Drying unit Flash series

Overview
Using gas suspension drying (GSD) technology, FLS flash dryers rapidly and economically dry a wide range of fine materials. Flash dryers suspend a dilute quantity of fine feed in a high-temperature gas stream so the material dries or heats in seconds rather than minutes, delivering high throughput, reduced energy use and controlled product quality.

Key benefits

• Low specific energy consumption — rapid drying in seconds and flue-gas recirculation for heat recuperation to lower fuel use.
• Consistent operation and product — automatic burner and control system adapts to feed moisture and maintains temperature within approximately ±5°C for consistent final moisture.
• Very low maintenance — no moving parts in the dryer core, reducing operating expenses and maintenance requirements.

How it works
Fine material is fed into the gas suspension dryer where it becomes entrained in hot gases and dries almost instantaneously. Dried particles are separated from the spent gas in a cyclone; spent gas is dedusted in a dust collector and product discharges from the cyclone/dust-collector underflow. Flue-gas recirculation can be applied to recuperate process heat. Optional features include a back-mixer for final moisture adjustment and flexible fuel options (including hydrogen firing). The process is characterised by very short residence time, fast response to control changes, and prevention of overheating or product degradation.

Applications and handled materials

• Engineered for a wide range of fine mineral materials including potash, phosphate, limestone fines, alumina, trona, clays, talc and similar mineral products.
• Can be supplied as a standalone dryer/heater or integrated into pyroprocessing lines (for example combined with rotary kilns, indirectly heated rotary kilns, gas suspension calciners or multiple hearth furnaces).

Maintenance & service
FLS provides design, pilot testing and process simulation via an in‑house test centre to support equipment selection. Services include commissioning and installation support, inspections, troubleshooting and optimisation, spare parts supply, retrofits and modifications, operator training, and support for conversions to alternative energy systems (e.g., hydrogen firing, oxy-fuel combustion, electric heating).

Frequently asked questions (summary)

• How does a flash dryer/heater work? — Fine feed is entrained in a hot gas stream and dries in seconds; particles are separated by cyclone and dedusted.
• What materials can it handle? — Wide range of fine minerals such as potash, phosphate, limestone fines, alumina, trona, clays and talc.
• How does it compare to alternatives? — Offers high thermal efficiency, compact footprint, low maintenance, rapid drying that prevents overheating and degradation, and broad feed versatility.
• How efficient is the technology? — Gas suspension drying delivers high energy efficiency with heat recuperation options.

Specifications / technical data

• Technology: Gas suspension drying (GSD) — flash dryer / flash heater.
• Typical throughput range: ≤1.0 tph up to ≥750 tph (configurable by design and application).
• Temperature control: Automatic burner/control system with tight regulation (approx. ±5°C) to maintain consistent product moisture.
• Residence time: Seconds (very short compared with other dryers).
• Heat recovery: Flue-gas recirculation possible to recuperate process heat and reduce fuel consumption.
• Particle separation: Cyclone separation plus dust collector for dedusting; product exits via cyclone/dust-collector underflow.
• Mechanical configuration: No rotating or moving parts in the dryer core (minimal mechanical wear, low maintenance).
• Fuel flexibility: Accommodates a wide range of fuels, including options for hydrogen firing and conversions (also oxy-fuel or electric heating integrations).
• Optional features: Back mixer for final moisture adjustment; integration capability with rotary kilns, calciners, multiple hearth furnaces and other pyro-equipment.
• Applications: Drying/heating of fine mineral products including potash, phosphate, limestone fines, alumina, trona, clays, talc and similar materials.