GEA drying and particle formation technologies for the world’s chemical industry 2 · CHEMICAL INDUSTRY Content 4 The right process for your product 23 Flash dryer types 6 The intelligence behind your process 24 Ring dryer 7 From conception to completion 25 SWIRL FLUIDIZER™ 8 The right technology for your product 26 Your rotary processing solution 10 Your spray drying solution 27 Rotary types 12 World-class system design 28 Rotary drying, cooling, calcining and conditioning 13 Spray dryer chamber designs 29 Contact column processors 14 The heart of your spray drying plant 30 Spray congealing – turn melt into powder 16 Your fluid bed drying solution 31 Spray dryer reactor – create chemical reactions 18 Fluid bed process systems 32 Complete efficiency and control 19 Fluid bed types 33 Stay productive, protected and compliant 20 Fluid bed – key features 34 Your project is in safe hands 22 Your flash drying solution 35 GEA Service – for your continued success WHATEVER YOUR NEEDS, GEA IS PERFECTLY PLACED TO HELP. CHEMICAL INDUSTRY · 3 GEA has provided world-class industrial drying solutions since 1928 that enable businesses like yours to stay competitive, profitable and at the forefront of their industry. Grow alongside your customers Breathe life into your product We understand that a successful business relies on its ability With GEA as your partner, our vast pool of drying knowledge, to adapt quickly to evolving market conditions. That’s why we expertise and technology is entirely at your disposal. Together, specialize in creating highly versatile drying solutions, calibrated we can bring your ideas to life with high quality powders engi- for your applications, with the flexibility and scalability to meet neered with your specific properties and precise characteristics. your customers’ demands. Whether it is expert advice on starting a new project, a more As the world’s leading powder engineering specialists, we are efficient process, plant upgrades, an entirely new installation or uniquely placed to help you develop a highly efficient process even innovative ways to save energy and reduce your environ- and a flawless end-product. Your success is our success; we are mental footprint, GEA has your ideal drying solution. here to support you with a dedicated service designed to grow your business and your bottom line. 4 · CHEMICAL INDUSTRY The right process for your product With the most advanced portfolio of drying technologies and the world’s best engineering minds focused on supporting your success, GEA helps you to make the most of new opportunities across a full spectrum of products. Nano materials Polymers When you need to get small Our leading range of atomizing technologies enables you to dry Nano particles into agglomerates with a low energy footprint and with full product, operator and environmental safety. • Inorganic nano material • Organic nano material •Pharmaceuticals Leading experience since 1952 Feedstocks in suspension, emulsion, dispersion or solution, water or solventbased, can be dried efficiently and according to your specifications. • Polymer melts • s-PVC, e-PVC, c-PVC •ABS •MBS •HDPE •PP •POM •PVA •PMMA • PVAc, EVA •PVP • Acrylic resins •Formaldehydes •EPS •PAN •PAM Hardmetals Ceramics Agrochemicals Tannins More than 130 installations Our broad experience means that you benefit from dense and free-flowing powders from different hard metal suspensions produced on a robust automated plant with good solvent recovery. • Tungsten carbides • Ready-to-press (RTP) powders Traditional through to high-tech We match your specifications to deliver a reproducible, free-flowing granulate for single step ceramic pressbody production. •Proppants •Hydroxyapatite •Carbides •Catalysts •Ferrites •Titanates • Al2O3, SiO2, FexOy •Kaolin • Silicium oxide/nitride • Zinc oxide • Zirconium oxide/silicate The broadest range of solutions We fulfill all your powder requirements, including granulometry, low dustiness and re-dispersion characteristics, plus all safety and environmental regulations. •Fungicides •Herbicides •Insecticides •Potash • Phosphate rock • Monoammonium phosphate • Diammonium phosphate • Calcium chloride • Ammonium nitrate • Ammonium sulphate •Urea Preserve tannin activity Create powders and agglomerates that can be easily re-dispersed in water using plants capable of handling a vast range of corrosive or abrasive materials. • Synthetic tannins • Basic chromium salts • Natural extracts • Sulphonated phenol • Chrome tannin • Chestnut, mimosa extract • Myrobalan, quebracho extract • Wattle extract CHEMICAL INDUSTRY · 5 Detergents Lithium batteries Dyestuff & pigments For household and industrial applications Create plain, agglomerated or granulated powders with low dustiness and superior redispersion properties. • Dispersing agents • Emulsifying agents • Chelating agents •Enzymes • Optical brightener •Phosphates •Sulphonates •Silicates • Surface active ingredient From Cathode to Anode Our unique atomization technologies deliver superior powders with uniform characteristics and our atomizing nozzles ensure particle sizes from a few μm to several hundred μm. • Cathode material • Anode material • Ultra-fine powders For a rainbow of colors Whether your feedstocks are in solution, suspension or paste form, our solutions are fully customizable to meet your exact requirements and ensure minimal risk of explosions or environmental pollution. • Acid / azoic dyes • Basic dyes • Disperse dyes • Reactive dyes • Dyestuff intermediates • Related fillers • Barium sulphate • Cadmium carbonate / sulphide • Calcium carbonate • Ceramic colorants • Iron oxide (black, red, yellow) •Kaolin •Lithopone •Phthalocyanines • Titanium dioxide • Zinc chromates Inorganic