Steam Tube Dryers

The Sakav Steam Tube Dryer was developed to dry high moisture organic by-products such as brewer's and distiller's spent grain. Today, this dryer serves thousands of applications, drying and processing inorganic and organic chemicals and other bulk solid materials.

The steam tube dryer generally operates at a lower temperature than other dryers and rotates at a slower speed. Material tumbles gently around the tubes which rotate with the shell, unlike the friction forces required by other types of dryers to process material. Consequently, it enjoys a longer life than most dryers and requires very little maintenance. Sakav Steam Tube Dryers have proved superior to other types of indirect-heat dryer installations in which hot gas, rather than steam, is used as the heat source. Maintenance savings alone have often prompted replacement of other dryer systems with the Steam Tube Dryer

The Sakav Continuous Seal Steam Tube Dryer offers tremendous advantages for solvent extraction or drying in an inert gas atmosphere. The CS unit's revolutionary design permits material to be processed in a positive or negative pressure atmosphere and alleviates product and gas leakage into or out of the dryer.

The dryer is operated as a counterflow unit. Air moves in the opposite direction of material flow. Sweep gas flow is used only to exhaust vapor and other gases created by the heating process, not to dry material.

Low sweep gas velocity through the dryer vastly reduces the amount of product entrained in the exhaust stream.

During solvent extraction, this not only means significant savings in the size and cost of recovery equipment, but simplifies dust collection requirements and reduces the cost of equipment required to handle the task.

ROTARY CASCADE AND ROTARY LOUVRE DRYER AND COOLER

1500 KGS.lHR. BONE MEAL COCURRENT ROTARY DRYER

SAKAV DRYERS handle all types of materials. Recognising that virtually every drying application is unique. Each Rotary Cascade Dryer is purposely designed to meet specific matenal characteristics by analysing the client's process requirement. the correct design solution is assessed & selected by.

Designed for Bulk drying of:

Minerals Metal Ores - Fertilisers Foodstuff - Chemicals -Industrial & Domestic waste.

WIDE RANGE OFF GRANULAR MATERIAL

• Aggregates' Aluminium Oxide' Ammonium nitrate' Ammonium sulphate' Andalousite
• Animal manure
• Barium Carbonate' Basic Slag' Bauxite' Benlonil - Blanose
• Bone meal
• Bone Powder' Borates
• Calcium Chloride' Carbon Black pellets' Cement Raw meals' Chicken waste' Chrome Ore' Citric Acid
• Clay earth' Clays' Coal' Cobalt oxide' Coke Breeze
• Copper Concentrates' Copper Lead tin alloy Copper Slag Copper Sulphate' Copper wastes
• Cotton seed' Crushed Glass' Crushed Marble' Crystals' Dextrose monohydrate' Dicalcium Phosphate' Egg shell' Feldspar- Ferrile
• Ferronickel
• Fertilisers
• Flint Chips' Garbage wastes Gypsum' Gypsum' Heamatite
• Herbicides' Herbicides' Ilmenite' Industrial wastes' Kaolin
• Lardstone
• Limestone' Maqnesiurn Sulphate' Maize germs' Montmorillonite clay Nickel
• Oily chlorate' Potassium Nitrate' PPT Silica' Quartz' Rawa
• Refractories' Rock Phosphate
• Rubber' Salt Sand' Sludges' Sodium Chloride' Sodium monoglutamate
• Spath fluor' Sugar
• Talc' Titanium Dioxide' Titanium oxide
• Urea' Wine tarter' zince oxide.

FEATURESHIGH AUTOMATION LOW MAINTENANCE CONTINUOUS OPERATION LOW OPERATING COST

OPERATING TEMPERATURE :- 60C to 1OOOC.

CAPACITY :- 5 TPD TO 150 TPD

SIZE & MOISTURE :- Capable of Handling different product particle size & moisturecontent.

SYSTEM

Drying / cooling is achieved by passing the material to be processed through a rotating cylinder through which also passes a current of tempered air. Lifters/flights or louvres in the case of rotary louvre dryer, are fitted to the Internal surface of the cylinder to give intimate contact between product and drying or cooling air stream. In Rotary Louvre dryers the material IS not lifted and dropped through the drying air stream, therefore less product breakdown occurs. Rotary Louvre dryers can also be arranged for multi-stage drying, or drying and cooling in one Unit.

DRYER PRINCIPLE

Co-current Flow Rotary Cascade Dryers, sticky and heat sensitive materials, since the wet material IS exposed to the highest temperature gases, the initial heat transfer rate is very high, rapidly evaporating surface moisture. The Immediate and dramatic fall in gas temperature prevents a sudden Increase in the matenal and shell temperatures. The final product is in contact with the lower temperature gases enabling the moisture content to be readily controlled thereby avoidrnq over-drying. Counter-Current Flow drying in a Rotary Cascade Dryer gives lower product moisture than co-current flow for a given inlet temperature. However, its use with heatsensitive rnatenals IS limited since the dryed product comes into contact with the heating medium at its highest temperature. It is suitable for application where an extremely low moisture content is required or where a higher product temperature is anadvantage.

