TECHNICAL MANUAL NO.

402

Spray Drying
Nozzles and Applications

1
 Technical Manual No. 402

Spray Drying Nozzles and Applications Manual

…including information on spray drying nozzle selection, performance,

maintenance and cleaning

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 Table of Contents Page No.

I. Introduction……………………………………………………….......................... 4
Objective of manual………………………………………………...................... 4
Spray drying industry progress…………………………………………………. 4
Other product drying methods……………………………………...................... 4
Advantages of the spray drying process………………………………............... 4
Atomizers…the key to successful spray drying………………………………… 5

II. Spray Drying Systems – General Information…………...……………............... 6

Process stages…………………………………………………………………… 6
Vertical (tower) spray dryers…………………………………………………… 7
Closed-cycle and semi-closed cycle systems…………………………………… 9
Horizontal (box) spray dryers ………………….………………………………. 9
Two-stage (multi-stage) dryers ………………………………………............... 9

III. Feed Stock Properties………………………………………………...................... 11

IV. Dried Powder Properties…………………………………………......................... 13

V. Spray Atomizers – General Information……………………………………….. 15

Pressure spray nozzles……………………………………………...................... 15
Two-fluid air atomizing spray nozzles……………………………..................... 16

VI. Spray Nozzle Selection, Performance, Maintenance and Cleaning…………… 18

Selection of nozzle……………………………………………………………… 18
Materials for orifice inserts and cores…………………………………………... 18
Static Corrosion Tests on Carbide ……………………………………………... 19
Nozzle capacity…………………………………………………………………. 20
Viscosity effect on nozzle capacity……………………………………………... 21
Spray angle……………………………………………………………………… 23
Droplet size information………………………………………………………... 24
Nozzle wear/corrosion……………………………………………...................... 25
Checking worn orifices and cores…………………………………..................... 26
Pressing orifice insert into cap……………………………………...................... 27
Nozzle leakage problem………………………………………………………… 27
Clogging problems……………………………………………………………… 27
Nozzle cleaning procedures………………………………………...................... 28
Typical application problems…………………………………………………… 28
Factors affecting powder properties………………………………..................... 30

VII. Spray Drying Industries and Products………………………………………….. 32

VIII. Spraying Systems Co. Spray Nozzles……………………………………………. 35

Pressure spray nozzles………………………………………………….............. 38
Two-fluid air atomizing nozzles………………………………………............... 42
Applications using Spraying Systems Co. nozzles……………………............... 43

IX. Appendix-Glossary of Terms…………………………………………………….. 44

Metric equivalents ……………………………………………………………… 54
Sieve sizes tabulation…………………………………………………………… 56
SprayDry Evaluation Form …………………………………………………….. 58

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 Section I - Introduction
Objective

This manual outlines the basics of spray drying with an emphasis on nozzles and atomization.
Complete and detailed information on nozzles and accessories is offered in Spraying Systems
Co. Bulletins 447, 504, and 527 including nozzle listings, spray performance data, part numbers,
materials, and ordering information. For more comprehensive information on specific
applications, refer to spray drying industry books and periodicals, as well as to equipment
manufacturers' technical literature.

Spray Drying Industry Progress

Spray drying emerged more than 100 years ago, with significant applications occurring in the
early 1900's in the milk and detergent industries. The most rapid industry growth took place in
the early 1940’s due to the heavy overseas demand for dried dairy and egg products. It was at
this time that Spraying Systems Co. introduced its SprayDry® nozzles and accessories
specifically designed to serve this rapidly expanding industry. Since then other nozzle types
have been added to make the SprayDry® nozzle line the most complete in the industry.

As advances in spray drying technology continued, the process was used for a wider variety of
food products, as well as for various chemical, ceramic, and pharmaceutical products.

In recent years variations of the spray drying technique have evolved into other applications
including economic recovery of waste materials such as whey, spent liquors, fermentation
residues, and sewage sludge; scrubbing flue gases to remove toxic constituents such as sulfur
dioxide; spray cooling (prilling) applications involving the "solidifying" of products with
melting points above ambient temperatures ...as well as spray freeze drying, wherein the actual
"drying" occurs by sublimation.

Other Product Drying Methods

The spray drying industry is large and diversified, but spray dried products are only a small
percentage of the total products being dried commercially. Most of the product drying continues
to be done by other methods such as rotary drum dryers, rotating tray dryers, fluid bed dryers,
conveyor dryers, tunnel dryers, steam tube dryers, freeze dryers, vacuum filters, and flash
dryers. The choice of a drying system depends on many factors including the equipment
available, the properties of the feed stocks and dried products, the capacity requirements, and
the investment, operating, and maintenance costs.

Advantages of Spray Drying

Spray drying is a continuous and complete operation, automatically controlled, producing a

finished and packaged powder product from the original liquid feed stock. Almost any pump
able solution, slurry, suspension, gel, paste, or emulsion can be spray dried. The spray drying
process is energy efficient and economical with respect to the handling, labor, operating, and
maintenance costs.

Heat and oxygen sensitive materials, high purity products, flammable and explosive materials,
odorous products, and toxic products can be spray dried in closed-cycle spray drying systems.
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Corrosive feeds can be economically handled, since the corrosive activity of dried products is
minimal.

Atomizers - The Key To Successful Spray Drying

A spray drying operation involves several very important factors including the nature of the feed
stock and product, drying gas temperatures, and the type of spray dryer and atomizer used. Each
spray drying application is customized to suit a specific combination of these important factors.

In each successful spray system the most essential element is proper atomization of the feed
stock. Without it the application will fail. This atomization is accomplished by one of three
different spray nozzle types; 1) pressure spray nozzles, small and medium capacity sizes
operating at high pressures; 2) pressure spray nozzles, larger capacity sizes operating at lower to
medium spraying pressures; and 3) two-fluid (or three-fluid) air atomizing spray nozzles. For
information on spray nozzle atomizers see sections V and VIII.

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 Section II - Spray Drying Systems – General Information

Process stages

Spray drying processes consist of many stages, including (A) preparation of feed stock, (B)
atomization of feed stock, (C) contacting the droplets with hot air to cause evaporation of the
water, (D) evaporation of water, and collecting and packaging the dried powder products. In
some installations multi-stage dryers are used wherein the drying in the first stage is incomplete,
and the final drying occurs later in a fluidized bed stage. Additional functions required of the
system include: separating the dried powder from the exhaust gas stream; cleaning exhaust
gases; controlling process stages; and possible further treatment of the drying product.

Typical Open Cycle Co-Current flow layout.

Exhaust to Atmosphere

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 Spray Dryers

The "heart" of the spray drying system is the spray dryer chamber. Finely atomized spray
droplets are brought into contact with the hot resulting in the rapid evaporation of about 95% of
the water from the droplets, usually in a matter of 15 to 40 seconds, depending on the dryer
type, size, hot air temperature and volume, and flow system.

There are many varieties of spray dryers, but most are variations of either the vertical (tower)
type -or -the horizontal (box) type.

Vertical (Tower) Spray Dryers

Vertical spray dryers are tall cylindrical chambers with pressure or two-fluid type spray nozzles
located at the top or bottom of the chamber with rotary atomizers located at the top. The inlets
for the hot air (or gas) can be at the top, bottom, or side of the chamber when using spray
nozzles ...but only at the top when using rotary atomizers. The positioning of the spray nozzle
depends on whether a co-current (con-current), counter-current, or mixed flow system is used.

In a co-current flow system the spray droplets and hot air flow in the same direction, with the
spray nozzles positioned close to the hot air inlet. In this arrangement the spray evaporation is
rapid, since the hottest air is contacting droplets containing the most moisture. During this short
and rapid evaporation period the spray droplet temperature remains low, since the droplet
remains at the wet bulb temperature; therefore, up to this point the product is not subjected to
any heat degradation. As the drying continues, the hot air carrying the drying particles has been
cooled somewhat, thereby further minimizing the potential for heat damage.

In a counter-current flow system the hot air and the spray droplets travel in opposite directions
with the spray nozzles at the top and the hot air inlet located at the bottom of the chamber. In
this counter-current flow system the "almost-dried" particles are exposed to the highest
temperature, since the hottest gas contacts the driest particles first. While this system provides
an excellent use of heat energy, it is not used with heat sensitive materials.

In a mixed flow system the feed and hot air inlets are at opposite ends of the vertical drying
chamber as in the counter-current flow, but with the spray nozzle atomizers positioned at the
bottom, spraying upwards. As in the counter-flow system, the powder is subject to relatively
high temperatures; therefore, the mixed flow system is usually not used for heat sensitive
products.

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Co-Current Flow – Air and Liquid travel in same direction

Counter-Current Flow – Air and Liquid travel in opposite directions

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 Closed-Cycle and Semi-Closed Systems

In applications involving a feed stock or product which is oxygen sensitive, inflammable, toxic,
odorous, explosive, or requires high purity, closed-cycle systems are used. In these cases a hot
inert gas, possibly nitrogen, is used in place of air as a drying medium. The inert gas is not
exhausted into the atmosphere, but remains in the system to be recycled.

A modification of the open-cycle and closed-cycle is described as a closed system, or as a "self-

innertizing" installation. This is accomplished by controlling the amount of excess combustion
air fed to a direct-fired air heater. This results in a hot drying gas flow having a low oxygen
content, as required with oxygen sensitive feeds or products. A semi-closed system is also used
with products that create odors, or contain toxic materials, which require the exhaust gases to be
treated before being discharged into the atmosphere. By limiting the amount of excess
combustion air a minimum amount of exhaust gas must be scrubbed or treated, thereby lowering
the investment and operating costs of the system.

Horizontal (Box) Spray Dryers

Spray nozzles in a box dryer usually project the atomized feed horizontally into the chamber,
contacting the hot air, with the resulting dried powder falling to the chamber floor or a “V”
shaped bottom. Since these dryers are relatively short, it is important to provide very fine
atomization to the spray droplets to achieve the proper drying in the limited dwell time available
in the drying chamber.

Two-Stage (Multi-Stage) Dryers

In a single-stage dryer, the usual final moisture content in spray dried products ranges from 2 to
5%. In a two-stage unit, the first stage is controlled so as to produce a powder particle having 5
to 10% moisture as it reaches the bottom of the chamber and enters the second stage. The
second stage can be a vibrating bed dryer or fluidized bed dryer, with the drying process
continuing in this stage until the product moisture drops to the 2 to 5% level. Since the first
stage maintains a relatively wet particle, it is important to keep the wet particles from contacting
the wall of the chamber. The basic advantage of a two-stage process is that it permits the use of
lower drying air temperatures in both stages while providing savings in energy costs and making
it most effective in processing heat sensitive materials.

In some applications the second stage is used as an agglomeration process, wherein moist
particles from the first stage are deposited on a vibrating bed, causing these particles to join
together to form larger particles. This second stage agglomeration process usually provides
higher bulk densities, better solubility, improvement of the flowing properties, and less dust. In
other installations, the wet particles from the first stage are sprayed with additional feed in the
second stage to soften their surfaces and/or to enlarge or “grow” the particles, as a result of the
additional spray build-up and the joining of wet particles. This process is called "rewetting
agglomeration" or "instantizing”.

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Agglomeration on a conveyor belt in stage (A).
Drying and cooling in stages (B) and (C).

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 Section III - Feed Stock Properties

The feeds to be atomized can be solutions, slurries, pastes, gels, emulsions, molten materials,
multi-component materials, suspensions, or sludge...so long as they are pumpable. In each spray
drying application the feed stock is prepared for the spray drying process with its specific
constituents at the required temperature. At the same time, these feeds have important physical
properties which can affect the spraying process, including the following:

Solids Content (Concentration): This property is indicated by a percentage of the solids

content, and may range from 20% to 70%, depending on the nature of the feed, dryer capacity,
and atomizers used. The solids concentration factor affects the spray atomizer choice in terms of
spray-ability, spraying pressure, atomizer wear life, as well as clogging. Higher total solids in
many feeds result in higher particle density and powder bulk density.

Specific Gravity (Density): This feed characteristic primarily affects the flow rate of
atomizers. The flow rate (GPH) (l/min) from a pressure spray nozzle is inversely proportional to
the square root of the specific gravity of the feed. Therefore, if water capacity tabulations are
used as the basis of nozzle choice, the nozzle capacity, when spraying a liquid lighter or heavier
than water, can be estimated from its specific gravity. Water, with a specific gravity of 1.0,
weighs 8.34 lbs. per gallon (1 kg/l). See section VI, Nozzle capacity, for a Specific Gravity
Factor tabulation. Aside from the specific gravity influence on capacity, the feed viscosity can
also affect the flow rate.

Viscosity: The feed viscosity is determined by the feed ingredients, solids content, and
temperature. A feed with a high viscosity does not atomize as easily or as finely as one with a
lower viscosity, thereby resulting in larger droplet/particle sizes as compared to those from a
lower viscosity feed, when using the same nozzle and spraying pressure. The viscosity can also
influence the flow rate through the spray nozzle, depending on the viscosity level, nozzle type
and size, and spraying pressure. In some nozzles an increase in viscosity results in a higher flow
rate at the same pressure -or provides the same capacity at a lower pressure. In other type
nozzles the influence on flow rates is minor. See section VI, Viscosity effect.

Surface tension: High surface tension liquids are more difficult to atomize and require higher
minimum spraying pressures. The surface tension values of most feed stocks vary only within a
limited range.

Feed temperature: This property can affect the feed viscosity as well as the heat transfer
function in the spray dryer chamber. The temperature factor should also be considered when
using spray atomizers containing gaskets, which may be subject to heat deterioration from the
drying air as well as the feed liquid.

Melting temperature: This factor is most important in spray cooling (prilling) applications
involving feeds which solidify at ambient temperatures.

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Thermo plastic: This identifies materials which could melt or become sticky at spray drying
temperatures.

