A Diffusion Model for a Drum Dryer Subjected to Conduction, Convection, and Radiant Heat Input

Drum dryers are commonly used for production of a flaky dry powder from thick suspensions. This article presents results of a simple diffusion-based model to predict the drying performance of a pilot-scale twin-drum dryer. Numerical results are compared with experimental data obtained for a biological sludge whose initial moisture content varied from 1.0 to 2.3 kg/kg db. The agreement of model predictions with the pilot-scale experimental data is favorable. Effects of film thickness, drum rotational speed, external air flow velocity, and its humidity are examined parametrically. Sludge film thickness is identified as the most critical operating parameter to control the final moisture content and productivity of the dryer. The validated model is used to predict performance of a drum dryer subjected to heat input by convection and radiation along with conduction through the drum wall. It is shown that dryer output can be enhanced significantly by increasing the film thickness and applying radiant heating in the initial period of drying. A simple mathematical model of this type can be used for the purpose of design and analysis as well as scale-up of industrial drum dryers based on simple laboratory-scale experiments.     

Mathematical Modeling and Simulation of Drying Using Two Industrial Concurrent and Countercurrent Rotary Dryers for Ammonium Nitrate

Drying of ammonium nitrate (AN) is accomplished in the Shiraz Petrochemical Complex (SPC) using a concurrent rotary dryer following a countercurrent rotary dryer. A mathematical model for these rotary dryers including heat and mass transfer was developed. The model was checked against industrial-scale data, which showed a good agreement. The average absolute deviation of the simulation results compared to the industrial data for the concurrent dryer was 4.0% for solids moisture, 1.3% for solids temperature, and 1.8% for air temperature and for the countercurrent dryer it was 9.0% for the solids moisture, 2.0% for solids temperature, and 4.6% for air temperature. These simulation results reveal that for outlet solid moisture, inlet AN moisture, and air temperature as well as the outlet temperature of product, the inlet solid and air temperature have major effects for both concurrent and countercurrent flow.     

EXPERIMENTAL STUDY ON DRYING OF CHILLI IN A COMBINED MICROWAVE-VACUUM-ROTARY DRUM DRYER

This paper presents new data on drying chilli in a microwave-vacuum-rotary drum dryer. This novel technique is designed to combine the advantages of vacuum drying and evenly dispersed microwave energy in a rotary drum. The drying kinetic and the specific energy consumption at particular product moisture content were measured experimentally. Moreover, the effect of pressure inside the chamber and the rotational speed of the drum were also determined.     

A physical description of solids transport in flighted rotary dryers

In this paper, a solids transport model for flighted rotary dryers is presented. Emphasis is placed on combining statistical and mechanistic modelling efforts to create a physically motivated compartment model involving pairs of perfectly mixed tank reactors linked in a series arrangement. Here, each tank pair, or cell, aims to physically describe a finite slice of a case study industrial rotary sugar dryer, and is hence governed primarily by flight geometry and dryer operational variables such as rotational speed and dryer inclination. Solids flow paths are structured to properly represent the different modes of transport in the rotary dryer, and values of transport coefficients are based on calculated rates of rotational and axial flows. A solids dispersion variable is used to correlate the model residence time distribution (RTD) prediction with available data from a tracer study conducted during industrial operation of a full-scale raw sugar dryer. RTD results from the model show intuitive responses to variations in solids feed rate, rotational speed and drum inclination.     

EXPERIMENTAL STUDY ON DRYING OF CHILLI IN A COMBINED MICROWAVE-VACUUM-ROTARY DRUM DRYER

ABSTRACT

This paper presents new data on drying chilli in a microwave-vacuum-rotary drum dryer. This novel technique is designed to combine the advantages of vacuum drying and evenly dispersed microwave energy in a rotary drum. The drying kinetic and the specific energy consumption at particular product moisture content were measured experimentally. Moreover, the effect of pressure inside the chamber and the rotational speed of the drum were also determined.     