HEATING MEDIUM

Gas. Diesel, oil, electric, stream. The drying gas are provided from either a direct fired furnace or an indirect heat exchanger within the range 100 to 1000 C using solid, gaseous or liquid fuel. Only products of combustion or indirectly heated gases enter the Rotary Cascade Dryer. This prevents surface contamination while reducing the risk of damage or fire when handeling more sensitive materials. A two fan balanced draught system IS used to provide the maximum degree of control & flexibility. In arrangements and the drying gases are provided by a locally mounted burner projecting the flame down the centre of the dryer through which the material cascades. This design gives even greater thermal efficiency due to the higher temperature differential, the direct flame contact and the radiation effect, when processing materials which can withstand high gas temperatures without deterioration.

CONSTRUCTION

Carbon, Stainless or custom alloy steel plate, with external reinforcing bands for fitting of tyres and drive rings. Flights and lifters or louvres are welded or bolted internally. Confifuration is determined by application.

DRIVE

Drum is rotated by an electric motor through V-belts, gearbox, pinion and either heavy duty chain to a chainwheel or spur gear drive ring bolted around the dryer drum. For high temperature operation, tangent plates are utilized to allow for differential expansion.

CLOSURES & SEALS

Ends of drum may be enclosed by carbon or alloy steel fabricated end plates or hood With Inlet/outlet chutes and suitable seals

CONTINEOUS FLOW VIBRATING FLUID DRYER-ROASTER COOKER

Fluidization of wet materials such as tea, grated coconut, spices and any Granular / powder is not possible by air alone. The SAKAV VFBD uses a combination of Vibration and a Special Air Distribution plate to effectively fluidize such materials.

Compact design of the SAKAV VFBD enables single pass drying, making it an ideal and fuel efficient drying equipment.

SAILENT FEATURES

Robust design / Long life Hygienic construction Minimum space requirement Suits any heater / fuel Easy to operate

MACHINE DESCRIPTION :-

The Machine consist of a Vibratory Conveyor over which is moulded either a gas fired infra red manifold. or an electrical manifold, or any other HotAir Media, steam, Gas etc. The material is fed onto the vibratory conveyor from a feed vibrator controlled by a rheostat. As the material pass under the infra-red burners they are subjected to a continuous vibration in order to turn the material over many times. This enables all the material to receive an equal amount of of infra-red burners can be varied so that the material can be dried, roasted or for various periods, in order that the materials may reach an internal temperature. The hot material are then immediately elevated into an insulated maturing holding bin. where they continue to cook with their own residual heat, for predetermined periods which can be varied as desired. Depending on the final reduction of moisture.

A measured quantity of material is fed onto a specially designed stainless steel perforated vibrating plate mounted on an aerodynamically designed plenum chamber. The entire assembly of plenum chamber and perforated plate is suspended on spring and vithrealed with electric Balanced Meter. Hot air from the heat source is sucked in and forced through the plenum chamber by a hot air blower.

The plant is complete with feed hopper, electrical control, cooler, insulated maturing holding bind, cooling fan. cyclone and airtrunking.

GAS FIRED INFRA RED BURNERS AVAILABLE.

OUTPUT :-

Output from 25 Kgs. / Hr. to 2 Tones / Hr. Heating Capacity varies from machine to machine depending material, Drying Time & etc.

CONSTRUCTION :-

All parts in contact with the product are in Stainless Steel constructions. The entire vibrating bed assembly is encased in a rugged self-supporting casing of channel frame construction

ADVANTAGES :

In ordinary Tray Dryer, heat passes through longer distance whereas in Fluid Bed Dryers the heat passes through floating material and vapor diffuses through a small distance, due to this the material dries very fast.

As the temperature through the Fluid Bed Dryer is uniform there is uniformity in drying of the materials, which in turn helps to achieve higher production as compared to other Dryers.

In Fluid Bed Dryer, the material comes in close contact with the drying air at low temperature and for a short period and hence there are less chances of the physical and chemical properties of the products/materials changing during the process of drying as compared to Tray Dryer where the material is not in close contact with the Drying Air.

In Fluid Bed dryer, the product / materials are kept in one container and this saves time, labor, cleaning, loading and Unloading, which is not in Tray Dryer.

The floor space required in Fluid Bed Dryer is less as compared to Tray Dryer.

In Fluid Bed Dryer, three times more production can be given within a specified period than in a Tray Dryer

SPECIFICATIONPRODUCT CONTAINER TROLLEY :

Fabricated out of heavy gauge Stainless Steel and provided with glass window. The base of the container is fitted with a specially designed plate of Sandwich Type construction and shall be air tight. This maintains even distribution of drying air and uniformity in drying.

HEATING :

The Fluid Bed Dryer can be heated either by electrically or by steam. Steam Units will be provided with Heat Exchanger and Electrical Units will be provided with Open Type Heating Elements.

PRODUCT FILTER :

This is fabricated of Fabric Cloth and can be easily fitted in the Dryer and can be removed as well whenever required for laundering conveniently.

CONTROLS :

All the main controls have been fitted together in a separate Control Box in front side of the Dryer. The Starter for Fan Motor and other electrical instruments shall be fitted in the Control Box.

Steam heated models shall be provided with solenoid valves for Temperature Control.

'SAKAV' is involved in continuous innovative developments to incorporate the latest technology. As such Specifications are subject to change without notice.

ROTARY ATOMISER

SAKAV with its in-house design capabilities ha built and supplied a range of Rotary Disc Atomizer. These are belt driven units with standard electrical motors. A number of models are available with wheel diameters of 100mm to 350mm and are suitable for capacities from 5 lit/hr to 10, 000 lit/hr Various configurations such as orifice, pin, vane with stainless steel and ceramic wear parts are available. A variety of lubrication systems starting from continuous drip to fully automatic forced lubrication systems can be provided. Speed variations are achieved by changed pulleys or variable frequency drivers.

