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Dryer Design

The document discusses the selection and operation of a rotary dryer. A rotary dryer is selected for its ability to handle free-flowing pellets continuously and cost-effectively. It operates by rotating a cylindrical shell to lift and shower solid materials through convection drying. Energy and mechanical calculations determine the dryer should be 1.57 meters in diameter, 11.28 meters long, rotate at 6 RPM, and require 7.5 kW of power.

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Gohar Abbas
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889 views9 pages

Dryer Design

The document discusses the selection and operation of a rotary dryer. A rotary dryer is selected for its ability to handle free-flowing pellets continuously and cost-effectively. It operates by rotating a cylindrical shell to lift and shower solid materials through convection drying. Energy and mechanical calculations determine the dryer should be 1.57 meters in diameter, 11.28 meters long, rotate at 6 RPM, and require 7.5 kW of power.

Uploaded by

Gohar Abbas
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as DOCX, PDF, TXT or read online on Scribd
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Drying Operation:

Drying of solids means the removal of relatively small amounts of water or other liquid from the
solid material to reduce the content of residual liquid to an acceptably low value. Drying is
usually the final step in a series of operation and the product from a dryer is often ready for
final packaging.

Why we select rotary dryer:

1. Type of feed: Our feed is free flowing pellets & rotary dryer best handles the free
flowing material.

2. Type of production: Our plant is based on continues operation & rotary dryer is
considered to be the best dryer as a “continues” unit.

3. Capital cost: Rotary dryer has a low capital cost per unit of output.

4. Method of operation: Convection is the method of operation & rotary dryer is


best suitable for this method.

5. Handling of wide size particles: In rotary dryer wide particle size distribution
can be handled

6. Availability of data: Either data is available for designing or not? Rotary dryer can
be scaled up with sufficient success from data given in the literature.

7. Quality of product: A dryer needs to balance a quality against cost of production.


& rotary dryer fulfills this need.

8. Maintenance cost: Maintenance costs are often a major consideration. Past


history shows rotary dryers have relatively low maintenance cost.

Operation of rotary dryer:


A rotary dryer consist of a revolving cylindrical shell, slightly inclined to the outlet. Wet feed
enters one end of cylinder, dry material discharges from the other. As the shell rotates internal
flights lift the solids and shower them down through the interior of shell. Rotary dryers are
heated by direct contact of heated gas with solids by hot gas passing through an external jacket
or by stream condensing in a set of longitudinal tube mounted on the inner surface of shell. The
last of these types is called a steam tube rotary dryer. Indirect rotary dryer in which hot gas first
passes through jacket and then through shell where it comes in contact with solids.

Design considerations:
1. Solid feed rate and inlet moisture contents.
2. Temperature of air and feed.
3. Diameter and length of dryer
4. Rotational speed of drum.
5. Lifting flights

From energy balance:

Stream 1:
Feed inlet temperature=25 °C = 298 K = 76.73 °F

Mass flow rate=1000 Kg/hr

Moisture = 8.76 %

Stream 2:
Air inlet temperature= 90 °C = 363 K = 194 °F

Humidity=0.005 lb/lb

Stream 3:
Air outlet temperature= 52 °C = 325 K = 125.6 °F

Humidity=0.03 lb/lb

Stream 4:
Feed outlet temperature= 50 °C = 323 K = 122 °F

Mass flow rate= 938.68 Kg/hr

Moisture= 2.8 %

Number of heat transfer units:


Nt = ln (Thb - Twb/ Tha - Twb)
Where

Nt = No of heat transfer units

Thb = Air inlet temperature (°F)

Twb = Product outlet temperature (°F)

Tha = Air outlet temperature (°F)

By putting all values

Nt = ln (194 - 122/125.6 - 122)

Nt= 2.99

Calculation of Heat duty:


Heat duty is calculated by equation given as

Qt/ms = cps (Tsb - Tsa ) + (Xa – Xb ) λ+ Xa cPL (Tv –Tsa)+ XbcPL (Tsb -TV)+ (Xa – Xb
) cpv (Tva –Tv)
Where

Qt = heat required to remove moisture =?