Modeling of Fertilizer Drying in Roto-Aerated and Conventional Rotary Dryers

Conventional rotary dryers are equipped with flights placed parallel along the length of the shell to promote a rain of solids across the dryer section. In the roto-aerated dryer the hot air flows through the particles that run on the bottom of the drum through a series of mini-pipes and there is no cascading. This study analyzed heat and mass transfer modeling between the air and the fertilizer particles in conventional rotary and roto-aerated dryers, as well as the simulation results with the experimental data. A good agreement between the simulated and experimental results was obtained for the two rotary dryer configurations analyzed.     

Modeling of heat pump tumble dryer energy consumption and drying time

The use of heat pump tumble dryers is nowadays more common because they offer huge energy savings compared to conventional tumble dryers. Earlier studies made on conventional tumble dryers have shown that parameters such as heater power, fan speed, drum speed, weight and initial moisture content of textiles and air leakage have a huge impact on the energy efficiency and drying time. In the present study, a modified commercial heat pump tumble dryer was evaluated for energy consumption and drying time by changing operating parameters including fan speed, drum speed, and mass load. The total energy consumption and drying time were measured and corrected for the initial and final moisture content in the textiles. The experimental results based on 27 drying tests were evaluated to develop linear regression models for energy consumption and drying time, which show a good agreement with the experimental data. The results show that a large mass load, a high drum speed, and a low fan speed give the highest energy efficiency, i.e. the lowest energy consumption per kg of drying load. Larger loads extend the length of the drying cycle while higher fan and drum speeds result in shorter drying time.     

INDIRECT THERMAL DRYING OF LIGNITE: DESIGN ASPECTS OF A ROTARY DRYER

An investigation of the thermal drying of lignite has been carried out, by using an indirect heat pilot rotary drum. The process aims at the production of dry lignite and clean steam as part of a gasification procedure. Both flighted and bare drum modes have been employed. Temperature profiles along the dryer length, the amount of evaporation (moisture conversion) and the solids residence time distribution (RTD) were measured. A non-isothermal model was tested under three different regimes of solids flow. Model integration, by taking account of experimental amount of evaporation at dryer exit and temperature profiles along the dryer length, has been utilized in the validation of drying kinetics and heat transfer correlations. Model predictions compare satisfactorily with the operating data of an indirect heat industrial lignite dryer. Overall heat transfer coefficients of the pilot rotary dryer were found to agree well with those reported for direct heat dryers.     

Simulation of Wood Particle Motion Through a Concurrent Triple-Pass Rotary Dryer

The retention time of solids in a drum is an important parameter for the design of rotary dryers, since it directly influences the mass and heat transfer rates. If it is too short, the wood particles do not become adequately dried. If it is too long, they become over-dried. Therefore, having an appropriate retention time is useful in terms of both energy and plant capacity. Wood particle mean retention time in a rotary dryer is affected by several variables, such as dryer dimensions, solid characteristics, and operational parameters. The purpose of this work was to simulate the effects of some wood particle characteristics and operational parameters on the mean retention time, drum holdup, and velocity of the wood particles during drying in a pilot-scale, closed-loop, triple-pass rotary dryer by means of a computer code. The simulation results of wood particle motion can be used for modeling, design, and optimization of closed-loop, triple-pass rotary dryers.     

INDIRECT THERMAL DRYING OF LIGNITE: DESIGN ASPECTS OF A ROTARY DRYER

ABSTRACT

An investigation of the thermal drying of lignite has been carried out, by using an indirect heat pilot rotary drum. The process aims at the production of dry lignite and clean steam as part of a gasification procedure. Both flighted and bare drum modes have been employed. Temperature profiles along the dryer length, the amount of evaporation (moisture conversion) and the solids residence time distribution (RTD) were measured. A non-isothermal model was tested under three different regimes of solids flow. Model integration, by taking account of experimental amount of evaporation at dryer exit and temperature profiles along the dryer length, has been utilized in the validation of drying kinetics and heat transfer correlations. Model predictions compare satisfactorily with the operating data of an indirect heat industrial lignite dryer. Overall heat transfer coefficients of the pilot rotary dryer were found to agree well with those reported for direct heat dryers.     