TEST FACILITY

Fully equipped dedicated Pilot Spray Dryers are available for conducting trials on customers samples and simulation of ideal drying parameters for individual products. Assessment of their physical properties such as moisture content, approximate particle size distribution and bulk density. Testing is an on-going process and SAKAV has, over the years, built-up a large data base for a wide variety of products.

THE CHAMBER OPTIONS

The chamber configuration plays an important part in meeting the end product requirements. As is apparent from the table there is an endless number of possible combination. Some of these have been depicted below.

FLAT ROOF

This is the most widely used configuration of spray chamber with flat roof construction. Co-current swirling air flow pattern is used in conjunction with centrifugal atomization. Generally used for producing a uniform fine powder. Dry powder can be collected partly under the chamber and the fines from the cyclone. Alternatively a single point collection under the cyclone can be provided. Can be adapted for nozzle atomization with an add-on air distributor.

TALL FORM - BUSTLE

The standard Tall Form Bustle construction with co-current linearized air flow pattern is sued with pressure nozzle atomization systems. The dry product is usually coarser than centrifugal disc atomized product. The bustle construction enables separation of coarse fraction below the chamber and the fines can be collected from the cyclone. This configuration is deal where fines recycle is used for product agglomeration.

TWO STAGE

A configuration consisting of Tall Form Spray Chamber with a second stage Fluid Bed Dryer is used for special applications. This configuration is used for products requiring longer drying times which cannot be provided in Spray Chamber. This occurs when a coarse product has to be dried to a very low moisture content or when the product to be dried is hygroscopic in nature.

A DECADE OF EXPERIENCE

SAKAV, established in 1985, has developed and supplied a wide range of SPRAY DRYING SYSTEMS to the Chemicals, Dyestuffs, Ceramics, Food, Polymers and Pharmaceutical Industries in India and Abroad. With its vast specializes experience, resources and innovative technical know-how, SAKAV offers the most appropriate systems for all Spray Drying requirements designed and delivered by Sakav incorporate practically every conceivable combination of system components to meet a variety of product requirements.

THE SPRAY DRYING OPTION

A spray drying system employs a single process to convert a solution/slurry into a powder.

The liquid is atomized, in a specially designed Drying Chamber, into a stream of hot air to evaporate the solvent. The dry powder is then separated from the air stream. Sakav custom designs a system to suit the product quality, feed conditions, heating source available and the local environment norms.

The chamber geometry, spray pattern and the air flow distribution have a decisive influence on the product characteristics.

Each system is a harmonious combination of individual process sections of Air Heating, Feeding, Atomization, Powder Collection and Dust Separation. The wide variation of combinations handled by SAKAV are given in the table below -

ROTARY ATOMISER

SAKAV with its in-house design capabilities ha built and supplied a range of Rotary Disc Atomizer. These are belt driven units with standard electrical motors. A number of models are available with wheel diameters of 100mm to 350mm and are suitable for capacities from 5 lit/hr to 10, 000 lit/hr Various configurations such as orifice, pin, vane with stainless steel and ceramic wear parts are available. A variety of lubrication systems starting from continuous drip to fully automatic forced lubrication systems can be provided. Speed variations are achieved by changed pulleys or variable frequency drivers.

TEST FACILITY

Fully equipped dedicated Pilot Spray Dryers are available for conducting trials on customers samples and simulation of ideal drying parameters for individual products. Assessment of their physical properties such as moisture content, approximate particle size distribution and bulk density. Testing is an on-going process and SAKAV has, over the years, built-up a large data base for a wide variety of products.

THE CHAMBER OPTIONS

The chamber configuration plays an important part in meeting the end product requirements. As is apparent from the table there is an endless number of possible combination. Some of these have been depicted below.

FLAT ROOF

This is the most widely used configuration of spray chamber with flat roof construction. Co-current swirling air flow pattern is used in conjunction with centrifugal atomization. Generally used for producing a uniform fine powder. Dry powder can be collected partly under the chamber and the fines from the cyclone. Alternatively a single point collection under the cyclone can be provided. Can be adapted for nozzle atomization with an add-on air distributor.

TALL FORM - BUSTLE

The standard Tall Form Bustle construction with co-current linearized air flow pattern is sued with pressure nozzle atomization systems. The dry product is usually coarser than centrifugal disc atomized product. The bustle construction enables separation of coarse fraction below the chamber and the fines can be collected from the cyclone. This configuration is deal where fines recycle is used for product agglomeration.

TWO STAGE

A configuration consisting of Tall Form Spray Chamber with a second stage Fluid Bed Dryer is used for special applications. This configuration is used for products requiring longer drying times which cannot be provided in Spray Chamber. This occurs when a coarse product has to be dried to a very low moisture content or when the product to be dried is hygroscopic in nature

The Sakav steam heated Drum Dryer is noted for its high thermal efficiency in the removal of water andor solvents from a wide range of solutions, slurries and suspensions. The ratio of steam consumption to evaporation can be as low as 1.2:1 and seldom more than 1.5:1, Cast iron or stainless steel clad cast iron with pneumatic operation as standard.

