Spray Drying Nozzles

Create powder products, such as milk, cheese, detergents, ceramics, and others from solutions and slurries by spraying into a heated chamber.


BETE Spray Dry Manual (PDF - 290 KB)

Spray drying is used by many industries to quickly and inexpensively transform food products, chemicals, and other products into dried powders. Powder is preferable because it has drastically reduced weight and increased storage life. Spray drying can be accomplished across a range of powder production rates, from a few pounds per hour to over 100 tons per hour.

The basic process is to first concentrate the feed stock in a liquid form, atomize it at high pressure to create small droplets consisting of liquid and particles, then allow a hot gas to evaporate the liquid away leaving only the dry particulate. The sprayed media feed stock can be a solution, slurry, paste, gel, suspension or a melt, as long as it has a solid component and a liquid component to carry the solids through the piping and then evaporate in the drying chamber. Any liquid that can be pumped can be spray dried, including feed stocks that are abrasive, corrosive, flammable, explosive, or toxic. Since the uses vary so much, a wide array of atomizers must be considered.

The function of a spray nozzle in a spray dry system is to control the feed stock flow rate and uniformly distribute atomized droplets/particles into the heated drying chamber. Spray dry nozzles typically operate at higher pressures or utilize air-atomizing techniques to produce droplets in the 30 - 120 micron range. This maximizes the surface area to volume of the particles, allowing them to dry much quicker than other drying methods. In many dryers, evaporation is 95% complete within seconds.

Specific spray dryer requirements and operating conditions can vary widely across the industry:

  • With hydraulic nozzles, typical operating pressures to achieve the atomization required for effective spray drying can range 3,000 - 5,000 psi with some products/applications requiring operating pressures up to 10,000 psi for efficient dryer operation. With the use of compressed air or other gas, air-atomizing nozzles can achieve fine atomization at lower pressures between 30 - 100 psi.
  • Typical operating temperatures to achieve the evaporation rates required for effective spray drying without damaging the end product can range from 175 - 450 °F with some products/applications requiring up to 600 - 800 °F and to incorporate other design features, such as those which reduce or eliminate bearding issues.

BETE produces a variety of hydraulic and air-atomizing nozzle types, features, and materials to fit your spray drying applications requirements. Consistent performance and quality allow for the production of high quality products through constant particles sizes with even moisture content. High strength, wear resistant, and high temperature material options allow for long service life and safe operation within the high pressure, high temperature, and abrasive applications found in the spray drying industry.
 

Selecting a Spray Drying Nozzle:

Important factors to consider:

  • Spray media density, viscosity, solids content, and particulate size
  • Dryer size, velocity, pressure, temperature, and humidity
  • Required materials of construction for corrosive environments
  • Spray media density and viscosity
  • Required spray media flow rate
  • Available pressure drop (∆P) across the nozzle
    • ∆P = supply pressure at nozzle inlet - process pressure outside nozzle
  • Our experienced engineers can help determine which nozzle will perform as required with your design details


Common Spray Drying Nozzle Uses and Industries:

Twist & Dry

  • Patented locking mechanism for quick and easy change-out of wear parts
  • Wide variety of interchangeable thick swirl and orifice discs for fine tuning flow rates, spray angles, and atomization
  • Optional bodies, materials, check valves available to optimize the nozzle assembly for specific applications
  • Multiple grades of wear parts available
Nozzle Type(s):
Whirl
Spray Pattern(s):
Hollow Cone
Flow Range:
.149 to 36.8 gpm
Typical Pressure Range:
3000 to 10000 psi
Angle Range:
50 - 85°
Common Materials:
Tungsten Carbide, 303, 316, Duplex
  • Tungsten carbide swirls and orifices provides maximum wear resistance at high pressure operation
  • 218 SS body provides excellent galling resistance under the high pressures and temperatures of spray drying applications

