Optimization of Solar Kiln for Drying Wood

Theoretical investigation of the physical process of solar drying of timber based on conventional heat and mass transfer equations is presented. The governing equations and boundary conditions of the mass diffusion through the wood timbers are derived; also the governing equations of the components of the solar kiln are presented. The finite difference technique is used to solve the set of these equations by means of a simulation program that is based on object-oriented approach. The simulation program is used to investigate the effect of several design parameters on the drying rate and duration of the wood timbers in order to accomplish the drying process with minimal drying defects. These parameters include the ventilation conditions that control the drying schedule inside the solar kiln, wood volume as a ratio to the solar kiln absorber area, wood timber thickness, season of drying, the drying air velocity, and the stresses that formed on the timber boards due to drying with these several parameters, leading to derive the limit of damage for a selected local wood type. The selected local wood type is Casuarina, which is common in Egypt, and it is commonly used in many simple industries.     

Optimization of Solar Kiln for Drying Wood

Abstract

Theoretical investigation of the physical process of solar drying of timber based on conventional heat and mass transfer equations is presented. The governing equations and boundary conditions of the mass diffusion through the wood timbers are derived; also the governing equations of the components of the solar kiln are presented. The finite difference technique is used to solve the set of these equations by means of a simulation program that is based on object-oriented approach. The simulation program is used to investigate the effect of several design parameters on the drying rate and duration of the wood timbers in order to accomplish the drying process with minimal drying defects. These parameters include the ventilation conditions that control the drying schedule inside the solar kiln, wood volume as a ratio to the solar kiln absorber area, wood timber thickness, season of drying, the drying air velocity, and the stresses that formed on the timber boards due to drying with these several parameters, leading to derive the limit of damage for a selected local wood type. The selected local wood type is Casuarina, which is common in Egypt, and it is commonly used in many simple industries.     

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.     

ENERGY QUANTIFICATION AND MECHANO-SORPTIVE BEHAVIOR IN THE KILN DRYING OF 2.5 cm THICK RED OAK LUMBER

ABSTRACT

Energy consumption was quantified in the drying of 2.5 cm thick red oak lumber in a 1.2 m³ steam heated experimental dry kiln. The aluminum pre-fab kiln is located indoors and was wrapped with 5 cm thick extruded polystyrene (R=10) for the experimental drying. Transmission loss accounted for about 80% of the energy/kilogram of water removed from the wood. The maximum value was for the 60°C DBT due to comparatively high transmission loss combined with maximum venting loss. Batch venting reduced average energy consumption per kiln run by over 6% compared to the conventional kiln schedule.

Average board shrinkage was over 2% less for drying with a low temperature schedule compared to drying by the conventional schedule for red oak. This was due to less compression set developing in the board interior at low wood temperatures, accompanied by more tension set in the surface layers. The mechano-sorptive results were in full agreement with McMillen's conclusions from his research on red oak.     

ENERGY QUANTIFICATION AND MECHANO-SORPTIVE BEHAVIOR IN THE KILN DRYING OF 2.5 cm THICK RED OAK LUMBER

Energy consumption was quantified in the drying of 2.5 cm thick red oak lumber in a 1.2 m³ steam heated experimental dry kiln. The aluminum pre-fab kiln is located indoors and was wrapped with 5 cm thick extruded polystyrene (R=10) for the experimental drying. Transmission loss accounted for about 80% of the energy/kilogram of water removed from the wood. The maximum value was for the 60°C DBT due to comparatively high transmission loss combined with maximum venting loss. Batch venting reduced average energy consumption per kiln run by over 6% compared to the conventional kiln schedule.

Average board shrinkage was over 2% less for drying with a low temperature schedule compared to drying by the conventional schedule for red oak. This was due to less compression set developing in the board interior at low wood temperatures, accompanied by more tension set in the surface layers. The mechano-sorptive results were in full agreement with McMillen's conclusions from his research on red oak.     

