Implemented unit
Spray dryer co-current
Feed and gas flow in the same direction. Commonly selected when lower product temperature exposure is important.
Drying Unit — Implemented in DyssolPro
Use spray dryer simulation software for co-current and counter-current spray drying inside a full dynamic flowsheet. Track droplet evaporation, particle growth, outlet moisture, and downstream separation — all in one process simulation.
Proven on industrial flowsheets including porcelain tile manufacturing and zeolite production. Backed by TUHH research.
Ready to drop into any flowsheet, no generic drying placeholder required.
Both co-current and counter-current spray dryers are first-class units. Configure them, connect upstream nozzles and downstream cyclones, and run the flowsheet.
Implemented unit
Feed and gas flow in the same direction. Commonly selected when lower product temperature exposure is important.
Implemented unit
Feed and gas flow in opposite directions. Commonly selected when residence time and outlet-moisture control are priorities.
Set up the spray dryer unit, connect the surrounding process, and run the simulation.
Choose either the spray dryer co-current or spray dryer counter-current unit from the library, depending on the flow arrangement you want to study.
Place the spray dryer in a larger flowsheet with implemented upstream and downstream units such as nozzle, cyclone, filter gas, heat exchanger, fluidized bed, or rotary kiln.
Evaluate spray drying inside a dynamic flowsheet and track particle-centered properties such as size, composition, and moisture across connected units.
| Unit | Flow arrangement | Typical priority |
|---|---|---|
| Spray dryer co-current | Feed and gas flow in the same direction. | Lower product temperature exposure is important. |
| Spray dryer counter-current | Feed and gas flow in opposite directions. | Residence time and outlet-moisture control are priorities. |
Time-dependent simulation covering startup, shutdown, batch, semi-batch, and continuous operation.
Particle-centered modeling with interdependent properties: size, composition, and moisture across connected units.
Full PSD tracking for spray drying tasks where droplet and particle evolution matter.
Model Maker for implementation, testing, and validation of company-specific spray dryer models.
Evaluate spray drying inside startup, shutdown, batch, semi-batch, and continuous flowsheet scenarios instead of limiting the study to steady-state behavior.
Use particle-centered, multidimensional property handling and population-balance workflows when particle size distribution, composition, and moisture evolution matter.
The integrated sensitivity analysis tool is available for implemented process units, which makes it suitable for spray drying parameter studies in DyssolPro.
The integrated optimization tool is available for implemented process units, so spray drying studies can be evaluated against target process or product properties.
Documented flowsheets where spray drying is one step of the full process.
Existing application example
Full wet-route line including milling, spray drying, storage, pressing, drying, and firing. Dyssol was used to evaluate recipe and operating parameters together in one dynamic flowsheet.
Sources: 10.1016/j.cirpj.2021.04.011, 10.3390/machines11020137, 10.1016/j.ceramint.2023.01.056
Existing application example
End-to-end catalyst process with synthesis, decanter washing, spray drying, and rotary-kiln calcination. Dyssol connected the downstream units into one process-level flowsheet.
Source: Processes 2022, 10(10), 2140
Yes. Both spray dryer co-current and spray dryer counter-current ship with the software.
Yes. Existing examples place spray drying inside porcelain tile manufacturing and industrial zeolite production flowsheets.
No. DyssolPro is a dynamic flowsheet simulator and supports time-dependent process behavior by default.
Model Maker supports custom model development, and DyssolTEC offers implementation services for company-specific models.
Yes. The integrated sensitivity analysis tool is available for implemented process units in DyssolPro.
Yes. The integrated optimization tool is available for implemented process units in DyssolPro.
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