Cps = Specific heat of solid = 1.926 KJ/Kg.K

CpL = Specific heat of liquid= 1 KJ/Kg.K

Cpv= Specific heat of vapor=0.45 KJ/Kg.K

ms= solid mass flow rate = 1000 Kg/hr

Tsb = Outlet temperature of solid= 323 K


Tsa = inlet temperature of solid= 298 K

Xa = moisture content at inlet = 0.0876

Xb = moisture content at outlet = 0.028

λ = Latent heat of vaporization at 122 °F= 2383.045 KJ/Kg

by putting all values we get

Qt/ms = 192.42

Qt=192.42(1000)

Qt =192422.64 KJ/hr=53.45 KJ/s

Mass flow rate of entering air is found from heat balance and humid heat

mg(1+xb)=QT/Csb(Thb-Tha)
Csb=0.240 KJ/Kg.K (McCaib Smith chap. 19)

mg(1+0.005)=53.45/0.240(323-298)

mg=3.4262 Kg/s

Maximum allowable velocity of air = 1.75 Kg/m2.s (perry section 12-55)

D= [4*(flow rate of air entering/max. allowable air velocity)/3.14]0.5


D= 1.57 m = 5.12 ft

Now we calculate length of dryer

L=Qt/0.125πDG0.67∆T
Where

∆T= LMTD

LMTD=30.07 K

By putting all values we get

L=11.28 m=37 ft
To calculate RPM of rotary dryer:
Peripheral speed=10m/min (perry section 12-56)

RPM=10/1.57

RPM=6.36 = 6

To calculate no. of flights and radial height of flight we have:


No. of flights = 3(D) = 3(1.57) = 4.71

No. of flights = 5

Radial height of flight = (1/10TH) D (Perry section 12-56)

Radial height of flight = 1.57/10 = 0.157 m = 6.18 in.

Mechanical design:
Material of construction = carbon steel

Density of carbon steel = 7850 Kg/m3

Permissible stress of material selected = 135 N/mm2 (RC VOL -6)

POWER TO DRIVE THE DRYER:


bhP= r (4.75dw+0.1925DW+0.33W)/100000 (Perry equation 12-60)
Where

bhP= brake horsepower

r= RPM

w=live load, material (Kg)

W=total rotating load, equipment plus material (Kg)

d=shell dia (m)

D= riding ring dia (m)


To calculate live load and total rotating load,

Volume of shell= (πD22-πD12) L/4

Volume of shell = [3.14(1.65)2-3.14(1.57)2)] 11/4

Volume of shell= 2.28 m3

Weight of dryer = volume (density) = 2.28(7850)

Weight of dryer=17905 Kg

Assume hold up of dryer = 0.2

Volume of dryer filled with material = (π D2 L/4).hold up

Volume of dryer filled with material= 4.364 m3

Density of feed in the dryer = 120 Kg/m3

Weight of material in the dryer (w) =4.364(120) = 523.68 Kg

W = weight of dryer = w +17905 = 18428.68 Kg

D=d+2 = 3.57 m

By putting all values we get

P= 10.1 bhp = 7.5 Kwatt

Time of passage:
Perry section 12-55

θ = (0.22L/SN0.9D) + (0.6 BLG/F)


Where

S is slope (4 cm/m)

B is constant which is given by

B =5 DP0.5

B= 5(0.008)0.5

B = 0.447
By putting all values we get

θ= 6.3 min

Specification sheet:

Equipment Dryer

Function to reduce the moisture contents

Operation Continuous

Type direct heat rotary dryer

Design data

Flow rate of solid =1000 kg/hr

Water removed = 61.32 kg/hr

Diameter =1.57m

Length = 11.28 m
power =7.5 KW

Number of flight =5

RPM =6

Radial height of
flight =0.15m

Time of passage 6.3min

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