product. Dried powder having a good fluidity will quickly fully fill in mold in a homogeneous way, keeping a constant content of residual water and looseness. The powder can be applied for molding products under static pressure to increase a service lifetime of mold 4-8 times in comparison with that used for mechanically granulated powder. The molded products have a good uniformity and high degree of finish, so they are widely used in the trades of porcelain bricks, tablewares ceramic wafers, ceramic materials, ferrite magnetic materials, etc.

 

◆ This equipment connects two functions,drying and granulating, together. The needed ball granule with certain size and ratio can be produced in accordance with requirements of process to adjust pressure, flow, and size of atomizing hole.

 

◆ The tower body, pipes and separator of the set where would contact the products are made of AISISUS304 or AISISUS304L or AISISUS316L or AISISUS316. There is a safe heat-preservation layer between inner and outer cases of the drying tower body. The filled material is fine glass cotton. The tower body is also equipped with observation door, sight glass, lamp-house, control meters and instruments that is controlled and displayed through electric control panel.

 

Product details

 

Material:	SUS316/SUS304/ CARBON STEEL ,ETC	Heating Source:	Steam / Electrical / Natural Gas / Diesel / Etc.
Capacity:	10-20000kg Per Hour	Water Evaporation:	12.5-50,000kg Per Hour
Temp:	120-600'C	Drying pattern:	Continuous Drying
Document:	FAT/ IQ / OQ / PQ	Certificate:	CE / UL /CU-TR
Control:	HMI & BUTTON	Atomizing mode:	nozzle atomizer
High Light:	chemical dryer machine, spray drying equipment

 

Technical parameters

 

type item

YPG -6

YPG -12.5

YPG -25

YPG -50

YPG -65

YPG -100

YPG -200

YPG -300

YPG -500

YPG -600

YPG -1000

YPG -2000

YPG -3000

Water evap. (kg/h)

6

12.5

25

50

65

100

200

300

500

600

1000

2000

3000

Atomizer type

Low pressure nozzle

Atomizing pressure(MPa)

Bottom atomizing0.6~4.0 ; top atomizing1.0~1.5

Tower diameter(m)

D

1.40 1.60 2.0 2.8 3 3.5 4 4.5 4.8 5 5.4 5.8 6.2 6.8 5.2 6.3 7.65 9.4 9.4 9.4 11.25 14.5 15.75 15.85 16 18 18.5 20 3 3.8 5 5.4 5.6 5.6 9 10 12 13 15 17 17.5 17.5 2 2.75 4.2 4.7 4.7 4.9 6.5 7 8 8.5 10 12 12.5 13

Tower Height(m)

H

Length(m)

L

Width(m)

W

Notes: The amount of water evaporation is related to the characteristics of the material, the solid content and the temperature of the hot air inlet and outlet.

 

Technical parameters

Spec.	Water evaporation capacity Kg/h	Overall dimension (ф*H) mm	High pressure pump pressure Mpa	Power kW	Inlet air temperature ℃	product water contents %	collection rate %	electric heater Kw	electricity +steam Mpa+Kw	hot air furnace ×104Kcal/h
50	50	1600×8900	2~10	8.5	200~300	less than 5 percent, and 5 percent can be achieved.	>97	75	0.5+54	10
100	100	2000×11500	2~10	14	200~300		>97	120	0.6+90	15
150	150	2400×13500	2~10	22	200~300		>97	150	0.6+108	20
200	200	2800×14800	2~10	24	200~300		>97	When the temperature is lower than 200, the parameters should be calculated according to the practical condition.		30
300	300	3200×15400	2~10	30	200~300		>97			40
500	500	3800×18800	2~10	82	200~300		>97			50
1000~ 10000	1000~ 10000	/	/	30~300	200~300		>97			120

 

Notes: The amount of water evaporation is related to the characteristics of the material, the solid content and the temperature of the hot air inlet and outlet.