EFFECTS OF SAWING PATTERN ON LUMBER DRYING: MODEL SIMULATION AND EXPERIMENTAL INVESTIGATION

ABSTRACT

The sawing pattern of lumber affects the drying rate due to transverse permeability differences. These permeability differences are considered in a single board drying model which is able to investigate the drying rates for boards with varying growth ring angles. For the drying of Pinus radiata lumber, the model predicts that the quartersawn boards need longer drying time than the flatsawn boards. The drying time difference was 10–15% of the total drying time for conventional temperature (CT) drying and accelerated conventional temperature (ACT) drying, but was less significant for high temperature (HT) drying. In the simulation of a kiln stack drying, a sawing pattern factor was introduced to the relative drying rate function, which reflected the effects of the growth ring angle and the drying temperatures. The modified kiln wide drying model was used to predict the drying rates for a kiln stack consisting of entirely flatsawn boards and a kiln stack consisting of entirely quartersawn boards. Drying tests were conducted using stacks of mixed flatsawn and quartersawn Pinus radiata sapwood boards. In the tests, three drying schedules were used which included CT, ACT and HT drying. The experimental results agree closely with the model predictions and thus, after further validation, the drying models can be used to predict commercial kiln drying of boards with different sawing patterns.     

EFFECTS OF SAWING PATTERN ON LUMBER DRYING: MODEL SIMULATION AND EXPERIMENTAL INVESTIGATION

The sawing pattern of lumber affects the drying rate due to transverse permeability differences. These permeability differences are considered in a single board drying model which is able to investigate the drying rates for boards with varying growth ring angles. For the drying of Pinus radiata lumber, the model predicts that the quartersawn boards need longer drying time than the flatsawn boards. The drying time difference was 10-15% of the total drying time for conventional temperature (CT) drying and accelerated conventional temperature (ACT) drying, but was less significant for high temperature (HT) drying. In the simulation of a kiln stack drying, a sawing pattern factor was introduced to the relative drying rate function, which reflected the effects of the growth ring angle and the drying temperatures. The modified kiln wide drying model was used to predict the drying rates for a kiln stack consisting of entirely flatsawn boards and a kiln stack consisting of entirely quartersawn boards. Drying tests were conducted using stacks of mixed flatsawn and quartersawn Pinus radiata sapwood boards. In the tests, three drying schedules were used which included CT, ACT and HT drying. The experimental results agree closely with the model predictions and thus, after further validation, the drying models can be used to predict commercial kiln drying of boards with different sawing patterns.     

Comparing Continuous and Cyclic Drying Schedules for Processing Hardwood Timber: The Importance of Mechanosorptive Strain

This work compares a conventional continuous drying schedule with a solar cyclic drying schedule for the seasoning of an Australian hardwood timber, Eucalyptus grandis, focusing on the simulated stresses and strains developed during drying as a measure of timber quality. The cyclic drying schedule has been found to give lower instantaneous strains, due to the effect of mechanosorptive strains in relieving stresses both in the initial stages of drying and over the entire drying period. The gentler initial drying conditions during cyclic drying are also beneficial compared to the harsher and unmodulated nature of conventional drying schedules. Without the modulation of the external drying conditions in intermittent or cyclic drying, the mechanosorptive strains are unable to relax or mitigate the stresses that are caused naturally by timber drying. There is some support for these conclusions by comparison with industrial experience and previous laboratory practice for intermittent and cyclic drying.     

A COMMERCIALLY VIABLE SOLAR WOOD DRYING KILN SYSTEM

The purpose of the study was to create a totally passive solar wood drying kiln that would dry lumber to 9% moisture content in a reasonable amount of time. A series of modifications led to a kiln design that dried freshly-cut lumber to 8% in a 29-day period with no case hardening or cracking. Air speed, internal and external temperatures and relative humidity levels were measured at 5-minute intervals. The average temperature inside the kiln was 12% higher with relative humidity levels 19% lower than outside the kiln. It is hypothesized that the daily cycles of heating and cooling permitted the interior moisture of the wood to reach the surface through diffusion, thus lessening stress and speeding drying of the lumber.     