Hollow Cone

Select a nozzle number below for performance graph, drawings, and to request a quote.
Nozzle Number Connection Sizes Spray Angles gpm @ psi     (density: 1 SG)
200 psi 500 psi 1000 psi 2500 psi 5000 psi 10000 psi
TD 1-37 1/4″, 3/8″, 1/2″, 3/4″ 80° .148 .235 .332 .525 .742 1.05
TD 2-34 1/4″, 3/8″, 1/2″, 3/4″ 70° .148 .235 .332 .525 .742 1.05
TD 1-49 1/4″, 3/8″, 1/2″, 3/4″ 85° .187 .295 .417 .660 .933 1.32
TD 2-40 1/4″, 3/8″, 1/2″, 3/4″ 75° .187 .295 .417 .660 .933 1.32
TD 3-40 1/4″, 3/8″, 1/2″, 3/4″ 70° .223 .353 .500 .790 1.12 1.58
TD 4-34 1/4″, 3/8″, 1/2″, 3/4″ 60° .223 .353 .500 .790 1.12 1.58
TD 4-40 1/4″, 3/8″, 1/2″, 3/4″ 65° .262 .414 .585 .925 1.31 1.85
TD 5-34 1/4″, 3/8″, 1/2″, 3/4″ 50° .262 .414 .585 .925 1.31 1.85
TD 3-49 1/4″, 3/8″, 1/2″, 3/4″ 75° .297 .470 .664 1.05 1.48 2.10
TD 4-43 1/4″, 3/8″, 1/2″, 3/4″ 65° .297 .470 .664 1.05 1.48 2.10
TD 3-55 1/4″, 3/8″, 1/2″, 3/4″ 75° .335 .530 .749 1.18 1.68 2.37
TD 4-46 1/4″, 3/8″, 1/2″, 3/4″ 70° .335 .530 .749 1.18 1.68 2.37
TD 5-40 1/4″, 3/8″, 1/2″, 3/4″ 60° .335 .530 .749 1.18 1.68 2.37
TD 6-37 1/4″, 3/8″, 1/2″, 3/4″ 50° .335 .530 .749 1.18 1.68 2.37
TD 4-52 1/4″, 3/8″, 1/2″, 3/4″ 70° .372 .588 .832 1.32 1.86 2.63
TD 5-43 1/4″, 3/8″, 1/2″, 3/4″ 60° .372 .588 .832 1.32 1.86 2.63
TD 6-40 1/4″, 3/8″, 1/2″, 3/4″ 50° .372 .588 .832 1.32 1.86 2.63
TD 3-67 1/4″, 3/8″, 1/2″, 3/4″ 80° .410 .648 .917 1.45 2.05 2.90
TD 4-58 1/4″, 3/8″, 1/2″, 3/4″ 70° .410 .648 .917 1.45 2.05 2.90
TD 5-49 1/4″, 3/8″, 1/2″, 3/4″ 60° .410 .648 .917 1.45 2.05 2.90
TD 3-70 1/4″, 3/8″, 1/2″, 3/4″ 80° .448 .709 1.00 1.58 2.24 3.17
TD 4-61 1/4″, 3/8″, 1/2″, 3/4″ 75° .448 .709 1.00 1.58 2.24 3.17
TD 5-52 1/4″, 3/8″, 1/2″, 3/4″ 65° .448 .709 1.00 1.58 2.24 3.17
TD 6-46 1/4″, 3/8″, 1/2″, 3/4″ 55° .448 .709 1.00 1.58 2.24 3.17
TD 4-70 1/4″, 3/8″, 1/2″, 3/4″ 75° .520 .823 1.16 1.84 2.60 3.68
