Method to Characterize the Air Flow and Water Removal Characteristics During Vacuum Dewatering. Part II—Analysis and Characterization

This is part II of a study reported earlier on a method to characterize the air flow and water removal characteristics during vacuum dewatering. This article presents experimental data and analysis of results from the use of a cyclically actuated vacuum dewatering device for removing moisture from wetted porous materials such as paper with the intermittent application of vacuum and accompanying air flow though the material. Results presented include sheet moisture content as a function of residence time and hence water removal rate under a variety of process conditions. Also, experimental results on air flow through the wet porous structure and hence the role and importance of air flow during vacuum dewatering are presented. Vacuum dewatering process conditions include exit solids content between 11 and 20% solid under applied vacuum conditions of 13.5 to 67.7 kPa (4 to 20 in. Hg). Regression analysis indicated that the exit sheet moisture content exhibited a nonlinear relationship with residence time with exit solids reaching a plateau after a certain residence time. Final moisture content correlated linearly with the average overall flow rate of air through the paper sample and the basis weight of the material.     

Method to Characterize the Air Flow and Water Removal Characteristics during Vacuum Dewatering. Part I—Experimental Method

An experimental method using a novel design to characterize the air flow and water removal during vacuum dewatering in paper manufacturing is discussed. The experimental setup involves the intermittent application of vacuum, similar to commercial systems, using a rotating disk with slot opening arrangement. The system is capable of commercially realistic residence times of the order of milliseconds. The intermittent application of vacuum simulates vacuum dewatering on commercial paper machines. The air flow rate is calculated from changes in pressure and temperature in the vacuum tank underneath the sample. The role and importance of air flow during vacuum dewatering is studied by accurately measuring the air flow, properly taking into account the leaks during vacuum dewatering. The method described here provides for the first time accurate air flow and water removal data during vacuum dewatering. Methods of analysis of the experimental data are also presented. This information can be used to better understand the water removal process as well the role and importance of air flow during vacuum dewatering.     

Method to Characterize the Air Flow and Water Removal Characteristics during Vacuum Dewatering. Part I—Experimental Method

An experimental method using a novel design to characterize the air flow and water removal during vacuum dewatering in paper manufacturing is discussed. The experimental setup involves the intermittent application of vacuum, similar to commercial systems, using a rotating disk with slot opening arrangement. The system is capable of commercially realistic residence times of the order of milliseconds. The intermittent application of vacuum simulates vacuum dewatering on commercial paper machines. The air flow rate is calculated from changes in pressure and temperature in the vacuum tank underneath the sample. The role and importance of air flow during vacuum dewatering is studied by accurately measuring the air flow, properly taking into account the leaks during vacuum dewatering. The method described here provides for the first time accurate air flow and water removal data during vacuum dewatering. Methods of analysis of the experimental data are also presented. This information can be used to better understand the water removal process as well the role and importance of air flow during vacuum dewatering.     

Mechanism of Through Air Drying of Paper: Application in Hybrid Drying

During through air drying the internal sheet drying history develops as a succession of local moisture content profiles in the sheet thickness dimension. These profiles were determined by interrupting the through drying of 180 g/m² 6-ply sheets, then quickly delaminating and determining the moisture content of each 30 g/m² ply. On the through flow inlet side of the sheet, large moisture differences, about 0.4-0.6 kg/kg dry per 30 g/m² ply, develop and move into the interior of the sheet provided that local moisture content is in the range 0.45-1.75 kg/kg. On the through flow exit side, moisture gradients only become significant for moisture content below about 1.25 kg/kg. From the through flow exit side of the sheet much of the water is removed by diffusion to the flow entry side where most evaporation into the through flow occurs. The kinetics of through drying reflect the interaction between these two mechanisms, local evaporation into the through flow and thickness direction diffusion. The moisture diffusivity-moisture content relation controls this balance. In any combination with cylinder drying to give some kind of hybrid dryer, through drying should be at the dry end where air permeability is highest and cylinder drying rate is lowest.     

