SCALE-UP OF LAYER DRYERS: A UNIFIED APPROACH

The concept of Specific Drying Rate is introduced for analysis of experimental drying data for layer dryers and as a convenient scale-up factor. In conjunction with data obtained from a batch laboratory simulation the method is applicable to most types of continuous layer dryers. Three illustrations of the use of this approach for scale-up are presented including a continuous convection heated rotary shelf dryer, an indirectly heated paddle dryer, and an indirectly heated plate dryer with heating zones.     

SCALE-UP OF SPOUTED BED DRYERS: CRITERIA AND APPLICATIONS

Abstract

The criteria required for reliable scale-up of the aerodynamics of spouted bed dryers of grains are stated and discussed. The dryer modeling role for effective scale-up, design and analyses of such dryers will be outlined. Suggestions are made on how small scale drying and aerodynamic data may be scaled up for spouted bed dryers. Appropriate empirical and semi-empirical correlations are listed. A flowchart is provided for design and analysis of a conventional and a two-dimensional spouted bed dryers.     

CONVENTIONAL BASIC DESIGN FOR CONVECTION OR CONDUCTION DRYERS

Abstract

The items to be considered prior to selection of dryers are explained, and a simple method for a rough estimation of dryer sizes was proposed based on data obtained from operating industrial dryers.

The equations of basic design for batch or continuous type dryers were derived. The heat was supplied to materials by convection and/or conduction. The equations were simplified to the case when the falling rate of drying is proportional to the moisture content of materials under the constant drying conditions. The heat transfer coefficient used in the equations can be determined based on the calculations or the data obtained from the experimental or industrial dryers. The equations are useful for estimating the scale-up effect of dryers.     

SCALE-UP OF CONTACT DRYERS

ABSTRACT

The scale-up of contact dryers is still based on experimental drying curves. In order to keep the effort to a minimum the drying curve is determined using a small laboratory or pilot dryer of similar geometry to the production dryer.

This paper introduces a new scale -up method for contact dryers. The new scale-up method is based on the assumption that heat transfer is the controlling mechanism. The scale-up method is derived from the material balance, the energy balance, the kinetic equation of heat transfer and thermodynamic equilibrium. The scale up method can be used to convert the drying time required to achieve a certain residual moisture content from the laboratory or pilot dryer to the production dryer and/or different drying conditions.

The scale-up method was verified by drying test with four different products in conical mixer dryers of 1, 60, 250, 1000 I volume. Two products were free flowing and two products were non free flowing in the wet state. The products can be considered non-hygroscopic in the moisture range investigated.     

MODELING AND SIMULATION OF CROSSFLOW MOVING BED GRAIN DRYERS

ABSTRACT

The drying of grain in dryers of a crossflow moving bed type was theoretically and experimentally studied. Two different dryer configurations were analyzed, a dryer with central air distribution and another with multiple air duels. Experimental information was obtained in pilot-size dryers. A mathematical model to simulate the process was developed. Hindered drying was accounted for by using the concept of relative drying rate. An adjustable factor, specific to the dryers, was used to account for the uncertainties of the contact area and the transfer coefficients encountered in the literature. Agreement between experimental results and simulations was fairly good. Simulations showed that distance between inlet air and outlet devices, air to solid flow ratio and dryer height to cross section ratio have great influence on the process. The mathematical model may be a useful tool for process exploration and optimization of this type of dryers.     

Design and Modeling of Plug Flow Fluid Bed Dryers

Plug flow fluid bed dryers (PFFBD) have been used for drying of particulate solids such as salts, ion exchange resins, grains, and a variety of other products. The present article describes the use of a mathematical model for the scale-up of lab-scale batch fluidization data to design an industrial-scale PFFBD. Axial dispersion theory was used in conjunction with the tanks-in-series model to describe the non-ideal flow. The model was implemented in Matlab 6.5 and it can be used for easily fluidizing particulate materials. The proposed model is capable of analyzing both the exponential falling rate and constant rate drying periods. The model predicts the required dryer dimensions for a given throughput and desired final moisture content. The model can also be used to study the effect of different process parameters such as solids feed rate, inlet air velocity, and temperature on the required dryer dimensions and it can also be used to predict the moisture and temperature profiles along the length of the PFFBD.     

