Modelling of Rotary Dryer

Dr.ir. W.Jan Coumans, TU Eindhoven

Symposium Ned. Werkgroep Drogen, Utrecht, 20 nov 2008

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Why modelling of dryer?

• Design of new dryer
• Optimise performance existing dryer
• Scale-up from lab-scale via pilot plant to
full-scale dryer

• No accurate design possible without

experimental work
• Modelling may reduce considerably
experimental work 2

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 Purpose of Dryer Models
• Macro balances models
– Capacity heater, blower
• Scoping models

complexity
Increasing
– Rough size estimates using simple data
• Scaling models
– Overall dimensions
– Performance figures
– Scale-up from lab to full scale
• Detailed models
– As scaling models
– Local drying conditions needed 3

Scientific Approach to Dryer Design

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 Rotary Dryer (convective type)

Feed
Air/Solid
Separator
Heater
Air

Product

Definition of Drying Problem

• Configuration
• Desired specifications / process conditions
• Estimated specifications / process
conditions
• Via macro balances
– Required air rate
– Required heating power

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 Phases in Modelling
• Physical model
• Mathematical model
• Numerical model
• Algoritm
• Programming code (e.g. Matlab)
• Testing
• Experimental input data for model
• Application of model
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Configuration
• No inner drum
• Co-current and Counter-current
• Single pass of air and particles
• Indirect heating of air (no flue gasses)
• Flights
several types possible
(shape, dimensions, number)

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 Assumptions at scale of dryer
• Stationary condition
at any position in dryer
all variables and fluxes are constant in time
• No residence time distribution of particles and
air
• Losses of heat over dryer wall
• No losses of air and product (no leakages)

Assumptions at scale of particles

• Instationary mass/heat transfer process (by
definition)
• Non-shrinking
• No temperature gradient inside particle

Taveraged = Tinterface

• Drying kinetics
Characteristic Drying Curve

• Sorption-isotherm
e.g. Halsey’s equation

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 Macro Model for Dryer
Qheater Qw
G Y0 G Yfinal
h0 Τg0 hfinal Τg,final
G Yfresh
Air
hfresh Τg,fresh

1 mass heat 2
P Xfinal
P X0 jfinal ΤP,final
Product
j0 Τp0

11 Known parameters 15 Unknown parameters

Fresh inlet AIR heater Tg,fresh , RHfresh G , Yfresh , hfresh
Inlet AIR dryer Y0 , Tg0 , h0
Outlet AIR dryer Tg,final Yfinal , hfinal , RHfinal
FEED P , X 0 , Tp0 j0
PRODUCT X final , ∆X eq , ∆Teq Tp,final , jfinal , X eq,final
Heater ηheater Q heater
Heat losses via wall floss Qw
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Global Design of Rotary Dryer

• Macro model
Heater capacity and Air rate
• Air rate + vg,superficial
Diameter D
s ible
pos
• Ratio L/D
Length of dryer ios
e nar
e r sc
Oth
• L and D
Volume of dryer
• Drying kinetics
estimated drying time τ
• τ + product rate + volume
Holdup

• Drying kinetics = f(material, process conditions )

• Hold-up = f(flights, slope, diam, rpm, friction coeff, .. )
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 Symbols &Q Units
w
h0
hfinal
Y0
Y Yfinal
G Tg vg
heat mass

P Tp vp X Xfinal
X0 0
z L jfinal
j0 • Flows
P = product flow kg dry solid/s
G = air flow kg dry air/s
• Moisture content:
X = moisture in product kg w/kg dry solid
Y = moisture in air kg w/kg dry air
• Enthalpy content:
j = enthalpy content product kJ/kg dry solid
h = enthalpy content air kJ/kg dry air
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Equations in Control Volume ∆z

∆Qw
h0
hfinal
Y0
Y Yfinal
G Tg vg
q jw

P Tp vp X Xfinal
X0 0 z z+∆z L jfinal
j0
• Conservation laws • Material transport
– Dry solid & dry air – Model Friedman & Marshall
– Moisture – Model Matchett & Baker
– Enthalpy • Material properties
• Heat & mass transfer – Characteristic drying curve
– q is heat flux in kJ/m2s – Sorption-isotherm
– jw is mass flux in kg/m2s • Psychrometric equations
– coupling q and jw • Physical properties
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1. Moisture Balance (stationary)
∆Qw
h0
hfinal
Y0
Y Yfinal
G Tg vg
q jw

