GEA spray nozzle increases safety level and plant productivity

With a continued focus on safety in its product evolution, GEA has introduced a camera system for monitoring the nozzle systems in spray dryers, aptly called SprayEye.

When using cameras located within the spray dryer’s air disperser, clients have a choice of either a visual or infrared monitoring system. The visual monitoring system allows the user to monitor the spray dispersal, identify nozzle leaks and any product build-up on the spray nozzles. The infrared monitoring system provides continual data and heat variation images pertaining to the spray of each nozzle, and irregularities therein.

Both systems were introduced to the South African market during GEA’s South African road show in mid-March. “Previously, there was no method to monitor nozzles and spray dispersal,” points out Wayne Labuschagne, after-sales and service, GEA Africa. “These systems increase safety and facilitate improved productivity – ultimately contributing to increased profitability.”

The system consists of air-cooled cameras, encased in stainless steel camera housings, located in the spray dryer’s air disperser – one for every two spray nozzles. The cameras show a continuous picture of the spray zone, allowing operators to ensure that there are no leaks, or build-up of solid matter, and that the spray dispersal remains at an optimum level.

The infrared version of the system monitors the temperatures, so smouldering lumps of powder building up due to a faulty nozzle, or an incorrect spraying pattern, will be clearly visible and detectable.

While the heat data images will not show a definitive leak, per se, the rise in temperature will alert operators to potential threats, allowing them to take preventative action.

“Disaster aversion is not the system’s only purpose,” Labuschagne points out. “It plays a pivotal role in facilitating increased production in factories in which it is installed.”

He explains that monitoring systems changes the risk profile, which allows clients to raise the drying air temperature, enabling a much faster production rate. “In other words,” he says, “it increases productivity to the maximum by safely optimising this part of the process.”