SYSTEM : The Sakav steam heated Drum Dryer is noted for its high thermal efficiency in the removal of water and/or solvents from a wide range of solutions, slurries and suspensions. The ratio of steam consumption to evaporation can be as low as 1.2:1 and seldom more than 1.5:1

CONSTRUCTION MAIN FRAMES : Heavy duty cast iron or fabricated carbon steel construction. DRYING DRUMS : High engineering hard chrome plate or hard cast iron, stainless steel or custom alloys. KNIFE BARS : Cast iron or stainless steel clad cast iron with pneumatic operation as standard. (Oscillating knife mechanisms optional). KNIVES : Sheffield steel, special stainless steel, Teflon, or stainless steel blade holders tipped with beryllium bronze for custom applications. DAM PLATES : Provided where necessary, faced with Teflon or similar. DRUM DRIVES : Fixed or variable speed. Safety gear : (Twin Drum) Spring loaded. ENCLOSURES : Vapor extraction hood, total, dust tight or nitrogen atmosphere capable. VACUUM CASING : Plain or steam jacketed. STANDARD AUXILIARIES : Side and cross conveyors, traversing feed gear, automatic feed control, product brakers. Applications : Milk products, baby foods, breakfast cereals, fruit and vegetable pulps, starches, spent yeast, chemicals, biologicals.

Batch Type Dryers uses a perforated belt to transfer feed materials through the dryer. Heated air is either passed under and through, or over and through the belt and product bed before being reheated and re-circulated. Units are normally multi zoned and may have differing airflow's in successive zones. Additionally each zone may use a different temperature profile and control. Saturated or close to saturated air is exhausted from the dryer via a central exhaust duct.

Batch Type Dryers may be multi pass units, in which the feed is transferred from one belt to another belt below it by gravity. These dryers are usually two or three pass machines. Additionally certain conveyor dryers, such as those used in vegetable dehydration have multiple belts in line, and the feed is transferred from one belt to another.

Feeding / discharge Manual, batch, automatic and continuous. Vibrators, oscillating feeders, gravity chutes Feed Characteristics Large granules, agglomerates, pellets, preformed (extruded) products (pressure agglomerates), small solid particles, large solid particles, agricultural products. Low to high feed rates

Heat Source Steam, electrical, coal, liquid fuels, or gas Exposure Mostly Direct. Flow can be through the bed (under to over, over to under, or both), cross, counter current or co-current. Indirect systems available for certain products. Residence time Highly Controllable. Residence time can be altered by varying the feed and discharge rates affecting the bed depth. Belt can be slowed and modulated.

Extraction Normally central induced. Re-circulating fans used in each zone.Exhaust connected to common headerDust CollectionTypically little required. For fine product a central bag house is sometimes used.

Control PLC control for each zone, infrequently solid state controllers.System controls on above bed temperature. Can modulate energy.

Benefits

• Very intimate contact with air/gas stream
• Good for heat sensitive products and products requiring long residence times
• Energy efficient due to recycling of process air Multiple zones offer flexibility for temperature and process control
• Excellent transfer of energy
• Can vary flows between zones
• Gentle handling of product
• Self contained with distributed foundation loading
• Unit can have integral cooling section.

Limitations

• High temperature units can be troublesome
• Heater can clog on carryover
• Belt tracking can be problematic
• Belt may clog, requires frequent cleaning
• Loss of fimes through perforations on flights or belt.

Gas, Electric, Steam And Hot Water Dryers. Batch Type And Conveyor Dryers.

Ideal for shelf processing applications such as Drying, Dehydrating, Pre-heating or any other heat processing of large or numerous parts at 1500C

Applications

The SAKAV Dryer has been developed to offer an economical answer to a wide range of applications like

Vacuum Shelf dryers provide rapid drying of heat sensitive, air-sensitive & pyrophoric materials, or materials that require drying without agitation. Heat sensitive materials can be dried at low temperatures under vacuum, since the environmental pressure is reduced below the vapour-pressure of the contained water or solvents. Oxidation or Contamination by Air is eliminated. Recovery of expensive solvents can be virtually complete. Hollow Fibers, Medical Devices, Chemical Salts, Fine Chemicals, Dyes, Glandular Products, Pharmaceuticals and Food Extracts (Gluten, Glues, Pepsin), Rubber Explosive, etc. are ideally suited for drying in this manner.

Environment

Principally, Drying under vacuum is environmentally friendly because the Evaporated Solvents can easily be re-condensed. These solvents can then either be recycled or disposed of without any problem.

Drying of solvents in Ex-proof ovens may solve the safety problem in the oven but not the environmental aspect. The solvent vapour is blown out of the oven through the exhaust system Furthermore, there is a risk of uncontrolled mixture formation.

Features :

• A major design feature incorporated in this series of vacuum dryers is the placement of all shelf and manifold connection outside of the chamber, avoiding the possibility that leaks might develop within a chamber and contaminate the product being dried. This feature also simplifies the maintenance of these connection by making access to them more convenient.
• Charge temperature measuring facility provides exact picture of the process. It measures the temperature directly at charge (material). A PT-100 Temp. Sensor enters the vacuum chamber via connection at the top Rear.
• "SANDWICH" Type High Thermal efficiency Stainless Steel Shelves with the heat transfer fluid circulation. Even heat distribution through whole shelf surface by baffles within shelves.
• Chamber walls are heated externally to prevent condensation on the internal walls.
• Rounded edges in walls shelves and product trays in order to facilitate cleaning and prevent accumulation of dry product residue and practical formation

Steam Tube Dryers

The Sakav Steam Tube Dryer was developed to dry high moisture organic by-products such as brewer's and distiller's spent grain. Today, this dryer serves thousands of applications, drying and processing inorganic and organic chemicals and other bulk solid materials.