Drying Suspensions in a Pulsed Fluidized Bed of Inert Particles

The drying of carbohydrate suspensions on polypropylene particles in a pulsed fluidized bed was studied by means of a 2⁵ experimental design, to determine the effect of the air flow and temperature, suspension flow rate, and free section and rotating speed of the rotary plate on the Nusselt number, the moisture content of the product, and the percentage of solids retained inside the bed (which were minimized to 4.9 and 14.4%, respectively) with an air flow of 600 m³/h at 90°C and 720 mmHg, a suspension flow rate of 6 L/h, and a plate with 6% free section, rotating at 50 rpm.

Additionally, the effects of temperature, air flow, and suspension flow rate on the residence time distribution (RTD) were determined, using the stimulus-response methodology. The RTD was represented by 1.1 to 2 tanks in series, according to this model. The mean residence time of the dried carbohydrate particles was between 5.4 and 8.2 min.

Finally, an egg suspension could be dried at 4 L/h, with air at 90°C, with a mean residence time about 50% longer that that found for drying carbohydrate suspensions.     

Hydrodynamic Characteristics of a Pilot-Scale Screw Conveyor Dryer

This article presents results of an experimental study on the flow characteristics of a pilot-size screw conveyor dryer (SCD). In particular, the effects of granular solids flow rate (15.2-206 kg/h) and screw speed (10.8-28 rpm) on the residence time distribution (RTD) were studied using sand as the model material. The RTD was measured using a dynamic step change in the solids flow rate. Parameters such as solids holdup, degree of fullness, mean residence time, and uniformity of the discharge flow were studied. The solids holdup and hence the degree of fullness was found to decrease with increase in the screw speed and decrease with the solids flow rate. The mean residence time was found to decrease with an increase in the screw speed, as expected. The screw speed and the solids flow rate strongly affected the discharge uniformity. An optimum value of the degree of fullness was observed with regard to the solids flow rate. Over the operating range examined, the solids flow pattern was close to plug flow, as indicated by high values of N and Pe number.     

Investigation on Moisture Transfer Mechanism in Porous Media During Rapid Drying Process

In this work, moisture transfer mechanism in wet porous media during rapid drying process is investigated experimentally and analytically. By use of scanning electron microscopic device, the rapid drying processes for potato, carrot, and radish species were observed and recorded. The microscopic drying experiments show that during high intense and rapid drying process, the mechanism of moisture migration in materials is mainly considered as a displacement flow driven by pressure gradient along a capillary passage. A simplified displacement flow model during rapid drying process is proposed and the time needed for moisture transfer in porous media is calculated. To examine this drying mechanism, one-dimensional displacement flow test device is built up and a set of experiments under different pressure gradients and temperatures are conducted. Glass beads of 0.8 mm in diameter are used as the porous material. The experimental results show that when pressure gradient is getting greater at constant temperature, the moisture removal time is getting smaller. On the other hand, under the same pressure gradient, when liquid temperature increases, the time for moisture transfer from the internal to the external surface decreases. The calculated moisture removal times are well agreed with the experimental data.     

A Study of the Limitations to Spray Dryer Outlet Performance

The concept of the product moisture locus was tested in this work using a pilot-scale modified Niro spray dryer (diameter 0.8 m, height 2 m), where the residence time of the particles inside this spray dryer is lower compared with larger industrial spray dryers. The moisture contents of skim milk powder produced from spray drying skim milk (solids content 8.8% w/v) at different operating conditions, namely different swirl vane angles (0°, 25°, 30°), inlet air temperatures (170°C, 200°C, 230°C) and process fluid flowrates (1.4 kg h^-1, 1.6 kg h^-1, 1.8 kg h^-1), were compared with the predicted equilibrium moisture contents. In addition, the residence time of the particles was also increased in the spray dryer by decreasing the inlet air mass flowrate from 0.016 to 0.013 kg s^-1. The outlet moisture contents of the skim milk powder for all the 23 runs carried out in this work were within 0.4% of the equilibrium values. Thus, the skim milk powder particles were in close equilibrium with the gas inside the drying chamber. These equilibrium limitations are confirmed by other literature data (Boonyai, P. Comparative Evaluation of Soymilk Drying in a Spray Dryer and Spouted Bed of Inert Particles. M.Sc. Thesis. Asian Institute of Technology: Bangkok, Thailand, 2000; 90 pp; Harvie, D.J.E.; Langrish, T.A.G.; Fletcher, D.F. A computational fluid dynamics study of a tall-form spray dryer. Trans IChemE 2002, in press). The use of this finding to predict spray dryer performance is demonstrated by mass and energy balance calculations.     