ATMOSPHERIC CONTACT DRYING OF GRANULAR BEDS WETTED WITH A BINARY MIXTURE

When regarding the atmospheric contact drying of granular beds wetted with a liquid mixture, both the drying rate and the selectivity of the process, i.e. the change of moisture composition, are of interest. The batch drying of a free flowing ceramic substance, wetted with a 2-propanol-water mixture, is investigated in a rotary dryer with heated wall and air flow.

The theoretical analysis is based on physical models for heat and mass transfer, moisture migration and particle transport, which are presented in examples.

The experimental and theoretical results show that higher selectivities can be achieved by reducing the particle size because of the lower liquid-phase mass-transfer resistance. An increase of the rotational speed leads to a higher drying rate with slightly decreased selectivity if the particles are sufficiently small, since contact heat transfer is enhanced.     

SNIPPET ON DRYING

ABSTRACT

When regarding the atmospheric contact drying of granular beds wetted with a liquid mixture, both the drying rate and the selectivity of the process, i.e. the change of moisture composition, are of interest. The batch drying of a free flowing ceramic substance, wetted with a 2-propanol-water mixture, is investigated in a rotary dryer with heated wall and air flow.

The theoretical analysis is based on physical models for heat and mass transfer, moisture migration and particle transport, which are presented in examples.

The experimental and theoretical results show that higher selectivities can be achieved by reducing the particle size because of the lower liquid-phase mass-transfer resistance. An increase of the rotational speed leads to a higher drying rate with slightly decreased selectivity if the particles are sufficiently small, since contact heat transfer is enhanced.     

Mathematical Modeling the Drying of Poplar Wood Particles in a Closed-Loop Triple Pass Rotary Dryer

Closed-loop drying systems are an attractive alternative to conventional drying systems because they provide a wide range of potential advantages. Consequently, type of drying process is attracting increased interest. Rotary drying of wood particles can be assumed as an incorporated process involving fluid–solid interactions and simultaneous heat and mass transfer within and between the particles. Understanding these mechanisms during rotary drying processes may result in determination of the optimum drying parameters and improved dryer design. In this study, due to the complexity and nonlinearity of the momentum, heat, and mass transfer equations, a computerized mathematical model of a closed-loop triple-pass concurrent rotary dryer was developed to simulate the drying behavior of poplar wood particles within the dryer drums. Wood particle moisture content and temperature, drying air temperature, and drying air humidity ratio along the drums lengths can be simulated using this model. The model presented in this work has been shown to successfully predict the steady-state behavior of a concurrent rotary dryer and can be used to analyze the effects of various drying process parameters on the performance of the closed-loop triple-pass rotary dryer to determine the optimum drying parameters. The model was also used to simulate the performance of industrial closed-loop rotary dryers under various operating conditions.     

A SIMPLE DYNAMIC MODEL FOR SOLID TRANSPORT IN ROTARY DRYERS

The solid particle movement in a rotary drum plays an important role in drying processes. The solid distribution in the drum affects the amount of contact surface between the solid and the gas. The retention time of solids influences the time particles can stay in contact with the gas in order to transfer heat and mass. Any heat and mass transfer model for a solid particle dryer must be able to predict solid flowrate and solid hold-up. There have been several reports in the literature regarding the modelling aspects of solid transport in dryers. If the model is developed for model-based control, it must be simple and yet represent dynamics of the system accurately. This paper addresses solid motion modelling and the effects of different variables involved in solid transport phenomena. Sugar drying process is the case study in this work. A steady state semi-empirical model was modified to predict solid hold-up and flowrate in rotary dryers. This model was incorporated into a heat and mass transfer model ;o predict solid moisture and temperature for inferential and model-based control purposes. Results of several experiments that have been used to investigate dynamics of the system in terms of solid motion and to validate the model are also presented. The approach advocated in this paper is directly applicable to the transport of other solids in rotary drum equipment and can thus be regarded as a generalized model.     