The steam tube dryer generally operates at a lower temperature than other dryers and rotates at a slower speed. Material tumbles gently around the tubes which rotate with the shell, unlike the friction forces required by other types of dryers to process material. Consequently, it enjoys a longer life than most dryers and requires very little maintenance. Sakav Steam Tube Dryers have proved superior to other types of indirect-heat dryer installations in which hot gas, rather than steam, is used as the heat source. Maintenance savings alone have often prompted replacement of other dryer systems with the Steam Tube Dryer

The Sakav Continuous Seal Steam Tube Dryer offers tremendous advantages for solvent extraction or drying in an inert gas atmosphere. The CS unit's revolutionary design permits material to be processed in a positive or negative pressure atmosphere and alleviates product and gas leakage into or out of the dryer.

The dryer is operated as a counterflow unit. Air moves in the opposite direction of material flow. Sweep gas flow is used only to exhaust vapor and other gases created by the heating process, not to dry material.

Low sweep gas velocity through the dryer vastly reduces the amount of product entrained in the exhaust stream.

During solvent extraction, this not only means significant savings in the size and cost of recovery equipment, but simplifies dust collection requirements and reduces the cost of equipment required to handle the task.

ROTARY CASCADE AND ROTARY LOUVRE DRYER AND COOLER

1500 KGS.lHR. BONE MEAL COCURRENT ROTARY DRYER

SAKAV DRYERS handle all types of materials. Recognising that virtually every drying application is unique. Each Rotary Cascade Dryer is purposely designed to meet specific matenal characteristics by analysing the client's process requirement. the correct design solution is assessed & selected by.

Designed for Bulk drying of:

Minerals Metal Ores - Fertilisers Foodstuff - Chemicals -Industrial & Domestic waste.

WIDE RANGE OFF GRANULAR MATERIAL

• Aggregates' Aluminium Oxide' Ammonium nitrate' Ammonium sulphate' Andalousite
• Animal manure
• Barium Carbonate' Basic Slag' Bauxite' Benlonil - Blanose
• Bone meal
• Bone Powder' Borates
• Calcium Chloride' Carbon Black pellets' Cement Raw meals' Chicken waste' Chrome Ore' Citric Acid
• Clay earth' Clays' Coal' Cobalt oxide' Coke Breeze
• Copper Concentrates' Copper Lead tin alloy Copper Slag Copper Sulphate' Copper wastes
• Cotton seed' Crushed Glass' Crushed Marble' Crystals' Dextrose monohydrate' Dicalcium Phosphate' Egg shell' Feldspar- Ferrile
• Ferronickel
• Fertilisers
• Flint Chips' Garbage wastes Gypsum' Gypsum' Heamatite
• Herbicides' Herbicides' Ilmenite' Industrial wastes' Kaolin
• Lardstone
• Limestone' Maqnesiurn Sulphate' Maize germs' Montmorillonite clay Nickel
• Oily chlorate' Potassium Nitrate' PPT Silica' Quartz' Rawa
• Refractories' Rock Phosphate
• Rubber' Salt Sand' Sludges' Sodium Chloride' Sodium monoglutamate
• Spath fluor' Sugar
• Talc' Titanium Dioxide' Titanium oxide
• Urea' Wine tarter' zince oxide.

FEATURESHIGH AUTOMATION LOW MAINTENANCE CONTINUOUS OPERATION LOW OPERATING COST

OPERATING TEMPERATURE :- 60C to 1OOOC.

CAPACITY :- 5 TPD TO 150 TPD

SIZE & MOISTURE :- Capable of Handling different product particle size & moisturecontent.

SYSTEM

Drying / cooling is achieved by passing the material to be processed through a rotating cylinder through which also passes a current of tempered air. Lifters/flights or louvres in the case of rotary louvre dryer, are fitted to the Internal surface of the cylinder to give intimate contact between product and drying or cooling air stream. In Rotary Louvre dryers the material IS not lifted and dropped through the drying air stream, therefore less product breakdown occurs. Rotary Louvre dryers can also be arranged for multi-stage drying, or drying and cooling in one Unit.

DRYER PRINCIPLE

Co-current Flow Rotary Cascade Dryers, sticky and heat sensitive materials, since the wet material IS exposed to the highest temperature gases, the initial heat transfer rate is very high, rapidly evaporating surface moisture. The Immediate and dramatic fall in gas temperature prevents a sudden Increase in the matenal and shell temperatures. The final product is in contact with the lower temperature gases enabling the moisture content to be readily controlled thereby avoidrnq over-drying. Counter-Current Flow drying in a Rotary Cascade Dryer gives lower product moisture than co-current flow for a given inlet temperature. However, its use with heatsensitive rnatenals IS limited since the dryed product comes into contact with the heating medium at its highest temperature. It is suitable for application where an extremely low moisture content is required or where a higher product temperature is anadvantage.