chemicals Organic chemicals From aluminium to zinc compounds Transform virtually any inorganic compound into a free-flowing product using feedstocks in liquid, suspended crystal or solid form, solutions and slurries of fine crystals, cakes and pastes. •Salts •Minerals •Zeolites •Silicates •Sands From fine crystals to coarse granulates Your feedstocks can be in liquid, suspended crystal or solid form. Solutions and slurries can be dried to free-flowing products or to coarse granulates. Cakes and pastes can also be dried and cooled. • Organic acids • Plant materials •Microorganisms • Waste water drying • Amino and fatty acids •Benzoates •Butyrates •Chloramines •Gluconates •Hydrazines •Phthalates • Purified terephthalic acid •Salicylates • Salicylic acid •Sorbates •Stearates • Bio-based chemicals 6 · CHEMICAL INDUSTRY The intelligence behind your process Whatever your product requirements, the GEA International Test Centers offer the largest and most sophisticated facilities for drying process development. Whether at the first stages of development or the final phases of Our guarantee – your process refinement, our test centers provide the intelligence that brings No matter which industry or market you or your customers your ideas to life. operate in, our International Test Centers exist to give you complete confidence that you have the most appropriate drying The world’s largest testing facility solution for your needs. Made up of over 35 pilot plants, the largest of the GEA International Test Centers houses the most advanced freeze, fluid bed, To show our commitment, we will guarantee that the process flash and spray drying technology available today. we’ve developed is set up in the most effective way to achieve your desired results. We are able to test a huge variety of conditions to make sure your powder is not only possible, but that its production process As every customer, plant and product comes with their own is viable, sustainable and cost effective. unique requirements, we make no assumptions as to how your new powder will behave. Our in-depth analyses cover every possible factor so you can make fully informed decisions regarding your product’s commercial potential. Ultrasonic field Suspended droplet OUR TEST FACILITIES COMPRISE MORE THAN 35 PILOT PLANTS AND HOUSE A COMPLETE RANGE OF ADVANCED AUXILIARY EQUIPMENT. · CHEMICAL INDUSTRY 7 From conception to completion Unique analytical and laboratory capability supports you in your product development. Our testing program includes: • Pilot testing – pilot tests obtain all the necessary data for • Feasibility studies – the first step for every new project is a feasibility study that evaluates whether your product is drying your product and to optimize your production process. able to be dried, agglomerated, extracted, concentrated or We cover all drying techniques to ascertain which gives the whatever you need it to be. If you already have a prototype, best results and fits with your existing capabilities. Our GMP- we can investigate the best ways to recreate it on an approved Pharma Test Station meets all regulatory guidelines industrial scale with the same (or better) characteristics. and is capable of producing samples for clinical trials. • Laboratory analysis – our analytics laboratory is fully • Pre-production analysis – with GEA's DRYING KINETICS ANALYZER™ it is possible to conduct early stage tests using equipped to investigate and allocate your product’s only a few milliliter of material, covering a wide range of characteristics. Key properties can be appraised, such as feed properties and drying parameters. This keep costs and droplet formation and expected behaviour during and after timeframes to a minimum and can be incorporated into the drying process, particle size distribution, bulk density, Computational Fluid Dynamics simulations to optimize your moisture content, photomicroscopic analysis, flowability process design. and hygroscopicity. Moisture DRYNETICS™ ANALYSIS by GEA Time Time Drying chamber • Size and position • Morphology • Temperature profiles • Adhesion/stickiness • Stickiness • Moisture • Deposits • Velocity profiles • Drying kinetics • Temperature 3. CFD simulations 2. Advanced data analysis 1. Single droplet experiments 8 · CHEMICAL INDUSTRY The right technology for your product Decades of engineering experience, first class application Whatever your application, our proprietary drying systems know-how and a passion for innovation have led us to create deliver exceptional results with the reliability and energy efficiency the world’s most complete portfolio of drying technologies. you need to maintain a consistent, profitable operation. TURN LIQUID INTO POWDER, AGGLOMERATES OR GRANULATES Use spray drying to remove the moisture from liquid feedstocks such as solutions, emulsions and pumpable suspensions. This is an ideal approach when your end-product must comply with precise powder properties. TURN WET POWDER INTO DRY POWDER, AGGLOMERATES AND GRANULATES Use fluid bed drying for powders, granules, agglomerates and pellets with an average particle size of 50-5,000 microns. TURN WET SOLIDS OR PASTE INTO POWDER Use flash drying to obtain a fine, homogeneous and non-agglomerated dry product from pastes, filter cakes and highly viscous liquids. TURN WET SOLIDS INTO DRY AGGLOMERATES AND GRANULATES Use rotary dryers, coolers and calciners to dry and cool solids under the toughest conditions. TURN MELT INTO POWDER Use spray congealing to transform melted feedstocks into free-flowing, spherical particulates of a controlled particle size. CREATE CHEMICAL REACTIONS Spray drying can be used to allow chemical reactions in atomized droplets to create products with specific