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Performance Analysis of A Tumble Dryer

The document presents a performance analysis of a tumble dryer, focusing on energy efficiency and moisture control during the drying process. Two projects were conducted in collaboration with ASKO Cylinda AB, resulting in a 9% energy saving and the development of a new control system for estimating drying time. The study highlights significant air leakage issues and proposes solutions to improve energy consumption and drying efficiency.

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0% found this document useful (0 votes)
29 views8 pages

Performance Analysis of A Tumble Dryer

The document presents a performance analysis of a tumble dryer, focusing on energy efficiency and moisture control during the drying process. Two projects were conducted in collaboration with ASKO Cylinda AB, resulting in a 9% energy saving and the development of a new control system for estimating drying time. The study highlights significant air leakage issues and proposes solutions to improve energy consumption and drying efficiency.

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2022-112068
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PERFORMANCE ANALYSIS OF A TUMBLE DRYER

Article · January 2004

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Drying 2004 – Proceedings of the 14th International Drying Symposium (IDS 2004)
São Paulo, Brazil, 22-25 August 2004, vol. B, pp. 821-827

PERFORMANCE ANALYSIS OF A TUMBLE DRYER

Jonas Berghel1, Lena Brunzell1 and Peder Bengtsson2

1. Department of Environmental and Energy systems, Division for Engineering Sciences,


Physics and Mathematics, Karlstad University, SE-651 88, Sweden,
E-mail: Jonas.Berghel@kau.se
2. Asko Cylinda AB, Jung, SE-534 82 Vara, Sweden

Keywords: clothes; energy efficiency; product moisture control; textile

ABSTRACT

The drying of clothes is an energy-intensive process, and a lot of effort is put into
energy saving. For several years, a research group at Karlstad University has worked
with the drying of sawdust in a spouted bed. In co-operation with the manufacturer, this
experience of drying sawdust is used to further develop the process of drying clothes in
a tumbler. Sawdust, as well as textiles, can be viewed as a hygroscopic-porous material.
This means that some results obtained from the drying of sawdust also can be used for
the drying of clothes. In collaboration with ASKO Cylinda AB, we have two ongoing
projects of drying clothes in a tumbler dryer: (1) energy analysis of the drying process
with special interest paid to leakage and the efficiency of the heat exchanger, (2)
identification of signals that can be used for calculating the remaining drying time. The
necessary demands on the signal are that it must be reliable, repetitive, and non-
sensitive to user disturbances. Project (1) has resulted in a redesign of the tumble dryer
prototype, and an energy saving of 9 %. The project continues with the aim of reaching
the goal, i.e., to decrease the energy consumption by 12%. Project (2) has resulted in a
new control system for the tumble dryer, and it will be put in production within two
years.

INTRODUCTION

Drying clothes is an energy-intensive process, and a lot of effort is put into saving energy. Improving
the energy efficiency of a tumble dryer (condenser dryer) has been a major objective for the
manufacturers. In Sweden, approximately 1% of the household energy is used for drying clothes.
For several years, a research group at Karlstad University has worked with the drying of sawdust in a
spouted bed. The idea of using temperature as a controlling unit for the drying of clothes and the use of
energy balances to improved the measuring system originates in results recovered from studies of drying
sawdust (Berghel and Renström, 2004).

