Spray Drying Plant Engineering Solutions for more sustainable Industrial Detergent Plants
Marsina Engineering spray drying plant is conceived to match the most recent requirements in terms of environmental protection, energy saving and sustainability.
Environmental Protection
The powder detergent plant is designed as an environmental friendly manufacturing plant.
A particular feature of the spray tower process is the high level of product recovery from occasional spills. Also in case of off-specification spills, they can be re-processed minimizing therefore the product unrecoverable loss.
The tower operation under mild vacuum avoids any risk of powder emission from the tower.
Operational effluents of the plant are the air streams from spray tower and from air lift, plus the minor air streams from silos dedusting filters.
Such effluents are treated in high efficiency air filters, able to retain almost 98.7% of the dust, to ensure therefore the release of dust in the amount of maximum 10 ppm.
Possible dust from the powder raw materials fallout into the process equipment is scrubbed with water, delivered on its turn to the water recovery system.
Again with the aim to minimize any environmental impact, all powder conveying equipment are covered type and equipped with dust extraction and filtration device.
Gaseous emissions from fuel users are minimized thanks to the installation of high performance burners and high thermal efficiency devices.
Energy Saving System
Marsina has developed a technology for recovery of residual energy contained in the exhaust air leaving the spray drying tower. This technology is based on the use of water as energy carrier, circulating in closed loop and transferring heat from the exhaust air to the drying hot air entering the spray drying tower.
This system allows to use the recovered residual heat of the exhaust air to pre-heat the drying air fed to the spray drying tower, therefore reducing the total net need of heat required to produce drying hot air necessary for drying of detergent base powder. This results of course in a lower requirement of fuel to be burnt to heat the drying air, therefore fuels saving, combustion emission reduction and more environmentally friendly plant.
In particular, this technology is based on the installation of two heat exchangers:
- A cooler is used to recover heat from the exhaust air leaving the spray drying tower, by means of circulating water as coolant
- A pre-heater is used to transfer the recovered heat to the drying air stream, by means of the same circulating water previously heated in the pillow-plate exchanger and used in this case as heating fluid.
Materials and Wastes
Particular attention is paid by Marsina to sustainability strategies in terms of materials consumptions, waste minimization and water recovery.
Recycling and Re-Processing are the main targets:
- for Liquids: Slurry coming from safety valves, sampling, lines cleaning and others, is recycled in the slurry preparation
- for Solids: Lumps from vibrating sieve are re-dissolved in the slurry preparation section. Fines from the main filters are recycled directly in the spray drying tower.
- Detergent powder: Possible detergent discharged from packing machines can be recycled in the air lift hopper.
Losses of materials are less than 0.1% of detergent powder.
Service water is recovered to be re-used as process water whenever possible.
100% Made in Italy & Europe
Our plants are designed and manufactured entirely in Italy and EU.
Certified Management System
We respect European standards and maintenance of ISO 9001 certification.
Innovation comes from experience
We constantly improve to assure the best quality and the newest technologies
Process Control and Automation
The integration of advanced control systems marks another significant advancement in chemical plant engineering. Modern sulphonation plants utilize sophisticated automation technologies that ensure precise process control while optimizing resource utilization.
Real-time monitoring systems continuously adjust operational parameters, maintaining optimal production conditions while minimizing environmental impact. This level of automation represents a cornerstone of modern chemical plant design.
Experience in Design and Construction all over the World
We supply plants all over the world, from Saudi Arabia to Kuwait, from Ukraine to Greece, from Egypt to Nigeria.
Chemical Plant Safety
Modern chemical plant design prioritizes safety alongside sustainability. Advanced monitoring systems provide comprehensive oversight of all operational parameters, while automated safety protocols ensure immediate response to any deviations. This integration of safety and sustainability exemplifies the holistic approach of contemporary chemical engineering.
