Examining the Suitability of the Reaction Engineering Approach (REA) to Modeling Local Evaporation/Condensation Rates of Materials with Various Thicknesses

The reaction engineering approach (REA) is examined here to investigate its suitability as the local evaporation rate to be used in multiphase drying. For this purpose, REA is first implemented to model the convective drying of materials with various thicknesses. The relative activation energy, as the fingerprint of REA, generated from one size of a material is used to model the convective drying of the same material with different thicknesses. Because the results indicate that REA parameters can model the drying of materials with various thicknesses, REA can be scaled down to describe the local evaporation rate (at the microscale as affected by local composition and temperature). The relative activation energy is used to describe the global drying rate in modeling the local evaporation rate. REA is combined with a system of equations of conservation of heat and mass transfer in order to yield the spatial reaction engineering approach (S-REA) as a nonequilibrium multiphase drying model. By using S-REA, the spatial profiles of moisture content, concentration of water vapor, temperature, and local evaporation rate can be generated, which can assist in comprehending the transport phenomena.     

Multiphase modeling of intermittent drying using the spatial reaction engineering approach (S-REA)

Several schemes of energy minimization of drying process including intermittent drying have been attempted. Intermittent drying is conducted by applying different heat inputs in each drying period. An effective and physically meaningful drying model is useful for process design and product technology. The lumped reaction engineering approach (L-REA) has been shown previously to be accurate to model the intermittent drying In L-REA, the REA (reaction engineering approach) is used to describe the global drying rate. In this study, the REA is used to model the local evaporation/condensation rate and combined with the mechanistic drying models to yield the spatial reaction engineering approach (S-REA), a non-equilibrium multiphase drying model. The accuracy of the S-REA to model the intermittent drying under time-varying drying air temperature is evaluated here. In order to incorporate the effect of time-varying drying air temperature, the equilibrium activation energy and boundary condition of heat balance implement the corresponding drying settings in each drying period. The results of modeling using the S-REA match well with the experimental data. The S-REA can yield the spatial profiles of moisture content, concentration of water vapor, temperature and local evaporation/condensation rate so that better understanding of transport phenomena of intermittent drying can be obtained. It is argued here that the REA can describe the local evaporation rate under time-varying external conditions well. The S-REA is an effective non-equilibrium multiphase approach for modeling of intermittent drying process.     

Spatial reaction engineering approach as an alternative for nonequilibrium multiphase mass‐transfer model for drying of food and biological materials

Drying is a complex process which involves simultaneous heat and mass transfer. Complicated structure and heterogeneity of food and biological materials add to the complexity of drying. Drying models are important for improving dryer design and for evaluating dryer performance. The lumped reaction engineering approach (L‐REA) has been shown to be an accurate and robust alternative for cost‐effective simulations of challenging drying systems. However, more insightful physics has to be shown spatially. In this study, the REA is coupled with the standard mechanistic drying models to yield the spatial‐REA (S‐REA) as nonequilibrium multiphase mass‐transfer model. The S‐REA consists of a system of equations of conservation with the REA representing the local evaporation and wetting rate. Results of the modeling using the S‐REA match well with the experimental data reported previously. This is the first comprehensive REA approach to model the profiles of water vapor concentration during drying of food and biological materials. This study indicates that the S‐REA can be an accurate nonequilibrium multiphase mass‐transfer model with appropriate account of the local evaporation rate. The overall REA concept is expected to contribute substantially for better and cost‐effective representation of transport phenomena of drying process. © 2012 American Institute of Chemical Engineers AIChE J, 59: 55–67, 2013     

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.     

Drying of a system of multiple solvents: Modeling by the reaction engineering approach

Drying is a very important industrial operation in society. In drying, solute may dissolve in an aqueous solvent, a nonaqueous solvent or a mixture of solvents. Many mathematical models have been published previously to model drying of solute in water. The reaction engineering approach (REA) is known to be an easy‐to‐use approach. It can describe well many drying cases of water removal. Currently, no simple lumped model has been attempted to describe drying of porous materials containing a mixture of solvents. In this study, for the first time, REA is constructively implemented to model drying in a mixture of one aqueous and one nonaqueous solvent. The REA is applied here to model the drying of polyvinyl alcohol/methanol/water under constant and time‐varying environmental conditions. Similar to the relative activation energy of water, that of methanol is generated through one accurate drying run. For modeling the time‐varying drying, the relative activation energies are the same as those for modeling convective drying under constant ambient conditions but combined with the equilibrium activation energies at the corresponding humidity, methanol concentration, and temperature for each drying period. The REA is accurate to model drying of a solute in nonaqueous solvent as well as in a mixture of noninteracting solvents. In the future, spatially distributed REA for nonaqueous or mixtures of both aqueous and nonaqueous solvent will be explored for fundamental understanding and for practical application. © 2016 American Institute of Chemical Engineers AIChE J, 62: 2144–2153, 2016     

