Through Air Drying

Process of through-air-drying is becoming increasingly popular in the manufacture of textiles, non-wovens, tissue, and towel. Very high drying rates, enhanced product properties, i.e., softness, bulk, absorbency, unique 3D structure are the driving forces behind its increasing popularity. In this article, experimental results on convective heat and mass transfer and fluid flow characteristics of tissue and towel products using commercially realistic structures are presented. Comparison with literature data using wet pressed, dried, rewetted sheets indicate significant differences in drying and permeability characteristics confirming that the internal structure of the material does indeed play a significant role in through-air-drying and should be taken into account in modeling, optimization, and control of commercial systems.     

GRANULATION AND DRYING OF POWDERY OR LIQUID MATERIALS BY FLUIDIZED-BED TECHNOLOGY

Abstract

Process of through-air-drying is becoming increasingly popular in the manufacture of textiles, non-wovens, tissue, and towel. Very high drying rates, enhanced product properties, i.e., softness, bulk, absorbency, unique 3D structure are the driving forces behind its increasing popularity. In this article, experimental results on convective heat and mass transfer and fluid flow characteristics of tissue and towel products using commercially realistic structures are presented. Comparison with literature data using wet pressed, dried, rewetted sheets indicate significant differences in drying and permeability characteristics confirming that the internal structure of the material does indeed play a significant role in through-air-drying and should be taken into account in modeling, optimization, and control of commercial systems.     

Modeling Superheated Steam Vacuum Drying of Wood

Abstract

A two-dimensional mathematical model developed for vacuum-contact drying of wood was adapted to simulate superheated steam vacuum drying. The moisture and heat equations are based on the water potential concept whereas the pressure equation is formulated considering unsteady-state mass conservation of dry air. A drying test conducted on sugar maple sapwood in a laboratory vacuum kiln was used to infer the convective mass and heat transfer coefficients through a curve fitting technique. The average air velocity was 2.5 m s^?1 and the dry-bulb temperature varied between 60 and 66°C. The ambient pressure varied from 15 to 11 kPa. Simulation results indicate that heat and mass transfer coefficients are moisture content dependent. The simulated drying curve based on transfer coefficients calculated from boundary layer theory poorly fits experimental results. The functional relation for the relative permeability of wood to air is a key parameter in predicting the pressure evolution in wood in the course of drying. In the case of small vacuum kilns, radiant heat can contribute substantially to the total heat transfer to the evaporative surface at the early stages of drying. As for conventional drying, the air velocity could be reduced at the latter stage of drying with little or no change to the drying rate.     

A Parametric Study of the Gas Flow Patterns and Drying Performance of Co-current Spray Dryer: Results of a Computational Fluid Dynamics Study

Abstract

A computational fluid dynamic study was carried out to investigate airflow pattern, temperature, and humidity profile at different levels in the drying chamber. Good agreement was obtained with published experimental data. The effects of operating pressure, heat loss from the chamber wall and inlet air conditions on the gas flow pattern, droplet trajectories, and overall dryer performance also were investigated. Results are presented and discussed in terms of the gas velocity, temperature, and humidity profiles within the chambers. The volumetric evaporation values, heat transfer intensity, and thermal energy consumption per unit evaporation rate were computed and compared for drying of a 42.5% solids solution in a spray chamber 2.215 m in diameter with a cylindrical top section 2.005 m high and a bottom cone 1.725 m high. Wall regions subject to formation of undesirable deposits are also identified.     

明胶软胶囊干燥特性的研究

在对流干燥实验台上进行了明胶软胶囊干燥特性的实验,研究了加热空气温度、风速、湿度对干燥过程的影响规律。实验结果表明,提高加热空气的温度,虽然提高了传热速率,但在第2降速阶段干燥速率下降,导致最终含水质量分数反而偏高;随着加热空气风速的提高,传热速率增加,干燥速率在第1降速阶段呈现加快趋势,软胶囊的最终含水质量分数稍有降低;而加热空气湿度的变化,对传热过程影响很小,但随着加热空气湿度的降低,干燥速率提高,使得最终含水质量分数明显降低。通过研究软胶囊的干燥特性,为制药工业中软胶囊的生产提供合理指导,对优化干燥过程、降低能耗、提高产品质量和经济效益具有重要意义。     