characteristics. CHEMICAL INDUSTRY · 9 SPRAY DRYING Spray drying starts with the atomization of a liquid feedstock into a spray of droplets. The droplets make contact with hot air in a drying chamber, evaporate and form particles. P10 FLUID BED DRYING AND PROCESSING Fluid bed drying achieves uniform processing conditions by passing a gas through a product layer under controlled velocity conditions to create a fluidized state. P16 FLASH DRYING Wet material is dispersed into a stream of heated air or other gas which conveys it through a drying duct where high heat and mass transfer rates rapidly dry the product. P22 ROTARY DRYING AND PROCESSING Rotary systems operate on the principle of lifting and conveying solids through a rotating drum while a hot or cold gas stream is brought into direct or indirect contact with the solid product. P26 SPRAY CONGEALING The melt is sprayed into a cooling chamber. After contact with cool air, the spray solidifies. The atomization is either done by nozzle spraying or by prilling using a rotary atomizer. P30 SPRAY DRYER REACTOR P31 Reactions between gas phase components and liquid phase chemicals are very rapid and have a uniform heat impact. As a result, spray dryers can be used to create substances such as paraformaldehyde, gelatinized starch and silica gels, and can also be used to reduce harmful emissions in flue gases. 10 · CHEMICAL INDUSTRY Your spray drying solution Our fully customizable and highly reliable spray dryers deliver quality powders that enable you to meet your customers’ needs today and tomorrow. The industry standard Our specialists will make sure you get the optimal spray drying Spray drying is the most widely used process for the production solution and support for your needs. Furthermore, in order to keep of powders, granulates or agglomerates from a liquid or a slurry. your employees safe and your environmental footprint low, GEA It is the preferred method for drying thermally-sensitive materials plants are fully compliant with all international regulations. and due to its consistent particle size distribution, the process is well suited to many other product types. Your products Spray drying converts liquid into a dry or semi-dry powdered Technology that meets your needs product. Our spray dryers range from conventional models through to • Agrochemicals highly sophisticated systems that can be specially calibrated for • Ceramics your individual requirements. • Detergents & surface active agents • Dyestuffs & pigments Every spray dryer consists of a feed pump, atomizer, air heater, • Hardmetals air disperser, drying chamber and systems for exhaust air clean- • Inorganic chemicals ing and powder recovery. The process converts a liquid feed into • Organic chemicals droplets which are evaporated under controlled conditions to • Polymers & resins produce a dry powder with specific properties. • Tannins and other products YOUR ADVANTAGES • Unique selection of atomizer systems and chamber designs • Tailor-made designs to meet your specific requirements • Superior powder quality with operational excellence and low energy consumption • Long operating intervals between cleaning CHEMICAL INDUSTRY · 11 12 · CHEMICAL INDUSTRY World-class system design Since your powder’s characteristics can vary depending on the initial product and your requirements, no single spray dryer is suitable for every application. Spray Dryer with VIBRO-FLUIDIZER™ Feed GEA offers a complete range of system and chamber designs that give you the flexibility and control to maintain a highly efficient process and production. Product Fluidized Spray Dryer FSD™ NOZZLE TOWER™ Feed Feed Product Product Spray Dryer, closed-cycle configuration HC Spray Dryer Feed Product Feed Product Product Fresh air Drying air Feed Product Exhaust air Powder discharge Condensate CHEMICAL INDUSTRY · 13 Spray dryer chamber designs 1. Co-current, with integrated fluid bed, rotary or nozzle atomizer. 2. Co-current, conical base with rotary atomizer, for both heat sensitive and stable products. 3. Co-current, flat base with rotary atomizer, for special products. Also suitable for spray congealing. 4. Co-current, with rotary atomizer, for drying chemicals at high inlet air temperatures. 5. Co-current, with rotary atomizer, for drying mineral concentrates at ultra high inlet air temperatures. 6. Co-current, compound air disperser with rotary atomizer, for very large volumes of high inlet air temperatures. 7. Co-current, with nozzle atomizer. 8. Co-current, with nozzle atomizer. 9. Co-current, with nozzle atomizer. 10. Counter-current, with nozzle atomizer. 11. Mixed flow, with nozzle atomizer for coarse powders of heat-stable products. 12. Mixed flow, with nozzle atomizer. 13. Mixed flow, with integrated fluid bed, rotary or nozzle atomizer for non-dusty, free-flowing products. 14. Counter-current, with integrated fluid bed, rotary atomization for spray cooling/congealing. 