[Haichuan’s Guide to Chemical Equipment] Comparison of Drying Equipment for Fine Chemicals, Analysis of Operating Costs, and Summary of Selection Criteria along with Recommendations

Key factors in operating costs: Energy consumption costs – The cost of steam heating for processing 1 ton of material is around 200–300 yuan, while the cost of electric heating is around 500–800 yuan. The drying process in a spray dryer requires a large amount of hot air (at temperatures of 150–300°C), and energy consumption accounts for 60%-80% of the operating costs. Vacuum dryers have a heat utilization rate of over 70%, but they require additional power for the vacuum system; as a result, their overall energy consumption is only 30%-50% that of conventional drying methods. Maintenance costs: The atomizer nozzles of spray dryers wear out quickly (with a lifespan of around 500–2000 hours), and the cost per replacement is 500–2000 yuan. The air ducts of hot air ovens are prone to blockage and severe dust accumulation, resulting in high maintenance costs. Material loss: Material loss due to sticking to the walls in spray drying is usually 2%-5% ； Sealed operation of vacuum dryers can minimize material loss.

Summary and Recommendations for Selection: When making a selection, it is necessary to conduct a comprehensive evaluation by taking into account factors such as the initial moisture content of the material, the desired moisture level, the processing capacity per hour, the thermal decomposition temperature of the material, the space available in the workshop, and the available utility systems (steam/electricity/heat transfer oil). For materials with a high degree of precision and high added value, vacuum-based equipment is the preferred choice to ensure quality ； For the large-scale continuous production of conventional materials, non-vacuum convection equipment is more economical ； For the need for one-step powder production from liquid raw materials, spray drying equipment is an irreplaceable option. It is recommended to conduct pilot tests and on-site inspections before making a selection, to ensure that the equipment fits perfectly with the production environment.

【Haichuan’s Guide to Chemical Equipment】Comparison of various drying equipment used in fine chemical industry, analysis of operating costs, as well as summary and recommendations for equipment selection https://bbs.hcbbs.com/forum.php?mod=viewthread&tid=5724601 (Source: Haichuan Chemical Forum (Hua Haichuan Liu hcbbs))

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