TD 5-58 1/4″, 3/8″, 1/2″, 3/4″ 65° .520 .823 1.16 1.84 2.60 3.68
TD 6-52 1/4″, 3/8″, 1/2″, 3/4″ 55° .520 .823 1.16 1.84 2.60 3.68
TD 4-76 1/4″, 3/8″, 1/2″, 3/4″ 80° .597 .944 1.33 2.11 2.98 4.22
TD 5-64 1/4″, 3/8″, 1/2″, 3/4″ 70° .597 .944 1.33 2.11 2.98 4.22
TD 6-55 1/4″, 3/8″, 1/2″, 3/4″ 60° .597 .944 1.33 2.11 2.98 4.22
TD 7-49 1/4″, 3/8″, 1/2″, 3/4″ 50° .597 .944 1.33 2.11 2.98 4.22
TD 5-70 1/4″, 3/8″, 1/2″, 3/4″ 70° .672 1.06 1.50 2.38 3.36 4.75
TD 6-61 1/4″, 3/8″, 1/2″, 3/4″ 60° .672 1.06 1.50 2.38 3.36 4.75
TD 7-52 1/4″, 3/8″, 1/2″, 3/4″ 50° .672 1.06 1.50 2.38 3.36 4.75
TD 4-91 1/4″, 3/8″, 1/2″, 3/4″ 80° .745 1.18 1.67 2.64 3.73 5.27
TD 5-76 1/4″, 3/8″, 1/2″, 3/4″ 75° .745 1.18 1.67 2.64 3.73 5.27
TD 6-64 1/4″, 3/8″, 1/2″, 3/4″ 65° .745 1.18 1.67 2.64 3.73 5.27
TD 7-58 1/4″, 3/8″, 1/2″, 3/4″ 55° .745 1.18 1.67 2.64 3.73 5.27
TD 5-82 1/4″, 3/8″, 1/2″, 3/4″ 75° .820 1.30 1.83 2.90 4.10 5.80
TD 6-70 1/4″, 3/8″, 1/2″, 3/4″ 65° .820 1.30 1.83 2.90 4.10 5.80
TD 7-61 1/4″, 3/8″, 1/2″, 3/4″ 55° .820 1.30 1.83 2.90 4.10 5.80
TD 5-88 1/4″, 3/8″, 1/2″, 3/4″ 75° .894 1.41 2.00 3.16 4.47 6.32
TD 6-76 1/4″, 3/8″, 1/2″, 3/4″ 65° .894 1.41 2.00 3.16 4.47 6.32
TD 7-64 1/4″, 3/8″, 1/2″, 3/4″ 55° .894 1.41 2.00 3.16 4.47 6.32
TD 5-109 1/4″, 3/8″, 1/2″, 3/4″ 80° 1.12 1.77 2.50 3.95 5.59 7.90
TD 6-88 1/4″, 3/8″, 1/2″, 3/4″ 70° 1.12 1.77 2.50 3.95 5.59 7.90
TD 7-76 1/4″, 3/8″, 1/2″, 3/4″ 60° 1.12 1.77 2.50 3.95 5.59 7.90
TD 8-67 1/4″, 3/8″, 1/2″, 3/4″ 50° 1.12 1.77 2.50 3.95 5.59 7.90
TD 6-103 1/4″, 3/8″, 1/2″, 3/4″ 75° 1.34 2.12 3.00 4.74 6.70 9.48
TD 7-85 1/4″, 3/8″, 1/2″, 3/4″ 65° 1.34 2.12 3.00 4.74 6.70 9.48
TD 8-76 1/4″, 3/8″, 1/2″, 3/4″ 50° 1.34 2.12 3.00 4.74 6.70 9.48
TD 6-115 1/4″, 3/8″, 1/2″, 3/4″ 75° 1.57 2.48 3.51 5.55 7.85 11.1
TD 7-97 1/4″, 3/8″, 1/2″, 3/4″ 65° 1.57 2.48 3.51 5.55 7.85 11.1