Paste Residence Time in a Spouted Bed Dryer. III: Effect of Paste Properties and Quality Interactions

The aim of this study was to evaluate the effects of paste properties on residence time during drying in a spouted bed dryer with inert bodies. The effect of paste solids content, surface tension, and viscosity on the residence time distribution and the mean residence times were studied using factorial experimental designs. The inert bodies used were glass and polyethylene beads. The mean residence times varied from 13.6 to 16.3 and 12.2 to 17.7 min for drying on glass and polyethylene beads, respectively. The analysis of variance showed that mean residence times significantly depended on solids content and surface tension for glass beads and also on viscosity for polyethylene beads. The residence time distributions for all conditions studied fitted well to the perfect mixing cell when applying the continuous stirred vessels in series model analysis. The powder density, flowability, and particle size depended on paste properties and inert type.     

Drying Rate Curves of Porous Solids in Steam and in Air under Low-Pressure Conditions

Drying of porous solids such as sintered glass beads, baked clay, and cemented glass balloons in both steam and air streams was investigated under low-pressure conditions. There was no significant difference between the normalized observed drying rate curves in air at low pressures of 0.71-1.19 kPa and those in steam at low pressures of 0.97-0.99 kPa. However, lower critical moisture contents and higher drying rates in superheated steam at subatmospheric pressures of 8.27-8.33 kPa were observed compared to those in steam at pressures in the range of 0.97-0.99 kPa. Moreover, two models were validated for the prediction of drying rate curves of sintered glass beads at subatmospheric and low pressures. The patterns of the drying rate curves, which depend on the drying medium and its pressure, were common to these materials.     

Effect of Hydrodynamics During Crystallization on Mechanical Dewatering of Salicylic Acid

Mechanical cake dewatering is always desired to reduce the load on thermal dewatering (drying). Any change in the upstream process such as crystallization can have a significant influence on the filtration as well as cake dewatering characteristics. The present study deals with the effect of hydrodynamics (mixing intensity) during salicylic acid crystallization on the air dewatering characteristics in the subsequent pressure filtration. The mixing conditions during crystallization were varied by using three different types of agitators (anchor impeller [AI], curved blade turbine [CBT], and bar turbine [BT]) and by varying the speed of agitation. The effect of operating pressure and dewatering time on the final moisture content of the cake was also studied.

The crystal properties (crystal size and size distribution) were found to vary with the mixing intensity, which further influenced the cake dewatering kinetics as well as the residual moisture content. An AI, which is a laminar flow impeller, produced crystals with a wide size distribution and higher mean particle size, which resulted in cake with high porosity and hence higher moisture content. The high porosity (as well as high cake permeability) caused early air breakthrough, which resulted in ineffective dewatering of cake. Therefore, in this case the residual moisture in cake was found to be higher (27%) even at higher dewatering pressure (1.5 bar gauge) and longer dewatering time (90 s). A BT creates high turbulence during mixing and produced crystals with a relatively narrow size distribution and lower mean particle size, which provided low-porosity cakes. Such cakes could be efficiently dewatered and the final cake moisture content was found to decrease to about 15%, a significant improvement in the filterability of the cake. The dewatering data were modeled according to the correlation between irreducible cake saturation and capillary number for predicting the cake dewatering characteristics (residual moisture as well as dewatering kinetics) and the results were compared with the experimental data.     

Comparison of Drying Kinetics of Paddy Using a Pneumatic Conveying Dryer with and without a Cyclone

The objective of the present work is to find the possibility of reducing the high initial moisture content of wet paddy using a small-scale, low-cost pneumatic conveying dryer that can be provided for each farming household. The dryer without a cyclone equipped at the exit of the dryer is studied and the data obtained from this system is compared with those obtained previously from the dryer with a cyclone. Parametric effects of the following variables are examined: velocity of drying air from 20 to 30 m/s, feed rate of rough rice from 150 to 350 kg/h, and drying air temperature from 35 to 70°C. From the experimental results it is found that the drying process with and without a cyclone are able to lead to very rapid drying without any grain quality problems such as cracks in the rice kernel. For the same experimental conditions, the cyclone-equipped dryer gives around 1% higher decrease of moisture content, 2°C higher average surface temperature of paddy, 3-4% higher average percentage of head rice yield, and 2 kg/h higher average evaporation rate. However, the energy consumption per evaporated mass of water is 20-30% lower than the non-cyclone-equipped dryer.     

