The major parameters in the design of spray dryers are discussed. A Lagrangian approach, combining experimental data with theoretical concepts, is proposed to develop design methods. Vortex flow patterns, obtained experimentally in a laboratory size chamber, are correlated and presented.
Based on this design methodology, computational methods are given to calculate droplet trajectories and hence to predict the optimum chamber dimensions and operating conditions for maximum thermal efficiency and/or minimum operating cost. Application of these basic principles is illustrated by the design of an industrial size, spray drying chamber for a specific feed solution and production rate.