Corrosiveness: Some feed stocks may contain corrosive chemicals which attack nozzles.
Nozzle materials providing effective corrosion resistance to the specific chemical at its
concentration and temperature should be used. This corrosion factor also applies to nozzle
cleaning solutions. See section VI, Nozzle Wear and Corrosion, and the following discussion on
abrasiveness.

Abrasiveness: The combination of abrasive feeds and high spraying pressures provides a most
serious wear problem for nozzle orifice inserts, cores, and whirl chambers. To suit the specific
requirements of wear resistance in each application many of these nozzle parts are available in a
choice of hardened stainless steel, or a variety of tungsten carbides. Hardened stainless steel is a
fraction of the cost of tungsten carbide, but it will need to be replaced more often. It has
generally been used where the sprayed chemical is not compatible with our “Y” or “M”
carbides. “M” carbide is definitely the longest wearing of our carbides except where chemical
compatibility is an issue. Then we suggest the “L” carbide, which is longer wearing with
corrosive chemicals than the “Y” or “M”. The “L” carbide will also last many times longer than
the hardened stainless steel.

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 Section IV - Dried Powder Properties

Spray dried powders have many properties, which are normally monitored during the drying
operation. These powder properties include:

Particle Shape: While some dried particles have spherical shapes, others do not. For non-
spherical particles the shape is defined as the ratio of the length of the side to that of the short
side, as measured through the center of gravity. These particles can be hollow, solid, or a
variation thereof, depending on the feed stock and drying process.

Particle Size: The unit used to measure the powder particle size is a micron of (1/1000 of 1
mm) (1/25,400 of 1 inch). If the particle is not round, an "apparent diameter” measurement is
used. This is the mean distance between extremities of the particle measured thru the center of
gravity of the particle. Rotary atomizers usually produce fine to medium size particles, ranging
from approximately 25 to 300 microns (micrometers), depending on the wheel diameter and
RPM. Pressure spray nozzles normally produce fine to coarse particles in the range of 20 to 600
microns (micrometers), depending on the nozzle type, size, and spraying pressure; while two-
fluid air atomizing nozzles can supply very fine particle sizes from 10 to 200 microns
(micrometers) and larger depending on the nozzle size, Spray Set-up, and air and liquid
pressures. See Table SS-1, section X, for sieve sizes.

Particle Size Distribution: Particle size distribution is a measure of the percentage of spray
that is within a certain drop size range. A customer would like all of the spray particles to be in
the same range, so the tighter the particle size distribution the better. Pressure nozzles give the
tightest drop size distribution.

Particle Density: Powder particles can be hollow, porous, or solid depending on the feedstock
and operating variables. It follows that the hollow type and the porous type particles have lower
particle densities than the solid particle type. Because of the many interrelated factors, it is
difficult to predict particle density. Whether a particle is mostly solid or mostly hollow is
usually a matter of the type of dryer that is used. Counter-current dryers produce a more solid
particle and co-current dryers produce a more hollow particle. Changes to the degree of
hollowness or solidness are controlled by the temperature of the drying air which affects the
droplets evaporation rate. Higher solids-content feed stock usually produce a higher bulk
density.

Bulk Density: This factor describes the weight of the dried powder per unit volume. This factor
influences the size of containers, storage bins, and handling costs. Generally, nozzle spray-dried
particles can have higher bulk densities than those from rotary atomizers. Factors affecting the
product bulk density include the following:

The Range of Particle-Size Distribution: When the size difference between the largest
and smallest spray dried particles is large, the bulk density will be greater than that from
narrower range of sizes ...assuming that there is an appreciable amount of product in the
smaller size range. This relationship can be explained by the voids between the large
particles being filled with the smaller particles, which are usually denser than the larger
ones.

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 Powder Moisture Content: As mentioned previously this property can be controlled by
varying the gas temperatures. Particles containing more moisture generally have higher
bulk densities.

Drying Air Temperature: In a co-current flow system; increasing the drying air
temperature usually decreases the bulk density because the original, faster, evaporation
causes an expansion of the particle as it dries.

Percentage of Solids in the Feed: Changing the amount of solids in the feed can
change the bulk density, depending on the simultaneous effect on atomization. For
instance, decreasing the solids content in some materials produces a smaller particle size
with an increase in bulk density. On the other hand, with some food product feeds an
increase in bulk density is obtained by increasing the solids in the feed.

Increase in Feed Temperature: While this usually produces somewhat lower bulk
densities, if pre-heating de-aerates the feed, the bulk density can increase.

Pre-heating of feed also usually reduces the feed viscosity, thereby improving the
atomization. In feeds subject to possible crystallization, heating of the feed will prevent
clogging in spray nozzles.

Outlet Air Temperature: Decreasing the outlet air temperature increases the moisture
content of the powder, thereby increasing the bulk density

Air Flow: As mentioned in the Counter-current Flow discussion, section II. the particles
may be more dense, because the liquid droplets originally contact air which has already
been partially cooled and moist, thereby slowing the evaporation rate. Therefore, the
particles do not expand as they would have in a co-current air flow system.

Residual Moisture Content in Powder Particles: This property, usually 2-4%, is controlled
by the outlet temperature of the drying air, but it can range from 0.5% to 7%.

Heat Sensitivity: This property describes the product's vulnerability to damage from excessive
heat exposure. It determines the maximum process temperature limitation for the spray drying
operation.

Hygroscopic: Describes products which absorb moisture from their surroundings.

Other Properties: Dried powder products have other characteristics which are important for
their final use, such as solubility, dispersability, porosity, flow-ability, sink-ability, wet-ability,
color, friability, dust component, oxidation, taste, appearance, and aroma. See section X.
Glossary of Terms.

The spray nozzle controls the feed droplet sizes and distribution, which are then reflected in the
dried powder particle sizes and distribution. Larger droplet/particle sizes can be obtained by
using larger capacity nozzles, lower spraying pressures, higher solids concentrations, and higher
viscosities. Conversely, smaller droplet/particles can be produced by using smaller capacity
nozzles, higher pressures, lower solids concentrations, and lower viscosities.

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 Section V - Spray Atomizers - General Information

The spray atomizer performs two functions, (1) accurate metering of feeds and (2) proper feed
atomization resulting in an acceptable dried product. The choice of a specific atomizer and
spraying pressure is made on the basis of the feed stock properties, the required powder sizes
and properties, atomizer capacity, and the dryer type and capacity. The important feed stock
characteristics are the solids content, viscosity, and specific gravity. The degree of atomization
controls the drying efficiency and the resulting powder particle size distribution and bulk
density. Compared to the total costs of a spray drying installation and operation, spray nozzle
atomizers are low cost items, which perform a most important function in the spray drying
application.

Three basic types of spray atomizers are available; (1) pressure spray nozzles - small capacity
type used at high pressures, (2) pressure spray nozzles - high capacity type used at lower
pressures, and (3) two-fluid and three-fluid (with two air rings) air atomizing nozzles. Each of
these spray nozzle types has its own droplet size performance characteristics, to suit a wide
variety of feed stocks and flow rate requirements.

Pressure Nozzles

Hydraulic type spray nozzles are known as "pressure spray nozzles" or " centrifugal pressure
nozzles", and derive their atomization energy from the liquid pressure (pump generated) in the
feed line. The pressure energy is converted into kinetic energy through the nozzle orifice. The
wide variety of pressure spray nozzle types provides a choice of spray performances in pressure
ranges from 100 to 7,000psi (7 to 483bar). Feed capacities range from 3.4 to more than 1000
GPH per nozzle at 1000psi (13 to more than 3800 l/h at 69bar). Mean powder particle sizes may
range from 20 to 600 microns (micrometers) depending on the nozzle type, capacity, and
spraying pressure.

Pressure spray nozzles are used in vertical dryers with the sprays directed vertically upward or
vertically downward. In horizontal dryers sprays are directed horizontally. Nozzles are used in
co-current, counter-current and mixed flow systems, as well as in open cycle and closed cycle
installations.

Pressure spray nozzles provide Median Volume Diameter water spray droplet sizes ranging
from 15 to 500 microns (micrometers), depending on the nozzle type, capacity, and spraying
pressure. See definition of "Median Volume Diameter" in section X. Glossary of Terms. These
same nozzles produce larger spray droplet sizes on feed stocks, depending on the flow
properties of the feed, the solids concentration, viscosity, etc. Because of the range of
droplet/particle sizes, the resulting powders usually have higher bulk densities as compared to
those obtained from rotary atomizers.

Viscous feeds up to 700 centipoise can normally be sprayed through pressure nozzles,
depending on the nozzle type, capacity, and spraying pressure. Feeds above 700 centipoise
would usually be sprayed through air-atomizing nozzles.

Pressure spray nozzles form a hollow cone spray pattern with relatively fine droplets, thereby
providing a large total droplet surface area for maximum effective contact between the droplet
surfaces and the hot air flow. There are many different types of pressure spray nozzles, each
15
with its own design parameters and materials, as well as performance characteristics, depending
on the nozzle capacity and spraying pressure. One of the most important spraying characteristics
is the spray droplet size range, which varies for each nozzle, pressure, and feed stock.

Because even a tight droplet size range provides some fine particles care must be taken to
achieve a critical heat as to evaporate -all the droplets, including the largest, without scorching
the particles from the finer droplets in that same spray droplet spectrum.

Pressure spray nozzles offer many advantages. They can be used in all types of dryers and flow
systems, as well as in open-cycle and closed-cycle installations. Nozzles can provide fine to
coarse powder particles, depending on the feed, nozzle size, and spraying pressure, along with a
high bulk density, and with low occluded air in the particles. Nozzles can be used with a wide
variety of feeds and products, including heat sensitive materials. Nozzle operation and
maintenance is simple and easily controlled. They provide a high degree of versatility...
including nozzle quantities, nozzle locations and spray direction in the dryer, range of capacities
and pressures, as well as spray angles. They are most useful in small and medium capacity
dryers, and are used frequently in tall vertical dryers because of their narrow spray patterns. For
applications requiring larger particles, large capacity pressure spray nozzles and/or low
pressures are required. To obtain smaller particles, low capacity nozzles are used at higher
pressures. Another important feature of pressure spray nozzles is the wide choice of materials
available in each nozzle type. For instance, hardened stainless steel orifices and cores are
sufficiently wear resistant to provide economical performance in many applications, while
tungsten carbide is available to handle abrasive feed stocks “L” carbide is used for chemically
corrosive feeds and cleaning solutions. These hardened stainless steel and carbide materials are
interchangeable within each nozzle type.

Nozzle clogging may occur when small capacity nozzles are used to spray coarse slurries.
Clogging may be lessened by using the MFP series of nozzles for the SK and SB lines. These
use cores with larger and fewer slots and the internal passages are opened up to let larger
particles pass through. The type 104 and SSTC nozzles have the largest free passage but these
are the highest flow nozzles and are not suitable for the low flows of the SK series and possibly
the mid flow range of the SB series.

NOTE: All references in this Manual to capacities, spray angles, and droplet sizes are based on
spraying water. These characteristics will be different for feed stocks, depending on many
factors including feed viscosity and specific gravity, and the nozzle type and size. References to
spraying pressures are based on the pressures at the nozzles and not at the pump.

Two-Fluid Air Atomizing Nozzles

The spray atomization energy in pressure nozzles comes from line pressure energy; the
atomization in 2-fluid air-atomized nozzles is derived from energy in compressed air, gas or
pressurized steam. The flow rate and degree of spray atomization in an air-atomized nozzle is
controlled by the combination of feed line pressure and air-line pressure. The range of control
varies in each application, depending on the nozzle type, nozzle size, Spray Set-up number, feed
characteristics, and the air/liquid pressures. Since air atomizing nozzles cause a cooling effect
inside the drying chamber with the relatively cool atomizing air, this factor must be taken into
account in the heat balance calculations.

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Air-atomizing nozzles can provide the finest droplets with a relatively narrow droplet size
range. Within each nozzle type and size, the droplet sizes can be changed by varying the
combinations of the pressures in the feed stock line and the air line. These two-fluid nozzles can
provide very low or very high capacity ranges, and are supplied with either internal or external
mix Spray Set-ups.

When using Spray Set-ups with internal mixing of liquid and air, the air and liquid pressures
must be balanced within specific ranges to obtain satisfactory atomization and capacity
performance. When using external mix Spray Set-ups the feed and compressed air mix
externally. External mix round and flat Spray Set-ups can provide a wider range of turndown
ratios, because the liquid flow is independent of the compressed air flow rate or pressure.
Turndown ratio is the ratio of the maximum capacity to the minimum capacity of a nozzle
within an acceptable spray performance range. In external mix pressure Set-ups the compressed
air is used primarily to control the degree of atomization.
.
Air-atomizing nozzles are useful in laboratory and pilot plant operations, because of the ease of
control and flexibility in developing different capacities with droplet size ranges from 10 to 200
microns (Median Volume Diameter) with water. A two-fluid nozzle provides this wide range of
capacities and droplet sizes by varying the liquid and/or air pressures. They are also used in
production spray drying applications requiring fine droplet sizes, or involving viscous or
abrasive materials, in capacities from 2 to 1700GPH (8 to 6400l/h), based on water, depending
on the nozzle size and Spray Set-up number. Because the nozzle orifices are relatively large and
liquid feed line pressures usually low, feed velocities through air-atomized nozzles are slower,
thereby minimizing the wear problem. When abrasive slurries are sprayed, these nozzles can be
supplied on a special basis with hardened stainless steel or tungsten carbide fluid orifice inserts
to minimize the wear problem. Another advantage of air atomizing nozzles is their relatively
large fluid orifice, which minimizes clogging potentials.

Because the atomization energy comes from compressed air/gas or pressurized steam, these
nozzles can be used with higher viscosity feeds. Usually fluid nozzles are used, with occasional
use of the three-fluid nozzle, which has two separate air passages and one liquid orifice.
Generally air atomized nozzles have larger orifices than pressure nozzles and are more flexible
in operation, by varying the feed stock and air line pressures.