HEATING MEDIUM

Gas. Diesel, oil, electric, stream. The drying gas are provided from either a direct fired furnace or an indirect heat exchanger within the range 100 to 1000 C using solid, gaseous or liquid fuel. Only products of combustion or indirectly heated gases enter the Rotary Cascade Dryer. This prevents surface contamination while reducing the risk of damage or fire when handeling more sensitive materials. A two fan balanced draught system IS used to provide the maximum degree of control & flexibility. In arrangements and the drying gases are provided by a locally mounted burner projecting the flame down the centre of the dryer through which the material cascades. This design gives even greater thermal efficiency due to the higher temperature differential, the direct flame contact and the radiation effect, when processing materials which can withstand high gas temperatures without deterioration.

CONSTRUCTION

Carbon, Stainless or custom alloy steel plate, with external reinforcing bands for fitting of tyres and drive rings. Flights and lifters or louvres are welded or bolted internally. Confifuration is determined by application.

DRIVE

Drum is rotated by an electric motor through V-belts, gearbox, pinion and either heavy duty chain to a chainwheel or spur gear drive ring bolted around the dryer drum. For high temperature operation, tangent plates are utilized to allow for differential expansion.

CLOSURES & SEALS

Ends of drum may be enclosed by carbon or alloy steel fabricated end plates or hood With Inlet/outlet chutes and suitable seals

CONTINEOUS FLOW VIBRATING FLUID DRYER-ROASTER COOKER

Fluidization of wet materials such as tea, grated coconut, spices and any Granular / powder is not possible by air alone. The SAKAV VFBD uses a combination of Vibration and a Special Air Distribution plate to effectively fluidize such materials.

Compact design of the SAKAV VFBD enables single pass drying, making it an ideal and fuel efficient drying equipment.

SAILENT FEATURES

Robust design / Long life Hygienic construction Minimum space requirement Suits any heater / fuel Easy to operate

MACHINE DESCRIPTION :-

The Machine consist of a Vibratory Conveyor over which is moulded either a gas fired infra red manifold. or an electrical manifold, or any other HotAir Media, steam, Gas etc. The material is fed onto the vibratory conveyor from a feed vibrator controlled by a rheostat. As the material pass under the infra-red burners they are subjected to a continuous vibration in order to turn the material over many times. This enables all the material to receive an equal amount of of infra-red burners can be varied so that the material can be dried, roasted or for various periods, in order that the materials may reach an internal temperature. The hot material are then immediately elevated into an insulated maturing holding bin. where they continue to cook with their own residual heat, for predetermined periods which can be varied as desired. Depending on the final reduction of moisture.

A measured quantity of material is fed onto a specially designed stainless steel perforated vibrating plate mounted on an aerodynamically designed plenum chamber. The entire assembly of plenum chamber and perforated plate is suspended on spring and vithrealed with electric Balanced Meter. Hot air from the heat source is sucked in and forced through the plenum chamber by a hot air blower.

The plant is complete with feed hopper, electrical control, cooler, insulated maturing holding bind, cooling fan. cyclone and airtrunking.

GAS FIRED INFRA RED BURNERS AVAILABLE.

OUTPUT :-

Output from 25 Kgs. / Hr. to 2 Tones / Hr. Heating Capacity varies from machine to machine depending material, Drying Time & etc.

CONSTRUCTION :-

All parts in contact with the product are in Stainless Steel constructions. The entire vibrating bed assembly is encased in a rugged self-supporting casing of channel frame construction

ADVANTAGES :

In ordinary Tray Dryer, heat passes through longer distance whereas in Fluid Bed Dryers the heat passes through floating material and vapor diffuses through a small distance, due to this the material dries very fast.

As the temperature through the Fluid Bed Dryer is uniform there is uniformity in drying of the materials, which in turn helps to achieve higher production as compared to other Dryers.

In Fluid Bed Dryer, the material comes in close contact with the drying air at low temperature and for a short period and hence there are less chances of the physical and chemical properties of the products/materials changing during the process of drying as compared to Tray Dryer where the material is not in close contact with the Drying Air.

In Fluid Bed dryer, the product / materials are kept in one container and this saves time, labor, cleaning, loading and Unloading, which is not in Tray Dryer.

The floor space required in Fluid Bed Dryer is less as compared to Tray Dryer.

In Fluid Bed Dryer, three times more production can be given within a specified period than in a Tray Dryer

SPECIFICATIONPRODUCT CONTAINER TROLLEY :

Fabricated out of heavy gauge Stainless Steel and provided with glass window. The base of the container is fitted with a specially designed plate of Sandwich Type construction and shall be air tight. This maintains even distribution of drying air and uniformity in drying.

HEATING :

The Fluid Bed Dryer can be heated either by electrically or by steam. Steam Units will be provided with Heat Exchanger and Electrical Units will be provided with Open Type Heating Elements.

PRODUCT FILTER :

This is fabricated of Fabric Cloth and can be easily fitted in the Dryer and can be removed as well whenever required for laundering conveniently.

CONTROLS :

All the main controls have been fitted together in a separate Control Box in front side of the Dryer. The Starter for Fan Motor and other electrical instruments shall be fitted in the Control Box.

Steam heated models shall be provided with solenoid valves for Temperature Control.

'SAKAV' is involved in continuous innovative developments to incorporate the latest technology. As such Specifications are subject to change without notice.

ROTARY ATOMISER

SAKAV with its in-house design capabilities ha built and supplied a range of Rotary Disc Atomizer. These are belt driven units with standard electrical motors. A number of models are available with wheel diameters of 100mm to 350mm and are suitable for capacities from 5 lit/hr to 10, 000 lit/hr Various configurations such as orifice, pin, vane with stainless steel and ceramic wear parts are available. A variety of lubrication systems starting from continuous drip to fully automatic forced lubrication systems can be provided. Speed variations are achieved by changed pulleys or variable frequency drivers.