14 · CHEMICAL INDUSTRY The heart of your spray drying plant As the central and most important part of your spray drying installation, GEA rotary atomizers and nozzles are engineered with precision and manufactured by us to the highest standards. Quality where you need it most Thanks to our proprietary designs, our feed systems handle Productivity, reliability and efficiency are not only a result of higher solids content and operate at relatively low pressures to superior design, but of quality components. For spray drying, keep your output high and energy costs low. one of the most important components is the GEA rotary atomizer, which sits at the heart of your system and forms the spray. As we often create application-specific solutions for the food and pharmaceutical industries, we also take great care when creating GEA offers a full range of atomizer types or corresponding systems that require exceptional hygiene and surface quality or nozzles. Different designs result in different powder that are prone to clogging and would otherwise require frequent characteristics; the right one for you depends on the nature of maintenance. your initial product and what you are aiming to achieve. Our specialists will help you understand which is most appropriate The GEA rotary atomizer for your requirements. Johan E. Nyrop (the founder of “Niro Atomizer”, the company which later became part of GEA), obtained his first patent for a Engineered for your application rotating atomizer in 1924. Since then, GEA’s exceptional rotary GEA rotary atomizers help you to obtain key production para- atomizer designs have led the industry for performance, availability, meters, such as, particle size, particle size distribution, density superior product quality and the lowest energy consumption. and through-put. YOUR ADVANTAGES • Unique and patented nozzle designs • Rotary atomizer with market-leading velocity • Broad selection of atomizer wheel designs • Abrasive and viscous feeds beyond the norm • Proprietary designs give you the broadest range of powder properties Decades of spray drying know-how goes into our patented technology, enabling you to create quality powders with specific properties. CHEMICAL INDUSTRY · 15 Co-current nozzle Fountain nozzle Rotary atomizer COMBI-NOZZLE™ 16 · CHEMICAL INDUSTRY Your fluid bed drying solution Perfect for heat sensitive products, fluid bed drying can be an exceptionally useful addition to your spray drying production process or a highly effective standalone solution. Higher drying rates Fluid bed drying is an efficient method to remove residual moisture from an existing powder. During the process, the moist powder is fluidized, dried and carried through each section of the fluid • Robust GILL PLATE™ distributor plate for easy emptying and conveying of oversized material • Hot air plenum chambers for excellent air distribution and easy draining bed using hot gas blown through specially perforated plates. • Heat panel banks on overhead rollers reduce heat damage Fluid bed drying is ideally suited for powders, granules, agglomer- • Internal BARRIER GAS™ heat tracing and flushing prevents and allow for easy inspections ates and pellets with an average particle size between 50 microns and 5 mm. wet deposits and condensation • Special high temperature fluidized-bed design for optimum energy efficiency CONTACT FLUIDIZER™ One of our most efficient fluid bed dryers, the CONTACT Your products FLUIDIZER™ is a prime example of how our latest systems Turn wet powder into dry powder and powder into agglomerates have been designed to meet your specific requirements. and granulates. • For drying moist or damp powders, filter cake or centrifuge cake Key features include: • Multiple drying sections for optimal heat economy and uniform powder properties • Proprietary rotary feed distributor for constant temperatures and moisture, superior fluidization and material dispersion • Optimal plug flow drying conditions using compartments connected by underflow gates to reduce backmixing • For powders, granules, agglomerates and pellets with average particle size of 50 microns to 5 mm • Plastics; s-PVC, HDPE, ABS, PE, PTFE, POM • PTA, CTA • Sodium carbonate, sodium bicarbonate • Silica, sand • Fertilizers • Calcium chloride, salts • Amino acids YOUR ADVANTAGES • Tailor-made systems • Unique rotary feed spreading system • Patented gas distribution system • Self-emptying design • Small plant footprint reduces overall building costs • High thermal efficiency • Can be supplied in open- or closed-cycle designs • Operates with low-pressure steam CHEMICAL INDUSTRY · 17 PRODUCT DRYING CURVE Volatile content Powder temperature Time 18 · CHEMICAL INDUSTRY Fluid bed process systems The GEA product range includes serveral types of fluid beds. We offer two types of fluid bed models, designed to optimize CONTACT FLUIDIZER™ the flow pattern of solids within the dryer and cater for particles of all sizes. • Back mix fluid bed drying – for feeds that require a degree of Feed drying before fluidization is established • Plug flow fluid bed drying – for powders that are directly fluidizable and can achieve the controlled residence time that is the pre-requisite for obtaining the right particle properties A fluid bed can be stationary or vibrating and is installed either as individual units or combined unit to form a specialized solu- Product tion for effective drying. CONTACT FLUIDIZER™ in side-by-side configuration, closed-cycle SPRAY FLUIDIZER™ Feed Feed Product Flash Dryer System Product Mechanical Granulation System Feed Liquid Granulator Feed Product Product Fresh air Drying air Feed Exhaust air Powder discharge Condensate CHEMICAL INDUSTRY · 19 Fluid bed types Back-mix flow Plug flow CONTACT FLUIDIZER™ (Type FBY) VIBRO-FLUIDIZER™ CONTACT FLUIDIZER™ with integrated filters CONTACT FLUIDIZER™ (Type FBC) HIGH TEMPERATURE FLUIDIZER 20 · CHEMICAL INDUSTRY Fluid bed – key features At GEA, we have invested in decades of research, drying expertise and application know-how to offer you the industry’s leading portfolio of fluid bed hardware. Our fluid beds can be used as a stand-alone unit for a specific GILL PLATE™ purpose or be incorporated into a larger system, depending on The GILL PLATE™ distributes the gas for the fluidization of the your requirements. All our systems are designed and built to powder. It ensures an even gas distribution, effective transport ensure you benefit from many years of trouble-free operation of lumps and emptying of the fluid bed. and efficient