As with pressure spray nozzles, air-atomized nozzles can be used in current, counter-current,
and mixed flow systems. In a closed-system, an inert gas or steam is used instead of compressed
air. Two-fluid nozzles are also used in applications involving difficult to spray non-Newtonian
liquids, heavy pastes, gelatins, slurries, plastics and glues. See page 49 for more information on
air atomizing spray nozzles.

Because of the cost of compressing air or gas, the total energy input in two fluid atomization is
greater than the energy required by the pump in a pressure atomization nozzle.

17
 Section VI

Spray Nozzle Selection, Performance, Maintenance and Cleaning

Spray nozzles perform two functions simultaneously; (1) metering the flow of feed stock to
provide the required drying performance and powder production, and (2) atomizing the feed
stock to result in efficient drying and powder particle sizes. The following pages provide
information relating to the selection, performance, maintenance, and cleaning of spray nozzles
to help the user choose the best nozzles for the application and to maintain satisfactory
performance during production runs. Please note that the references to spray angles, capacities,
and droplet sizes are based on water.

Selection of Nozzle and Size

As described in section V. Spraying Systems Co. offers a wide range of spray nozzle capacities
beginning at 2GPH (8 l/h), with the two-fluid air atomizing type J nozzles up to the WhirlJet
nozzles which provide water capacities up to 1350GPH (5100l/h) at 1000psi (69bar). In between
these capacity extremes are the SK and SB series SprayDry® nozzles. See our bulletins 447,
504, and 527 for a complete description of the different types of nozzles and capacities for the
WhirlJet type, the SB type, and SK type respectively. While several different nozzles can
supply the same capacity at different pressures, the object is to choose the combination of
nozzle size and spraying pressure best suited for the specific application requirement. Usually
this decision is based on the droplet size requirement. For the same flow rate, smaller droplets
will be formed by smaller capacity nozzles at higher pressures, while larger droplets will be
formed by larger capacity size nozzles at lower spraying pressures.

In some applications the spray angle can be an important factor, as when nozzles are positioned
close to the drying chamber wall. In horizontal dryers wider spray angle nozzles are used to
prevent droplets from impinging on the opposite wall. In such cases, references to nozzle
performance tables will provide relative nominal spray angle values for different orifice insert-
core combinations. See the "Spray Angle" discussion on page 23.

Materials for Nozzle Bodies, and Core Bodies

Standard nozzle bodies, caps, and core bodies are made of type 303 stainless steel. Other
materials including type 316 stainless steel are available on special request.

Materials for Orifice Inserts and Core Tips

Once the nozzle type, capacity size, and spraying pressure are selected, the next important step
is to choose the best nozzle materials, which are identified in section VIII. for each nozzle type.
For applications involving non-abrasive or mildly abrasive feeds, hardened stainless steel orifice
inserts and cores will provide a reasonable wear life.

For applications involving abrasive non-corrosive feeds, “Y” and “M” tungsten carbide orifice
inserts, cores, and whirlchambers provide excellent wear life. On the other hand, when the feed
is both abrasive and corrosive, a better choice is “L” carbide. The “L” carbide provides good
wear characteristics, combined with the best general corrosion resistance. When chemical
18
compatibility is not an issue the M carbide will give the longest wear, but L carbide has better
chemical resistance and good wear resistance. Specialized carbides and coatings are a available
but at a high price.

Corrosion can also be caused by cleaning solutions, depending on the chemical, its
concentration and temperature; and exposure time. As with corrosive feeds, L carbides and the
specialized carbide also provide better resistance to corrosive cleaning solutions than Y or M
carbide. See “Nozzle Cleaning Procedures” later in this section VI. “Static Corrosion
Comparison Test" tabulation is shown as a selection guide for three carbides.

Static corrosion comparison tests -on carbide materials*

Key: N – Negligible Attack M – Moderate Attack (-) – No Data

L – Light Attack H – Heavy Attack

CHEMICAL CONCENTRATION (%) TEMP. TEMP. M&Y L

°C °F CARBIDE CARBIDE
Acetic Acid, Glacial 99.8 20 68 L N
Acetic Acid, Glacial 99.8 75 167 H N
Acetic Acid 10 20 68 L N
Acetic Acid 10 75 167 H M
Acetic Acid (Unaerated) 4 20 68 M L
Acetone - 20 68 N N
Alcohol - 20 68 N N
Calcium Hydroxide Sat. 20 68 N N
Calcium Hydroxide Sat. 75 167 N N
Citric Acid 10 20 68 L N
Citric Acid 10 75 167 H M
Cobalt (l l) Chloride 10 20 68 N N
Cobalt (l l) Chloride 10 75 167 H L
Copper (l l) Nitrate 10 20 68 H N
Copper (l l) Nitrate 10 75 167 H M
Ethylene Glycol 50 20 68 H N
Ferrous Sulfide Slurry in 20 68 M M
Water
Hydrochloric Acid 10 20 68 L N
Hydrochloric Acid 10 75 167 H L
Hydrochloric Acid 37 20 68 H H
Hydrochloric Acid 37 100 212 H H
Nickel (l l) Sulfate 10 20 68 N N
Nickel (l l) Sulfate 10 75 167 M N
Nitric Acid 5 20 68 H H
Nitric Acid 5 100 212 H H
Nitric Acid 10 20 68 H L
Nitric Acid 10 75 167 H M
Nitric Acid 20 20 68 M N
Nitric Acid 20 75 167 H M
Oil, Crude (w/High Sulfur) - 20 68 M M

19
Continued

CHEMICAL CONCENTRATION TEMP. TEMP. M&Y L

(%) °C °F CARBIDE CARBIDE
Phosphoric Acid 50 20 68 M N
Phosphoric Acid 50 75 167 H M
Phosphoric Acid 85 20 68 H M
Potassium Hydroxide 10 20 68 H N
Potassium Hydroxide 10 75 167 H N
Sodium Cyanide 10 20 68 H H
Sodium Hydroxide 10 20 68 N L
Sodium Hydroxide 10 75 167 H N
Sodium Hydroxide 50 20 68 N N
Sodium Hydroxide 50 75 167 N N
Sodium Hypochlorite 5 20 68 H L
Sodium Hypochlorite 5 75 167 H H
Sulfuric Acid 5 20 68 M M
Sulfuric Acid 5 100 212 H M
Sulfuric Acid 10 20 68 M N
Sulfuric Acid 10 75 167 H L
Sulfuric Acid Sat. 20 68 M N
Sulfuric Acid Sat. 75 167 M L
Water, Distilled Pure 20 68 N N
Water, Distilled Pure 75 167 M L
Water, Sea - 20 68 N N
Water, Sea - 75 167 M L
Water, Tap - 20 68 L L

*NOTE: This information is to be used only as a relative guide. Tests should be made under
actual operating conditions to determine material suitability.

Nozzle Capacity

The flow rate through a spray nozzle depends on the feed pressure at the nozzle, not on the
pressure at the pump. Because of pressure drops caused by friction losses in pipes and fittings,
the pressure at the nozzle can be considerably lower than at the pump. Since all capacity
tabulations are based on the spraying pressure at the nozzle, it is important to know this pressure
when checking actual spray nozzle performance against capacity tabulations.

Spray nozzle performance tabulations are based on spraying water, having a specific gravity of
1 and weighing 8.34 lbs. per gallon (1kg/l). When feed stocks having different specific gravities
are sprayed, the nozzle flow rates are inversely proportional to the square root of the specific
gravity of the feed, as based on water flow rate tabulations. The following conversion factor
table can be used to estimate flow rates for feeds weighing more than water.

20
Specific Gravity correlation table

Weight Per Gallon- 9.2 10.0 10.8 11.7 12.5 13.3 14.2 15.0 15.8 16.7
Lbs./Gal.
Specific Gravity 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0
(or density in kg/l)
Multiply Water .95 .91 .88 .85 .82 .80 .77 .75 .73 .71
Cap. by Factor

Typical specific gravity conversion factors for eggs and milk with 24% to 55% solids are
approximately .8 and .65 meaning that these feed stocks have only 80% and 65% of the water
flow rate respectively.

The specific gravity affect on capacity is a most important factor, but other factors, such as
viscosity may also affect the nozzle flow rate, depending on nozzle type, capacity, and pressure.
Many operators determine this flow rate variation between the feed flow and water tabulations
by checking the actual feed flow rate and then comparing this feed flow rate to the water
tabulation rate, at the same pressure at the nozzle. This calculated capacity conversion factor can
then be used for the same feed for different orifice/core size combinations of the same nozzle
type. However, for other nozzle types, this feed capacity to water capacity conversion factor
may be different. The conversion factor for the SK series may not be the same as for the SB or
WhirlJet types.

Viscosity Effect on Nozzle Capacity and Spraying pressure

When viscous liquids are sprayed, capacities may vary slightly or substantially from those
published for water depending on nozzle design. With viscous liquids, nozzle types SK and SB,
which have smaller whirlchamber to orifice diameter ratios, provide capacities relatively close
to those tabulated for water, if the specific gravity of the liquid is close to that of water.

However, nozzles having larger ratios of whirlchamber diameter to orifice diameter (SBC and
WhirlJet types) produce much higher flow rates with viscous feeds as compared to water
tabulated figures for same pressure. Likewise they produce the same viscous feed flow rates as
in the water capacity tabulations but at lower pressures. The higher flow rate at the same
pressure increases pump and nozzle wear life, but it also can produce larger droplets/particles.
This same lower pressure operation with viscous feeds can be matched with the SK and SB
nozzles by using orifice-core combinations with larger capacities. In choosing an orifice insert-
core combination it is important to aim at achieving the best powder product quality at the
lowest acceptable spraying pressure.

As noted in the "Capacity" discussion, the specific gravity of the feed also affects the flow rate.
Actual tests are required to determine the orifice insert-core sizes and pressures which produce
the best powdered product at the desired flow rate.

21
The following table, which is based on actual tests, lists a few examples of the effects that
higher viscosity fluids with higher specific gravities have on nozzle flow rates.

Fluid Sprayed: Aqueous sugar solution

Specific Gravity: Approximately 1.3

Viscosity: Varies in each test (see tabulation)

1 2 3 4 5 6 7 8

NOZZLE VISCOSITY SPRAYING TABULATED EQUIV. FLOW ACTUAL % INCREASE % CHANGE

CAPACITY OF SUGAR PRESSURE WATER RATE OF A TEST OR DECREASE OF FLOW
SIZE SOLUTION PSI (BAR) FLOW "NON-VISCOUS" FLOW RATE OF FLOW RATE CAUSED
RATE OF 1.3 S.G. OF VISCOUS RATE CAUSED BY BOTH
NOZZLE LIQUID SUGAR SOL. BY VISCOSITY VISCOSITY &
GPH (l/hr) GPH (l/h) 1.3 S.G. EFFECT SPECIFIC
GPH (l/h) ALONE GRAVITY

WhirlJet 300 cps 380(26) 62(235) 54(204) 92(348) +70% +48%

2-2 30 cps 800(55) 91(344) 80(303) 92(348) +15% +1%

SBC-8 350 cps 1700(117) 52(197) 46(174) 75(284) +63% +44%

40 cps 3900(269)* 79(299) 69(261) 75(284) +9% -5%
SK-56-27 250 cps 3300(228) 84(318) 74(280) 65(246) -12% -23%
30 cps 2900(200) 79(299) 69(261) 65(246) -6% -18%
SK-69-21 350 cps 3800(262) 37(140) 32(121) 31(117) -3% -16%
30 cps 4600(317) 41(155) 36(136) 31(117) -14% -24%

*Maximum pressure recommended for type SBC-nozzles is 2000 psi

The figures in the first three columns and in the sixth column were derived from, "The Effect of
Viscosity on the Pressure-Flow Rate Relationship of Some Centrifugal Pressure Atomizing
Nozzles", by Dr. C. G. Bloore, New Zealand Dairy Research Institute, and published in the New
Zealand Journal of Dairy and Technology. Data is used with permission of author.

Dr. Bloore’s report summary concludes that the degree of viscosity sensitivity is related to the
nozzle design. Specifically it indicates that larger ratios of “whirlchamber” diameter to orifice
diameter produce higher flow rates when spraying high viscosity feeds. This is borne out in the
tabulation which shows capacity increases in the WhirlJet and SBC nozzles, while the SK
nozzles show decreases in capacities.

The tabulated data in the four columns was calculated based on values estimated from curves
shown in the test report and should be considered approximate. As noted in the "Capacity"
discussion, nozzle flow rates are also affected by the specific gravity of the feed.

In column 5 the equivalent flow rate of the sugar solution, based on the 1.3 specific gravity
alone, was obtained by multiplying the water flow rate by .88 (see “Conversion Factor"
tabulation on page 21). This means that the higher specific gravity effect alone on the solution
would have been lower flow rates for this sugar solution as compared to water flow rates.

22
Therefore, it follows that the difference between these lower equivalent 1.3 specific gravity
liquid flow rates and the actual sugar solution flow rates is caused by the higher viscosity of the
sugar solution. This difference expressed as a + or - % figure is tabulated in column 7. Column
8 tabulates the actual capacity % change caused by the combination of the higher viscosities and
specific gravity.

In summary we conclude that the decrease in capacity caused by the specific gravity applies to
all spray nozzle types equally, while nozzles with larger ratios of diameter to orifice diameter
produce increased capacities for higher viscosity fluids. On the other hand, the usual higher
viscosity influence on type SK nozzles is shown to be a capacity decrease, as expected, because
of the smaller ratio of "whirlchamber" diameter to orifice diameter. To adjust for these flow rate
decreases, or to use lower spraying pressures, higher capacity orifice insert-core sizes can be
used.