EVALUATION AND MODELING OF TWO-STAGE OSMO-CONVECTIVE DRYING OF APPLE SLICES

Two-stage drying kinetics of cylindrical pieces of apples were evaluated by subjecting test samples first to various osmotic treatments and then to convective air drying to complete the drying process. Osmotic drying was carried out with cut apple cylinders of three different sizes (12, 17 and 20 mm diameter), all with a length to diameter ratio of 1 : 1, in a well agitated large tank containing the osmotic solution at the desired temperature. Solution to fruit volume ratio was kept greater than 60. After the osmotic treatment, apple slices were further dried in a cabinet drier at an average temperature 58°C. A central composite rotatable design (CCRD) with five levels of sucrose concentrations (34-63°Brix) and five temperatures (34-66°C) was used for osmotic treatment. Half-drying time and solids gain time were used as measures of rate of drying and associated diffusion coefficients for moisture loss and solids gain were evaluated. Half-drying time decreased with an increase in temperature or concentration, or a decrease in sample size. Diffusion coefficients were lower for smaller samples, and were higher for migration of moisture as compared to solids. For a given level of moisture removal, air drying times were shorter than osmotic drying times. Composite models were developed to describe the effect of process variables and particle size on the drying behavior of apple slices.     

The Change of Body Temperature During Convective Drying of Cube-Shaped Apple Pieces

When using the convective drying method, the mass transfer between drying air and moisture diffusion of the material is very important. The moisture moves inside the material because of the volume change caused by the increased temperature. This movement is additionally affected by the texture of the material. According to the research dealing with colloid capillary porous texture of vegetables and fruit, the humidity migration inside the material occurs in both fluid and steam condition at the same time. This migration is stimulated by the heating and decreasing humidity along with the flow. In this research, winter varieties of apples (Jonathan, Golden Delicious, and Idared) were studied by heating of a 20 × 20 × 20 piece of apple with a thermocouple in it. On the basis of the measurements it can be stated that for the fruits with a high percentage of moisture (75-90%), when making the drying condition, the moisture gradient is influenced by the fractured cells of the cut area. It was found that the variety of apple is very important in relation to the heating and water loss gradient. According to the results, the wet volume change due to the heating highly influences the water loss. The models that describe the temperature of the material have a connection with the water loss.     

An Experimental Study of the Thermal Performance of a Screw Conveyor Dryer

In the present study drying of fine crystalline solid was carried out in a non-insulated jacketed screw conveyor dryer SCD of 3 m length and 0.072 m screw diameter. It is nitrogen-swept to carry off the evaporated moisture. Dryer performance was evaluated in terms of the final moisture content, heat-transfer coefficient, thermal efficiency and power consumption. From the experimental results it was observed that drying under low pressure gives 92% moisture removal compared to 30-40% using low flow rates of nitrogen. The initial moisture content was in the range of 5 to 6%. Over the parameter range studied, the overall heat transfer coefficient was found to be in the range of 46-102 W/m²K. The average rise in the temperature of the product was 40 to 50°C. Thermal efficiency (based on sensible and latent heat) of the dryer obtained was found to be in the range of 25-62%, typical values obtained in falling rate drying period. Power consumption per metric ton of dried material was found to be a strong function of screw speed and material feed rate, material properties, and drive efficiency.     

Stepwise Development of a Mathematical Model for Air Flow in Vacuum Dewatering of Paper

Part of the dewatering in a paper machine takes place via vacuum suction boxes situated below the moving web. In addition to the removal of liquid water, considerable amounts of air are sucked through the paper. The air flow that accompanies dewatering is a crucial parameter for the electricity consumption of a vacuum system. The present study models this air flow, combining differential conservation equations with fiber characterization. Measured air flow rates for different vacuum levels, basis weights, and pulp types are compared to model predictions. More than 70% of the data agree within the range of experimental error.     