Simulation of Drying Using a Kiln Model

A mathematical model was developed for simulating a convective batch lumber drying process. The model incorporates mass and heat transfer relationships within the lumber stack, as well as thermodynamic properties of the wood and drying air. It takes into account the change of air properties along the stack and its effect on the mass and heat transfer parameters. The model relies on a drying rate function that is an empirical correlation based on single-board tests. A drying rate function for western hemlock (Tsuga heterophylla) lumber was developed. The drying rate function was obtained based on experiment results from 500 small boards dried over a range of conditions used in commercial practice. The model was first validated against data available in the literature and then against large batches of hemlock dried in a laboratory kiln. In both cases, the model output was in good agreement with the average moisture content, the drying rates, and the temperatures measured in the larger batches.     

Analysis of the Shrinkage Effect on Mass Transfer During Convective Drying of Sawdust/Sludge Mixtures

Convective drying of wastewater sludges and sawdust/sludge mixtures was studied. The first part of this work was an experimental study performed in a cross-flow convective dryer using 500 g of wet material extruded through a disk with circular dies of 12 mm. The results showed that the sawdust addition has a positive impact on the drying process from a mass ratio of 2/8, on a dry basis, with observed drying rates higher than the original sludge. The second part of this work consisted of developing a drying model in order to identify the internal diffusion coefficient and convective mass transfer coefficient from the experimental data. A comparison was made between fitted drying curves, well represented by the Newton's model, and the analytical solutions of the diffusion equation applied to a finite cylinder. Variations of dimensional characteristics, such as the volume and exchange surface of the sample bed, were obtained by X-ray tomography. This technique allowed us to confirm that shrinkage, which is an important phenomenon occurring during sludge and sawdust/sludge mixture drying, must be taken into account. The results showed that both the internal diffusion coefficient and convective mass transfer coefficient were affected by mixing and sawdust addition. The internal diffusion coefficient changed from 7.77 × 10^?9 m²/s for the original sludge to 7.01 × 10^?9 m²/s for the mixed sludge and then increased to 8.35 × 10^?9 m²/s for the mixture of a mass ratio of 4/6. The convective mass transfer coefficient changed from 9.70 × 10^?8 m/s for the original sludge to 8.67 × 10^?8 m/s for the mixed sludge and then increased to 12.09 × 10^?8 m/s for the mixture of a mass ratio of 4/6. These results confirmed that sawdust addition was beneficial to the sludge drying process as the mass transfer efficiency between the air and material increased. Reinforcing the texture of sludge by adding sawdust can increase the drying rate and decrease the drying time, and then the heat energy supply will be reduced significantly. The study also showed that neglecting shrinkage phenomenon resulted in an overestimation for the internal diffusion coefficient for the convective drying of sludges and sawdust/sludge mixtures.     

Modeling of Convective Drying of Sawdust Using a Reaction Engineering Approach

Drying as a simultaneous heat and mass transfer process can be modeled via the reaction engineering approach (REA) where the apparent activation energy of the material is established and related to its moisture content during drying. This relationship is unique as the normalized activation energies can be collapsed into a single equation irrespective of the drying conditions and dryer types. Here, REA was applied to model the drying kinetics of sawdust using convective hot air in a laboratory setup. The normalized (relative) activation energy curve generated from one drying experiment was employed to predict the drying kinetics and temperature profiles. The REA can describe well the convective drying kinetics of sawdust, and major physics of the drying process was captured well with this technique.     

Mathematical modeling and simulation of shrunk cylindrical material's drying kinetics—Approximation and application to banana

In the present work, a diffusion-based model was adopted to represent the convective drying behavior of cylindrical banana samples, taking into consideration the shrinkage along drying. The developed model simulated a significant number of situations resulting from the variations of some operating conditions. The temperatures tested were 50, 60, 67 and 70 °C, the air velocities were 3, 4 and 4.5 m/s and the relative humidity range of the drying air was from 3.5 to 11.5%. The calculated drying curves were compared to the experimental ones in order to determine apparent moisture diffusivity. An empirical equation was suggested, describing the apparent moisture diffusivity within the banana versus product temperature and local moisture content. A good agreement was found between experimental and calculated drying kinetics.     