It should be noted that the MFP versions of the SK and SB nozzles do not experience as much
pressure drop due to viscosity as the non-MFP versions. This is an added benefit of the opened
passages leading to the core.

NOTE: The above data is based on a few selected nozzle types, sizes, and on a sugar solution
at several viscosities. The numerical conclusions reached apply only to these specific of factors
and would not necessarily apply to other solutions, nozzle types and sizes, or pressures.

Spray Angle
Occasionally, as when spray nozzles are close to a chamber
wall, the spray angle from a nozzle can become an important
factor. Published nominal spray angle values are based on
spraying water at 1000psi (69bar); these readings were ob-
tained by protractor measurements.

But, this spray angle pattern holds only for the first one or two
Spray
feet from the nozzle at 1000psi. At higher pressures the spray
pattern “pulls in”, and does not get wider but begins to move Angle
in the same axis as the nozzle and remains about the same,
rather than spreading out. The accompanying sketch illustrates
this point. The distance from the nozzle at which the spray angle
"pulls in" varies with the nozzle type, size, feed, pressure, air
direction and velocity. The only purpose for including a spray
angle value in tabulations is to provide a general guide as to the Actual
relative spray coverage of different spray nozzle sizes and not Spray
for calculating or estimating actual spray pattern dimensions. Coverage

23
 Droplet Sizes

Droplet sizes are critical in spray drying applications, since they control the dried powder
particle sizes as well as the drying process efficiency. Spray atomization from a nozzle results in
a range of droplet sizes, rather than one uniform size. In practice, this droplet size spectrum is a
function of the nozzle type and capacity, spraying pressure, feed stock properties, and to a much
lesser extent the spray angle.

Smaller spray droplets are obtained by using smaller capacity nozzles and/or by spraying at
higher pressures. Larger capacity spray nozzles and/or spraying at lower pressures produce
larger droplets/particles. Wider spray angles may provide somewhat smaller droplet sizes, as
compared to those from narrower spray angle sprays, for the same nozzle capacity and pressure.

Below is a representative curve of drop size verses pressure for select SB type nozzles. Note the
characteristic leveling off in drop size as pressure increases toward 1900 psi. Below about 2000
psi the drop size increases rapidly as pressure decreases but above 2000 psi not as much change
in drop size can be attained from a change in pressure.

SB AND SB-MFP Drop Size

120

100
Volume Median Diameter (Micrometers)

80

60

40

20

0
500 700 900 1100 1300 1500 1700 1900

Pressure (psi)
53/425, 53/27, 53/425-MFP, 53/27-MFP 42/625, 42/28, 42/625-MFP, 42/28-MFP
35/632, 35/32, 35/632-MFP, 35/32-MFP 30/640, 30/40, 30/640-MFP, 30/40-MFP
24/650, 24/50, 24/650-MFP, 24/50-MFP

The Information above is based on spraying water, but this information serves only as a guide
for comparing dried powder particle sizes. Droplet sizes in water sprays also provide larger
dried particle sizes. Particles can either shrink or expand during the drying phase depending on
the feed and dryer performance. The smallest droplet sizes can be obtained by the use of two-
fluid air atomizing nozzles. For droplet size range information see Section V “Pressure
Nozzles”.
24
 Miscellaneous Data on Droplet Sizes and Droplet Surface Areas

1. The volume of one large droplet equals the volume of eight droplets having diameters of
one-half that of the large droplet.

Also note that the surface area of the 8 small droplets is twice that of the one large droplet.

2. If the total suspended droplet surface area is doubled, the absorption of heat and evaporation
rate will double.

3. If the droplet retention time in the spray chamber is doubled the absorption of heat and the
evaporation amount will also double.

Nozzle Wear/Corrosion

All spray nozzle orifices and cores wear, especially so with abrasive feeds at higher pressures.
Wear varies, depending on solids in the feed stock, orifice and core sizes, spraying pressure, and
nozzle materials. It is important to note that the wear problem may be aggravated by corrosion
from the feed stock or from the nozzle cleaning chemical solutions. Our spray nozzle orifice
inserts and cores can be supplied in different materials such as hardened stainless steel, M
tungsten carbide and L tungsten carbide. Therefore, the wear/corrosion problem can be
minimized by a proper choice of nozzle materials, cleaning solutions, and cleaning procedures.
Also, special materials for the nozzle body, cap, and core body can be supplied on special
request.

How can wear be detected? As the orifice and core slots wear, several spray performance
changes take place. First, the nozzle capacity gradually increases. Secondly, depending on the
location and the extent of the wear, the spray pattern deteriorates, usually by forming "streaks".
Simultaneously, while capacity is increasing and streaks are forming the spray droplets become
larger and the powder may contain more moisture than desired. As the wear continues, it will
causes problems of wet powders, and possibly caking on the chamber wall.

To prevent the costly consequences of worn nozzles, preventative steps should be taken during
production runs. Since each spray drying application has it’s own set of operating factors and
product requirements, a single generalized statement as to the “permissible” degree of wear
would be unwise. Precautionary procedures include an on-going inspection of the powder, as
well as the spray nozzle orifice inserts and cores.

25
 Checking Worn Orifices and Cores

Determining exactly when worn orifice inserts and cores should be replaced is not a simple
matter. In each application the operator makes the decision based on product quality, with the
objective of getting the most wear life without jeopardizing the product quality. Therefore, this
decision is based on anticipating the point at which product deterioration begins, and replacing
the worn items before this happens.

It is important to point out that the final quality control decision on the orifice insert and core
during their original manufacturing processes is based on a water flow rate check at 100psi
(6.9bar), and not on a dimensional inspection of the orifice and slot sizes. For this reason, during
a spray drying process, a check which is based solely on the orifice and core slot dimensions is
not recommended, as it is not a reliable indication of the actual amount of change in flow rate,
although it does confirm that wear is taking place.

An effective way of visually checking the extent of wear on the orifice and core slots would be
to view them through a microscope. This type of viewing would confirm that the wear effect is
not equally distributed over the orifice or slot surfaces, and, therefore, would be difficult to
measure. Also, it could be seen that some types of wear, like the rifling grooves worn inside of
orifice insert chambers, do not materially affect the flow rate of the orifice insert-core
combination, but they can affect the atomization and pattern distribution.

Specifically the recommended flow rate check can be made by two different methods:

1. The preferred method is to check the water flow rate and spray pattern, at 100psi
(6.9bar) or higher, of the orifice insert-core combination being used, and
compare it to the flow rate and pattern of this same combination when it was new
and unused. The flow rate check can be done by spraying into a calibrated
graduate or flask for given time period, with these readings repeated at different
times during the spray drying process to determine the percentage increase in
flow rate. At the start of this test it is suggested that the operator tap the nozzle
gently to make sure that the floating core seats itself properly against the orifice
insert. At these lower pressures the cores may not always seat themselves
properly against the orifice insert. The worn orifice insert and core should be
replaced when their increased flow rate reaches pre-determined level, based on
powder quality.

2. However, if the orifice insert and core are found to wear at drastically different
rates, they can be checked independently of each other, to determine whether one
or both of them should be replaced.
a. To check for orifice wear only: Check the flow rate of the orifice insert
with a new core which should be the standard testing core and never used
in the spray drying process.
b. To check for core wear only: Check the flow rate with a new orifice
insert which should be the standard testing orifice insert and never used in
the spray drying process.

Testing procedure (1) is recommended, because it gives the surest protection for high quality
products. Replacing the used orifice insert and core simultaneously is suggested, rather than to
try to obtain a bit more wear life out of the “less worn” orifice insert or core, and possibly
damage some of the powder product quality.
26
 Pressing Orifice Insert into Cap

Nozzle caps can be purchased with orifice inserts already pressed into position, but many
operators choose to reuse undamaged caps by replacing worn orifice inserts as required. This
practice is satisfactory for hardened stainless steel orifices, but carbide orifice inserts should be
retained in the caps to prevent damage when they are removed and replaced in caps.
We recommend the use of our Orifice Insert Presses which are specifically designed to simply
and accurately remove and install orifice inserts in and out of caps ...without damage. This is
especially important when installing carbide orifice inserts which are brittle and chip if
mishandled. Once a carbide insert is pressed into a cap, it should not be removed until it wears
out because of the possibility of cracking or chipping. Several orifice insert press models are
available for installing and removing orifice inserts from caps or bodies of nozzles. See the
"Orifice insert presses" paragraph in section IX and Data Sheet 22779.

Nozzle Leakage Problem in Nozzles with Gaskets

To prevent leakage through the nozzle gasket area, between the cap and nozzle body, care must
be taken to make certain that each nozzle has a new and undamaged gasket. Damaged or worn
gaskets can cause serious leakage problems which can result in damage to the powder. Further,
the caps should be tightened properly, but not over tightened, to provide a leak-tight
engagement. The recommended torque wrench setting is 50 to 60 ft-lbs (70 to 80 Newton-
meters) for the SK series, 60 to 70 ft-lbs (80-95 Newton-meters) for SB series, and 75-85 ft-lbs
(100-115 Newton-meters) for the 104 and SSTC series. Each time a nozzle cap is removed from
the nozzle assembly, the gasket should be inspected carefully and replaced if it is damaged or
ineffective in any way. This will eliminate the need to over tighten the cap and thereby extend
its useful life.

It is also important to point out that "over tightening" the

nozzle cap can damage the cap threads' and distort the
internal chamber of the cap. This core chamber distortion
can cause a core fit problem; if the core cannot slide freely
in and out of the chamber, the cap should be replaced. For
proper spraying it is necessary for the core tip to seat properly
against the inside beveled surface of the orifice insert;
otherwise the spray nozzle will not provide the proper capacity
and atomization. As soon as damaged cap threads or distorted
core chambers are noticed, the cap should be replaced.

Over tightening is not a problem with the SKH and SBH series since they use O-rings for
sealing and only require hand tightening. Torque spec recommendations are 20in-lbs (1.48
Newton-meters) and 30in-lbs (3.4 Newton-meters) respectively. O-rings and back-up rings
should be replaced after every usage. See MI ABSKH-KIT and MI ABSBH-KIT.

Clogging Problems

If clogging occurs in the nozzle orifice or in the core slots, the clogging material should be
removed carefully with a fine probe that is not as hard as the insert or core, so as to not damage
the orifice or slot surfaces. Tabulated orifice and core slot dimensions should be checked and an
orifice insert and core size chosen to minimize clogging whenever clogging becomes a problem.
27
Occasionally nozzle clogging takes place in the core chamber of the nozzle cap, between the
chamber wall and the core body. If clogging is an issue the MFP versions of the SK and SB
series nozzles should be used. Actually all customers can use the MFP versions since it has
been determined experimentally that drop size remains the same with MFP versus non-MFP
versions of the SK and SB series. The 104 and SSTC WhirlJet nozzles are larger in capacity
and therefore their passages are larger so that they usually do not experience clogging.

Nozzle Cleaning Procedures

Periodic nozzle cleaning is a most important factor in providing proper metering and
atomization as well as in clogging prevention procedures. Since corrosive chemicals are often
used for cleaning nozzles, it is important to choose the chemicals and nozzle materials to be
compatible on the basis of their corrosion action and resistance. For instance, an occasional
complaint is made that nozzle orifices and cores wear out in much shorter times than previously,
and it is usually directed at "defective" materials for the orifice and core. In many of these cases,
it was found that the cleaning chemicals and/or procedures were changed since the last
production run, to the point where nozzle parts were being corroded by new chemicals, higher
chemical temperatures, or longer periods of contact with the chemical. Therefore, it is important
to note that chemical cleaning solutions can corrode nozzle parts. If corrosion occurs,
consideration should be given to changing the chemical solution, temperature, or the contact
time between the chemical and parts. Another option is to change the materials in the spray
nozzle to those having better resistance to the specific chemicals in the cleaning operation.
Chemical corrosion can also be caused by chemicals in the feed stock, thereby accelerating the
wear/corrosion on the orifice and core. If so, the nozzle materials should be changed to
minimize the corrosion problem.

Also, when cleaning carbide cores and orifices, special care should be exercised not to chip this
brittle material, since this results in defective spray performance.

For a typical cleaning procedure we warn against soaking the tungsten carbide components in
acid solutions and strong detergents. Both of these chemicals are known to affect the service
life of tungsten carbides by corroding the binder metals. Cleaning is more easily carried out if
the nozzles are removed and disassembled before the feed stock dries on the components. Our
cleaning instructions shown on data sheet 22779 states that only a mild dish soap and brush
should be used on the carbide. After washing and rinsing the components should be blown dry
with compressed air if they are not used right away. In general the L carbide can handle
stronger acids and bases than the M carbide.

Typical Problems in Spray Drying Applications

Feed stock - To provide consistently acceptable spray drying performance in repetitive

production runs it is necessary to maintain strict control over each of the process factors. This
control begins with providing the same composition, viscosity, and temperature of feed stock.
Variations in the feed stock can result in variations in nozzle wear life or powder quality
problems -and necessitate changes in other factors such capacity size, spraying pressure, air
temperatures, etc.

Excessive Nozzle Wear or Corrosion - This problem can often be corrected by a choice of better
wear resistant and/or better corrosion resistant materials. For instance, if hardened stainless steel
28
orifices and cores are used, more wear life could be obtained from M carbide (note M and Y
carbide are similar in chemistry, but M carbide is longer lasting than Y). If the nozzle has M (or
Y) carbide orifices and cores, the “wear” problem may actually be one of corrosion. In this case
the L carbide should be used. Please note that the L carbide has better chemical resistance than
the M or Y carbides, but may not last as long in situations where chemical attack is not an issue.
It is better to begin with the M carbide and if a drastic change in wear life is noted, then SSCO
will work with the customer to determine if chemical attack is an issue, in which case the L
carbide should be suggested. The corrosion problem can be caused by chemicals in the feed
stock or by chemicals in the nozzle cleaning solutions. In these cases, the corrosive solution
must be identified in order to choose the proper nozzle materials. Also, higher temperature
solutions are usually more corrosive. Another factor is the amount of time that the parts are kept
in the cleaning chemicals. See page 19 for information on the relative corrosion resistance of
carbide materials.

