How models improve our world Optimization of spray drying operations with NIZO Premia

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1 How models improve our world Optimization of spray drying operations with NIZO Premia November 8 th, 2011 Matthew de Roode matthew.deroode@nizo.nl Han Straatsma Gert van Houwelingen Natalie Hotrum Peter de Jong

2 NIZO food research Independent, private contract research company for the food industry HQ in The Netherlands (Food Valley) Offices in France, UK, USA, Japan 200 professionals Four business segments Health Taste & Texture Processing & Safety Processing centre Largest independent food grade pilot plant in Europe Product preparation Upstream processing Pasteurisation & UHT Separation Drying

3 Drying at NIZO Bench top Glatt agglomerator (1 5 kg) Spray drying (max 100 g batch size) Freeze drying Up to 2 kg Drum drying Single drum (110 L water/h) Double drum (60 L water/h) Spray drying Single stage (25 L water/h) Rotary or nozzle Multistage (250 L water/h) Nozzle

4 Spray drying context Over spray dryers commercially in use From few kg to kg/h of drying capacity Broad product range Agrochemicals, Biotechnology products, Fine and heavy chemicals, Dairy products, Dyestuffs, Mineral concentrates, Pharmaceuticals Advantages Handle both heat and non-heat sensitive products Controllable particle size, moisture content, Continuous processing Disadvantages High installation costs Low thermal efficiency Product deposit in the drying chamber

5 Reduce the disadvantages A stepwise approach where we integrate process and product properties Step 1 Process scan Step 2 Product analysis Step 3 Simulation (Premia) Reduced processing costs & optimal quality

6 Process scan Identify important process streams Product in Feed flow Temperature Dry matter Air in Air flow Temperature Absolute humidity Air out Temperature Absolute humidity Product out Moisture content

7 Product analysis By lab-measurements on the powder Adsorption behaviour Measure powder moistere at different T an RH combinations Fit to the GAB-relation W = W m 1+ ( cg 1) K aw K a ( ) w + cg 1 K aw 1 K aw Water activity (-) 1,0 0,8 0,6 0,4 0,2 Sorption isotherms milkpowder 23 C 45 C 75 C Sticky behaviour Measure powder stickyness at different T and RH combinations Fit to the Gordon-Taylor relation 0,0 0,00 0,05 0,10 0,15 0,20 0,25 Moisture content in fat free dry matter (kg/kg) T st = T + w 1 T g,1 w 1 + k w 2 + k w 2 T g,2

8 Modelling In our case: NIZO Premia Dryspec2 A software platform written in Delphi developed by NIZO Serves as a motherboard for a range of modeling programs Enables our process experts to quickly find opportunities in current food production lines

9 Near equilibrium approach water vapour pressure product air IN Time/location OUT

10 Optimisation Increase production, while remaining non-sticky Non-sticky Sticky T air in = 180 T air in = 200

11 Result optimisation Trade off between feed flow and powder moisture All curves are within the non-sticky region

12 Other optimization possibilities Optimize production for a current sticky powder Reduce energy need Evaluate the effect of summer/winter conditions on production Resolve heat load issues with additional powder measurements and subsequent modelling

13 Real time optimisation Premia Connects Real time communication with OPC server Real time process settings are fed into Dryspec2 Real time calculation of powder quality Use powder quality as set point Real time feedback of optimum process settings

14 Creating the future together Technology for your success 14