DRYNETICS™
Computational fluid dynamics (CFD) can be used in the design and optimization of spray dryer performance. Now in a world’s first, GEA Niro has vastly improved the accuracy of this simulation technique with a proprietary new method called DRYNETICS™ that puts the software on a more scientific footing.
DRYNETICS™ was a solution developed to overcome problems with unrealistic drying models in CFD. Conventional CFD software is not able to take all parameters, such as drying time and stickiness, of a given feed into account when making a simulation.
Advantages of DRYNETICS™
- possible to simulate the drying process with unprecedented accuracy
- evaluation of the plant design, before the plant is even built
- optimization of existing spray dryers.
DRYNETICS™ provides the solution by incorporating real-world measurements into the CFD software. Experiments are conducted on individual droplets of a feed to determine its actual drying properties. The results are then transferred to the CFD software with the help of appropriate mathematical models, making it possible to simulate the drying process with unprecedented accuracy.
Using DRYNETICS™ to improve the drying process inevitably leads to better results, whether you define that as better equipment, a better product, a better bottom line, or more likely, all. Moreover, DRYNETICS™ can be used with virtually any type of dairy, food, chemical, biological, or pharmaceutical product. It’s an important step forward for designers of spray dryers as well as those who use then, brought to you by GEA Niro.
Figure 1
The DRYNETICS™ method consists of three different stages (figure 1) The stages are:
- single droplet drying experiments
- advanced data analysis
- CFD (Computational Fluid Dynamics) simulations
The drying experiments are conducted using the DRYING KINETICS ANALYZER™, where a droplet of the feed in question is suspended in an ultrasonic field and dried under well-defined conditions. Read more about the
DRYING KINETICS ANALYZER™ here. During drying the droplet size, temperature and vertical position in the ultrasonic field are recorded and the stickiness properties are determined.
Single droplet drying experiments for drying kinetics and particle stickiness are done with different process conditions (e.g. drying air temperature and humidity). However, the sets of different process conditions, which are tested, are obviously limited. For input in CFD-simulations it is important to know the drying kinetics and stickiness at all thinkable and changing process conditions. This information is obtained in DRYNETICS™ by mathematical modeling.
The modeling is based on fundamental understanding of the physical phenomena occurring during drying rather than being a simple fit of the experimental data. Special DRYNETICS™ software has been developed to perform the advanced model calculations.
Step three of DRYNETICS™ is the implementation of models for the drying properties of the feed in question into 3D CFD-simulations of a full scale spray dryer. The results of the simulations are predictions of e.g. particle trajectories, temperature and moisture but also characteristics of deposits in the dryer. The CFD-simulations allows evaluation of the plant design, before the plant is even built as well as optimization of existing spra
y dryers.
DRYNETICS™ depicts the drying process as it really is thanks to the use of experimental data. In this figure the volume of sticky particles indicates the accumulation of troublesome wall deposits that would otherwise be overlooked.
DRYNETICS™ will be demonstrated at Anuga FoodTec- read about GEA Niro's presence on the exhibition here.
Information Request
If you are interested in learning more about DRYNETICS™ or visit the test centre at GEA Niro, please contact the GEA Niro Research and Development department.
Download the DRYNETICS™ brochure here (PDF)