Another important factor in nozzle wear life is the high velocity of abrasive feed stock through
the orifices and cores. Nozzle wear can be reduced by lowering the feed pressure. However,
occasionally this change adversely affects product quality. Another option is the use of multiple
orifice nozzles _-3SK at lower pressures to provide three separate spray patterns with relatively
large total capacities and smaller droplet sizes. Still another possible solution would be to use
more smaller capacity nozzles at lower pressures, to achieve the same total product quantity
with the desired droplet/particle sizes.

Occasionally an operator notices that the orifice inserts and cores do not last as long as
previously and concludes that the insert and core materials are defective. However, in almost all
of these cases it has been found that the problem was not in the nozzle materials, but in a
process change such as: change of feed stock temperature or composition; change of pressure;
or change in cleaning solution, temperature, concentration, or exposure time. When this
happens, the process or cleaning changes should be reconsidered or a better material for the
orifice insert and core should be substituted.

Powder Moisture Content Too High -This can occur when (1) nozzle flow rates are too high, (2)
the droplet sizes are too large, (3) not enough heat is supplied for the evaporation process,
and/or (4) excess water in feed.

Possible changes include (1) using smaller capacity nozzles, (2) using higher pressures, (3)
increasing the heat input in the drying chamber, and/or (4) decreasing water in feed.

Powder Moisture Content Too Low -This can occur when (1) nozzle flow rate is too low, (2)
droplet sizes are too small, (3) too much heat in drying chamber, and/or (4) not enough water in
feed.

Possible changes include (1) using larger capacity nozzles, (2) increasing droplet size by
lowering the pressure, (3) reducing the heat input into the drying chamber, and/or (4) increasing
water in feed.

Caking of Chamber Walls -This problem can be caused by (1) spray droplets being too large, (2)
nozzles being too close to the wall or having wide spray angles; and/or (3) not enough heat input
into the drying chamber, with the drying air temperature or volume being too low.

Possible changes include (1) providing smaller droplets by increasing the spraying pressure,
possibly with smaller capacity nozzles, (2) positioning further away from the wall or use
29
narrower spray angle nozzles, and/or (3) introducing more heat into the drying chamber with
higher air temperatures with more hot air.

Too Many Fines in Powder -This can be caused by spray nozzles producing too many fine
droplets. In this case, a larger capacity nozzle, spraying at a lower pressure should be
considered. If an air atomizing type nozzle is used, the air pressure could be reduced, or the
feed pressure increased. However, from a practical point of view all of the fine droplets cannot
be completely eliminated from sprays.

Another possible consideration would be to increase the solids concentration of the feed. Also,
the original dried powder may be of the correct size, but if these particles are over-dried, they
may be fractured or broken during the product collection and conveying process.

In some installations fines are returned to the system thru the chamber ceiling to become
agglomerated with the atomized wet droplets. In other installations products are instantized by
agglomerating in two stages. Powder agglomeration is achieved by allowing the powder to be
moist on leaving the chamber; the moist powder particles then agglomerate, and are finish dried
on a vibrating bed. The final powder particles are coarse and free of fines.

Bulk Density Too Low -This problem may have several possible causes. If there is a low solids
feed concentration, it can be increased. Possibly the hot air or feed temperature in a co-current
flow system is too hot, with the particles becoming puffed up in size, due to the high vapor
pressure of the rapidly evaporating water. Also, it is possible that the moisture content is too low
because the powder is being over-dried. See "Bulk Density" discussion in section IV.

Factors Affecting Powder Properties

As noted above, spray drying operations are complex, in that they involve many inter-related
factors. Each specific property of a spray-dried product can be affected by several different
factors.

For instance, product bulk density can be affected by powder moisture content, particle size
distribution, porosity of particles, drying air temperature, and percentage of solids contents in
the feed.

Moisture content of the particles varies with the drying air temperature, humidity, droplet sizes,
and the retention times of droplets as they drop through the chamber.

Particle size distribution is controlled by the nozzle type and capacity, spraying pressure,
agglomeration tendency, and various drying conditions.

Powder flow ability is affected by powder moisture, as well as by the particle sizes, size
distribution, and particle shape.

Powder dispersability depends to a great extent on bulk density of the product, the porosity of
the powder particles, and particle size distribution.

30
Properties such as purity, taste, and color can be affected by the feed, particle sizes and
distribution, dwell time of the droplets in the chamber, spray pattern, air flow interface, and
drying air temperature.

NOTE: In making process changes only one factor should be changed at one time, so that a
proper relationship of cause-and-effect can be established.

As discussed above, each product, combined with a specific set of spray drying conditions, must
be handled in a manner which provides the best final powder product. To do this, each operation
has to be customized in all aspects, and constantly controlled and monitored in all operations.
Based on trial-judgment procedures, ultimately each spray dried powder project becomes a
standardized repeatable routine.

31
 Section VII - Spray Drying Industries and Products
Food industry... including carbohydrates, dairy products, egg products, flavoring products, food
products, plant extracts, fruits, and vegetables.

Chemical industry... including ceramic materials, soaps, detergents, dye fertilizers, mineral oil
concentrates, cements, pesticides, plastics, resins, and organic and inorganic chemicals.

Bio-chemicals industry… pharmaceuticals, antibiotics, drugs, enzymes, hormones, vaccines,

vitamins, amino acids, and yeast products.

Timber industry... tanning extracts from bark and wood, and cellulose.

Slaughter house and fish industries...animal protein, blood, gelatin, fish flour, fish meal, and fish
soluble.

Products listed below have been spray dried with spray nozzles and others with rotary atomizers

Abrasive Slurries Barium Ferrite Carbonates

Acetates Barium Hydroxide Carborundum
Acrylates Barium Sulfate Carbowax
Agar-Agar Barium titanate Carboxymethycellulose
Albumin Bark extracts Carnallite
Alcoholic extracts Beef extracts Carrots
Alfalfa Beet root Casein, acid
Alumina gels Bentonite Casein hydrolyzed
Alumina Benzoate Caseinates
Aluminates Berylia Catalysts
Aluminum Bile extract Cauliflower
Aluminum chloride Bismuth carbonate, Cellulose acetate
Aluminum hydroxide nitrate Cellulose hydrate
Aluminum hydroxide gels Black liquor Celery
Aluminum sulfate Blast furnace slag Ceramics
Amino acids Bleaching agents Ceramic colors
Ammonium chloride Blood-Albumen, Serum Ceramic enamels
Ammonium phosphate Whole Cereals
Animal blood Borates Cermets
Antibiotics Boric Acid Cheese
Apples Bouillon Chelates
Arsenates Brain Chicken broth
Arsenic acid Bran Chicken slurry
Ascorbic acid Chicory
Aureomycen Cabbage China clay
Azo dyes Cake Mix Chlorides
Calcium Butyrate Chlorinated rubber
Baby foods Calcium chloride Chlorophyll
Bacitracin Calcium phosphate Chromates
Baking Compounds Calcium saccharate Chrome-iron oxides
Bananas Carbamide Resin Chromium sulfate
Barium Chloride Carbon black Citrates

32
Clays Freon Malt extract
Cocoa Fruit juice Malt syrup
Coffee Fruit pulp Maltase
Color Pigments Fullers’ earth Malted Milk
Copper Oxide Fungicides Mangos
Copper Sulfide Mayonnaise
Corn Starch Garlic Meat protein
Corn steep liquor Gels Mealmine resins
Corn syrups Glands Mercury compounds
Cosmetics Glauber salt Metal powders
Cream Glazes Metallic soaps
Cyanide, sodium Glucose Milk
Glues Mimola
Dairy products - skim Glutens Mineral concentrates
milk, butter, butter- Graphite Molasses
milk, chocolate milk, Ground glass Monoglycerides
whey, cheese, sodium Gums
caseinate, cream, edible Gypsum Nickel compounds
casein)
Dates Herbicides Olive paste
Detergents Hexamine Oranges
Dextran Hip Organic compounds
Dextrose Hormones Ovaries
Diatomaceous earth Hydride, magnesium Oxalic acid
Dioxides Hydroxides Oxide ceramics
Distillery by-products Hypochlorites
Dithane Pancreas
Ice Cream Mix Pantothenate, calcium
Eggs, whites, yolks Inorganic Chemicals Papaya
Emulsified enamels Insecticides Paper fiber
Enzymes Instant Coffee, Tea Paprika
Epoxy resins Iron Oxide Peanut milk
Fabric softeners Pectin
Fats (spray cooling) Kaolin Penicillin
Feldspar Pentachlorophenate
Ferric Chloride Lactates Pepsin
Ferric Oxide Lactose Peptones
Ferric Sulfate Latex Perfumes
Ferrites Lead zirconate Peroxides
Ferrous Oxide Lemons Pharmaceuticals
Ferrous Sulphate Licorice Phenolic resins
Fertilizers Ligonin Phosphates
Fish albumen Lithium chloride Phosphoric acid
Fish meat, hydrolized Liver Phosphors
Fish pulp Liver extract Photographic emulsions
Flavors Pigments
Fluorides Magnesium Carbonate, Plastic clay
Food colors Silicate Plastic emulsions
Formaldehyde resins Magnesium Oxide, Salts, Pollen extracts
Formate sodium Sulfates Polycarbonate
Forsterite Maleic acid Polyethylene
33
Polymers Sodium acetate Tobacco,extracts,pulp
Polymethacrylate Sodium Adipate
Polypropylene Sodium Bisulfate Tomatoes
Polystyrene Sodium chloride Tungsten Oxide
Polyvinyls Sodium Chlorite
Porcelain Sodium fluoride Undecylenates
Potassium acetate Sodium hypochlorite Uranium Oxides
Potassium carbonate Sodium phosphate Urea-Formaldehyde
Potassium nitrate Sodium silicate
Potassium phosphate Sodium sulphate Vanadium Oxides
Potassium sulfites Sorbate Vegetables extracts
Potatoes Sorbose Vegetables fats
Potato waste liquor Soups Vegetables proteins
Powdered metals Soy bean protein Vitamins
Propionates Soy flour
Proteins Soy isolates Wall tile slurries
Pudding powder Spinach Waste products
PVC emulsions Starch products Water glass
Stearates Wax
Stearic acid Weed killers
Quartz slurries Steatite slurries Wetting agents
Quaternary salts Stick water (fish Wheat glutin
soluble’s) Whey
Refractory clays Streptomycin
Rennet Sugar Yeast
Resins Sulfates Yeast extract
Resin soap Sulfide, zinc Yeast hydrolysates
Rubber chemicals Sulfate spent liquors
Rubber latex Sulfite Lye Zeolites
Rutile Sulfonates Zinc Ammonium
Sulfur suspensions Chloride
Salicylic acid Sulphonated Naphtalene Zinc Arsenate
Salicylates Surface active agents Zinc Chromate
Seat water Zinc Stearate
Sea weed extract Talc Zinc Sulfate
Selenides Tannin extract
Senna Tapioca
Sequestering agents Tartaric acid
Shellac Tartrates
Silica-Alumina gels Tea
Silicates Teepol
Silicon carbide Titanates
Soap Titanium Dioxide

34
 Section VIII - Spraying Systems Co. Spray Nozzles

General performance features of SSCo. SprayDry® nozzle types

1) Hydraulic Atomizing Nozzles

A) Low Capacity / High Pressure

B) Medium Capacity / High Pressure
C) High Capacity / Medium Pressure
D) Miscellaneous Nozzles

2) Two – Fluid Atomization

A) 1/4J
B) 1/2J
C) 1J

---------------------------------------------------------------------

General performance features

1) Hydraulic Atomizing Nozzles

A) Low Capacity / High Pressure Nozzle type SK series including SK, SK-MFP,
SKH-MFP, and SKHN-MFP. See Bulletin 527.

- Hollow cone spray pattern

- Water capacities from 32.8 to 400 gph (10.8 to 1460 l/hr) based on water at 70
degrees F.

- Maximum pressure 7000 psi (483 bars)

- Three spray angle sizes for every capacity increment

- Orifice insert and core material: specially treated hardened stainless steel, and
tungsten carbide.

- Flow rates not drastically affected by viscosities below 400 cp.

- SK-MFP, SKH-MFP, and SKHN-MFP have maximum free passage for

dramatically reduced clogging.

- SKH-MFP has hand tight o-ring seal

- SKH-MFP has an anti-bearding front end

35
 - SKH-MFP has an integrated check valve to keep liquid from draining into the
tower when the pump is shut off.

- SKHN-MFP has all the features of the SKH-MFP except it does not have the
check valve.

B) Medium Capacity / High Pressure SB series Nozzles including SB, SB-MFP,

SBH-MFP, and SBHN-MFP. See Bulletin 504.

- Hollow Cone Spray Pattern

- Water capacities from 38.9 to 1508 gph (148 to 5510 l/hr)

- Maximum pressure 7000 psi (483 bars)

- Three spray angle sizes for every capacity increment

- Orifice insert and core material: specially treated hardened stainless steel, and
tungsten carbide.

- Flow rates not drastically affected by viscosities below 400 cp.

- SB-MFP, SBH-MFP, and SBHN-MFP have maximum free passage for

dramatically reduced clogging.

- SBH-MFP has hand tight o-ring seal

- BKH-MFP has an anti-bearding front end

- SBH-MFP has an integrated check valve to keep liquid from draining into the
tower when the pump is shut off.

- SBHN-MFP has all the features of the SBH-MFP except it does not have the
check valve.

C) High Capacity / Medium Pressure 104 series nozzles. See Bulletin 447.

- Hollow Cone Spray Pattern

- Water capacities from 16.1 to 3019 gph (61.5 to 11340 l/hr)

- Maximum pressure 5000 psi (340 bars)

- Three spray angle sizes for every capacity increment

- Orifice insert and core material: tungsten carbide.