Three-Dimensional Numerical Modeling of Convective Heat Transfer During Shallow-Depth Forced-Air Drying of Brown Rice Grains

We describe here a three-dimensional (3D) numerical study of the convective thermal transfer during forced-air drying of brown rice grains with the inclusion of moisture evaporation. Three levels of temperature were tested across a range from 40 to 60°C. The objective of the study was to determine the temperature distributions in the drying chamber as well as the surface and intra-kernel temperature gradients during convective drying of rice grains. The numerical model was based on the Navier-Stokes equation for fluid flow and the Fourier's equation for heat transfer. Results of the numerical solution showed that temperature distribution in the air and brown rice grains during the early minutes of drying were significantly influenced by the direction of flow of the heated air. Air gaps between grains and at the periphery of the drying chamber affected the rate and direction of airflow. The temperature history of the rice grains showed variations at different levels within the layers of grains. Moreover, the stream of heated air showed regions with airflows eight times greater than the inlet air velocity.     

Modeling Superheated Steam Vacuum Drying of Wood

A two-dimensional mathematical model developed for vacuum-contact drying of wood was adapted to simulate superheated steam vacuum drying. The moisture and heat equations are based on the water potential concept whereas the pressure equation is formulated considering unsteady-state mass conservation of dry air. A drying test conducted on sugar maple sapwood in a laboratory vacuum kiln was used to infer the convective mass and heat transfer coefficients through a curve fitting technique. The average air velocity was 2.5 m s^-1 and the dry-bulb temperature varied between 60 and 66°C. The ambient pressure varied from 15 to 11 kPa. Simulation results indicate that heat and mass transfer coefficients are moisture content dependent. The simulated drying curve based on transfer coefficients calculated from boundary layer theory poorly fits experimental results. The functional relation for the relative permeability of wood to air is a key parameter in predicting the pressure evolution in wood in the course of drying. In the case of small vacuum kilns, radiant heat can contribute substantially to the total heat transfer to the evaporative surface at the early stages of drying. As for conventional drying, the air velocity could be reduced at the latter stage of drying with little or no change to the drying rate.     

From Laboratory Experiments to Design of a Conveyor-Belt Dryer via Mathematical Modeling

Abstract

A conveyor-belt dryer for picrite has been modeled mathematically in this work. The necessary parameters for the system of equations were obtained from regression analysis of thin-layer drying data. The convective drying experiments were carried out at temperatures of 40, 60, 80, and 100°C and air velocities of 0.5 and 1.5 m/sec. To analyze the drying behavior, the drying curves were fitted to different semi-theoretical drying kinetics models such as those of Lewis, Page, Henderson and Pabis, Wang and Singh, and the decay models. The decay function (for second order reactions) gives better results and describes the thin layer drying curves quite well. The effective diffusivity was also determined from the integrated Fick's second law equation and correlated with temperature using an Arrhenius-type model. External heat and mass transfer coefficients were refitted to the empirical correlation using dimensionless numbers (J _h , J _D  = m · Re ⁿ ) and their new coefficients were optimized as a function of temperature. The internal mass transfer coefficient was also correlated as a function of moisture content, air temperature, and velocity.     

Transversale Schüttgutbewegung und konvektiver Stoffübergang in Drehrohren. Teil 2: Mit Hubschaufeln

Lifting flights used in rotary cylinders allow the transport of particles into the gas cross-section and therefore increase both the gas-solid mass transfer area and the mass transfer coefficient. The cascade characteristics, i.e. the lifting flight holdup as a function of the angular position, can be calculated from force balances and geometric considerations. By defining a normalized flight holdup, we can represent the cascade characteristics in a general dimensionless form, which is assumed to be linear. The average falling velocity and the mass transfer area of the falling particles can be obtained from the analysis of the height of the fall, assuming free fall. In order to describe the convective mass transfer at the falling particles, an effective velocity is defined by combining the velocities of both gas and particles. Experimental data obtained from drying experiments allow a general correlation to be fitted for the convective heat and mass transfer at the falling particles. Contrary to the corresponding transfer area, the convective mass transfer coefficient is nearly independent of the rotational speed.     

