High Tower Spray Drying Detergent Powder Plant

What is a high-tower spray-drying laundry detergent production line?

A high-tower spray-drying laundry detergent production line is a complete chemical production line. Liquid and powder raw materials are precisely metered according to the formula, neutralized, aged, and homogenized to form a slurry, which is then pumped by a high-pressure pump to the top of a spray tower for atomization. Upon contact with hot air generated by a hot air furnace, the slurry is instantly dried, forming hollow bead-like particles at the bottom of the tower. After the post-processing system adds heat-sensitive ingredients such as enzymes and fragrances, the final product is a medium-to-high-grade laundry detergent.

Laundry detergent produced by this process typically has a bulk density between 0.25 and 0.50 g/cm³, with uniform particle size (0.5-1.5 mm), resulting in a good visual appearance and user experience.

Core Processes

1. Slurry Preparation and Aging
Powder raw materials (such as sulfonic acid, soda ash, silicates) and liquid raw materials are precisely metered according to the formula and fed into the mixing tank for mixing.

After neutralization, the slurry enters the aging system to fully hydrate and homogenize it.

The slurry is then ground and filtered through a colloid mill or homogenizing pump to ensure it is fine and free of particles.

2. Spray Drying
A high-pressure pump sends the slurry to the top of the tower, where it is atomized into tiny droplets through nozzles.

Hot air (from a hot air furnace, fuel oil/gas/coal/biomass) comes into contact with the droplets.

Instant drying forms hollow particles with a bulk density of 0.25~0.35 g/cm³.

The exhaust gas is treated by cyclone dust removal and water film dust removal before being discharged in compliance with standards, and the fine powder is recycled.

3. Post-Blending Mixing
The base powder, after pneumatic aging and sieving, enters the post-blending mixing system.

Functional ingredients such as enzymes, fragrances, nonionic surfactants, and colored particles are added.

A high-efficiency rotary mixer ensures uniform distribution of the components.

Core Advantages and Technical Features

1. Superior Product Quality
The laundry detergent granules produced by the high-tower spray process are hollow spheres with the following characteristics:

Rapid Dissolution: Disintegrates and disperses rapidly in water, leaving no residue.

Good Flowability: Does not clump, ensuring smooth metering and packaging.

Visually Appealing: Uniform, white granules with high added value.

2. Energy-Saving and Environmentally Friendly Design
Modern high-tower production lines integrate multiple environmental protection technologies:

Zero Wastewater Discharge: Fully enclosed circulation system, no process wastewater discharge.

Heat Recovery: Waste heat from exhaust gas can be used for slurry preheating or workshop heating.

Fine Powder Recovery: All fine powder collected by the dust removal system is returned to the tower for reuse.

Clean Workshop: A comprehensive dust removal system ensures a clean production environment.

3. Flexible Production Capacity
Equipment configurations are flexibly selectable to meet different product requirements:

Single Spray Tower: Produces ordinary hollow granule laundry detergent (density 0.25-0.35)

Agglomeration Granulation Tower: Produces concentrated high-density laundry detergent (density 0.45-0.80)

Tower + Agglomeration Composite Process: The same production line can produce products across the entire density range; 70% of the material is added through the agglomeration system, resulting in significant energy savings.

Core Advantages and Technical Features