- Flow rates increase drastically with viscosity increases.

- Whirchamber type nozzles have maximum free passage for dramatically

reduced clogging.
36
 D) Miscellaneous Nozzles

- 3SK series has three of the SK orifice and cores along with a built-in strainer

- SSTC Whirlchamber type nozzles use the same whirlchamber and orifice as the
104 style but is only rated to 1000 psi. Use the 104 style for new customers.

- SBC nozzles are rated to 2000 psi. Use the SK-MFP style for new customers.

2) Two – Fluid Atomization. 1/4J, 1/2J, and 1J

- Cone and flat spray patterns

- Droplet sizes from very fine to medium

- Capacities from 2 to 1700 gph (8 to 6400 l/hr), based on water

- External mix round and flat spray set-ups permit wide range in atomization
without affecting feed flow rates.

-Internal mix round and flat spray set-ups can provide variations in atomization
accompanied by simultaneous changes in feed flow rates.

- Low pressure operation: less than 125 psi (8.6 bars) for compressed air and
feed.

- Choice of brass, stainless steel, hardened stainless steel, or tungsten carbide

orifice inserts available.

- Spray can spray viscous liquids over 700 cp and with less viscous liquids the
nozzles can produce many fine mist-like droplets.

37
 1) Spraying Systems Co. Pressure Spray Nozzles

Spraying Systems Co. pioneered the development of specialized nozzles for the spray drying
industry in the early 40’s. It continues to offer a wide choice of nozzle types, flow capacities
and spray angles, materials of construction, operating pressure ranges, droplet sizes, and pipe
connection sizes. SprayDry® nozzles are designed to provide good atomization with uniform
spray distribution throughout the hollow cone circular pattern in a wide range of spraying
pressures. These precision built nozzles are of durable construction and are designed to allow
quick and easy assembly and disassembly. For complete information on these spray nozzles and
their performance data see Bulletin 527 for the SK series, Bulletin 504 for the SB series, and
Bulletin 447 for the 104 and other WhirlJet series.

A) SK SprayDry® Nozzles – Low Capacity / High Pressure Nozzles

SKHN-MFP SprayDry Nozzle

The type SK nozzle series provides orifice insert-core combination sizes with a water capacity
range from 2.8 to 400 GPH (10.8 to 1460 l/hr). The spray angles, as measured close to the
orifice, vary from 45° to 90°, depending on the orifice-core combination. The SK series offers a
selection of interchangeable materials for the orifice insert and core tip, to meet the erosion and
chemical resistance requirements in each spray drying application.

The nozzle body, cap, and core body are made of 303 stainless steel. Type 316 stainless steel
parts are also available. The interchangeable orifice inserts and cores are supplied in specially
treated and hardened stainless steel, tungsten carbide in either the Y or preferred M versions and
also the L carbide. The Y and M grades of tungsten carbide are similar chemically but the M
carbide is a finer and longer lasting grade. New customers should be directed to the M carbide
and an effort should be made to change over our existing Y customers to the M carbide. The L
carbide is formulated to have more chemical resistance than the Y or M. When chemical
compatibility with the Y or M is not an issue then the Y or M will last significantly longer than
the L. SSCO headquarters will work with the sales offices and customers to be sure L carbide is
the correct choice.

NOTE: All references in this Manual to capacities, spray angles, and droplet sizes are based on
spraying water. These characteristics will be different for feed stocks, depending on many
factors including feed viscosity and specific gravity, and the nozzle type and size. References to
spraying pressures are based on the pressures at the nozzles and not at the pump.
38
SprayDry® is a trademark registered by Spraying Systems Co.
For the SK and SK-MFP versions, the maximum recommended temperature when spraying
varies with the choice of gasket materials: fiber is rated at 300°F (150°C); nylon, 300°F
(150°C); aluminum 1000°F (540°C). For the SKH-MFP and SKHN-MFP the standard O-ring is
Viton and the standard back-up ring is PEEK. The operating temperature rating is 400°F
(240°). A higher temperature Kalrez gasket is also available with a rating of 600°F (316°C).
Pipe connection sizes are _, 3/8, and 1/2 in either NPT or BSPT female. Thread-less welded
bodies are also available on request. Drop sizes vary with the properties of the feed stock and
are in the Medium Volume Diameter range of 20 to 120 microns based on spraying water.

There is no longer a cup top version of the SK series nozzles. These have been replaced with
the MFP design. The MFP design, like the old cup top version, provides less pressure drop
when spraying viscous liquids and will, therefore, provide better atomization. The MFP design
also is a dramatic improvement when clogging is an issue. For complete nozzle and spray
performance information see Bulletin 527.

B) SB SprayDry® Nozzles -larger capacities

SBHN-MFP SprayDry Nozzle

Type SB SprayDry® nozzles are the same design as type SK except that the SB nozzles are
larger and provide higher capacities. With water the SB nozzles provide a capacity range from
38.9 to 1508 GPH (148 to 5510). Depending on specific orifice insert-core combinations, the
spray angles at the orifice range from 34° to 109°.

The nozzle body, cap, and core body are made of 303 stainless steel. Type 316 stainless steel
parts are also available. The interchangeable orifice and cores can be supplied in a choice of
specially treated hardened stainless steel or tungsten carbide in either the Y or preferred M
versions and also the L carbide. The Y and M grades of tungsten carbide are similar chemically
but the M carbide is a finer and longer lasting grade. New customers should be directed to the
M carbide and an effort should be made to change over our existing Y customers to the M
carbide. The L carbide is formulated to have more chemical resistance than the Y or M. When
chemical compatibility with the Y or M is not an issue the L should not be specified because the
Y and M will last significantly longer than the L. SSCO headquarters will work with the sales
offices and customers to be sure the L carbide is the correct choice.

39
Flat top cores are standard however cup top cores are still available in all materials. New
customers should be directed to the flat top MFP version of the M carbide if possible. The cup
top option was made to provide better atomization of viscous liquids by reducing the pressure
drop leading up to the core slots. The MFP flat top version does a better job of reducing
pressure drop in viscous liquids and is longer lasting; along with dramatically reducing the
chance of clogging. Existing customers of the cup top cores should also be encouraged to use
the flat top MFP as the better option.

C) TYPE 104 WhirlJet® Nozzles

AA104 SprayDry Nozzle

Type 104 SprayDry® WhirlJet® nozzles are used for larger capacity requirements, as well as
for larger drop sizes, usually at lower spraying pressures. Water capacities range from 16.1 to
3019 GPH (61.5 to 11340 l/hr).

Supplied with an internal slope bottom design type WC-X whirlchamber minimizes erosion on
the whirlchamber bottom and results in longer wear life. Standard design, flat bottom type WC-
whirlchambers are also available. Orifice inserts and slope bottom whirlchambers are offered in
tungsten carbide.

Body, cap, and lock screw are made of type 303 stainless steel. The whirlchamber is held
securely in place with a lock screw, while the orifice insert is pressed into the nozzle cap. Large
passages and large holes in the whirlchambers make this a maximum free passage design.

Interchangeable caps and bodies provide over 150 different capacities and spray angles. For
tabulation and spray performance information see Bulletin 447.

The maximum recommended spraying pressure is 5000psi (345bar). The maximum

recommended temperature while spraying depends on the gasket: 300°F (150°C) for fiber and
nylon gaskets; 1000°F (540°C) for aluminum gaskets.

40
Type 104-AA nozzles have 1/4”, 3/8”, and 1/2” NPT (F) inlet connections. Type 104-3/8 has a
3/8” NPT (M) inlet, while type 104-1/2A has a 1/2” NPT (F) inlet connection, also available
with BSPT connections. The range of droplet sizes for type 104 spray nozzles, spraying water is
from 25 to 275 microns, Median Volume Diameter.

D) Miscellaneous Nozzles

1/4-3SK Multi-orifice SprayDry® Nozzles, with strainers: This multi-orifice nozzle has
three orifice mounted in the cap. Capacity is three times that of SK nozzles. Built-in strainer.
Type 303 stainless steel construction. High flow rates with small droplet sizes. Specially treated
hardened stainless steel orifice inserts and cores.

Orifice inserts and cores are available in the same materials as the standard SK series. Inlet
connections are also available in 3/8 and _ NPT(F) an also BSPT.

Maximum recommended spraying pressure is 7000psi (483bar). Maximum recommended

temperature when spraying is based on the gasket: fiber-300°F (150°C); aluminum-1000°F
(540°C). Overall length is 5-1/2” (14cm), with 1-7/8” (4.8cm) body outside diameter. See
Bulletin 527 for orifice and core sizes and PL 3SK for other components.

TYPES AA-SSTC, BB-SSTC AND AAA-SSTC WhirlJet® Nozzles: Type AA-SSTC

WhirlJet® nozzles have 1/4”, 3/8”, and 1/2” NPT (F) inlet connections; type 3/8BB-SSTC has a
3/8” NPT (M) inlet; and the type 1/2AAA-SSTC has a 1/2” NPT (F) inlet connection, also
available with BSPT. Their spray performances are identical to those of the type 104- WhirlJet®
spray nozzles except that the pressure rating is a maximum of 1000psi..

Type SSTC WhirlJet® nozzles consist of six parts: nozzle body, cap, gasket, internal spring,
whirlchamber, and orifice insert. The nozzles are type 303 stainless steel construction, with
abrasion resistant carbide whirlchambers and orifice inserts.

The optional slope bottom whirlchambers provide an extended wear life and are supplied in
tungsten carbide. Standard flat bottom whirlchambers are also made in tungsten carbide.

Orifice inserts are available in tungsten carbide. All whirlchambers and orifice inserts are
interchangeable, thereby providing over 150 different combinations of capacities and spray
angles. For listing of sizes and spray performances see SprayDry® Nozzles Bulletin 447.

Maximum recommended operating pressure is 1000psi (69bar); maximum recommended

spraying temperature varies with the gasket: fiber 300°F (150°C); Teflon 300°F (150°C); and
aluminum 1000°F (540°C). Since there are no internal obstructions, performance is clog-free.

SBC SprayDry® Nozzles: The compact type SBC nozzles provide a hollow cone spray with
uniform distribution of droplets. Interchangeable orifice insert sub-assemblies are changed by
simply unscrewing the nozzle cap. BY-HSS-orifice insert sub-assemblies contain a hardened
stainless steel orifice while the BY-HSSTC-sub-assemblies have a tungsten carbide orifice
insert. No need to change cores since the same core, without slots, is used for all capacity sizes.

41
With water at 1000psi (69bar), the Median Volume Diameter droplet sizes range from 50 to 120
microns with a capacity range from 15 to 70GPH (57 to 262l/h). The square body cores provide
larger passages, thereby reducing clogging.

Five part nozzle: nozzle body, core, cap, gasket, and orifice insert sub-assembly. All SBC-
nozzle assemblies use the same (not-slotted) hardened stainless steel core. Body and cap are 303
stainless steel. Nozzle capacity sizes are changed simply by interchanging the orifice insert sub-
assemblies. Maximum recommended spraying pressure is 2000psi (138bar). The maximum
recommended spraying temperature is based on the gasket used: fiber-300°F (150°C); nylon-
300°F (150°C); or aluminum-1000°F (540°C). Inlet connection is 1/4” NPT (F), also available
with BSPT.

The flow rate range of this older SBC design is in the range of the SK series and the SKH-MFP
should be specified for new customers. Existing customers of the SBC may also benefit by
switching to the SKH-MFP.

See Data Sheet 24311 for capacity data.

2) Spraying Systems Co. Two-Fluid Air Atomizing Nozzles

1/4JBC Air Atomizing Nozzle 1/4J Air Atomizing Nozzle

Two-fluid nozzles are used to obtain very fine particles and to spray viscous or abrasive feeds
(above 700cp), which cannot be properly atomized with pressure spray nozzles. Frequently used
in laboratory and pilot plant installations. The atomizing energy in a two-fluid nozzle is supplied
by the compressed air, pressurized steam, or a pressurized inert gas, which shears the fluid
leaving the fluid nozzle orifice, thereby forming very fine spray droplets.

When spraying abrasive feeds, external-mix air-atomizing nozzles are used. In these external
mix set-ups, the contact between the feed and the compressed air, gas, or steam takes place
outside of the nozzle chambers. This minimizes erosion and clogging problems.

The feed capacity range can vary depending on the specific application, nozzle type, spraying
pressures, and spray set-up. The spray pattern can be round or flat, depending on the spray set-
up chosen. See the most recent Spraying Systems industrial catalog for the 1/8J, 1/4J, 1/2J, and
1J options.

42
Water capacities can range from 2 to 70GPH (8 to 262l/h) with 1/8J- and 1/4J- type nozzles type
having 1/8” and 1/4” NPT (F) connections. Larger water capacities up to 1700GPH (6400l/h)
can be obtained by using larger size 1/2J and 1J air atomizing nozzles having 1/2” or 1” NPT
(F) connections. Also available with BSPT connections. All type J nozzles are available in
brass or stainless steel. Other materials are available on special request. Droplet sizes depend on
many factors, including the spray nozzle size, Spray Set-up, feed stock, and the air and feed
stock pressures. Spraying water, the Median Volume Diameter droplet size ranges from 10 to
200 microns. For applications requiring wear resistant materials, hardened stainless steel and
tungsten carbide orifice inserts can be supplied on a special basis.

Maximum recommended pressure is 125psi (8.6bar). The maximum recommended spraying

temperatures depend on the gasket materials: Buna-N 300°F (150°C); Teflon 600°F (320°C);
aluminum and copper 1000°F (540°C).