A Numerical Simulation for Solving the Dippusion Equations in the Drying of Hardware Timber

A numerical simulation is described for solving the thermal conduction and mass diffusion equations in boards of hardwood timber, and the Einite-volume method used here has been applied to the drying of Eucalypt timber, an Australian hardwood. The predictions of the variation in the average moisture content with time agree well with both ex~erimental data from the literature and analvtical solutions of the-diffusion equation. The nume ical simulation treats the boundary conditions more accurately than the analytical solutions when the moisture movement is two dimensional, as it is through the cross-section of a timber board. This feature makes the simulation useful when describing the drying process under intermittent drying conditions. These conditions are encountered in the drying of timber in solar kilns, and this simulation may be used to predict the distributions of temperature andmoisture content inboards of timber which are being dried intermittently inside conventional kilns. The numerical simulation for intermittent drying has shown, inthe example studied here, chat the same overall change in average moisture concentration can be achieved with 12-hour active drying and 12-hour relaxationperiodaas forcontinuousdryingbyincreasingthedry-bulb temperature by 10°C for this timber. In spite of the higher dry-bulb temperature used in the active drying period of intermittent drying. the moisture concentration profiles within the board are predicted to be more uniform than with continuous drying, because the internal moisture diffusion process continues during the relaxation period. These mare uniform moisture concentration profiles in intermittent drying are likely to result in lower stress levels within the timber than with continuous drying.     

THE EFFECT OF DRYING TEMPERATURE ON THE MECHANO-SORPTIVE BEHAVIOR OF RED OAK LUMBER

ABSTRACT

Matched units of 3.2 cm thick red oak lumber were dried simultaneously in a steam heated and dehumidification kiln. The two pairs of runs are designated Set I and Set II. The objective was to compare the mechano-sorptive behavior and board shrinkages while using the recommended U.S. Forest Products Laboratory schedule with the steam kiln and comparatively low temperature drying in the dehumidification kiln.

Drying rates in Set I and Set II were comparable for the two kilns up to approximately 450 hours, which illustrated the dependence of the drying rate on the relative humidity of the kiln air rather than its temperature. Subsequently, the stepwise increases in dry bulb temperature for the steam kiln were accompanied by accelerated drying.

Less compression set developed in the interior mechano-sorptive slices for the dehumidification kiln runs. On an average, the maximum compression set for the core slices from the dehumidification kiln was about S0% of that for core slices from the steam heated kiln. Simultaneously the surface slices from the dehumidification kiln developed more tension set than those from the steam heated kiln. Board width shrinkage at the end of drying, at the same average moisture content, was greatest for the steam kiln. The greater shrinkage is attributed to greater compression set due to the higher drying temperatures. These results support McMillen)s explanation for the effect of drying temperatures upon sets and the shrinkage of red oak lumber.     

A Method for Determination of Porosity Change from Shrinkage Curves of Deformable Materials

The novel low-cost band thermodynamic dryer equipped with a solar collector, a parabolic focusing collector, a heat exchanger, screw fan, and a drying cabinet with a band was designed and tested. The maximum temperature in the solar collector reached 85°C, which was 55°C above the ambient temperature. The required drying time was 4.5 h, much reduced from the traditional solar drying time of 48 h. The final moisture content of the Roselle calyx was 12% w.b., which is the recommended storage moisture content. Measurements of ambient temperature and humidity, air temperature, and relative humidity inside the dryer as well as solids moisture loss-in-weight data are employed as a means to study the performance of the dryer. Solar drying was compared with conventional sun drying and heated air drying, using the following evaluation criteria: drying time, dried Roselle color, texture, taste, and production cost. For evaluation, a model-based Technique for Order Preference by Similarity to Ideal Solution (TOPSIS) methodology was used. After the evaluation, the proposed continuous solar dryer was found to be better than conventional drying and heated air drying due to slower drying rate and better quality of the dried Roselle.     