Comparison Between Drying of Timber in a Solar Dryer and in an Electrically-Heated Kiln

ABSTRACT

Solar dryers have been considered for timber drying in a number of countries because of the expected savings in drying costs. From a review of past works on solar, natural, and conventional drying it was observed that while solar dryers were able to dry timber faster compared to natural drying, the difference was only marginal in some instances. The drying rates are expected to be dependent upon ambient conditions in which the dryera are operated. Solar dryers would operate more efficiently in countries with low humidity than in tropical regions. Thus the thermal performance and also the economics of solar dryer is country dependent. In the present paper, a comparison of the drying rates obtained with a solar dryer is made with that obtained with an electrically operated drying kiln.     

CONCURRENT FLCW RICE DRYING

ABSTRACT

Long- and medium-grain rice were dried in a commercial multi-stage concurrent-flow dryer. Drying air temperatures varied fran 82°C to 177°C. Over six points of moisture were removed in one dryer pass without affecting the rice head-yield. Energy consumption of the dryers was half that of conventional rice dryers. Simulation played a major role in the design of the mUlti-stage concurrent-flow rice dryers.     

A GRAPHICAL DESIGN METHOD FOR A PARTIAL SOLAR DRYER FOR CORN

ABSTRACT

This paper presents the application of a design method for a partial solar heating system of polyvalent modular dryers called “GJ-ABAQUE” to the drying of thick layers of grains.

This method is based on the use of charts or polynomial correlations. In the actual case where the drying air is not recycled, we only need one chart which allows one to determine the fraction of the monthly heating load supply by solar energy as a function of two dimensionless parameters. The latter implies the use of monthly average radiation data, the collector surface and estimates of drying loads.

The “GJ-ABAQUE” method was applied for drying 777 kg of corn, corresponding to 1 m³ of fresh product, in a thick layer in each modular dryer.     

HEAT TRANSFER IN A CONDUCTIVE-HEATING AGITATED DRYER

Abstract

The heat transfers between the heating plane and the granular materials in both the “Stationary heating-plane type” and the “Moving heating-plane type” of the conductive-heating agitated dryers were discussed mainly from the view point of the scale-up of the dryer. Under the condition of complete mixing in the bed of bulk materials, the heat transfer models proposed for both the two types of dryers can predict the heat transfer coefficients in any sizes of the dryers. However, the complete mixing is not usually accomplished in the large scale of dryer. Hence, an “Incomplete mixing model” was proposed to estimate the effect of the incompleteness of mixing on the heat transfer coefficient. In this model, the incompleteness of mixing can be apparently taken into consideration only by increasing the contact time.     

COMPARISON OF RESIDENCE TIME MODELS FOR CASCADING ROTARY DRYERS

ABSTRACT

The predictions of the models of Matchett and Baker (1988) Saeman and Mitchell (1954) and Friedman and Marshall (1949) for the solids residence time in rotary dryers have been compared with both pilot-scale and industrial-scale data. A countercurrent pilot-scale dryer of 0.2m diameter and 2m long has been used with air velocities up to 1.5 ms^?1 to measure the residence times of sorghum grain, The average discrepancy for the solids residence time between the predictions and the experiments that were carried out in the pilot-scale rotary dryer is — 10.4% Compared with the models of Friedman and Marshall (1949) and Saeman and Mitchell (1954) for the pilot-scale data obtained here, the Matchett and Baker model is more satisfactory for predicting the solids residence time in this pilot-scale dryer. It has also been found that the model of Matchett and Baker describes the industrial data of Saeman and Mitchell (1954) than the correlation of Friedman and Marshall (1949).     

MATHEMATICAL MODELLING AND APPARATUS ARRANGEMENTS OF DEEP DRYING PROCESS OF GRANULAR POLYMERS

ABSTRACT

A computer - aided analysis is made of the factors influencing the kinetics of the continuous deep drying of granular polymers on the basis of a two-level mathematical model. In terms of the lower (microkinetic) level, which deals with the drying of separate granules, consideration is given to the accuracy of determining the moisture diffusion coefficients in polymers as functions of temperature and concentration D=f(U,t). The expedience of employing the solution of linear and non-linear differential diffusion equations in microkinetic calculations is also considered. In terms of the macrokinetic level, which takes account of the influence of the hydrodynamic and heat-and-mass transfer drying conditions in the dryer, a numerical study is undertaken of how the kinetics is influenced by the granules’ dimension nonuniformity and by the difference in the granules’ residence time in the dryer. The results are graphically presented in generalised variables. The travel of 12 granular polymers in the shaft (column) dryers is experimentally studied depending on definite determining parameters. Accordingly, some recommendations aimed at ensuring the uniform drying are given. Presented are also the experimental results on the longitudinal mixing for different polymers for a continuous shaft dryer with a ring material layer and with the drying agent performing the radial motion. The findings make it possible to determine the mixing rate and to outline some practical recommendations. The investigations carried out allow one to find the rational construction of the dryer for the deep drying of granular polymers and to refine the kinetic calculations.     

