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Abstract Energy conservation has become a priority for industry nowadays. Also, the process performance has been evaluated according to the overall energy efficiency and the energy recovery potential.Among this work we studied the probability of recover heat from the exhaust air out of the spray dryer unit using high temperature heat pump system and reuse the recovered energy for preheating the inlet air to the dryer instead of exhausting the hot outlet air into the environment. This work is applied by developing a successful model using an Aspen Plus simulation program after data acquisition for the process operating parameters and the dryer main dimensions by developing a mathematical model numerically and by using Excel software to let the modifications and results more clear and near to the real. The Aspen Plus simulation model was implemented using the following two major steps:(1) Spray dryer unit sizing; mass and energy balance to calculate the desired amount of air and its temperature to dry the slurry to a blown powder.(2) The exhaust air from a spray dryer was moved to a heat pump system to exploit its high temperature for preheating the fresh air to the spray dryer. The developed system succeeded to recover about 17% of the waste energy and an economical heat pump system of about 4 COP. |