821
In collaboration with ASKO Cylinda AB – a manufacturer of tumble dryers – we have two ongoing
projects treating the drying of clothes in a tumble dryer: (1) Energy analysis of the drying process with
special interest paid to leakage and the condenser. (2) Identification of signals that can be used for
controlling the tumble dryer.
Relatively little is published in the open literature on the potential for reducing the energy used for
laundry drying. A model for the drying of textile in a tumble dryer was built by Lambert, Spruit and
Claus (1991). Conde (1997) demonstrates that a conventional tumble dryer can be improved by using heat
exchangers. Bansal, Braun and Groll (2001) show that the tumble dryer technology can be improved by
heat recovery using heat exchangers. Two different existing designs of household tumble dryers, and two
possible designs were evaluated. Braun, Bansal and Groll (2002) present an air pump cycle for tumble
dryers that offers considerable potential for improving the energy efficiency. Bassily and Colver (2003)
have presented several proposals for increasing the energy efficiency, e.g., improving the drum seals to
reduce air leakage. The research referred to above was mainly carried out on the venting type of tumble
dryers. However, only few results are presented in the literature on increasing the energy efficiency of the
condensing type of tumble dryers. This article presents experimental results for this type of dryer.
There is a considerable leakage of warm air from the recirculating air system in the tumble dryer, which
indicates an energy loss from the system. According to The Swedish Consumer Agency 1996:3, it is
desirable to decrease the energy consumption by 12% during the drying of a standard 5.0kg load of dry
cotton containing 3.5kg of water to reach an energy efficiency classification B for the machine. The aim
of project (1), therefore, is to examine the influence of leakage on the drying process in order to decrease
energy consumption. This is performed by finding the amount and the location of air leaking out of the
closed air system.
On the condenser dryer, the remaining time is displayed throughout the drying process as user
information. The remaining time is calculated from an algorithm using the moisture sensor signal. The
reliability of the remaining time indicator is insufficient due to moisture sensor irregularity. The aim of
project (2) is to find a signal that is reliable, repetitive and non-sensitive to user disturbances.
This study is performed by experimentally testing different running conditions, and evaluating the effect
of various dryers’ parameters on energy efficiency and drying time. The article presents results from these
tests, which were performed on a tumble dryer of condensing type, as well as a signal that can be used for
the reliable calculation of the remaining time.

METHOD

The tested condensing tumble dryer consists of a rotating drum, a fan, a condenser and an electric
heater, as shown in Figure 1. This dryer has two different airflows, one internal and one external. The
internal airflow is transporting water from the wet clothes to the condenser. The air leaving the condenser
is heated in the electric heater before it enters the drum, making the internal system a theoretically closed
system. To condense the water vapor of the internal airflow, the condenser is cooled by an external air
flow that holds the same temperature as the surroundings.

822
Electric
h eater
2500W

D ru m

Figure 1. The condensing tumble dryer with internal and external airflows. Temperature sensors are indicated at Ta,Tb and Tc.

The temperature of the internal airflow was measured at three locations: Ta,Tb and Tc, situated as in
Figure 1. The relative humidity of the internal airflow was measured between the electric heater and the
drum.
The experimental tests performed in project (1) are presented in Table 1: a leakage survey, tightening of
the internal system, and tightening of the outer cover of the machine. A cotton load was moistened during
a rinse program in a washing machine, and spin-dried at different rounds per minute. To confirm the
amount of water added to the dry textiles, the load was weighed before and after the tests.
Table 1. Number of tests performed in project (1): leakage survey, tightening of the internal system and tightening of the outer
cover of the tumble dryer. A cotton load was used and moistened in a washing machine.

Tests performed Dry load Treatment for moisture content Number of test runs
Leakage survey 5kg Spin-dried at 800rpm 3
Tightening of the 5kg Spin-dried at 800rpm 10
internal system
Tightening of the 5kg Spin-dried at 1200rpm, stopped 3
outer cover when the load contains 3.5kg water

The internal airflow was measured before and after the fan to estimate the proportion of leakage. Velocity
profiles were determined in each cross section.
In order to decrease leakage, the internal system was tightened. The back of the drum was tightened with
an extra sealing (A). A return tube, transporting condensed moisture from a condensation water container
to the water pump, has been sealed (B). The condenser was tightened in both ends to decrease leakage
between internal and external flows (C). Finally, the shaft of the fan was tightened with a radial sealing
(D). All the joints between the various components were tightened. Test runs with the different
tightenings were performed with two different fans, one normal and one large. This was carried out to
maintain an almost constant airflow in the internal system.
The tumble dryer with the extra tightening described above was wrapped in plastic to provide a tight outer
machine cover. Three centimeters of insulation were attached to the cover of the machine to decrease
energy losses. The external flow was led in and out of the machine using tubes. The energy consumption
for the process was measured during each test. The tests were performed as follows:
• The external flow was turned off until the air temperature outside the drum reached 60˚C.
• The temperature of the air leaving the drum was held constant by controlling the electric heater.
• The electric heater was turned off when 90% to 95% of available energy had been consumed.
The load used in the tests consists of 5.0kg of cotton and 3.5kg of water as ordained by The Swedish
Consumer Agency 1996:3.