TEST FACILITY

Fully equipped dedicated Pilot Spray Dryers are available for conducting trials on customers samples and simulation of ideal drying parameters for individual products. Assessment of their physical properties such as moisture content, approximate particle size distribution and bulk density. Testing is an on-going process and SAKAV has, over the years, built-up a large data base for a wide variety of products.

THE CHAMBER OPTIONS

The chamber configuration plays an important part in meeting the end product requirements. As is apparent from the table there is an endless number of possible combination. Some of these have been depicted below.

FLAT ROOF

This is the most widely used configuration of spray chamber with flat roof construction. Co-current swirling air flow pattern is used in conjunction with centrifugal atomization. Generally used for producing a uniform fine powder. Dry powder can be collected partly under the chamber and the fines from the cyclone. Alternatively a single point collection under the cyclone can be provided. Can be adapted for nozzle atomization with an add-on air distributor.

TALL FORM - BUSTLE

The standard Tall Form Bustle construction with co-current linearized air flow pattern is sued with pressure nozzle atomization systems. The dry product is usually coarser than centrifugal disc atomized product. The bustle construction enables separation of coarse fraction below the chamber and the fines can be collected from the cyclone. This configuration is deal where fines recycle is used for product agglomeration.

TWO STAGE

A configuration consisting of Tall Form Spray Chamber with a second stage Fluid Bed Dryer is used for special applications. This configuration is used for products requiring longer drying times which cannot be provided in Spray Chamber. This occurs when a coarse product has to be dried to a very low moisture content or when the product to be dried is hygroscopic in nature.

A DECADE OF EXPERIENCE

SAKAV, established in 1985, has developed and supplied a wide range of SPRAY DRYING SYSTEMS to the Chemicals, Dyestuffs, Ceramics, Food, Polymers and Pharmaceutical Industries in India and Abroad. With its vast specializes experience, resources and innovative technical know-how, SAKAV offers the most appropriate systems for all Spray Drying requirements designed and delivered by Sakav incorporate practically every conceivable combination of system components to meet a variety of product requirements.

THE SPRAY DRYING OPTION

A spray drying system employs a single process to convert a solution/slurry into a powder.

The liquid is atomized, in a specially designed Drying Chamber, into a stream of hot air to evaporate the solvent. The dry powder is then separated from the air stream. Sakav custom designs a system to suit the product quality, feed conditions, heating source available and the local environment norms.

The chamber geometry, spray pattern and the air flow distribution have a decisive influence on the product characteristics.

Each system is a harmonious combination of individual process sections of Air Heating, Feeding, Atomization, Powder Collection and Dust Separation. The wide variation of combinations handled by SAKAV are given in the table below -

ROTARY ATOMISER

SAKAV with its in-house design capabilities ha built and supplied a range of Rotary Disc Atomizer. These are belt driven units with standard electrical motors. A number of models are available with wheel diameters of 100mm to 350mm and are suitable for capacities from 5 lit/hr to 10, 000 lit/hr Various configurations such as orifice, pin, vane with stainless steel and ceramic wear parts are available. A variety of lubrication systems starting from continuous drip to fully automatic forced lubrication systems can be provided. Speed variations are achieved by changed pulleys or variable frequency drivers.

TEST FACILITY

Fully equipped dedicated Pilot Spray Dryers are available for conducting trials on customers samples and simulation of ideal drying parameters for individual products. Assessment of their physical properties such as moisture content, approximate particle size distribution and bulk density. Testing is an on-going process and SAKAV has, over the years, built-up a large data base for a wide variety of products.

THE CHAMBER OPTIONS

The chamber configuration plays an important part in meeting the end product requirements. As is apparent from the table there is an endless number of possible combination. Some of these have been depicted below.

FLAT ROOF

This is the most widely used configuration of spray chamber with flat roof construction. Co-current swirling air flow pattern is used in conjunction with centrifugal atomization. Generally used for producing a uniform fine powder. Dry powder can be collected partly under the chamber and the fines from the cyclone. Alternatively a single point collection under the cyclone can be provided. Can be adapted for nozzle atomization with an add-on air distributor.

TALL FORM - BUSTLE

The standard Tall Form Bustle construction with co-current linearized air flow pattern is sued with pressure nozzle atomization systems. The dry product is usually coarser than centrifugal disc atomized product. The bustle construction enables separation of coarse fraction below the chamber and the fines can be collected from the cyclone. This configuration is deal where fines recycle is used for product agglomeration.

TWO STAGE

A configuration consisting of Tall Form Spray Chamber with a second stage Fluid Bed Dryer is used for special applications. This configuration is used for products requiring longer drying times which cannot be provided in Spray Chamber. This occurs when a coarse product has to be dried to a very low moisture content or when the product to be dried is hygroscopic in nature

The Sakav steam heated Drum Dryer is noted for its high thermal efficiency in the removal of water andor solvents from a wide range of solutions, slurries and suspensions. The ratio of steam consumption to evaporation can be as low as 1.2:1 and seldom more than 1.5:1, Cast iron or stainless steel clad cast iron with pneumatic operation as standard.

