Induction heating-based pulsed spray drier for dewatering of alkali metal halide salts: Numerical model and its experimental validation

Abstract

Dewatering of alkali metal halide salts in conventional co-current or counter-current spray driers to obtain low moisture content and agglomeration in resultant dried powders is difficult owing to their hygroscopic nature. Co-current spray driers offer the advantage of good heat transport characteristics in spray zone while counter-current spray driers offer better thermal utilization throughout the drying chamber. In the present work, modified prototype of a conventional counter-current spray drier is developed to obtain both these advantages in the drying chamber by employing induction heating and mechanical pulsation techniques. After carrying out several experiments in this prototype viz. Induction heating-based pulsed spray drier (IH-PSD), the optimal process parameters are obtained which maximize thermal utilization throughout the drying chamber and minimize both moisture content and agglomeration in resultant dried powders of sodium and potassium halide salts. The initial droplet and final particle size distributions are obtained using laser diffraction analyzer and sieve shaker experiments respectively. An experimentally validated numerical model implemented using open-source computational solvers is utilized to obtain average drying rates in IH-PSD. It is observed that the average drying rate lies between 0.03 and 0.18 mg/s and 0.04 and 0.14 mg/s for sodium and potassium metal halide salts respectively.

Highlights

• Spray drying prototype coupled with Induction heating and mechanical pulsation.

• Dewatering of sodium and potassium metal halide salts using the spray drying prototype.

• Numerical-neural network model implemented by open source computational solvers.

• Utilization of Laser diffraction analyser for measurement of initial droplet size.

• Model calculates the average drying rate with an accuracy around 83%.

GRAPHICAL ABSTRACT

Keywords:

• Spray drying
• induction heating
• numerical model
• laser diffraction
• alkali metal halide salts

Acknowledgments

The authors are thankful to Shri. N. S. Ghuge and all personnel of PDL building of AMMD for their assistance in constantly monitoring the safety aspects of experiments. The authors are especially thankful to Shri. S. Y. Sarang for his constant assistance in operation of IH-PSD setup. The authors are thankful to Shri. Sanal P. Kumar, RRMD, BARC for assistance in in-house fabrication works required for experimental setup. The authors are also thankful to Ms. Olviya Gonsalves of ICT Mumbai for assisting with SEM characterization of samples.

Disclosure statement

The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this article.