TD 8-82 1/4″, 3/8″, 1/2″, 3/4″ 55° 1.57 2.48 3.51 5.55 7.85 11.1
TD 6-127 1/4″, 3/8″, 1/2″, 3/4″ 80° 1.78 2.82 3.98 6.30 8.91 12.6
TD 7-106 1/4″, 3/8″, 1/2″, 3/4″ 70° 1.78 2.82 3.98 6.30 8.91 12.6
TD 8-91 1/4″, 3/8″, 1/2″, 3/4″ 60° 1.78 2.82 3.98 6.30 8.91 12.6
TD 9-82 1/4″, 3/8″, 1/2″, 3/4″ 50° 1.78 2.82 3.98 6.30 8.91 12.6
TD 6-142 1/4″, 3/8″, 1/2″, 3/4″ 80° 2.01 3.18 4.49 7.10 10.0 14.2
TD 7-118 1/4″, 3/8″, 1/2″, 3/4″ 70° 2.01 3.18 4.49 7.10 10.0 14.2
TD 8-100 1/4″, 3/8″, 1/2″, 3/4″ 60° 2.01 3.18 4.49 7.10 10.0 14.2
TD 9-88 1/4″, 3/8″, 1/2″, 3/4″ 50° 2.01 3.18 4.49 7.10 10.0 14.2
TD 7-127 1/4″, 3/8″, 1/2″, 3/4″ 75° 2.23 3.53 5.00 7.90 11.2 15.8
TD 8-106 1/4″, 3/8″, 1/2″, 3/4″ 65° 2.23 3.53 5.00 7.90 11.2 15.8
TD 9-94 1/4″, 3/8″, 1/2″, 3/4″ 55° 2.23 3.53 5.00 7.90 11.2 15.8
TD 7-145 1/4″, 3/8″, 1/2″, 3/4″ 75° 2.62 4.14 5.85 9.25 13.1 18.5
TD 8-121 1/4″, 3/8″, 1/2″, 3/4″ 65° 2.62 4.14 5.85 9.25 13.1 18.5
TD 9-106 1/4″, 3/8″, 1/2″, 3/4″ 55° 2.62 4.14 5.85 9.25 13.1 18.5
TD 10-103 1/4″, 3/8″, 1/2″, 3/4″ 50° 3.00 4.74 6.70 10.6 15.0 21.2
TD 8-133 1/4″, 3/8″, 1/2″, 3/4″ 70° 3.00 4.74 6.70 10.6 15.0 21.2
TD 9-115 1/4″, 3/8″, 1/2″, 3/4″ 60° 3.00 4.74 6.70 10.6 15.0 21.2
TD 10-118 1/4″, 3/8″, 1/2″, 3/4″ 55° 3.35 5.30 7.49 11.8 16.8 23.7
TD 8-145 1/4″, 3/8″, 1/2″, 3/4″ 70° 3.35 5.30 7.49 11.8 16.8 23.7
TD 9-127 1/4″, 3/8″, 1/2″, 3/4″ 60° 3.35 5.30 7.49 11.8 16.8 23.7
TD 8-157 1/4″, 3/8″, 1/2″, 3/4″ 70° 3.72 5.88 8.32 13.2 18.6 26.3
TD 9-136 1/4″, 3/8″, 1/2″, 3/4″ 65° 3.72 5.88 8.32 13.2 18.6 26.3
TD 9-148 1/4″, 3/8″, 1/2″, 3/4″ 65° 4.10 6.48 9.17 14.5 20.5 29.0
TD 10-136 1/4″, 3/8″, 1/2″, 3/4″ 60° 4.48 7.09 10.0 15.8 22.4 31.7
TD 9-154 1/4″, 3/8″, 1/2″, 3/4″ 70° 4.48 7.09 10.0 15.8 22.4 31.7
TD 10-151 1/4″, 3/8″, 1/2″, 3/4″ 60° 4.85 7.67 10.8 17.2 24.3 34.3
TD 10-157 1/4″, 3/8″, 1/2″, 3/4″ 65° 5.20 8.23 11.6 18.4 26.0 36.8