SYSTEM : The Sakav steam heated Drum Dryer is noted for its high thermal efficiency in the removal of water and/or solvents from a wide range of solutions, slurries and suspensions. The ratio of steam consumption to evaporation can be as low as 1.2:1 and seldom more than 1.5:1

CONSTRUCTION MAIN FRAMES : Heavy duty cast iron or fabricated carbon steel construction. DRYING DRUMS : High engineering hard chrome plate or hard cast iron, stainless steel or custom alloys. KNIFE BARS : Cast iron or stainless steel clad cast iron with pneumatic operation as standard. (Oscillating knife mechanisms optional). KNIVES : Sheffield steel, special stainless steel, Teflon, or stainless steel blade holders tipped with beryllium bronze for custom applications. DAM PLATES : Provided where necessary, faced with Teflon or similar. DRUM DRIVES : Fixed or variable speed. Safety gear : (Twin Drum) Spring loaded. ENCLOSURES : Vapor extraction hood, total, dust tight or nitrogen atmosphere capable. VACUUM CASING : Plain or steam jacketed. STANDARD AUXILIARIES : Side and cross conveyors, traversing feed gear, automatic feed control, product brakers. Applications : Milk products, baby foods, breakfast cereals, fruit and vegetable pulps, starches, spent yeast, chemicals, biologicals.

Batch Type Dryers uses a perforated belt to transfer feed materials through the dryer. Heated air is either passed under and through, or over and through the belt and product bed before being reheated and re-circulated. Units are normally multi zoned and may have differing airflow's in successive zones. Additionally each zone may use a different temperature profile and control. Saturated or close to saturated air is exhausted from the dryer via a central exhaust duct.

Batch Type Dryers may be multi pass units, in which the feed is transferred from one belt to another belt below it by gravity. These dryers are usually two or three pass machines. Additionally certain conveyor dryers, such as those used in vegetable dehydration have multiple belts in line, and the feed is transferred from one belt to another.

Feeding / discharge Manual, batch, automatic and continuous. Vibrators, oscillating feeders, gravity chutes Feed Characteristics Large granules, agglomerates, pellets, preformed (extruded) products (pressure agglomerates), small solid particles, large solid particles, agricultural products. Low to high feed rates

Heat Source Steam, electrical, coal, liquid fuels, or gas Exposure Mostly Direct. Flow can be through the bed (under to over, over to under, or both), cross, counter current or co-current. Indirect systems available for certain products. Residence time Highly Controllable. Residence time can be altered by varying the feed and discharge rates affecting the bed depth. Belt can be slowed and modulated.

Extraction Normally central induced. Re-circulating fans used in each zone.Exhaust connected to common headerDust CollectionTypically little required. For fine product a central bag house is sometimes used.

Control PLC control for each zone, infrequently solid state controllers.System controls on above bed temperature. Can modulate energy.

Benefits

• Very intimate contact with air/gas stream
• Good for heat sensitive products and products requiring long residence times
• Energy efficient due to recycling of process air Multiple zones offer flexibility for temperature and process control
• Excellent transfer of energy
• Can vary flows between zones
• Gentle handling of product
• Self contained with distributed foundation loading
• Unit can have integral cooling section.

Limitations

• High temperature units can be troublesome
• Heater can clog on carryover
• Belt tracking can be problematic
• Belt may clog, requires frequent cleaning
• Loss of fimes through perforations on flights or belt.

Gas, Electric, Steam And Hot Water Dryers. Batch Type And Conveyor Dryers.

Ideal for shelf processing applications such as Drying, Dehydrating, Pre-heating or any other heat processing of large or numerous parts at 1500C

Applications

The SAKAV Dryer has been developed to offer an economical answer to a wide range of applications like

Vacuum Shelf dryers provide rapid drying of heat sensitive, air-sensitive & pyrophoric materials, or materials that require drying without agitation. Heat sensitive materials can be dried at low temperatures under vacuum, since the environmental pressure is reduced below the vapour-pressure of the contained water or solvents. Oxidation or Contamination by Air is eliminated. Recovery of expensive solvents can be virtually complete. Hollow Fibers, Medical Devices, Chemical Salts, Fine Chemicals, Dyes, Glandular Products, Pharmaceuticals and Food Extracts (Gluten, Glues, Pepsin), Rubber Explosive, etc. are ideally suited for drying in this manner.

Environment

Principally, Drying under vacuum is environmentally friendly because the Evaporated Solvents can easily be re-condensed. These solvents can then either be recycled or disposed of without any problem.

Drying of solvents in Ex-proof ovens may solve the safety problem in the oven but not the environmental aspect. The solvent vapour is blown out of the oven through the exhaust system Furthermore, there is a risk of uncontrolled mixture formation.

Features :

• A major design feature incorporated in this series of vacuum dryers is the placement of all shelf and manifold connection outside of the chamber, avoiding the possibility that leaks might develop within a chamber and contaminate the product being dried. This feature also simplifies the maintenance of these connection by making access to them more convenient.
• Charge temperature measuring facility provides exact picture of the process. It measures the temperature directly at charge (material). A PT-100 Temp. Sensor enters the vacuum chamber via connection at the top Rear.
• "SANDWICH" Type High Thermal efficiency Stainless Steel Shelves with the heat transfer fluid circulation. Even heat distribution through whole shelf surface by baffles within shelves.
• Chamber walls are heated externally to prevent condensation on the internal walls.
• Rounded edges in walls shelves and product trays in order to facilitate cleaning and prevent accumulation of dry product residue and practical formation