 

The configuration for a set of pressure spray dryer system

 

1. Air inlet system: it consists of air filter (such as Pre & post-filter & Sub- high efficiency filter and high efficiency filter), air heater (such as electrical heater, steam radiator,gas furnace and so on) draft fan and relative air inlet duct.

2. Liquid delivery system: it consists of diaphragm pump or screw pump, material stirring tank and related pipe.

3. Atomizing system: pressure pump with inverter.

4. Main tower: it consists of the conical sections, straight sections, air hammer, lighting device,manhole and so on.

5. Material collecting system: it consists of cyclone separator and cloth bag filter or water scraper.This parts should be equipped based on customer needs.

6. Air outlet system: it consists of suction fan, air outlet duct and post filter or high efficiency filter.(For the filter chose, it is based on the customer request.)

 

Brief introduction to work flow

 

The liquid of raw material is pumped in through diaphragm pump. The liquid of raw material be atomized into tiny droplets. Then it gathers with hot air and falls off. Most parts of powder material will be collected from the outlet of the main tower’s bottom. For the fine powder, we will still continuously collect them by the cyclone separator and cloth bag filter or water(wet) scrubber. But it should depend on the material property.

 

The pressure type spray granulation dryer is mainly composed of a feeding system, a drying system, a dust removal system, a heating system and an electrical system, and each system includes some related equipments.

 

The feeding system consists of a mixing barrel, a filter, a diaphragm pump and a spray gun. The ball-milled secondary slurry is transferred from the ball mill to the mixing tank, and is pumped and transported by the diaphragm pump through the filter, and then enters the drying tower through the spray gun.

 

The slurry enters the drying tower from the spray gun nozzle to start the spray granulation drying process. The specific process is divided into three stages:

 

Slurry atomization

 

The slurry is pressed into the drying tower from the nozzle at a certain pressure by the diaphragm pump in the feeding system. The energy of the pressure is converted into kinetic energy. The slurry is sprayed from the nozzle from the bottom to the top to form a high-speed liquid film, which immediately splits into droplets. The size of the droplets produced by atomization is inversely proportional to the pressure, and the production capacity of the nozzle is proportional to the square of the pressure.

 

Granular powder discharge

 

The blower that conveys hot air to the drying tower, drying tower and exhaust fan constitute the drying system.

 

The dust removal system is composed of high-efficiency cyclone separator, bag filter, centrifugal fan and etc.. The exhaust fan sends the finer particles and dry air into the high-efficiency cyclone separator. After effective separation, the finer particles enter the receiving pot at the bottom of the separator for recovery. The waste gas containing a very small amount of remaining fine particles is sucked into the bag filter by the centrifugal fan for dust collection again, which realizes the harmless treatment of the waste gas, and the final waste gas is discharged from the chimney.

 

In addition, a heating system composed of electric heaters and gas-fueled air heater(furnace) provides hot air for the drying tower. The electrical system composed of the electrical control cabinet and on-site sensors installed at the air inlet and outlet to monitor the temperature, can monitor and control the main links of the entire spray granulation dryer to ensure the normal operation of the entire plant.

 

The droplets are dried into a spherical shape.

 

Drying between the droplets and hot air is carried out in a mixed flow, and the hot air enters the tower through the hot air distributor on the top cover. The hot air distributor generates a downward streamline air flow, and the droplets are sprayed into the hot air flow from bottom to top. The droplets form a spherical shape due to the effect of surface tension. At the same time, because the droplets have a large surface area, the water evaporates and dries quickly, and finally shrinks to form a dry spherical granular (particle) powder. The spherical granular powder formed gradually settles in the drying tower and is separated from the hot air. The funnel cavity at the bottom of the tower collects the granular materials and discharges them from the discharge port. The finer particles and dry air are drawn by the exhaust fan connected to the upper part of the funnel cone to enter the dust removal system.

 

The importance of testing in equipment selection and technical design

 

◆ Because different products have different drying technologies and particle rules, there is no single type of spray dryers that meet all requirements. Now spraying is still regarded as a kind of technology. The test is the base of correctly choosing the types. The machine produced by the "YIBU" Company is specially used for carrying out the technological tests of materials. This kind of pragmatic attitude contributes to the success of many turn-key projects, such as: detergent powder, polymerized resin, white carbon,Mn3O4,soybean milk, lipase, sea cucumber Chinese traditional medicine and etc.