Application of the reaction engineering approach (REA) for modeling intermittent drying under time-varying humidity and temperature

A ‘good’ drying model is important for the design of dryer, evaluation of dryer performance and prediction of product quality. Among the available models, the reaction engineering approach (REA) is a lumped model, proven to be simple, robust and accurate to model drying of several materials. In this paper, the REA is implemented to model intermittent drying, which is usually practiced for saving energy consumption and maintaining product quality during drying, under time-varying drying air temperature and humidity, which is a challenging drying case to model. For this purpose, the equilibrium activation energy (ΔE_v,b) is defined according to the drying settings in each time period and combined with the relative activation energy (ΔE_v/ΔE_v,b) generated from the convective drying experimental data obtained under constant drying conditions. The mass and heat balances also implement the corresponding drying settings in each time period during the intermittent drying. The results indicate that the REA can describe both the moisture content and temperature profiles of the intermittent drying under time-varying drying air temperature and humidity well. The accuracy, simplicity and robustness of the REA for the intermittent drying under time-varying drying air temperature and humidity are proven here. This has provided a major and significant extension of the REA on modeling challenging drying cases.     

Multiscale Modeling of Superheated Steam Drying of Particulate Materials

A multiscale model for predicting the superheated steam drying behavior of a packed bed filled with particulate porous material is presented. By using a reaction engineering approach (REA) a semi-empirical model is developed that can describe the heat and mass transfer between a single particle and the surrounding drying agent. By analogy between superheated steam drying and hot air drying, the relative activation energy of the REA model is formulated. Next, the single-particle drying model is fed into a continuum-scale model of a packed bed. The temperature and moisture content of the solid and the vapor temperature are successfully predicted by the bed-scale model. To endow the bed-scale model with predictive capabilities, simulation results are compared with experimental literature data.     

Reaction Engineering Approach (REA) to model the drying kinetics of droplets with different initial sizes—experiments and analyses

Droplets with different initial sizes, which are typical in conventional liquid atomization for spray drying applications, will result in varying drying and crust formation histories. It is essential for any droplet drying model to accurately capture such fundamental phenomena. This study used a newly constructed glass-filament single droplet rig to evaluate the applicability of the Reaction Engineering Approach (REA) in describing such effect. For the three initial sizes (1, 2 and 3 μL) tested, the glass filament gravimetric method clearly distinguished the different drying kinetics and the crust formation phenomenon, delineated by the drying behavior. Analysis from the drying kinetics revealed that the main premise of the REA, which utilizes a material-specific master activation energy curve, is applicable to droplets of different initial sizes at all the three air temperatures tested. This allowed the REA to accurately predict the different temperature and moisture histories given by droplets with different initial sizes. The result supports the REA as a good modeling approach for a wide range of initial droplet conditions. A new master curve approach was proposed to predict the diameter change of droplets with different initial concentrations. Validation with the current and past experimental data revealed that this approach has strong potential to account for the different feed concentrations typically found in spray drying applications.     

Superheated Steam Drying of Single Wood Particles: Modeling and Comparative Study with Hot Air Drying

A deterministic model is developed to describe the superheated steam drying process of single wood particles. A comparison between calculated data and experimental observations infers that the moisture‐dependent effective diffusivity is suitable to be used for beechwood material drying. To reduce the computational cost of the deterministic drying model, a semi‐empirical model is proposed within the framework of a reaction engineering approach (REA). The validity of the proposed model is checked by comparing against experimental data from literature. The experimental drying behavior may fairly be reflected by the reduced model. Due to the simplicity and predictive ability of the REA model, this semi‐empirical model can be implemented to describe heat and mass transfer between a population of single particles and a drying agent in dryer models.     

Comparative study of droplet drying models for CFD modelling

CFD simulation is used to study wall deposition and agglomeration phenomena commonly encountered in industrial spray dryers. This paper initially provides a comparison of two drying kinetics models: Characteristic Drying Curve (CDC) and Reaction Engineering Approach (REA). Comparisons are made with experimental data with application to carbohydrate droplet drying obtained from past workers. These models were then extrapolated to actual drying conditions to assess their performance. The REA model predicts the progressive reduction in drying rate better than the CDC model for the carbohydrate droplets. A modified CDC model incorporating a convex falling rate produced better agreement than the conventional linear falling rate model. Further analysis showed that the REA model can be extended to simulate the particle surface moisture which may affect the agglomeration process. The proposed concept was compared with reported simulation results from a diffusion model which showed reasonable fit with data.     