performance. • Patented GEA design Feed spreader The GEA rotary feed spreader ensures uniform distribution of • Number, size, and pattern of the gills are tailored to the application the wet feed material. This is an important stage for maintaining • Excellent emptying and conveying of oversize material (if any) the homogeneity of the Back-Mix section and thereby overall • No backwards flow of particles system performance. • Not prone to clogging • No discolored particles as rounded corners ensures no deposits • Minimizes formation of lumps • Efficient utilization of the Back-Mix section GILL PLATE™ GEA rotary feed spreader CHEMICAL INDUSTRY · 21 BARRIER GAS™ system The patented BARRIER GAS™ heat tracing and flushing system lowers your investment costs. It is a highly effective way to prevent wet deposits and condensation, which helps to reduce possible corrosion damage. • Flushing of ceiling and fluid bed walls above the product layer • Internal hot air tracing instead of outside hot water tracing • Allows for single wall construction • No hot water tracing system means lower costs • Easier and cheaper installation BARRIER GAS™ • Less maintenance Internal heating panels Our heating panels have been engineered for maximum thermal efficiency and are a highly reliable and vital component for transferring energy required for evaporation. • Fully submerged in the fluidized powder • High heat transfer • Designed with virtually no horizontal surfaces, reducing risk of heat damage to powder Internal heating panels • Panel banks run on overhead rollers • Heating panels can be inspected and cleaned externally • External, movable frame with a trolley for easy outside inspection High temperature chamber Our high temperature chamber design allows highly efficient drying with underbed temperatures up to 650oC. • Insulated modular design overcomes expansion • Optimized low airflow • Internal insulation wall with continous and washable lining • Small space requirement High temperature chamber 22 · CHEMICAL INDUSTRY Your flash drying solution The flash dryer is particularly suited to products that dry with a short residence time owing to the easy removal of free moisture or where diffusion to the surface occurs readily. Flash drying process Your products Flash drying is defined as the drying of particles that are sus- A broad range of feed materials including powders, cakes, granules, pended and conveyed in a hot air stream. Drying takes place in crystals, flakes, pastes, gels, and slurries can be processed. For a matter of seconds. Wet material is dispersed into a stream of slurries, pastes, or sticky materials, back mixing of the wet feed heated air or other gas which conveys it through a drying duct with a portion of dry product to produce a suitable conditioned where high heat and mass transfer rates rapidly dry the product. material is required. • Agrochemicals Product is separated using cyclones, and/or bag filters. Typically, • Calcium silicate cyclones are followed by scrubbers or bag filters for final cleaning • Calcium phosphate of the exhaust gases to meet current emission requirements. • Coal • Lignin Gentle drying of large quantities • Lithium carbonate High drying temperatures can be used with many products since • Polystyrene (EPS) flashing-off of surface moisture instantly cools the drying gas • Ferrous and non-ferrous ores and powders without overheating the product. Many of the largest dryers in the world are flash dryers – some exceeding 20 tonnes of water evaporation per hour in a single system. Inlet air temperatures range from 100°C to 650°C while airflow can exceed 200,000 m³/h. YOUR ADVANTAGES • Promotes quality on temperature sensitive products • Flexibility to work with different dewatering systems and to enable use with friable and non-friable wet feeds • Enables energy savings and system integration • Suitable for operation with solvent and recovery thereof • Cost effective and reliable with low maintenance and cleaning requirements Ring dryer CHEMICAL INDUSTRY · 23 Flash dryer types GEA offer you a market leading range of flash dryer types designed to your product and capacity requirements. Flash Dryer Product Feed Feed-type Ring Dryer Feed-type Ring Dryer with partial gas recycle Product Product Feed Feed Ring Dryer SWIRL FLUIDIZER™ Product Feed Product Feed DUAL FEED SYSTEM Liquid feed Fresh air Drying air Feed Exhaust air Powder discharge Condensate 24 · CHEMICAL INDUSTRY Ring dryer The presence of an internal manifold as classifier differentiates the ring dryer from the flash dryer. Ring dryers provide control of residence time and particle size. Efficient and even drying Ring dryers employ the same basic principle as flash dryers in that the material to be dried is dispersed and conveyed through the dryer in a hot air stream. Particle size reduction is often provided by a disintegrator within the dryer. Ring dryers incorporate a centrifugal classifier allowing selective internal recirculation of semi-dried solids, effectively lengthening the retention time of larger particles in the dryer, while finer material, which dries more rapidly, exits the dryer and gets directly into the cyclone. Thermal efficiency To optimize thermal efficiency and where inertization is required, recycling of exhaust gases can be used. This Partial Gas Recycle (PGR) configuration can be implemented on all our drying systems as well as retrofitted on customer’s existing drying operations. Two feed-type ring dryer with partial gas recycle Ring dryer YOUR ADVANTAGES • Use of the disintegrator/disperser in combination with the manifold provides close control of particle size, product moisture and exhaust temperature • Provides the highest driving force to