 

Imported pressure nozzles of internationally renowned brands

 

Multi-gun adjustable spray gun group

 

Multi-stage air intake

Large-scale equipment better controls mixing, drying and agglomeration

Each venturi is equipped with a multi-stage spray gun and independent fine powder recovery tube

  

                                                                                                                                      Low temp. agglomeration

                                                                                   Low temp. agglomeration

 

Features of YPG series pressure spray granulation dryer

 

 

1. High yield ratio, energy saving and High efficiency;

2. No powder deposit onto the wall;

3. Fast drying,especially applicable for heat-sensitive material:

The surface area of the material liquid is greatly increased after atomization. In the hot air flow, 95-98% of the water can be evaporated in an instant, and the drying time is only ten seconds to tens of seconds;

4. The obtained product is spherical particles with uniform particle size, good fluidity, good solubility, high product purity and good quality.

5. Wide range of application: According to the characteristics of the material, it can be dried with hot air or granulated with cold air, which has strong adaptability to the material.

6. Simple and stable operation, convenient control, easy to realize automatic operation.

7. For the heating system of the plant, it is very flexible. We can configure it based on the customers’ specific conditions such as steam,electricity, gas furnace and so on, of which we can all design to match our spray dryer;

8. Advanced Industrial Automation Control System

 

The control system has more choices, such as push button, HMI+PLC and so on.

 

The automatic control system is made up of PLC controller, applying SIEMENS company’s programmable logic controller of S7-315 2DP, and based on STEP 5.5 programming software, the start and stop and interlocking of the plant , PID loop control and alarming of process parameters and etc. Can be realized. The control system first accepts the commands of the operator and then judges whether the logic conditions of the process program will be fulfilled according to the collected field information. If conditions are set up, the control program outputs signals in a specific order to activate or close all kinds of equipment in the control process.

 

The HMI human-machine interface is configured by SIEMENS's configuration software SIMATIC WinCC, which realizes the operation of dryer’s control system, operation status monitoring, data analysis, recording and printing of the drying equipment control system. It has completed the organic combination of field equipment and personnel. Through the HMI, the operator can input the commands, and input different process parameters or formulas to complete the production of different products.At the same time, we can get information about the state of the system. We can also inquire about the current production information of the system, or trace (inquire) the important record data of historical production process. If there is an abnormal situation, the system will send out the alarm signal.

 

PSD-90 precision centrifugal spray dryer ICP control panel interface diagram

 

The field data is collected through S7-315 PLC, and the collected data is displayed and recorded on the computer which takes the WinCC as configuration software by using CP343-1 module through TCP/IP protocol.

 

The data collected in the PLC is also sent to a remote computer through the industrial router (HUB).

 

PLC software and host computer software programming apply the S88 program structure and modularized design.

 

According to different control objects, motor templates (two types including inverter control and direct start control) are written, including valve modules, analog input templates, analog output templates, PID control loop templates and etc..

 

In view of process control, the GRAPH block of SIEMENS is applied for programming, making the process clearer.

 

The drying process is refined to a number of small processes (such as cold operation, hot operation, water operation, material operation, drying, etc.).operation, drying, etc.).

 

The purpose of the automatic control system is to ensure the normal operation of the equipments and achieve the stability of product quality by controlling and monitoring the important process parameters of the spray dryer.

 

Large spray tower on-field control:

 

Large spray tower field control cabinet:

 

SIMATIC Program Logic Control System & Touch Panel

 

Scope of applications:

 

◆ Food Industry: Fatty milk powder, protein, cocoa milk powder, substitute milk powder, egg white (yolk), food and plant, oats, chicken juice, coffee, instant dissoluble tea,seasoning meat,protein, soybean, peanut protein, hydrolysate and so forth. Sugar, corn syrup, corn starch, glucose. pectin, malt sugar, sorbic acid potassium and etc.

