The Project
CAISA undertook a comprehensive optimisation of an existing spray drying plant, achieving a tenfold (×10) increase in production capacity compared to the original installation. The project required an exhaustive analysis of each process stage to identify bottlenecks and propose the most efficient technical improvements.
The main interventions included the installation of a new, higher-power combustion chamber and burner, a new air diffuser with optimised geometry, and a new state-of-the-art CMT TLC-30 atomiser. This oil-free atomiser incorporates multiple alarm and telemetry systems that significantly improve process reliability and control. In addition, the drying chamber outlet was redesigned and new connecting ducts, a new gas scrubber were installed, and the fans were upgraded to optimise the overall energy efficiency of the installation.
Specifications
| Improvement | Description |
|---|---|
| Combustion chamber | New, higher power |
| Atomiser | CMT TLC-30 (oil-free, multiple alarms) |
| Air diffuser | New optimised geometry |
| Drying chamber outlet | Redesigned |
| Gas scrubber | New |
| Fans | Upgraded, improved energy efficiency |
| Production increase | ×10 vs original installation |
Results
The optimised plant reached the established production target — ten times the previous capacity — with a simultaneous improvement in energy efficiency. The new CMT TLC-30 atomiser significantly reduced maintenance downtime by eliminating the oil lubrication system and providing real-time diagnostics.
This project demonstrates CAISA’s capability to approach the modernisation of existing plants in a comprehensive manner, combining process engineering expertise with the fabrication and installation of high-technology equipment.