A SIMPLE DYNAMIC MODEL FOR SOLID TRANSPORT IN ROTARY DRYERS

ABSTRACT

The solid particle movement in a rotary drum plays an important role in drying processes. The solid distribution in the drum affects the amount of contact surface between the solid and the gas. The retention time of solids influences the time particles can stay in contact with the gas in order to transfer heat and mass. Any heat and mass transfer model for a solid particle dryer must be able to predict solid flowrate and solid hold-up. There have been several reports in the literature regarding the modelling aspects of solid transport in dryers. If the model is developed for model-based control, it must be simple and yet represent dynamics of the system accurately. This paper addresses solid motion modelling and the effects of different variables involved in solid transport phenomena. Sugar drying process is the case study in this work. A steady state semi-empirical model was modified to predict solid hold-up and flowrate in rotary dryers. This model was incorporated into a heat and mass transfer model ;o predict solid moisture and temperature for inferential and model-based control purposes. Results of several experiments that have been used to investigate dynamics of the system in terms of solid motion and to validate the model are also presented. The approach advocated in this paper is directly applicable to the transport of other solids in rotary drum equipment and can thus be regarded as a generalized model.     

煤调湿装置蒸汽管回转干燥系统研究

介绍了煤调湿技术的意义、原理和煤调湿煤粉蒸汽管回转干燥系统的工艺、设备特点和开发设计中干燥机出口产品水分的控制方式,研究了在保障干燥机出口煤粉湿含率不变的条件下,干燥机进料量、进料湿含率、进料温度与干燥用蒸汽的关系。     

Drying kinetics study of irregular fibril materials in a “differential” laboratory rotary dryer: Case study for cut tobacco

Rotary dryers are commonly used in the modern large-scale tobacco drying industry that consumes huge amounts of energy. In fact, rotary dryers are commonly used in chemical industry in general. It is difficult to investigate the drying behavior at industrial scale. A “differential” laboratory rotary dryer was therefore designed and tested. The large diameter of the industrial dryer was preserved, but the width was a section of the industrial dryer. The drying characteristics of cut tobacco from top leaves and bottom leaves with initial moisture contents (22.5?±?1.0% on the wet basis) were studied in the “differential” dryer at air temperatures of 65, 85, 105, 125, and 145°C, respectively. The results show that increasing drying temperature accelerated the drying process, whereas the surface temperatures of the cut tobacco samples stayed in the temperature range of 48–71°C when their moisture contents were reduced to 12.0?±?1.0% (wb). This 12.0% (wb) was required by commercial operations. Uniquely, the drying kinetics was captured using the reaction engineering approach (REA). Although different settings were applied, the model can be used to describe all the data well. The unique relationship between the normalized activation energy and the moisture content is approximated which is independent of the drying air temperature and the tobacco origin. The different drying behaviors for the cut tobacco from top leaves and bottom leaves can be attributed to their different equilibrium isotherms. Through controlling the drying time as predicted by REA model, the outlet moisture contents of cut tobacco from top leaves dried at 95°C/RH0.034/320?s and 115°C/RH0.017/250?s were shown to be 12.3 and 11.8% (wb), with the relative deviations of 2.5 and 1.7%, respectively, and these were within the industrial permissible range.     

Simulation of Recirculating Circular Grain Dryer with Tempering Stage

The diiffusion model describing internal diiffusion of moisture within a grain kernel during drying and tempering stages was incorporated in the cross-flow drying model to simulate the recirculating circular grain dryer with drying and tempering stages. Experiments were conducted on an experimental prototype recirculating circular grain dryer for wheat and rough rice drying. The simulated grain temperature and moisture content were compared with the experimental data of drying wheat and rough rice, the maximum deviation of the outlet grain temperature was 5°C and the maximum deviation ofthe final grain moisture content was 0.3% w.b. The simulating program for recirculating circular grain dryer was used for analyzing the effects of structure parameters and hot air parameters on the dryer performance. Recommendations for design of the recirculating circular grain dryers are drawn from the experiments and simulation.