CFD-aided population balance modeling of a spray drying process

Buchholz, Moritz; Haus, Johannes; Pietsch‐Braune, Swantje; Jäger, Frank; Heinrich, Stefan

doi:10.1016/j.apt.2022.103636

Cited by 8 publications

(9 citation statements)

References 24 publications

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“…This chapter evaluates the simulation results for the synthesis and rotary kiln models, as well as for the entire zeolite production process. The evaluation and validation of the decanter centrifuge and spray dryer models can be found in previous publications: [32][33][34]50] and [35], respectively.…”

Section: Resultsmentioning

confidence: 99%

“…A multi-compartment approach is used to model the co-current spray drying process by discretization along the dryer's vertical axis, according to the work of Buchholz et al [35]. The model structure is schematically shown in Figure 6.…”

Section: Spray Dryermentioning

confidence: 99%

“…Due to negligible transient behavior, the system is modeled as quasi-stationary. The respective balance and constitutive equations are summarized in [35].…”

Section: Spray Dryermentioning

confidence: 99%

“…The solid-liquid separation stage is described by a multi-compartment centrifuge model, developed by Gleiss et al [32][33][34], which considers sedimentation and compaction of the cake. The population balance approach for a co-current spray drying model, presented by Buchholz et al [35], allows us to consider different drying kinetics and particle solidification inside the drying chamber. The information on the drop movement through the spray dryer is extracted from computational fluid dynamics (CFD) simulations to further increase the accuracy of the model [35].…”

Section: Introductionmentioning

confidence: 99%

“…The population balance approach for a co-current spray drying model, presented by Buchholz et al [35], allows us to consider different drying kinetics and particle solidification inside the drying chamber. The information on the drop movement through the spray dryer is extracted from computational fluid dynamics (CFD) simulations to further increase the accuracy of the model [35]. The calcination of zeolites is performed within a rotary kiln.…”

Section: Introductionmentioning

confidence: 99%

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Use of Multiscale Data-Driven Surrogate Models for Flowsheet Simulation of an Industrial Zeolite Production Process

et al. 2022

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The production of catalysts such as zeolites is a complex multiscale and multi-step process. Various material properties, such as particle size or moisture content, as well as operating parameters—e.g., temperature or amount and composition of input material flows—significantly affect the outcome of each process step, and hence determine the properties of the final product. Therefore, the design and optimization of such processes is a complex task, which can be greatly facilitated with the help of numerical simulations. This contribution presents a modeling framework for the dynamic flowsheet simulation of a zeolite production sequence consisting of four stages: precipitation in a batch reactor; concentration and washing in a block of centrifuges; formation of droplets and drying in a spray dryer; and burning organic residues in a chain of rotary kilns. Various techniques and methods were used to develop the applied models. For the synthesis in the reactor, a multistage strategy was used, comprising discrete element method simulations, data-driven surrogate modeling, and population balance modeling. The concentration and washing stage consisted of several multicompartment decanter centrifuges alternating with water mixers. The drying is described by a co–current spray dryer model developed by applying a two-dimensional population balance approach. For the rotary kilns, a multi-compartment model was used, which describes the gas–solid reaction in the counter–current solids and gas flows.

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Section: Resultsmentioning

confidence: 99%

Section: Spray Dryermentioning

confidence: 99%

“…Due to negligible transient behavior, the system is modeled as quasi-stationary. The respective balance and constitutive equations are summarized in [35].…”

Section: Spray Dryermentioning

confidence: 99%