Typical applications using Spraying Systems Co. nozzles

Because of the many different possible combinations of spray dryer types and capacities, feed
stock properties, product quality requirements, temperatures, and pressures used, the choice of
spray nozzle and spraying pressure for a specific application is made by a trial and judgment
process. In many cases different types and sizes of nozzles, operating under different dryer
conditions, can produce similar quality products. Normally the same type nozzle is used in
different plants for the same product but with different orifice inserts, cores, and spraying
pressures; in each case a high quality product results.

For instance, type SK-spray drying nozzles are used for many applications including dye stuffs,
food powders, milks, gelatins, pharmaceuticals, proteins, vegetable powders, wheat gluten, lard,
whey, and yeast, animal blood, blood plasma, sodium caseinate, cheese, eggs, fruit powders,
acids, animal milk replacement, digestive animal bi-products, sodium laurel sulfate, whipped
topping, proteins, and tea.

Applications for larger capacity type SB nozzles include: cheese, coffee, dye stuffs, eggs, food
powders, milk, cocktail drink mixes, sugar substitutes, wheat starch, vegetable oils, proteins,
tea, wheat gluten, and whey. Type 104-WhirlJet spray nozzle applications include: animal
blood, detergents, and catalysts (petrol). Type SSTC WhirlJet nozzles are used frequently for
spray drying coffee, detergents, dye stuffs, tungsten carbide, cobalt, acetone, and paraffin.
Typical applications for type SBC--spray drying nozzles include detergents, eggs, meat extracts,
and milk.

Similarly, type J two-fluid air atomizing nozzles have been used for spray drying very viscous
liquids, starches, gelatins, synthetic resins and rubbers. Laboratory and pilot plant installations
are frequently operated with air atomizing nozzles.

43
 Section IX - Appendix

GLOSSARY OF TERMS

ABSORBERS (Dry) -Atomizer systems using reagent feed stocks to absorb and react with toxic
gases, such as SO2, HCL, etc. The resulting newly formed compound is a non-toxic dried
powder.

ACIDIC -Tending to form an acid (pH below 7.0).

AFTER-TREATMENT -The joining together of two or more spray dried wet particles to form a
larger porous particle in a fluid bed instantizer (2-stage spray drying). Used to provide
“instantizing” qualities to the powder.

AIR ATOMIZATION -See Pneumatic Atomization.

AIR BROOM -Blowing air to sweep clean and/or cool dryer chamber walls.

ALKALINE -Tending to form a base

ANNULUS -A circular ring-like passageway for air or liquid, as in an air atomizing spray
nozzle.

ATOMIZER -Equipment which breaks up liquid bulk into small droplets forming a spray, such
as spray nozzles or rotary atomizers.

ASEPTIC SPRAY DRYING -A system designed and maintained to provide sterile conditions
for production of powders free from disease-producing and putrefying micro-organisms.

BAG COLLECTOR -A filter which separates dried powder from the exhaust drying air.

BALL MILLING -Pulverizing equipment having a rotating cylinder containing steel balls.

BED DRYING -Drying of particles by hot air passing through a perforated base, above which
are the fluidized particles being dried.

BLUNGING -Mixing of ceramic materials in a liquid by agitation.

BOX DRYER – (Horizontal) -A rectangular shaped spray dryer with nozzles spraying
horizontally into the drying chamber.

BTU (BRITISH THERMAL UNIT) -A unit of heat energy to raise 1 lb. of water 1°F at
atmospheric pressure. (1 BTU = 252 Calories) (1 Calorie = 0.004 BTU).

BULK DENSITY -Weight of dry powder product per unit volume.

CAKING -The collection of powders in a solid dry crust, usually by continued heating of
adhering wet particles.

44
CALCINER -A furnace which produces a chemical-thermal reaction in a product, without
melting the product.

CALORIES -Unit of heat energy to raise 1 gram of water 1°C at atmospheric pressure. (1 BTU
= 252 calories) (1 Calorie = 0.004BTU).

CAPACITY -Flow rate per unit of time (atomizers); or amount of water evaporated per unit of
time dryers); or amount of product produced per unit of time (spray dryers).

CAVITATION -Formation of gas or vapor filled cavities within liquids by mechanical force.

CENTIPOISE-A unit of viscosity equal to 0.01poise.

CENTRIFUGAL ATOMIZATION -Breaking up of a liquid into droplets by rotary atomizer.

C.I.P. -Clean in place ...nozzles or manifold systems installed in processing equipment and used
for cleaning.

CLOSED SYSTEM (Closed Loop) -a spray drying system that recycles the hot inert gas, such
as nitrogen...as well as the liquid in the feed stock. (No exhaust into the atmosphere.)

COLLECTORS -Equipment to separate powder from exhaust drying air by filters, cycles, or
precipitators.

CO-CURRENT FLOW (Con-current flow) -The flow of hot drying in the same direction as the
sprayed feed.

CONCENTRATOR -Equipment which concentrates liquids by evaporating some of the water or

solvent. This process increases the percentage of solids content in the food.

CONGEALING -The process of solidifying spherical droplets of low melting point materials by
contacting them with cooling ...such as waxes, caustic soda, sulfur, etc.

COUNTER-CURRENT FLOW -The flow of the hot drying air/gas in the opposite direction as
the sprayed feed. Spray nozzles are mounted at top of vertical dryer -and the hot air enters dryer
from the bottom.

CRITICAL MOISTURE -The moisture content of a drying droplet at the point where the drying
rate drops sharply, but continues at a falling rate.

CRYSTALIZATION -Formation of crystalline substances from solutions.

CYCLONES (WET OR DRY) -Conical chambers wherein solid particles are removed by
centrifugal action. Wet type cyclones use spray nozzles to wet particles for easier recovery.
DEGRADATION -Deterioration or destruction of desirable powder qualities, as by overheating.

DIRECT HEATER SYSTEM -Provides direct contact between spray dried materials and the
gaseous products of combustion. Efficiency ranges from 95% to 98%.

DISPERSABILITY -The property of dried powders which allows them to scatter freely in all
directions when put into water.
45
DROPLET DIAMETER -Diameter of atomized feed stock droplet, usually measured in microns
(micrometers). Since spray nozzles provide a distribution of droplet sizes rather than the same
size diameter, droplet size usually made in terms of Median Volume Diameter (Volume Median
Diameter) or Sauter Median Diameter.

DROPLET SIZE DISTRIBUTION -Describes the array of spray droplet diameter sizes in
relation to the volume percentages of the spray.

DROPLET SIZE RANGE -The sizes of the largest and smallest droplets in a spray.

DRY SCRUBBING -The process used in absorbers (for toxic and obnoxious gases), wherein
sprayed feeds react chemically with the gases, forming harmless non-toxic compounds, which
are then collected as solid powder particles. See ABSORBERS (Dry).

DUST -Very fine powder particles capable of temporary gas/air suspension.

DWELL (RETENTION) TIME -The amount of time in seconds, that a spray droplet spends
traveling through a drying chamber before it is deposited as a dried powder.

EMULSION -A stable dispersion of one liquid in a second immiscible (non-mixing) liquid,

such as milk.

ENCAPSULATING -The encasing of particles in an inert protective carrier to help preserve the
quality of the (particle) ingredients.

EVAPORATOR -Equipment for concentrating feed stocks to provide a higher percentage solids
content, usually prior to spray drying operations.

EXTRACTOR -Equipment for concentrating feed stocks to provide higher percentage solids
content, usually prior to spray drying operations ...as in the process of spray drying coffee.

EXTERNAL MIX NOZZLES -Air atomizing nozzles which provide the liquid atomizing air
contact outside of the nozzle, at the liquid and air orifices location.

FALLING FILM EVAPORATOR -Equipment used for concentrating feed stocks, wherein the
liquid flows downward forming a fine film on the inside of metal tubes, which are heated (on
the outside) by steam. Evaporation of some liquid increases solids concentration in feed.

FEED (FEED STOCK) -Liquid solutions, slurries, suspensions, melts, sludge’s or pastes which
are atomized in spray dryer.

FGD (FLUE GAS DESULFURIZATION) -Removal of toxic or obnoxious gases, such as SO2,
HCL, etc. from flue gases. See ABSORBERS.

FINES -Extremely small sizes of liquid droplets or solid particles (approaching dust-like).

FLASHING (FLASH DRYING) -Rapid evaporation of moisture from particles by sudden

reduction in pressure, or by placing them in updraft of hot air/gas. This process is usually used
with temperature sensitive materials to prevent product degradation.

46
FLOWABILITY -Ability of solid particles to move by flowing. Depends on particle size
distribution.

FOAM SPRAY DRYING -Producing puffed powders by spraying a liquid concentrate into
which a liquefied gas has been injected in the high pressure line between the pump and the
spray.

FLUID BED AGGLOMERATORS -Fluidized beds, used after the first spray drying stage,
wherein additional feed is sprayed on to the fluidized bed particles to increase the size of the
particles, or to add other ingredients. Occasionally additional feed is not required, but only
warm moist air is used to cause the wet particles to join together, forming larger particles as
they dry.

FLUID BED -Perforated bed through which drying or cooling air passes and suspends particles
above the bed.

FLUID BED COOLERS -Fluidized bed using cold air or gas to cool particles.

FLUID (FLUIDIZED) BED DRYERS -Fluidized bed using hot air or gas to complete the
drying process.

FRIABLE -The property of powders capable of being easily crumb led or pulverized.

GRANULATION -The process of reducing solid materials to smaller particles by mechanical

action.

HEAT DEGRADATION -Deterioration of the quality of heat sensitive products by being

exposed to (too) high temperatures.

HEAT SENSITIVE MATERIALS -Products whose desirable properties are damaged or

destroyed by heat.

HOMOGENIZER -Equipment that blends or emulsifies a substance by forcing it through fine

passages against a hard surface.

HORIZONTAL (BOX) DRYER -Rectangular shaped drying chamber with nozzles usually
spraying horizontally.

HYDRATION -Combining with water.

HYGROSCOPIC -Readily absorbing or abstracting moisture, such as from air.

INDIRECT HEATER DRYING -The process in which the drying air or gas is heated by
contacting the metal fins of tubes through which steam or hot combustion gases are flowing.
Efficiencies range from 70% to 85%.

INSTANT PROPERTIES -The properties of powders which allow them, upon being put into
water, to be wetted very quickly, sink down into the water, disperse in the water, and quickly
dissolve.

INSTANTIZER -Equipment that produces instant products. See REWET AGGLOMERATION.

47
INSTANTIZING -Process of transforming spray dried powder particles into porous
agglomerates through the use of a 2-stage spray drying process. See REWET
AGGLOMERATION. The “instantizing” quality of spray dried products describes their
quickness in dissolving in water, and is the result of the combined wet-ability, sink-ability,
dispersability, and solubility properties of the dried powders.

INTEGRATED FLUID BED SPRAY DRYER –A spray dryer with a stationary fluidized bed
section.

INTERNAL MIX NOZZLES -Air atomizing nozzles which provide the air contact inside the
nozzles in the internal r of the

INTERSTITIAL AIR -Air space between dried powder particles, affecting the bulk density.

ISOSTATIC -A dry pressing process in which spray dried free flowing ceramic agglomerates
are compacted by applying simultaneous direction hydraulic pressure to the powder, thereby
consolidating the powder. This newly formed "green" compact is then used for further shape-
forming operations, such as turning, drilling, grinding, etc.

KINETIC ENERGY -Energy by a mass in motion, such as liquid flowing under pressure.

LATENT HEAT -The amount of heat needed to change the state of a material ... such as water
being evaporated, from a liquid to a vapor.

LECITHIN -A group of phosphatized products made commercially from egg yolk, etc. and used
in processing foods.

LOW TEMPERATURE SPRAY DRYING -Spray drying process which uses dehumidified air,
warmed moderately over the ambient temperature, to dry products which are extremely heat
sensitive.

MECHANICAL SWEEP -A mechanical arm which moves the spray dried powder from the
drying chamber floor to a conveyor.

MEDIAN VOLUME DIAMETER (MVD) -A unit (usually expressed in microns or

micrometers) used as a liquid droplet size reference and based on the volume or mass of the
liquid sprayed. Specifically it is the droplet diameter size where 50% of the total volume or
mass of the liquid sprayed is made up of droplets with diameters larger than the Median Volume
Diameter and 50% of the mass or volume is in droplet diameters smaller than the Median
Volume Diameter. Also known as VMD (Volume Median Diameter) and

MICRON (MICROMETRE) -Unit of linear measure. (One micron = .001mm = 1/254000 of an

inch). Symbol is or m.

MIXED FLOW DRYER -A dryer in which the drying air/gas enters counter currently to the
spray direction, but leaves the dryer in the same direction as the dried powder.

MOTHER LIQUOR (DISCHARGED LIQUOR) -Liquid which remains after a processing

operation; can be the effluent or product.

48
MULTI-STAGE DRYER -A dryer in which the sprayed wet powder falls onto an integrated
stationary fluidized bed for preliminary drying, after which it goes to a vibrating bed or
fluidized bed for agglomeration, cooling, or further drying.

NEWTONIAN FLUID -Fluid that has flow characteristics of water, except as affected by
viscosity. The liquid shear is proportional to the stress.

NON-AQUEOUS SOLVENTS -Solvents without any water.

NON-NEWTONIAN FLUID -Fluid which does not flow as water. The liquid shear is not
proportional to the stress.

OCCLUDED AIR -Air which is trapped inside particles.

ONE STAGE DRYING -A drying process which produces a finished dried powder in one
operation.

OPEN SYSTEM -The usual spray drying system which uses hot air with combustion gases as
the drying medium, which is later exhausted into the atmosphere.

OVER DRYING -The problem in which dried powder has less moisture content than required
and perhaps, its desirable properties have been degraded or destroyed.

OXIDATION -A chemical reaction which increases the oxygen content of the product. This can
be prevented by spray drying in a self-innertizing system or in a closed system.

PARTICLE DENSITY -Density of individual particles -as distinguished from Bulk Density.