THE DEVELOPMENT AND VALIDATION OF A SYSTEM MODEL FOR A COUNTERCURRENT CASCADING ROTARY DRYER

ABSTRACT

An overall system model for a countercurrent rotary dryer has been developed with the ullimale aim of assessing controller pairings in these dryers. This model is based on heat and mass balances within dryer regions combined with two subsidiary models, one describing the equipment (which determines particle transport and heat transfer)and the other describing the behaviour of the material (the drying kinetics). Six partial differential equations have been set up to evaluate six state variables: solids moisture content, solids temperature, gas humidity, gas temperature, solids holdup and gas holdup as functions of time and rotary dryer length. A control-volume method has been used to reduce the six partial differential equations with respect to time and the length of the rotary dryer to six ordinary differential equations in time.

The drying model has been implemented in the SPEEDUP flowsheeting package (with FORTRAN subroutines) The model has been validated by fifteen experiments-in a pilot scale countercurrent-flow rotary dryer (0.2m in diameter and 2m in length)     

SCALE-UP OF SPRAY DRYERS

Abstract

Commercial success of a new spray dryer investment depends upon the dryer meeting its specified performance in all respects, and this puts great importance on the scale-up procedures used in the projecting of the new spray dryer. Scale-up still relies heavily on the experience of the designer. However, as the applications and specifications become more and more complex, so does the need for improved test work in pilot plants, and computational fluid dynamics simulations become more important, so that better scale-up tools are available to minimize the possibility for personal errors that may lead to the new dryer investment becoming an unsuccessful commercial venture.     

SIMULATION AND OPTIMIZATION OF CROSS FLOW GRAIN DRYERS

Abstract

In this paper simulation and optimization study on Beidahuang 5HT-15 cross flow grain dryer is presented. The p. d. e. model is employed to establish the simulation program, and the backward difference method and the predictor-corrector integration are used in the thin layer drying process estimation. The optimal analysis is conducted in a 9-dimensional domain and the specific energy consumption is taken as the main target as a weighted sum of heat and mechanical energy according to the factor of cost while the less-important features of performance are put into the target function as penalty factors. The complex polygon method is used in the optimization program. By running the optimization program, a group of optimal policies about the operation of 5HT- 15 dryer have been proposed. Possible improvement and renovation of the cross flow dryers, both in structure and in performance, have also been approached in the simulation and optimization study.     

Heating/Drying Using Particulate Medium : A Review Part II. Equipment

ABSTRACT

This paper presentS an overview of particulate medium dryers developed to evaluate the drying of grains using heated particulate media. Components of particulate medium heating and drying equipments as well as the devices employed to conduct the materials through the machine are described. How these components accomplish the basic processes involved in conduction/particulate medium heating is also explained.

To characterize the performance of these dryers based on criteria developed for farm level dryers was not possible because of the different methods employed by researchers and the various conditions the equipment were subjected to. So in order to assess the operating characteristics of each design. the dryers were compared based on their ability to remove moisture and their thermal and drying efficiency. Comparison was made on the methods utilised by each design to accomplish heating of the medium, mixing the medium with grain, the separation of the medium from grain, and the means of recirculating the medium.

Several studies conducted to evaluate the different parameters which influence drying using heated particulates are discussed. The granular media used in heating the grain and the corresponding types of grains used in the tests are also presented.     

DRYING IN COMMERCIAL RICE PARBOILING PLANTS

ABSTRACT

Two rotary dryers were replaced by one three-stage concurrent flow(CCF) dryer in a commercial rice parboiling plant. Utilization of the CCF dryer has resulted in a 34 percent savings in fuel energy and a significantly higher quality of the final product. Additional advantages include space, power and labor savings.     

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.     

Model-Based Analysis of Convective Grain Drying Processes

ABSTRACT

Simulation results for convective drying processes in cross-flow packed bed grain dryers are discussed in this article. A mathematical model developed in order to enable easier design of convective dryers and optimization of operating conditions for agricultural materials (wheat, corn, sunflower seed, etc.) is used in the study. On the basis of calculated values of the state variables of the gas phase and the solids, a clear image of the process itself can be obtained, as well as an overview of advantages and disadvantages of a specific design, supporting and facilitating decisions about the choice of dryer type and operating scheme. The case of double passing of drying agent, with and without additional heating, for a cross-flow continuous dryer, as well as the case of different materials processed in a series of cross-flow batch dryers, is analyzed.