Spray Dryer Optimisation - Minimise Variance in Powder Output

Spray Drying presents a unique challenge in controlling output and cost, especially in milk and coffee production. Spray Dryer Optimisation provides a new level of proven opportunity to bring the process under control by reducing waste, costs, and stabilising the output product to satisfy delivery first time. Plus, applying Advanced Process Control, which uses multivariate optimisation, will enable predictable powder quality over changing conditions.
Proven Optimisation Results for Spray Dryers
  • 10% increase in throughput from initial “recipe” conditions.
  • 8% reduction in specific energy consumption.
  • Auto compensation for ambient air humidity changes.
  • Powder moisture in-specification at all times.
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Advanced Process Control, Enables New Levels of Stability Above Traditional Control
  • Understand process constraints and complex process interactions.
  • A mathematical model of the process input / output dependencies is used to predict the future process output trajectories.
  • Multivariate correlation between variables and actuators, causes and effectsPredict impact of known disturbances on the operation
  • Make co-ordinated moves on multiple actuators
  • Exploit all opportunities to push quality and / or throughput close to constraint
  • Multivariable model-predictive dynamic control (MPC)
  • Steady-state economic optimisation by Linear Programme (LP)
  • Inferential virtual sensor modelling by neural network – to enable continuous product quality measurement by calculating the estimated value.
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Capture Process Data from Existing Automation Systems
  • Connect to 1000s of different control system
  • OPC connectivity to all DCS/PLC systems
  • Integrated data capture and historisation, trending
  • Custom calculations
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Minimise Output Powder Variation, Maximise Product Quality
  • Maximise product moisture content – maintaining product quality while reducing specific energy consumption
  • Maximise use of drying capacity (e.g. respond to ambient air humidity, optimise distribution between dryer and fluidised beds)
  • Improved energy efficiency
  • Reduce process variability
  • Coordinated optimisation of multiple units.
  • Increase product yield or process throughput
  • Minimise specific energy consumption
  • Maintain product quality
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Enable Visualisation of predicted vs actual, enable virtual sensors
  • Continous improvment by comparing different modeling Senarios
  • Compare Actuals vs predicted Data
  • Enable Virtual Sensors for increased quality awareness and control
  • Intutive User configuration experience
  • Implement a project and get results in 10-12 weeks
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Multi - Unit Coordination and Optimisation
  • APC’s Linear Programme (LP) Optimiser can span the individual local control functions.
  • Open connectivity to all local PLC control systems
  • Individual unit models are consolidated into a single multi-unit model.
  • Allows the reconciliation of plant-wide constraints, locates the true global optimum operating point:
  • Maximise throughput
  • Minimise energy consumption
  • Downloads real-time operating targets to the control layer.
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