823
The first minutes of the process have been studied in project (2) to create a remaining program run time
based on the temperature of the internal airflow leaving the drum. The time it takes for the outgoing flow
to reach 40˚C, and the temperature gradient during the first 120 seconds, have been related to the program
run time. The tests have been performed with various dry loads of cotton. The loads weighed 0.5kg,
1.5kg, 3.0kg and 5.0kg. Various amounts of water were added during a rinse program of the washing
machine, and the cotton was then spin-dried at 800, 1200 or 1600rpm. Each combination was performed
twice, which added up to 24 tests. The load was weighed before and after each test.

RESULTS

There is important leakage of warm, dry air from the internal system. Flow measurements in project
(1) before and after the fan confirm a leakage of 20%-40% of the total internal flow. A considerable
amount of the leakage is situated between the heating element and the drum. There is also a leakage
through the joints before and after the condenser. It is determined that the relative humidity of the internal
airflow between the condenser and the heating element only reaches a value of 60%.
Tightening performed on the internal system of the tumble dryer show an increasing value of relative
humidity between the condenser and the heating element. The relative humidity takes a value between
75% and 80% in the tests performed. The energy consumption of the process increases, and there is still a
considerable leakage of approximately 20% from the internal system. The energy consumption of the
tests is shown in Figure 2.
Energy consumption
kWh The original tumbler dryer compared to tightening of the internal system
5

4.5

3.5

2.5

2
Original machine Tightening (A) Tightening (A), Tightening (A, B), Tightening (A, B, Tightening (A, B,
large fan large fan C), large fan C, D), large fan

Figure 2. Energy consumption of the tumble dryer, tests performed on an internal system with various degrees of tightening,
A-D. In the tests, a cotton load of 5.0kg containing water added during a washing machine rinse program was spin-dried at
800rpm.

Tests performed with a tight outer tumble dryer cover show a decrease in energy consumption compared
with the original machine, see Figure 3. The energy consumption has decreased with 6.5%-9% in the
three tests performed. The dashed line in Figure 3 shows the energy consumption of a tumble dryer with
the energy classification B (The Swedish Consumer Agency 1996:3).

824
Energy consumption
The original tumbler dryer com pared to a tighte nd outer cover
kWh
4

3.5
Classification B
3.2kWh
3

2.5

2
Test 1 Test 2 Test 3 Original machine

Figure 3. Energy consumption of the tumble dryer, tests performed with the standard load of 8.5kg containing 3.5kg of water.
The dashed line shows the energy consumption of a tumble dryer with classification B in compliance with The Swedish
Consumer Agency 1996:3.

Results from project (2) indicate that the remaining program run time has a strong correlation with the
amount of water in the tumble dryer. This is shown in Figure 4, where actual program run times, and two
calculated program run times are plotted. The time it takes for the outgoing flow to reach 40˚C, and the
temperature gradient during the first 120 seconds are related to the total program run time. This provides
algorithms to calculate the total program run time during the first two minutes of the process.
Minutes Program run time
120

100

80

60 Real run time

40 Calculated run time based on the gradient


during 120 seconds
20 Calculated run time based on the time to
reach 40 -C
0
0 0. 5 1 1. 5 2 2. 5 3 3. 5 4 4.5
Water amount in the textile (kg)
Figure 4. The program run time plotted against the amount of water in the textiles. The actual program run time is compared
with two calculated program run times. The calculated run times are based on the time it takes for the internal airflow leaving
the drum to reach 40˚C and the gradient during the first 120 seconds of the drying process in the experimental tests.

The mean difference between the calculated program run time, based on the time it takes for the airflow
leaving the drum to reach 40°C, and the actual program run time is 5.7 minutes. The gradient during the
120 first seconds has a mean difference of 7.3 minutes.