Effect of Electro-Osmotic Dewatering on the Quality of Tofu Sheet

As a new dewatering technology with high efficiency and energy saving, electro-osmotic dewatering can be applied to food processing. The objective of this work was to study the effect of combined field dewatering (CFD) involving electro-osmosis and mechanical pressure on the quality of tofu sheet. Combined field dewatering was performed on the dewatering process of tofu sheet for 10 to 30 min at a voltage ranging from 30 to 50 V under various pulse-time ratio (t₊ = 120 s, t_- = 5 s) electric field and 0.047 MPa pressure field. The texture and structure of tofu sheet after treatments were examined by a rheometer and scanning electron microscope (SEM). The result showed that the three quality indexes, i.e., hardness, tensile strength, and ductility of tofu sheet near the anode were 45%, 30%, and 12% higher respectively than those dewatered by common mechanical pressure method. However, those near the cathode were 15%, 25%, and 10% lower respectively. When the electric field was applied for 10 min at 30 V, these indexes reached their maximum values. Meanwhile, the tofu sheet structure near the anode was more compact and homogeneous than that near the cathode. The result indicated that CFD could enhance the quality of tofu sheet.     

The Role of Nonuniformity in Convective Heat and Mass Transfer through Porous Media,Part 1

Through-air drying is commonly used in the drying of high-quality tissue and towel products. A representative elementary volume method was used to model the fluid flow and heat and mass transfer during through drying in heterogeneous porous biobased materials such as tissue and towel products. Results of flow both upstream and downstream of a modeled porous sheet allowed visualization of the effects of mixing at the top and bottom of the porous medium. The effect of initial nonuniformity on fluid flow and convective heat and mass transfer in heterogeneous porous media was studied. The effect of material nonhomogeneity and associated transport properties on moisture content of the porous material as a function of drying time was studied. Modeling results indicate that for the first time it is possible to simulate the effect of nonuniformity on fluid flow and convective heat and mass transfer in porous media during through-air drying of paper. Moisture and structural nonuniformity contributing to nonuniformity in air flow might contribute significantly to drying nonuniformity. Depending on the moisture regimes and degree of saturation of the convective medium, heat and mass transfer coefficients may have varying effects on the overall drying.     

Filter Press for Electrodewatering of Waterworks Sludge

An electrodewatering filter press was designed and its performance was evaluated for basic operating parameters such as the electric field strength, time of electric field application, and changes in pressure. Dewatering efficiency improves with the increase of the electric field strength, application time, and pressure. Considering the operating costs due to energy consumption and electrode erosion, the optimal conditions were found to be 70 V/cm of electric field strength, 30 min of application time, and 588 kPa of pressure. The rate of electrodewatering doubled compared with that of mechanical dewatering (MDW) while the water content of the dewatered cake decreased by 25%. When an electric field is applied to the cake, clogging of the filter cloth becomes minimized due to electrophoretic mobility. The discharge of water from the cake porous matrix is facilitated owing to electroosmosis and thermal effect due to joule heating. As a result, the dewatering capacity of electrodewatering improves compared with the mechanical dewatering. The energy consumption of electrodewatering was about 370-450 kWh/t (dry solid), which accounts for only one tenth of the existing sludge treatment costs.     

Filter Press for Electrodewatering of Waterworks Sludge

An electrodewatering filter press was designed and its performance was evaluated for basic operating parameters such as the electric field strength, time of electric field application, and changes in pressure. Dewatering efficiency improves with the increase of the electric field strength, application time, and pressure. Considering the operating costs due to energy consumption and electrode erosion, the optimal conditions were found to be: 70 V/cm of electric field strength, 30 min of application time, and 588 kPa of pressure. The rate of electrodewatering doubled compared with that of mechanical dewatering (MDW) while the water content of the dewatered cake decreased by 25%. When an electric field is applied to the cake, clogging of the filter cloth becomes minimized due to electrophoretic mobility. The discharge of water from the cake porous matrix is facilitated owing to electroosmosis and the thermal effect due to joule heating. As a result, the dewatering capacity of electrodewatering improves compared with the mechanical dewatering. The energy consumption of electrodewatering was about 370-450 kWh/t (dry solid), which accounts for only one tenth of the existing sludge treatment costs.