Experimental and Numerical Study of Flat Plate Sludge Drying at Low Temperature by Convection and Direct Conduction

This article deals with the drying of the waste by-product of an activated sludge manure treatment plant. The studies concern the low temperature drying of planar plates 3 cm thick. The upper face of the sludge is subjected to a tangential air flow controlled for speed, temperature, and humidity. The lower face can be subjected to contact heating. The maximum temperature for air and the bottom of the product is 60 °C. After characterizing the main thermophysical and hygric properties of the product, the laboratory set-up specifically designed for this study is described. Experiments are performed to determine temperature, mass loss, and deformation evolutions for different boundary conditions. These experimental data are used to build a numerical one-dimensional heat and mass transfer model to predict temperature and moisture content fields. Sludge is assimilated with a hygroscopic porous medium, and shrinkage is not taken into account. To validate this model, several comparisons between simulated and measured data are made for different drying methods (hot or fresh air convective drying, contact drying, and combined drying) and various drying conditions.     

A Parametric Study of the Gas Flow Patterns and Drying Performance of Co-current Spray Dryer: Results of a Computational Fluid Dynamics Study

A computational fluid dynamic study was carried out to investigate airflow pattern, temperature, and humidity profile at different levels in the drying chamber. Good agreement was obtained with published experimental data. The effects of operating pressure, heat loss from the chamber wall and inlet air conditions on the gas flow pattern, droplet trajectories, and overall dryer performance also were investigated. Results are presented and discussed in terms of the gas velocity, temperature, and humidity profiles within the chambers. The volumetric evaporation values, heat transfer intensity, and thermal energy consumption per unit evaporation rate were computed and compared for drying of a 42.5% solids solution in a spray chamber 2.215 m in diameter with a cylindrical top section 2.005 m high and a bottom cone 1.725 m high. Wall regions subject to formation of undesirable deposits are also identified.     

EFFECTS OF OPERATIONAL CONDITIONS ON DRYING CHARACTERISTICS IN CLOSED SUPERHEATED STEAM DRYING

The effects of operational conditions on the drying performance in closed superheated steam drying were examined theoretically and experimentally. The vapor generated from the sample was circulated in the drying chamber. In the theoretical analysis, the replacement of air with vapor in drying chamber and the convective vapor transfer in sample were considered. At the start of drying, the drying chamber was filled with air. As the drying proceeded, the air was replaced with the vapor generated from sample. The calculated results explained the characteristics of experimental data. The pore diameter of sample had little effect on the drying characteristics. During the internal evaporation period, the evaporation occurred in the narrow zone, which moved from the surface to the bottom of sample. The convective vapor transfer in sample had a significant influence on the drying performance. The excess increments in temperature and velocity of drying gas hardly contributed to shortening the drying time.     

EFFECTS OF OPERATIONAL CONDITIONS ON DRYING CHARACTERISTICS IN CLOSED SUPERHEATED STEAM DRYING

The effects of operational conditions on the drying performance in closed superheated steam drying were examined theoretically and experimentally. The vapor generated from the sample was circulated in the drying chamber. In the theoretical analysis, the replacement of air with vapor in drying chamber and the convective vapor transfer in sample were considered. At the start of drying, the drying chamber was filled with air. As the drying proceeded, the air was replaced with the vapor generated from sample. The calculated results explained the characteristics of experimental data. The pore diameter of sample had little effect on the drying characteristics. During the internal evaporation period, the evaporation occurred in the narrow zone, which moved from the surface to the bottom of sample. The convective vapor transfer in sample had a significant influence on the drying performance. The excess increments in temperature and velocity of drying gas hardly contributed to shortening the drying time.     

A review of: “Developments in Drying,Vol. 2” Edited by A.S. Mujumdar and S. Suvachittanont Kasetsart University Press,Bangkok, Thailand 2000

Although pulse combustion devices exhibit a high thermal efficiency and low pollutant emission when used in a drying process, a broad application of these dryers has been limited because of a lack of understanding of the fundamental controlling heat and mass transfer. This paper reports the results of an experimental investigation of heat transfer between unsteady airflow and a brass sphere under various oscillating frequencies. In order to generate an unsteady flow, we constructed a gas-fired, water-cooled pulse burner. The burner is of a Helmholtz type and its operating frequency can be adjusted by changing the tailpipe length. The heat transfer coefficient between unsteady air outflow and brass was determined by the lumped capacity method. The effect of airflow oscillating frequency on heat transfer coefficient was investigated and their correlation was established. Refractory clay particles in the oscillating airflow were dried and the effect of the frequency on the drying process was predicted using the heat transfer coefficients obtained.