Microwave drying at various conditions modeled using the reaction engineering approach

ABSTRACT

One of the most significant process intensification schemes in drying is microwave drying. Modeling the process of microwave drying is very useful. The lumped reaction engineering approach (REA) is now coupled with appropriate equations for modeling microwave heating. Here, a slight modification of the equilibrium activation energy is needed since the product temperature is higher than the ambient temperature. Unlike the diffusion-based approach, the REA drying parameters were generated from minimum number of drying runs. It has been found that the modifications lead to excellent agreements between the predicted and experimental data. The results of modeling match well with the experimental data. The overall model is accurate to describe the moisture content and temperature profiles. Comparisons with the diffusion-based approach indicate that the REA can achieve comparable or even better agreement toward the experimental data. This exercise has demonstrated that a simple combination of the lumped reaction engineering approach and the microwave energy absorption is versatile in predicting the microwave drying process accurately; thus, this worked example will be illustrative for future needed studies.     

A composite reaction engineering approach to drying of aqueous droplets containing sucrose,maltodextrin (DE6) and their mixtures

Recently, several studies have been published on the spray drying of sucrose and other low‐molecular‐weight sugars which are typically sticky materials. Sticky materials can not be processed under normal drying conditions and may require addition of high‐molecular‐weight carbohydrates such as maltodextrin. Predicting appropriate drying conditions are however difficult due to the unavailability of drying kinetics. In this article, we have formulated the drying kinetics model using the reaction engineering approach (REA) for the drying of aqueous sucrose and aqueous maltodextrin (DE6) droplets. The relative activation energy was empirically obtained based on experimental measurements. To model the drying of droplets containing both solutes (sucrose and maltodextrin), a new “composite” REA has been established and presented here for the first time. Results demonstrated that the composite REA forms a reliable framework to model the drying of aqueous solutions of pure carbohydrates and their mixtures. © 2008 American Institute of Chemical Engineers AIChE J, 2009     

Application of the reaction engineering approach (REA) for modeling of the convective drying of onion

In this study, the drying of thin layers of the “Violet de Galmi” onion (a variety mainly grown in West Africa) is presented in this article, along with the reaction engineering approach (REA) modeling for a comprehensive understanding of the drying kinetics. The experiments were conducted on a lab-scale dryer to form thin layer of cylindrical onion slice. By performing this experiment, the standard activation energy is evaluated and modeled. The model is validated by simulating the drying rates under various drying conditions. The comparison of simulation and experimental data is found to be satisfactory. This approach allows the determination of the internal characteristics of the onion for the further studies such as design of solar dryer for onion.     

CFD Evaluation of Droplet Drying Models in a Spray Dryer Fitted with a Rotary Atomizer

Computational fluid dynamics (CFD) modeling of spray dryers requires a simple but sufficiently realistic drying model. This work evaluates two such models that are currently in discussion; reaction engineering approach (REA) and characteristic drying curve (CDC). Two versions of the CDC, linear and convex, drop in drying rate were included. Simulation results were compared to the overall outlet conditions obtained from our pilot-scale experiments. The REA and CDC with a linear drop in drying rate predicted the outlet conditions reasonably well. This is contrary to the kinetics determined previously. Analysis shows that the models exhibit different responses to changes in the initial feed moisture content. Utilizing different models did not result in significantly different particle trajectories. This is due to the low relaxation time of the particles. Despite the slight differences in the drying curves, both models predicted similar particle rigidity depositing the wall. For the first time in a CFD simulation, the REA model was extended to calculate the particle surface moisture, which showed promising results for wet particles. Room for improvement was identified when applying this concept for relatively dry particles.     

Modeling of Drying Curves of Silica Nanofluid Droplets Dried in an Acoustic Levitator Using the Reaction Engineering Approach (REA) Model

The use of nanoparticles has become of great interest in different industrial applications. The spray drying of nanofluids forms nanostructured grains, preserving the nanoparticle properties. In this work, individual droplets of silica nanofluids were dried in an acoustic levitator. Tests were carried out under different experimental conditions to study the influence of the variables on the drying process. The drying curves were experimentally obtained and an REA model was used to obtain the theoretical curves and the correlations for the activation energy. The critical moisture content theoretically obtained was used to predict the grain diameter.     

