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Journals / Gazi Üniversitesi Fen Bilimleri Dergisi Part C: Tasarım ve Teknoloji / 2026 / Cilt: 13 Sayı: 1

Evaluating the Trade-Off Between Energy Efficiency and Energy Saving in Spray Drying Operations

Gülşah Karaca Dolgun(FACULTY OF TECHNOLOGY)0000-0002-6219-6016
Pages
285–295
Publication Date
2025-03-24
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AI Summary & Key Takeaways

AI Insight
⚡ TL;DR(Too Long; Didn't Read)

To maintain product quality, it was found that the maximum acceptable temperature of 60°C could be achieved at by-pass ratios of 40% or lower.

📌 3 Key Takeaways

🎯
Objective & Hypothesis:In this study, modelling simulations were employed to analyze the effects of inlet drying air flow rate and temperature, product feed rate, and heat recovery ratio in a spray dryer.
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Key Findings & Data:As the heat recovery ratio (by-pass ratio) increased, total energy savings improved, though energy efficiency declined at a slower rate compared to energy savings.
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Conclusion & Impact:To maintain product quality, it was found that the maximum acceptable temperature of 60°C could be achieved at by-pass ratios of 40% or lower.
🔬Design:Modeling & Simulation
📍Scope:Comprehensive Sample
⚙️Variables:Spray dryer · energy efficiency · energy saving

Abstract

In this study, modelling simulations were employed to analyze the effects of inlet drying air flow rate and temperature, product feed rate, and heat recovery ratio in a spray dryer. The energy efficiency, energy savings, and final product outlet temperature were investigated. As the heat recovery ratio (by-pass ratio) increased, total energy savings improved, though energy efficiency declined at a slower rate compared to energy savings. The modelling study, conducted with five different by-pass ratios (100%, 70%, 50%, 30%, and 0%), indicated that the optimal by-pass ratio was 30%. At this ratio, energy efficiency decreased by 5%, while energy savings increased by approximately 16%. Additionally, at higher by-pass ratios, the product outlet temperature rose significantly. To maintain product quality, it was found that the maximum acceptable temperature of 60°C could be achieved at by-pass ratios of 40% or lower.

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Cite This Article

Dolgun, G. K. (2025). Evaluating the Trade-Off Between Energy Efficiency and Energy Saving in Spray Drying Operations. Gazi Üniversitesi Fen Bilimleri Dergisi Part C: Tasarım ve Teknoloji, Cilt: 13 Sayı: 1, 285–295. https://doi.org/10.29109/gujsc.1562960

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