DISCUSSION

A survey of the magnitude of air leakage and its location in the tumble dryer indicates a leakage of
20%- 40% of the total internal airflow. The air leakage out of the internal system is mainly located in the
condenser and at the drum inlet. The results from the airflow measurements in the closed system show

825
some uncertainties due to the turbulence in the airflow, and variations in the cross section area, which
make it difficult to calculate the correct velocity profile.
The decrease in internal airflow leakage from the tightened internal system led to an increase in the
energy consumption, see Figure 2. This is due to changes in the process parameters, which leads to a
decrease in condenser capacity. All tightening performed in the system lowered the leakage to 20%. The
result illustrates the difficulties faced with when making the internal system completely sealed.
Tightening the outer cover of the tumbler was successful. The tests that were carried out on the tumbler
that was wrapped in plastic to provide a tight outer machine cover show a 6.5%-9% decrease in energy
consumption.
Project (1) has resulted in a redesign of the tumble dryer prototype, and an energy saving of 9%. The
project continues with the aim of reaching the goal of a 12% decrease in energy consumption.
Figure 4 shows the relationship between the actual drying time and calculated drying time. Two
correlations are plotted. The first relationship (A) is based on the time it takes for the air temperature out
of the drum to reach 40°C compared with the total drying time. The risk that the machine has recently
been used and, consequently, too quickly reaches a temperature of 40°C is a disadvantage with this
method. The second relationship (B) is based on the temperature gradient for the outgoing air leaving the
drum during the first 120 seconds. With this method the temperature gradient should be independent of
the machine being warm or cold at the beginning of the drying process, which is an advantage. Both
methods, A and B, correspond well with the actual time it takes to dry loads containing up to 3.5kg of
water, see Figure 4. For method A, the mean error for the calculated remaining time is 5.7 minutes, and
for method B it is 7.3minutes.
Project (2) has resulted in a new control system for the tumble dryer, and will be put in production within
two years. The control system use the temperature of air leaving the dryer drum as a control parameter of
the moisture content of the clothes; nearly the same control system has been used for the drying of
sawdust.

CONCLUSIONS

The leakage of humid air from the closed system ranges between 20%-40% of the total airflow in the
closed system. The main leakage is located at the entrance of the drum, and between the heat exchanger
and the electric heater.
It proved successful to tighten the shell of the tumble dryer, and not the components of the internal
system. Further tests will be carried out on a new prototype manufactured by ASKO Cylinda.
The remaining time indicator can be based on the temperature gradient during the initial 120sec.

REMARKS FROM THE MANUFACTURER

For ASKO Cylinda, it is important to be one of the leading manufacturers regarding knowledge in
technology. The tumble dryer is of special interest because of the small volumes that are manufactured.
Our plan is to renew outdated assortments, and reduce the number of tumbler models. Fewer models will
give us a better chance of improving our means to focus on the development for us new technology. The
next step is to produce a new tumble dryer generation.
The control system of our tumble dryers today should be replaced with a better and cheaper control
system. This has to contain a method that works well in detecting program run times at an early stage to
make it user friendly. During the last few years, we have, without success, worked hard to reduce the
energy consumption of our tumble dryers. The skills in drying at Karlstad University have resulted in
them presenting us with two proposals that will lead to a joint project.

826
LITERATURE

Bansal, P. K., Braun, J. E., and Groll, E. A., 2001, Improving the energy efficiency of conventional
tumbler clothes drying systems: International Journal of Energy Research, v. 25, p. 1315-1332.

Bassily, A. M., and Colver, G. M., 2003, Performance analysis of an electric clothes dryer: Drying
Technology, v. 21, p. 499-524.

Berghel, J., and Renström, R., 2004, Controllability of Product Moisture Content when Non-Screened
Sawdust is Dried in a Spouted Bed: Drying Technology, v. 22, p. 505-517.

Braun, J. E., Bansal, P. K., and Groll, E. A., 2002, Energy efficiency analysis of air cycle heat pump
dryers: International Journal of Refrigeration, v. 25, p. 954-65.

Conde, M. R., 1997, Energy conservation with tumbler drying in laundries: Applied Thermal
Engineering, v. 17, p. 1163-72.

Lambert, A. J. D., Spruit, F. P. M., and Claus, J., 1991, Modelling as a tool for evaluating the effects of
energy-saving measures. Case study. A tumbler drier: Applied Energy, v. 38, p. 33-47.

The Swedish Consumer Agency 1996, Konsumentverkets föreskrifter om information om


energiförbrukning hos elektriska torktumlare för hushållsbruk: KOVFS 1996:3

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