Parametric CFD Study of Spray Drying Chamber Geometry: Part II—Effects on Particle Histories

Abstract

Particle histories critically influence product quality in spray drying processes, encompassing statistical data on particle dynamics and behavior inside the chamber, including temperatures, moisture levels, wall impacts, and residence times. This study presents the first systematic parametric assessment of how chamber geometry influences particle histories in spray drying, extending previous work on airflow dynamics. A design of experiments (DOE) methodology combined with cost-efficient CFD simulations was employed to establish quantitative parameter–response relationships. The results reveal two distinct classes of particle responses: (i) residence time, moisture content, and wall temperature, which are primarily governed by chamber aspect ratio and drying air flow rate, and (ii) particle–wall impact behavior, which is dominated by chamber topology. Inlet swirl modulates all particle histories, differentially impacting final product quality and energy efficiency. These findings provide predictive guidelines for chamber design and operation, while the methodology offers a general framework for scale-up analyses and parametric CFD studies of particle-laden multiphase processes.