P Tp vp X Xfinal
X0 0 z z+∆z L jfinal
j0

∆X ∆Y
P⋅ + G⋅ =0
∆z ∆z

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2. Enthalpy Balance (stationary)

∆Qw
h0
hfinal
Y0
Y Yfinal
G Tg vg
q jw

P Tp vp X Xfinal
X0 0 z z+∆z L jfinal
j0
∆j ∆h ∆Q w
P⋅ +G⋅ + =0
∆z ∆z ∆z
j = cps Tp + X ⋅ cps Tp
∆Q w
h = cpa Tg + Y ( ∆hv0 + cpd Tg ) = U ( Tg − Tambient )
∆z
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¾. Mass & Heat Transfer Rates
3
dX
− = f ⋅ k mρf ( Yi − Y ) ⋅ a s
dt
m2/kg ds
p
f=Φ
X − X eq
Φ=
X cr − X eq

4
DRYING KINETICS
qp = αh ( Tg − Tp )
Characteristic Drying Curve (CDC)

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Xeq and Sorption Isotherm

• Equilibrium Moisture Content Xeq at a
given temperature Tp and relative humidity
of air
• Generally
aw=aw(Xeq,Tp)
• Numerous equations in literature
• Example: Halsey’s equation
 
 c 
a w = exp −
 X m
 ( eq ) 
c and m are fitting parameters,
and may depend on temperature
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 5. Coupling of Mass & Heat
Transfer
• Enthalpy-balance over particles in ∆z
• Control ‘volume’ ~ 1 kg dry solids
• Instationairy wet-bulb equation
dX dj
q p ⋅ as = − ⋅ ∆hv,Ti +
1
424 3 14 dt
4244 3 1424dt 3
heat enthalpy enthalpy
to for accumulation
particles evaporation in particles

as = m2/kg ds, X = kg w/kg ds, j = kJ/kg ds

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6. Velocity vp of Particles
Model Friedman & Marshall

1 a 0.6083 G plus
counter-current

= ± ⋅
v p Sd N 0.9 D dp P minus
co-current

2.304 dz
n  vp =
a = 0.2657 + 0.2322  f  dt
 12 
P v ps
v ps = holdup =
π 2 vp
D ρbulk
4
ATTENTION: this model is not consistent with CDC !!!

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 6. Velocity vp of Particles
Model Matchett & Baker-1

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6. Velocity vp of Particles
Model Matchett & Baker-2
h0
∫ sin ( θ ) ⋅ dh
2De 0
Nta ta = ⋅
v1 + v 2 g cos ( α ) h0
φ
vp = h0
Nta
+1 ∫ θ ⋅ dh
φ 1 0
φ= +
nf πh0
This model is consistent with CDC

h is holdup in a single ‘flight’ ……

…which will be a function of the rotation angle θ of the drum
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 Flight Design
segmented
flight

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Flight holdup (h)

h=F(flight geometry, rotation angle, friction factor)

rectangular
flight

φ θ horizontal
friction factor rotation
tan(φ) angle θ

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 6. Velocities of Particles
Gas Phase and ‘Dense’ Phase
Model Matchett & Baker-3
v1 = v10 + v1d  gasfase
Under loaded
g ⋅ sin(α)
v10 = ⋅ ta
2
µv g ta
v1d = 7.45 ⋅ 10 −4 ⋅ Re 2.2 ⋅ Design loaded
ρp dp2

v 2 = fa ⋅ a ⋅ N ⋅ D ⋅ tan(α)  ‘dense’ phase

Over loaded
fa corrects for ‘overloaded’ drum

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numerical and graphical results

Matlab programs and functions

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 Air
temperature

Product
temperature

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Conclusions

Would I recommend you to start

building dryer models?

I am curious myself to know which

conclusions I am going to draw!

14 november 2008

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