minimize required airflow and resulting dryer size and fan power. CHEMICAL INDUSTRY · 25 SWIRL FLUIDIZER™ The SWIRL FLUIDIZER™ is a cost-effective system for obtaining fine, homogeneous high quality powders from pastes, filter cakes and other viscous liquids. Disintegration and drying in a single step Your products The SWIRL FLUIDIZER™ is a flash type dryer for products that Obtain a fine, homogeneous and non-agglomerated are difficult to pump and disintegrate. It produces a fine powder dry product from pastes, filter cakes and highly viscous in a single step without the need to dilute or back-mix the feed liquids in one compact process step. before drying and is suitable for a wide range of products and • Titanium dioxide applications. • Iron oxide • Kaolin Its ability to handle even thick pastes makes the SWIRL • Silica FLUIDIZER™ an ideal alternative to a conventional spray dryer. • Zeolite Unlike many other types of systems, processing time is short • Aluminium and magnesium hydroxide and eliminates the need for costly post-treatments. GEA’s SWIRL FLUIDIZER™ is available as open, semi and closed-cycle plant. Dual feed system (patent pending) Our Dual Feed System is able to dry products that have previously been impossible due to their solid content or low viscosity. The dual feed technology means that: • The enlarged, moist surface ensures a rapid evaporation of the liquid • Liquid feed-rate can be controlled very accurately • Evaporation load of the dryer can be kept constant • No need for additional mixing equipment YOUR ADVANTAGES • Designed for non-pumpable products • Good tolerance towards changes in feed properties • Plant requires minimal space • Maintenance-friendly design • Handles very high drying temperatures • Compatible with heat-sensitive products • Dual Feed System 26 · CHEMICAL INDUSTRY Your rotary processing solution A GEA rotary system is your perfect choice for processing of heavy products, products with long retention times and for high temperature operations under the toughest process conditions. Principles of rotary processing Heat transfer, product distribution and efficiency are influenced Rotary processors operate on the principle of showering or by the internal design, type of heating and product flow arrange- cascading the product through a hot or cold gas stream moving ment, while the long but variable retention time governs the rate either in parallel or counter-flow. The gas induces the evapora- of water diffusion or degree of cooling. tion of the moisture or the cooling of the solid material. Your products Rotary drums consist of a slightly inclined rotating cylinder, fitted Processing of solid material like powder, granulate and crystals with a series of peripheral flights arranged to lift, distribute and • Minerals transport the material. The flights are designed to suit the particular • Fertilizers handling characteristics of the material, which may vary with • Phosphate rock increasing dryness. • Potash • Sand & aggregates • Bauxite • DDGS • Fine chemicals YOUR ADVANTAGES • Robust and simple construction • High reliability under toughest working conditions • Suited for heavy products and long retention times • Permits high temperatures and variable particle sizes • No pretreatment required for high moisture products CHEMICAL INDUSTRY · 27 Rotary types Rotary systems include indirectly heated rotary dryers and calciners, direct fired rotary calciners, direct or indirect rotary Rotary Dryer coolers, as well as conditioning drums for glazing and coating. Feed Product Rotary Dryer with partial gas recycle Rotary Calciner, indirectly heated Combustion exhaust Feed Feed Product Product Rotary Conditioner Rotary Cooler Product chamber Feed Solution pump Cooling liquid Product Rollers Fresh air Drying air Feed Exhaust air Powder discharge Condensate 28 · CHEMICAL INDUSTRY Rotary drying, cooling, calcining and conditioning Whether fine chemicals or heavy-duty minerals – you will find flexibility and reliability in a GEA rotary system. Rotary dryer / cooler Rotary dryers handle a vast range of materials. Noted for their process flexibility and robust construction, the design permits the use of the highest possible drying temperatures. Compared to other dryers they are insensitive to wide fluctuations in throughput and product size. GEA supplies two basic forms of rotary coolers, the counterflow cascade type, and the indirect type which uses recirculated cooling water, either sprayed on the outside of the drum, or circulated through internal channels. Cascade coolers are widely used for coarse and granular materials. Indirect coolers are more Rotary dryer / cooler suitable for the gentle handling of high temperature, fine and dusty products discharged from kilns, calciners and ovens. Rotary calciner Calciners are used for applications where it is necessary to change the “state” of the material or drive a chemical or physical reaction. Direct fired units are suited to high-temperature applications and indirectly heated calciners are used for fine, dusty materials, including those necessitating an inert atmosphere, or for applications where contamination is to be avoided. Conditioning Rotary calciner Conditioning systems feature a condition drum and fluid bed for glazing, polishing and drying of granular material, which significantly improves product quality, operating efficiency and minimizes dust loading. The lifters, drum angle, spray pattern, rotation speed and residence time are be adjusted to meet the required product specification. Rotary conditioner CHEMICAL INDUSTRY · 29 Contact column processors GEA’s contact column processors are used for efficient cooling or heating of free-flowing powders, crystals and granules – your ecological and economical solution for this application. Feed The column processor works on the principle of gravity. The Feed product slowly descends in plug flow through a column incor- Powder discharge porating bundles of thermal contact plates, in which the cooling or heating medium flows: cooling water, thermal oil, steam etc. Heating or cooling medium Your products Capacities range from pilot plant scale up to 100 tons / hour for key applications including: • Salts • Potash • Ammonium sulphate • Calcium chloride • Metal powders • Sand • Polymers YOUR ADVANTAGES • Highly efficient heating or cooling process • No moving parts • Easy to operate and maintain • No or minimal air handling equipment required • Long residence time possible Product 30 · CHEMICAL INDUSTRY Spray congealing – turn melt into powder Spray congealing is the most effective method for transforming your melted feedstock into spherical particles of a specific size to create powders that meet your ideal flow-rate specifications. Spray congealing is the term given to the transition of a melt Your products from a soft or fluid state to a rigid or solid state by cooling. Create average particle sizes of 50-2,000 microns (or even 3-50 microns using our special nozzles). The liquid melt is atomized into a spray of fine droplets of spheri- • Wax cal shape inside a spray cooling chamber. Here, the droplets meet • Stearic acid a sufficiently cold airstream to solidify the droplets into spherical • Glycerides powder particles, creating a high quality free-flowing powder. • Emulsifiers • Bisphenol A Quality and control • Magnesium chloride As the atomization and air distribution technology for spray • Monoglycerides congealing is the same as that applied in the spray drying • Sodium bisulphate process, GEA offers unmatched application know-how and • Paraformaldehyde production control to ensure your product has exactly the Spray atomization and final powder in spray congealing of melted fat and hydrogenated vegetable oils. right properties. Our advanced spray congealing technology means you can even create average particle sizes ranging from 50 to 2,000 microns. If you require even smaller sizes, our special GEA two-fluid nozzles can create particles ranging from 3 to 50 microns. YOUR ADVANTAGES • Compact plant design means a smaller building • Rotary prilling wheel atomization using our unique rotary atomizer • Flexible particle sizes using simple prill wheel modification • Integrated fluid bed design • Simple operation • Narrow and uniform particle distribution for free-flowing products GEA spray congealing chamber with integrated fluid bed. CHEMICAL INDUSTRY · 31 Spray dryer reactor – create chemical reactions This spray drying process can be used to create rapid and highly uniform chemical reactions between gas phase components and liquid phase chemicals. Feed Polymerization and Gelatinization Feed Spray drying can also be used to create polymerization reactions with specific properties by controlling the drying atmosphere. The resulting product is discharged as a finished powder, that requires no further treatment. Spray drying is well suited for creating gelatinized products. Consistent quality is achieved due to the immediate and uniform heat impact from the drying gas, giving Fresh air Drying air ideal conditions for the gelatinization process. Also, two different Feed liquids can be mixed at the moment of atomization, resulting in a Exhaust air powder that typically will be ready for use out of the dryer. Powder discharge Effective pollutant removal The spray drying process is effective in cleaning flue gases from coal fired power stations and waste incineration plants. The acidic components are absorbed into slaked lime to create a dry powder that is often used in building materials, or allows for depositing in landfill. Spray drying reactor design Product 32 · CHEMICAL INDUSTRY Complete efficiency and control A class-leading installation is one half of your solution; a powerful automation and control system that gives you complete command over its vast array of complex processes completes the picture. Advanced software systems An intuitive user interface allows you to monitor and control every With unmatched competence in every aspect of the spray drying part of your installation with ease and our intelligent, automated process, GEA provides reliable, flexible and user-friendly soft- safety systems alert you at the first sign of irregularity so you can ware systems that drive performance and efficiency across your address any issue far in advance of it becoming a serious problem. plant’s operations. Our advanced plant management solutions include: Optimized performance • PLC and SCADA programming and development As the central ‘brain’ that integrates and governs your network • Track and trace control of components, hardware and systems, our plant management • Instrumentation and industrial net-working software enables you to oversee and optimize production and • Data logging and reporting to keep productivity in line with your commercial and strategic • Electrical design, hardware and instruments objectives. • Risk assessment and failure-mode effect analysis (FMEA) Our systems also keep you compliant with all international standards. GEA’s state-of-the-art control system integrates historian logging, tracking, tracing and reporting into a comprehensive and fully customizable plant management solution. CHEMICAL INDUSTRY · 33 Stay productive, protected and compliant Keeping your plant in optimal condition is the best way to extend its lifespan and to make sure you stay compliant and your workforce stays safe. Safety first Our safety services cover: The very nature of powder