PARTICLE SIZE -For spherical dry particles it is the diameter of the particle. For non-spherical
particles it is the "apparent" diameter, which is the "mean" distance between the long and short
sides of the particle as measured through its center of gravity.

PASTE -A soft, smooth, very viscous, and moist substance.

PASTE NOZZLE -An air atomizing type nozzle used for spray drying pastes.

PENETRATIBILITY -Same as sink-ability.

PERCENT SOLIDS -Percentage of solids in feed stocks (by weight).

PITOT TUBE -for measuring air velocities in ducts.

PNEUMATIC ATOM ZATION (AIR ATOMIZATION) -Feed atomization by 2-fluid (or 3-

fluid) spray nozzles using compressed air energy to break up the feed into fine spray droplets.

PNEUMATIC CUP -In rotary atomizers ...the combination of a rotating cup with an air flow
directed at the cup rim.

POISE -A unit of liquid viscosity. Equals 100centipoise.

POROSITY -Property of solid particles relating to the minute open spaces within the particle.

49
PRESS CAKE -Nonflowing uniformly dispersed mass of mixture of water and solids.

PRESSURE SPRAY NOZZLES -Spray nozzles which provide feed stock atomization high
pressure feed flows through small orifices..

PRILLING (SPRAY COOLING) -The formation of pellets or crystals by the cooling action of
upward flowing cooling air in towers, through which spray droplets are falling. The melting
temperatures of the feeds are above the temperature of the cooling air, and usually above the
temperature of the ambient air.

PUFFING -The enlargement of a particle caused by a vapor which is formed within the droplet
and expands as the droplet temperature increases.

PSEUDO PLASTIC -A fluid whose apparent viscosity decreases with an increase in sheer rate.

REACTOR (REACTOR TOWER) -Process vessel in which chemical reactions take place
during a chemical conversion process such as in dry FGD systems, in which the sprayed feed
stock combines chemically with toxic components of a flue gas to form new compound powders
which are non-toxic and disposable.

RECONSTITUTION -The process of wetting powders to return them to their original fluid-
solid suspension state.

RESIDENCE -See Dwell Time.

RETENTION -See Dwell Time.

REWET AGGLOMERATION (SPRAY FLUIDIZERS) -An agglomeration process wherein

moist spray dried powders are sprayed with water or feed stock while over a fluidized bed,
thereby causing wet particles to join together, before the final cooling and drying over a
fluidized bed. This process makes dustless granules.

REWET INSTANTIZER -Equipment for the rewet agglomeration process.

ROTARY AIR LOCK (VALVE) -Equipment which provides a control led discharge of a
powder from hopper, while maintaining either a positive pressure or vacuum inside the
container.

ROTARY DRYER -Rotating drum dryer through which hot air passes to dry the product
tumbling or cascading in the dryer.

SAUTER MEAN DIAMETER -The Sauter Mean Diameter expresses a uniform droplet size
diameter in terms of the actual total surface area produced by the totality of droplets in a given
spray. It is obtained by summing the surface areas of all the droplets produced by the spray in a
given time, and the total volume of all the droplets. The total volume of all the droplets is then
divided by the total surface area of all the droplets to find the diameter of a droplet having the
same volume to surface area ratio. This droplet diameter value is the Sauter Mean Diameter. It
is used in heat-transfer applications.

SCRUBBER -Equipment for removing solid particles, or toxic or obnoxious gases or fumes,
from gas streams, usually flue gases.
50
SEALED CLOSED-CYCLE SYSTEMS -A spray drying system where the hot inert drying gas
and the liquid in the feed are recycled, and not released into the atmosphere.

SELF INERTIZING SYSTEM -A spray drying system using aqueous feeds where the dried
product must not contact large amounts of air/oxygen due to the risk of a powder explosion or
product degradation (by oxidation). It is also used to limit atmospheric emissions whenever
necessary, since the amount of air bled from this system is closely controlled and is very small
in relation to the total gas flow required for the drying operation. It is usually used with gas fired
heaters and with the combustion air (used by the burner) precisely controlled, resulting in a
drying gas flow with a very low oxygen content. This is a form of semi-closed cycle. See
section II.

SEMI-CLOSED CYCLE -This is a compromise between open-cycle and closed-cycle plants.

The dryers are not gas tight. The basis of this layout is to limit the amount of gases sent into the
atmosphere. See SELF INITIALIZING SYSTEM.

SENSIBLE HEAT -The total heat content of a substance.

SEPARATION -The process of removing dried particles from the drying

exhaust.

SINGLE FLUID NOZZLE -Pressure spray nozzle which provides atomization by liquid
pressure alone.

SINKABILITY -Ability of a powder to sink down into the water after being wetted.

SLUDGE -Semi-solid mass.

SLURRY -Suspension of solid particles in a liquid.

SOLUBILITY -The rate of dissolving...or the total solubility, such as the solubility index.

SOLUTION -A single homogeneous liquid mixture in which the components are uniformly
distributed.
SPECIFIC GRAVITY -Ratio of density o f another material to that of water, which weighs 8.34
lbs. per gallon and 62.4 lbs. per cubic foot (1kg per liter).

SPIN FLASH DRYER -Converts wet granules, paste, or filter cake into powder by dispersing
the feed into drying chamber with a rotating agitator and into a stream of hot drying air.

SPINNING DISC-Rotating wheel of a rotary atomizer.

SPRAY ABSORPTION -Absorption of gases by sprayed feed droplets. See Absorbers.

SPRAY CONCENTRATION -Evaporation of a small amount of the liquid in feed stocks by

spraying into a hot air/gas stream. The product remains as a liquid, with less water, and with a
higher solids concentration.

SPRAY COOLING -See Prilling

51
SPRAY FLUIDIZER -See REWET AGGLOMERATION

SPRAY DRYER -Equipment in which an atomized feed stock is dried into a powder by direct
contact with a flow of hot

SPRAY FREEZE DRYING -Process of spraying product into -freezing air, following which the
frozen particles are subjected to a vacuum thereby, sublimating/evaporating the moisture from
the particles. Sometimes the particles are also heated to remove the trapped vapors.

SPRAY REACTION -Process of spraying liquids into hot gases for purpose of achieving a
chemical reaction between the gas and liquid. See Absorbers.

STATIONARY FLUID BED -A non-vibrating fluid bed which can be an integral part of the
spray drying chamber.

SULFONATION -Chemical for converting compounds, such as benzene, into an acid (by
adding an SO2H group).

STRAIGHT-THROUGH DRYER -One in which fines are returned to the atomization zone in
the drying chamber for initial agglomeration.

SURFACE TENSION -The force acting on the surface of a liquid to minimize it's surface area.
Liquids with high surface tension are difficult to atomize.

SUSPENSIONS -See Slurry

TANGENTIAL VELOCITY -The instantaneous linear velocity of a body moving in a circular

path; its direction is tangential to the circular path at the point in question.

THERMOPLASTIC PRODUCTS -Products which would melt or become sticky at spray drying
temperature.

THIXOTROPIC -Property of certain gels which liquefy when subjected to shaking or vibration
and then solidify when left standing.
THREE-FLUID NOZZLE -An air atomized nozzle with one central liquid orifice surrounded by
two channels or annular rings of air outlets. Used for more viscous materials.

TOWER DRYER -A tall vertical round spray dryer as contrasted to the box type horizontal
spray dryer.

TWO-FLUID NOZZLE' -An air atomizing nozzle usually with one central fluid orifice and with
the atomization energy provided by high velocity compressed air through the nozzle.

TRAY DRYER -Vertical process tower having the height filled with a series of trays designed
to cause intimate contact between the falling liquid droplets and a rising current of hot drying
air/gas.

TURNDOWN-RATIO -Ratio of the maximum capacity to the minimum capacity of a nozzle

within an acceptable spray performance range.

52
TWO STAGE DRYER -A spray dryer in which the usual first drying stage is combined with a
fluidized bed acting as an after-dryer, cooler, or agglomerator.

VIBRATING FLUID BED -A fluid bed with a vibrating perforated plate above which spray
dried particles are fluidized by a flow of hot air through the perforated plate. This type fluid bed
also has a self emptying feature.

FLUIDIZER -See Vibrating Fluid Bed.

VISCOSITY -The flow resistance of liquids usually stated in poise, centipoise, or Saybolt
Seconds Universal (SSU) units.

VOLUME MEDIAN DIAMETER (VMD) -See MEDIAN VOLUME DIAMETER

VORTEX -A continuous powder discharge technique for cyclones, used with pneumatic power
conveyors.

WALL SWEEP -An air flow from perforated sheets or straightening vanes in a spray dryer for
the purpose of keeping the drying particles from settling on the dryer walls.

WETTABILITY -Ability of the particle to absorb water on its surface...to be wetted.

WET SCRUBBER -Installation for removing solid particles or gases from an stream by using
liquid sprays.

WHEY -The watery part of milk separated from the curd in the cheese making process.

53
Celsius-Fahrenheit
Temperatures
ºC ºF ºC ºF ºC ºF ºC ºF
20 68 74 165 128 262 182 360
22 72 76 169 130 266 184 364
24 75 78 172 132 270 186 367
26 79 80 176 134 274 188 370
28 82 82 180 136 237 190 374
30 86 84 183 138 280 192 378
32 90 86 187 140 284 194 382
34 93 88 190 142 288 196 386
36 97 90 194 144 291 198 389
38 100 92 198 146 295 200 392
40 104 94 201 148 299 205 401
42 108 96 205 150 302 210 410
44 111 98 208 152 306 215 419
46 115 100 212 154 310 220 428
48 118 102 216 156 314 225 437
50 122 104 220 158 317 230 446
52 126 106 223 160 320 235 455
54 129 108 226 162 324 240 464
56 133 110 230 164 327 245 473
58 136 112 234 166 330 250 482
60 140 114 237 168 334 255 491
62 144 116 240 170 338 260 500
64 147 118 244 172 341 265 509
66 151 120 248 174 345 270 518
68 154 122 251 176 349 275 527
70 158 124 255 178 352 280 536
72 162 126 259 180 356 285 545
290 554
300 572

54
 Conversion Factors - U.S. to
Metric
Multiply By To Obtain
British Thermal Units (Btu) 252 Calories (cal)
Cubic Feet (ft3) 28.3 Liters (l)
* Fahrenheit (quantity) .56 * Celsius (quantity)
Feet (ft) .3 Meters (m)
Gallons (U.S.) (Gal) 3.79 Liters (l)
Gallons (U.S.) per Minute 3.79 Liters per Minute (l/min)
(GPM)
Gallons (U.S.) of Water (Gal) 3.79 Kilograms of Water (kg)
Miles per Hour (MPH) 1.61 Kilometers per Hour (km/h)
Pounds (Lbs.) .45 Kilograms (kg)
Pounds per Square Inch (psi) .069 Bar (bar)
Pounds per Square Inch (psi) .068 Atmospheres (atm)
Pounds per Square Inch (psi) .070 Kilograms per Square Centimeters
(kg/cm2)
Pounds per Square Inch (psi) 6.9 Kilopascals (kPa)
Square Feet (ft2) .093 Square Centimeters (cm2)

Note: One U.S. Gallon equals .83 Imperial Gallons

*This is not a conversion factor for temperature readings. This factor specifically
converts a temperature drop (or rise) in ºF to ºC, and vice-versa.
Example:A temperature drop (or rise) of 10º F equals a temperature drop (or rise) of 5.6º C

55
TABLE SS-1 -
SIEVE SIZES
SIEVE OPENING MESH NO.
INCHES MICRONS U.S. BRITISH GERMAN
(APPROX.) (MICROMETRES) STD. STD. STD.
.033 841 20
.031 800 0.80
.028 710 22
.0278 707 25
.031 630 0.63
.024 600 25
.023 595 30
.020 500 35 30 0.50
.017 420 40 36
.016 400 0.40
.014 355 44
.014 354 45
.0124 315 0.315
.012 300 52
.0117 297 50
.010 250 60 60 0.25
.008 210 70 72
.0078 200 0.20
.0071 180 85
.0070 177 80
.0063 160 0.16
.006 150 100 100
.005 125 120 120 0.125
.004 105 140 150
.0039 100 0.1
.0035 90 170 170 0.09
.0031 80 0.08
.0030 75 200
.0029 74 200
.0027 0.071
.0025 63 230 240 0.063
.0022 56 0.056
.0021 53 270 300
.002 50 0.050
.0018 45 350 0.045
.0017 44 325
.00153 39
.0015 37 400 0.04

56
References

Masters, K., "Spray Drying Handbook", Fourth Edition Halstead Press, A Division of John
Wiley & Sons, Inc., New York, 1985.

Marshall, Jr., W.R., "Atomization and Spray Drying”, Chemical Engineering Progress
Monograph Series, No. 2 Vol. 50 1954, American Institute of Chemical Engineers, New York.

Lee, David A., “Comparison of Centrifugal and Nozzle Atomization Spray Dryers”, Ceramic
Bulletin, Vol. 53, No. 3 (1974)

Westergaard, Vagn, “Milk Powder Technology Evaporation and Spray Drying" 3rd Rev.
Edition, November 1983.

Reinauer, T.B., Monat, J.P., and Mutsakis, M., “Dry FGD on an Industrial Boiler”, CEP, March
1983.

Katta, S. And Galvin, W.H., "Some Fundamental Aspects of Spray Drying", AlChE Journal,
Vol. 21, No. 1, January 1975.

Davidson, A., "Spray Drying and Dry Neutralization of Powdered Detergents", J. AM. Oil
Chemists “S.O.S.”, January 1978 (Vol . 55).

Koedt, Jan P., "The Application of Spray Drying and its Allied Processes in the Food and
Agricultural Industries" October 1980.

Master, Keith, "Spray Drying the Unit Operation Today", Industrial Engineering Chemistry,
Vol. 60, No. 10, October 1968.

Various spray drying equipment manufacturers' sales and technical publications.

57
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