Establishing Kiln Drying Schedule for Beech (Fagus orientalis) at 5-cm Thickness from the Neka Region

To establish a kiln drying schedule for beech (Fagus orientalis) lumber, 5-cm-thick boards were kiln dried down to a final moisture content of 8%. Three replications were made utilizing three kiln schedules of T5-C3, T5-C4, and T6-C4. With due attention to the effect of thickness on wood drying intensity, the t-test showed no significant difference between the thicknesses of the three drying schedules at a significance level of 99%. Therefore, the results of this study can be applied for 5-cm-thick boards.

The primary dry bulb temperature in each of the three schedules was adjusted to 41°C and the final dry bulb temperatures were adjusted to 71, 71, and 82°C, respectively. The schedule offering the shortest drying time for the desired quality was chosen. Specific gravity and dry specific gravity were measured as 0.52 and 0.61, respectively. Longitudinal, radial, tangential, and volumetric shrinkage were 0.46, 5.8, 10.2, 16.48%, respectively. The extent of defects including crook, bow, twist, and three longest surface checks of the lumber was determined for each drying schedule. Quality control graphs were used to analyze the lumber defects in order to determine the best drying schedule.

Analysis of the results indicates that with either of three kiln schedules the extent of defects before and after drying was not statistically different. However, the distribution of defects in the third schedule (T6-C4) was more uniform with respect to the average line compared to other two schedules. At the end of this schedule, a 17-h equalization and 24-h conditioning treatment is recommended.     

PROBABILISTIC ANALYSIS AND DESIGN OF THE INDUSTRIAL TIMBER DRYING PROCESS

The distribution in the moisture content of dried planks is an important parameter for kiln operators. The evolution of variability in the moisture content of timber boards during a batch drying process is investigated. This random variability in moisture content arises from a distribution in plank initial moisture content and dispersion in plank drying rate. A simple deterministic model of timber drying is outlined. Theoretical probabilistic analysis is applied to this model to predict the mean and standard deviation in board moisture content as a function of time. The solution is assessed with representative industrial kiln drying data. The utility of the approach in suggesting strategies to promote uniformity in final moisture content is outlined using some design studies. These strategies include sorting of the timber by moisture content and adjusting the drying rate and equilibrium moisture content to reduce variability. It is also demonstrated that the probabilistic approach can yield a better estimation of kiln average moisture content.     

Real-Time Moisture Content Measurement of Wood Under Radio-Frequency/Vacuum (RF/V) Drying

Hinoki timber was dried under radio-frequency at 6.7 kPa using two drying schedules, schedule A and schedule B. Moisture content (MC) was measured at 58 points in various locations of the timber using a new in-process monitoring concept. This concept uses the relationship between temperature, pressure, and equilibrium moisture content (EMC). Factors affecting the accuracy of MC measurement were also investigated in this study. The results showed that small wood pieces reached equilibrium at constant conditions within 1.5 h of the fiber saturation point (FSP) and that using the mean value of temperature and pressure within 30 min during radio-frequency/vacuum (RF/V) drying for MC measurement was an efficient method. The accuracy of moisture content measurement was the same for both drying schedules A and B. It can be concluded that air in wood was removed completely with drying schedule B and that below the FSP, pressure in the wood was maintained only by water vapor pressure during drying. It was possible to obtain accurate MC measurement. Above or near the FSP, MC cannot be measured using this method, whereas below the FSP, whatever the MC is, it can be measured practically anywhere in the timber.     

THE EFFECT OF DRYING TEMPERATURE ON THE MECHANO-SORPTIVE BEHAVIOR OF RED OAK LUMBER

Matched units of 3.2 cm thick red oak lumber were dried simultaneously in a steam heated and dehumidification kiln. The two pairs of runs are designated Set I and Set II. The objective was to compare the mechano-sorptive behavior and board shrinkages while using the recommended U.S. Forest Products Laboratory schedule with the steam kiln and comparatively low temperature drying in the dehumidification kiln.

Drying rates in Set I and Set II were comparable for the two kilns up to approximately 450 hours, which illustrated the dependence of the drying rate on the relative humidity of the kiln air rather than its temperature. Subsequently, the stepwise increases in dry bulb temperature for the steam kiln were accompanied by accelerated drying.