production means that your process • EU directives and harmonized standards – consultation on will generate a fine dust that is suspended in air, which can lead matters related to the directives and the CE marking of plants to explosions or fires. and equipment • Technical consulting service – review of all compliance issues Each year, hundreds of companies rely on our comprehensive and procedures, with advice for risk reduction measures safety assessment programmes to safeguard against these dangers • Technical documentation service – guidance in drafting an EC and minimize risks to their equipment, employees and reputation. Declaration of Conformity and other mandatory documentation • Explosion protection advisors – on-site inspection, reports and Evaluating safety advice for the specification and installation of safety equipment GEA offers a complete range of services for the evaluation of your on new installations and existing plants plant’s condition and operating environment. If additional safety measures are needed, we will help you plan the best way to im- Protective measures plement them with minimal disruption, downtime and expense. • Venting systems to direct explosive pressure away from We ensure that your GEA drying plant complies with all inter- • Suppression systems that prevent the release of hazardous equipment national legislation, including ATEX, and can also provide the chemicals input for a detailed Explosion Protection Document – something • Designing the plant to withstand explosions (containment) many authorities and insurance companies demand as a guaran- • Isolation systems that prevent propagation of an explosion tee of compliance. • Automated fire extinguishing systems SAFETY SYSTEMS • Temperature switches • Air flow switches for cooling air • CO monitoring • Flow control • Vibration monitoring of rotary atomizer 34 · CHEMICAL INDUSTRY Your project is in safe hands With over 10,000 installations across virtually every industry and hundreds of new projects in progress every year, we offer unparalleled experience in managing your project from start to finish. The right people On time and on budget Over eight decades, we’ve fine-tuned our approach to maintain- Thanks to our vast expertise, our proven and trusted approach ing the highest standards of quality and efficiency at every stage. ensures a reliable outcome every time, on time and on budget. As a key part of this, we allocate a dedicated Project Manager as This includes: your single point of contact to keep everything transparent and • Initial meetings to get to know everyone involved and outline tightly organized, and who fronts a larger team of specialists hand-picked for your specific project. project expectations • Basic Engineering Package to highlight potential technical issues and solutions The right training We have invested heavily in training all our Project Managers to have the right skill set, application expertise and experience to guide you seamlessly through the process. To be qualified as a GEA Project Manager, our staff must have extensive exposure on accounts of all sizes, locally and globally, and have passed an international project management course. • Planning for key milestones, site management, installation, commissioning and safety audits • 3D CAD plant design, including ERP systems, for optimization and fault-finding prior to construction • Transparent and timely management of your plant’s construction and installation • Commissioning by the project manager, process control expert and process technologist Not only does this guarantee excellent technical and organizational strengths, it also ensures they possess every attribute Finally, when everything has been thoroughly tested and your necessary for the smooth running of your project, including employees trained in its operation, the plant is handed over to strong communication skills, multiple languages and solid you for production, with our on-going support as needed. problem-solving abilities. TAILORED FINANCE SOLUTIONS Our finance team can help you set up a package tailored to your requirements, from a simple leasing contract to complete project support. CHEMICAL INDUSTRY · 35 GEA Service – For your continued success For us, service and partnership go hand in hand. We will provide the proactive support you need over your plant’s lifecycle to keep you updated, upgraded and able to upscale as opportunities arise. Working with GEA Service means partnering with a dedicated team of service experts. Our focus is to build, maintain, and improve customer performance throughout the entire life cycle of the plant and its equipment. • Beginning of Life Services – Getting you started with seamless support for instant productivity and performance • Lifetime Services – Keeping it running with the cost-efficient way of ensuring safety and reliability • Extended Life Services – Constantly improving by sharing our knowledge to safeguard your investment • Consulting & Enhanced Operations – Together with you by enduring commitment to you and your business We live our values. Excellence • Passion • Integrity • Responsibility • GEA-versity GEA is a global technology company with multi-billion euro sales operations in more than 50 countries. Founded in 1881 the company is one of the largest providers of innovative equipment and process technology. GEA is listed in the GEA Denmark GEA Process Engineering A/S Gladsaxevej 305 Tel +45 39 54 54 54 gea.com/contact DK-2860 Soeborg Fax +45 39 54 58 00 gea.com BTC0010-EN 0917 CBC © GEA Company. All rights reserved. Subject to modifications. Printed in Germany STOXX® Europe 600 Index. In addition, the company is included in selected MSCI Global Sustainability Indexes.