Recent initiatives in effective modeling of spray drying

Abstract

Recent initiatives covered in this review can be divided into three broad categories. The first category concerns mathematically describing the spray drying process using a plug-flow model which allows quick what-if evaluations of the process. Intricacies associated with capturing the drying of a range of droplet sizes are discussed. Challenges in adapting the plug-flow simulation approach to counter-current spray drying, which is common in the production of non-heat sensitive detergent powder, was further elaborated. The second broad category features modeling the spray drying process using the Computational Fluid Dynamics technique. A critical review was provided to guide readers on a common dilemma plaguing this area of spray drying modeling. Recent developments in agglomeration modeling in spray dryers are discussed as well. The final part of this review touches on modeling techniques which can be used to predict the development of specific powder qualities. This includes modeling the degree of protein denaturation during spray drying, predicting the characteristics of crystalline type spray dried powder, and determining the properties of the powder surface at the molecular scale.

Keywords:

• Spray drying
• CFD
• modeling
• surface composition
• surface coverage
• evaporation induced self-assembly
• solute migration and aggregation
• coarse-grained model

Acknowledgments

Ramin Razmi thanks Fonterra for the technical and financial support for his PhD study.

Disclosure statement

The authors report no conflicts of interest. The authors alone are responsible for the content and writing of the paper.

Correction Statement

This article has been republished with minor changes. These changes do not impact the academic content of the article.

Additional information

Funding

Jie Xiao would like to appreciate the fund from the National Natural Science Foundation of China (21978184).

Notes on contributors

Ramin Razmi

Ramin Razmi is a PhD student in the Department of Chemical & Materials Engineering, University of Auckland. His PhD project focusses on the process modelling of the spray drying of milk.

Hasan Jubaer

Hasan Jubaer has recently obtained his PhD from the Department of Chemical Engineering, Monash University. His PhD project focused on Computational Fluid Dynamics (CFD) modeling of spray drying, particularly the agglomeration process during spray drying of milk powders. His research interests include modeling and simulation of various industrial processes.

Michał Krempski-Smejda

Michał Krempski-Smejda, chemical engineer associated with the Lodz University of Technology. He specializes in freezing and low temperature drying, organic volatile substances and plug flow mechanics.

Maciej Jaskulski

Maciej Jaskulski, chemical engineer associated with the Lodz University of Technology. He studies issues related to spray drying, such as: agglomeration of particles or the morphology of loose materials. Its specialty is CFD modeling processes of heat and mass transfer in a discrete phase.

Jie Xiao

Jie Xiao is a Jiangsu Provincial Chair Professor and the Deputy Head of School of Chemical and Environmental Engineering at Soochow University. His research interests include multiscale systems science and engineering.

Xiao Dong Chen

Xiao Dong Chen is a University Distinguished Professor and the founding Head of School of Chemical and Environmental Engineering at Soochow University. He has a wide interest on drying, food engineering, bio inspired chemical engineering and powder technology.

Meng Wai Woo

Meng Wai Woo is an Associate Professor in Chemical and Materials Engineering. He has a wide interest in spray drying research and in new spray dried product development.