Less compression set developed in the interior mechano-sorptive slices for the dehumidification kiln runs. On an average, the maximum compression set for the core slices from the dehumidification kiln was about S0% of that for core slices from the steam heated kiln. Simultaneously the surface slices from the dehumidification kiln developed more tension set than those from the steam heated kiln. Board width shrinkage at the end of drying, at the same average moisture content, was greatest for the steam kiln. The greater shrinkage is attributed to greater compression set due to the higher drying temperatures. These results support McMillen)s explanation for the effect of drying temperatures upon sets and the shrinkage of red oak lumber.     

Rotary cement kiln coating estimator: Integrated modelling of kiln with shell temperature measurement

Coating thickness protection in the burning zone of a rotary cement kiln during operation is important from the viewpoint of the kiln productivity. In this paper, an integrated model is presented to estimate the coating thickness in the burning zone of a rotary cement kiln by using measured process variables and scanned shell temperature. The model can simulate the variations of the system, thus the impact of different process variables and environmental conditions on the coating thickness can be analysed. The presented steady‐state model derived from heat and mass balance equations uses a plug flame model for simulation of gas and/or fuel oil burning. Moreover, the heat transfer value from shell to the outside is improved by a quasi‐dynamic method. Therefore, at first, the model predicts the inside temperature profile along the kiln, then by considering two resistant nodes between temperatures of the inside and outside, the latter measured by shell scanner, it estimates the formed coating thickness in the burning zone. The estimation of the model was studied for three measured data sets taken from a modern commercial cement kiln. The results confirm that the average absolute error for estimating the coating thickness for the cases 1, 2, and 3 are 3.26, 2.82, and 2.21 cm, respectively.     

Effect of Outer Surface Sealing Treatment on the Reduction of Surface Check Occurrence During the Drying of Center-Bored Round Timber

A significant amount of time and energy is required to dry green timber with a large cross-section. Due to long-lasting internal moisture gradients, internal stress is high during the drying of large cross-sectional timber, and the potential for check occurrence is significant. Although many researchers have aimed to develop a method for drying large pieces of wood without the occurrence of drying defects, a procedure for rapidly drying wood without cracks has not yet been developed. In the present study, an outer surface sealing method and center-boring process (i.e., drilling a hole along the central longitudinal axis) was developed to dry timber with a large cross-section without the occurrence of checks. The proposed center-boring procedure reduces the movement of heat and moisture inside the wood and expedites the drying process by sustaining a small MC gradient. Moreover, the outer surface sealing treatment changes the drying stress direction and controls check occurrence. By kiln drying center-bored (80-mm diameter) and outer-surface-sealed round timber pitch pine (Pinus rigida) with an initial MC of 30% and an outer diameter of 140 mm, a final MC of 6% was obtained within 40 hours without the occurrence of any drying defects.     

External Heat and Mass Transfer Coefficients for Kiln Drying of Timber

ABSTRACT

Comlations are derived relating the heat-transfer coefficient to the mass- transfer coefficient in kiln drying of timber boards by using the Chilton-Colbum analogy. Existing experimental data for the mass-transfer coefficient of naphthalene vapour in the airstream at low temperature are convened to coefficients under commercial timber drying conditions. The calculated results from this analysis are compared with the values employed by wood drying modellers in their models and it appears that the external transfer coefficients used by the drying mcdellers are generally below the values calculated from the laboratoly data.     

基于太阳能的工业物料干燥技术研究

以工业废料(铬渣)为干燥对象,研究探索利用太阳能干燥工业物料的方法和技术。在研究物料的物理特性与传统的干燥工艺的基础上确定了基于太阳能的物料干燥工艺;对空气集热器模型进行试验、优化,得出空气集热器的主要技术参数;利用计算机三维造型,设计了适于铬矿渣烘干的隧道式烘干窑和干燥架;最终设计出由太阳能空气集热器、常用的热风炉和隧道式烘干窑组合而成的混合型干燥系统。经理论计算与虚拟实验,用于工业物料的干燥是可行的。