◆ Medicine: Traditional Chinese medicine extract, ointment, yeast, vitamin, antibiotic, amylase, lipase and etc.

◆ Plastic and resin : AB, ABS emulsion, uric acid resin, phenolic aldehyde resin, urea-formaldehyde resin, formaldehyde resin, polythene, poly- chloroprene and etc.

◆ Detergent :common washing powder, advanced washing powder, soap powder, soda ash, emulsifier, brightening agent, orthophosphoric acid and etc.

◆ Chemical industry :Sodium fluoride (potassium ), alkaline dyestuff and pigment, dyestuff intermediate, Mn3O4, compound fertilizer, formic silicic acid,catalyst, sulphuric acid agent, amino acid, white carbon and so on.

◆ Ceramic :aluminium oxide, ceramic tile material, magnesium oxide, talcum and so on.

◆ Other :Aluminum hydroxide, calcium chloride, stearic acid agent and the cooling spray.It is widely used in food dyes, intermediates and other industries.

 

 

Physical pictures of pressure spray dryers at construction sites at home and abroad

 

YPG-2000 Downstream Spray Dryer (Shaanxi Polyaluminum Chloride PAC Project)

3D drawing for spray drying plant

 

Pressure spray dryer tower under construction

 

Large pressure spray tower on foreign construction site

 

Flow chart for top spray Co-current type pressure nozzle spray dryer

 

Flow chart for bottom spray type counter-current pressure nozzle spray dryer

 

Spray dryer performance introduction

 

The bottom-spray, top-spray method pressure spray dryer adopts the membrane pump for supplying materials with the flux of 6-5000kg/h, pressure of 2.5-15Mpa and flow precision of <1%. It can be equipped with the fine powder recovery and re-moisture adhesion systems to meet the users' requirements of granule diameter of materials. It adopts many new technologies, such as Auto-cleaning filter, anti-choking spray gun, etc. and its reliability has improved further.

 

Optional Choice:

 

◆ This kind of complete plant is manufactured based on customized design. Not all functional features are provided with all designs. The actual configuration should be made in accordance with the contract or signed agreement.

 

◆ For the main electrical components, we have choices of international brands, such as ABB, Siemens or Schneider or others.

 

◆ For the construction material of the plant, we can choose AISISUS304, AISISUS304L, AISISUS316, AISISUS316L, carbon steel, etc.

 

◆ For the control system, we can choose buttons, PLC + HMI, etc.. We can design the control system as needed.

 

◆ We can design explosion-proof systems for spray dryers according to customer requirements.

 

◆ For the matching system for the spray dryer, we can supply it, such as feeding system, pneumatic conveying system and so on.

 

◆ For the heating system for the plant, it is very flexible. we can configure it based on the customer’s site conditions, such as steam, electricity, gas furnace and so on, of which we can all design to match our spray dryer.

 

◆ If there is no heating system, it can be used as a cooler to make particles with cooling air.

 

◆ Complete and professional R&D plants, scientific and reasonable product testing service, extensive and in-depth production technology exchange, research and exploration service platform:

 

The XIANDAO company can provide customers with various services of process experiment and test verification in the lab size,pilot scale or even production size test units for a small amount product such series as YPG, LPG, PSD, BYP, PFSD and etc.. These plants verify the feasibility of technical application of many series of products, determine the optimal production process conditions, and provide samples for market analysis.

 

Attention to order

 

1. Liquid name and property:solid contents (or water contents), viscosity,surface tension and PH value.

2. Dry powder density residual water contents allowed,particle size,and maximum temperature allowed.

3. Output:shift time daily.

4. Energy that can be supplied:steam pressure, electricity properly,fuel of coal,oil and natural gas.

5. Control requirement:whether or not the inlet and outlet temperatures should be controlled. Powder collection requirement: whetherit's necessary to use cloth bag filter and the requirement of the environment of the exhausted gas.

6. Other special requirements.