Integration of a heat recovery system in a Spray Drying Process : Model Simulation Analysis and Economic Feasibility

The spray drying process is widely established in the industry worldwide. However, due to its complexity in predicting variables, the technology is often regarded as a "Black box" process. In this study, a model based on energy and mass balances is designed and validated using Matlab/Simulink software and real data from a medium-sized machinery, specifically the Production Minor manufactured by GEA NIRO S/A. Additionally, the simulation incorporates a heat recovery system based on a heat pump, and its economic feasibility is examined.The simulation is validated for a narrow range of variables and demonstrates an accuracy of approximately 95% in most cases.The heat recovery system achieves an average natural gas savings of 0.43 kg/h. However, this saving is accompanied by an additional electrical consumption of 2.1 kW resulting from the operation of the heat pump.The economic feasibility study of the heat recovery system reveals an extra production cost of 0.1€/h in exchange for a 36% average reduction in natural gas dependency.