DRYING OF CARROTS. I. DRYING MODELS.

Three models of different complexity are proposed to describe the falling rate period of the carrot drying process with shrinkage. A moving or fixed boundary problem as well as a constant or local moisture and temperature dependent effective diffusivity are considered. The moving boundary problem is solved by an explicit finite difference method. Heat transfer coefficient and effective diffusivity identification were carried out. The results of the heat transfer coefficient show a good agreement with other sources. Using experimental data and the models. describing the heat and mass transfer three different expressions for the effective diffusivity are established. Two of them are only temperature dependent considering or not particle shrinkage. The third one takes into account temperature and local moisture as well as shrinkage.

Drying of foods is a complicated process involving simultaneous coupled heat and mass transfer phenomena which occur inside the material being dried (Chiang and Petersen, 1987). Several models are found in the literature, representing mass and energy transfer which take place during food drying (King, 1968; Sokhansanj and Gustafson, 1980). Usually, approximate solutions are obtained with these     

Modeling Intermittent Drying of Wood under Rapidly Varying Temperature and Humidity Conditions with the Lumped Reaction Engineering Approach (L-REA)

For improving product quality and minimizing energy consumption during drying, intermittent drying is often recommended. The mathematical models that are used to describe intermittent drying are usually transport phenomena based, complex models. In this study, the lumped reaction engineering approach (L-REA) is implemented to model wood drying under rapid periodically changed drying air temperature and humidity with high number of cycles of intermittency. The equilibrium activation energy (ΔE _v,b ), an important parameter for REA approach, is evaluated according to the corresponding drying air temperature and humidity in each drying section. The results of modeling suggest the L-REA works well with the experimental data. The simplicity of the L-REA is obvious and is hoped to be used in an industrial setting more readily. The L-REA can be used for sustainable processing in industries to assist in energy audit and management.     

Application of the reaction engineering approach (REA) to model cyclic drying of thin layers of polyvinyl alcohol (PVA)/glycerol/water mixture

Rapid development of industrial polymer-based product requires considerable research in polymer drying. Cyclic or intermittent drying is used occasionally to save energy and improve product quality. Most published studies employ diffusion-based models. Reaction engineering approach (REA) is a lumped parameter model which is comparably simple and is now applied to cyclic situation for the first time. New definitions of equilibrium activation energy (ΔE_v,b) had to be introduced. With these definitions, very reasonable agreement between the predicted and published experimental data is shown. It has advantage over the diffusion model where in general complex diffusivity functions are used and had to be established using experimental data anyway. REA may be used in plant-wide simulations, where the drying kinetics has to be coupled with many other equations to be solved together. In this case, the computation time would be generally reduced if there is no need to solve the spatial distribution of water content inside the product.     

Unraveling the droplet drying characteristics of crystallization‐prone mannitol – experiments and modeling

Spray‐dried mannitol is a potential lactose replacement in pharmaceutical formulations, yet the drying behavior of individual mannitol droplets within the spray chamber has not been fully understood. This work explored the drying characteristics of mannitol by employing the reaction engineering approach (REA) in data analysis. A glass filament single droplet drying technique was used to monitor the changes in droplet temperature, mass, and diameter. The drying kinetics data obtained clearly demonstrated the droplet “wet‐bulb” period, the crust formation, and the crystallization phenomena. The master activation‐energy curves developed from REA modeling responded sensitively to varying drying temperatures, which could have led to different crystallization events. The deviation of these plots from the expected norms that do not encounter a phase change was used effectively to discern the physics involved. A REA kinetic model was proposed to assist in process optimization of large‐scale spray‐drying operations. © 2017 American Institute of Chemical Engineers AIChE J, 63: 1839–1852, 2017     

A Simulation Study on Convection and Microwave Drying of Different Food Products

It is now well recognized that matching the external drying condition with the drying kinetics of a material can lead to substantial savings of energy and in the case of heat-sensitive products, even to higher quality product. In this work, the effect of convection and microwave heat input and other product parameters on the batch drying characteristics of model materials, potato and carrot slabs, whose thermo-physical data are readily available in the literature, was modeled using a one dimensional liquid diffusion model. The influence of various thermo-physical properties of the product in drying of heat-sensitive materials was quantitatively assessed. Heat of wetting, temperature and moisture dependent effective diffusivity and thermal conductivity are considered in this model. The effect of moisture diffusivity on drying using convection and a microwave field is simulated in view of the interest in predicting the drying performance by simplified method. Conditions under which the drying rate is controlled by the external drying conditions and the internal thermo-physical properties of the product are computed and discussed.