These values are filtered based on search criteria or application and do not represent the full range of nozzles for this series. Click here to see all available series offerings.

TDL

  • Compact design and low flow rates are ideal for small scale and pilot operations
  • Interchangeable swirl and orifice discs for variable flow rates and spray angles
  • Patented locking mechanism for quick and easy change-out of wear parts
Nozzle Type(s):
Whirl
Spray Pattern(s):
Hollow Cone
Flow Range:
.048 to 2.05 gpm
Typical Pressure Range:
1000 to 5000 psi
Angle Range:
70 - 75°
Common Materials:
Tungsten Carbide, 303, 316
  • Tungsten carbide swirls and orifices provides maximum wear resistance at high pressure operation
  • 218 SS body provides excellent galling resistance under the high pressures and temperatures of spray drying applications

Hollow Cone

Select a nozzle number below for performance graph, drawings, and to request a quote.
Nozzle Number Connection Sizes Spray Angles gpm @ psi     (density: 1 SG)
200 psi 500 psi 750 psi 1000 psi 2500 psi 5000 psi
TDL 4-18 1/4″, 3/8″ 70° .048 .075 .092 .107 .168 .238
TDL 4-20 1/4″, 3/8″ 70° .051 .080 .098 .113 .179 .253
TDL 4-22 1/4″, 3/8″ 70° .056 .088 .108 .125 .198 .279
TDL 4-24 1/4″, 3/8″ 70° .064 .101 .124 .143 .226 .320
TDL 4-27 1/4″, 3/8″ 70° .074 .118 .144 .167 .264 .373
TDL 1-22 1/4″, 3/8″ 70° .082 .130 .159 .183 .290 .410
TDL 1-24 1/4″, 3/8″ 70° .093 .147 .180 .208 .329 .465
TDL 1-27 1/4″, 3/8″ 70° .108 .171 .210 .242 .382 .541
TDL 1-30 1/4″, 3/8″ 70° .123 .195 .238 .275 .435 .615
TDL 2-30 1/4″, 3/8″ 70° .148 .235 .288 .332 .525 .742
TDL 2-33 1/4″, 3/8″ 70° .168 .266 .326 .376 .595 .841
TDL 2-36 1/4″, 3/8″ 70° .187 .295 .361 .417 .660 .933
TDL 2-38 1/4″, 3/8″ 70° .198 .313 .383 .443 .700 .990
TDL 2-40 1/4″, 3/8″ 70° .216 .342 .419 .484 .765 1.08
TDL 2-42 1/4″, 3/8″ 70° .223 .353 .433 .500 .790 1.12
TDL 2-44 1/4″, 3/8″ 70° .231 .364 .446 .515 .815 1.15
TDL 2-46 1/4″, 3/8″ 70° .243 .385 .471 .544 .860 1.22
TDL 2-48 1/4″, 3/8″ 70° .262 .414 .507 .585 .925 1.31
TDL 2-50 1/4″, 3/8″ 70° .272 .429 .526 .607 .960 1.36
TDL 2-52 1/4″, 3/8″ 70° .294 .465 .570 .658 1.04 1.47
TDL 2-54 1/4″, 3/8″ 70° .307 .485 .594 .686 1.08 1.53
TDL 2-56 1/4″, 3/8″ 70° .314 .496 .608 .702 1.11 1.57
TDL 3-50 1/4″, 3/8″ 70° .335 .530 .649 .749 1.18 1.68
TDL 3-52 1/4″, 3/8″ 70° .356 .563 .690 .797 1.26 1.78
TDL 3-54 1/4″, 3/8″ 70° .378 .597 .731 .844 1.34 1.89
TDL 3-56 1/4″, 3/8″ 70° .399 .631 .772 .892 1.41 1.99
TDL 3-58 1/4″, 3/8″ 70° .410 .648 .794 .917 1.45 2.05

These values are filtered based on search criteria or application and do not represent the full range of nozzles for this series. Click here to see all available series offerings.

XAER

  • Air atomizing nozzle with external-mix design provides independent control of flow rate and drop size
  • Wide variety of hardware configurations
  • Available with clean out and shut off capabilities
  • Nickel alloy and other 300 series stainless steels available by request
Nozzle Type(s):
Air-Atomizing
  • Air-atomizing nozzles allow for fine atomization at low operating pressures
  • Ideal for low flow rates and higher viscosity spray media
  • Lower shear than high pressure hydraulic nozzles
Spray Pattern(s):
Full Cone
Angle Range:
10 - 30°
Common Materials:
316