PROPOSAL FOR A NOVEL CHEMICAL HEAT PUMP DRYER

ABSTRACT

A new chemical heat pump (CHP) system for ecofriendly effective utilization of thermal energy in drying is proposed from the viewpoints of energy saving and environmental impact. CHPs can store thermal energy in the form of chemical energy by an endothermic reaction and release it at various temperature levels for heat demands by exo/endothermic reactions. CHPs have potential for heat recovery and dehumidification in the drying process by heat storage and high/law temperature heat release. In this study, we estimate the potential of the CHP application to drying systems for industrial use. Some combined systems of CHPs and dryers are proposed as chemical heat pump dryers (CHPD). The potential for commercialization of CHPDs is discussed.     

EXPERIMENTAL STUDIES ON A NOVEL CHEMICAL HEAT PUMP DRYER USING A GAS-SOLID REACTION

The authors have been studying Chemical Heat Pumps (CHP) from the viewpoints of energy saving and environmental impact. The CHP can store thermal energy in the form of chemical energy by an endothermic reaction, and release it at various temperature levels during heat demand periods by exo/endothermic reactions. The authors have proposed in an earlier study a novel chemical heat pump (CHP) system for environmentally-friendly effective utilization of thermal energy in drying as a chemical heat pump dryer (CHPD). In this exploratory study, we test the effectiveness of operating the proposed CHPDs experimentally. Basic experiments on the CHPDs such as hot dry air production for convective drying are performed on lab-scale CHPD apparatuses using gas-solid reactions in calcium oxide/calcium hydroxide reactant beds. The proposed CHPDs are found to produce hot air by CHP operation for drying. The temperature levels of the produced hot air and the reaction rates/conversions are as good as in the case of hot water supply system using basically same CHP operation. The cold heat for air dehumidification is also found to be generated/recovered by the same CHPD system. The generated heat amounts can be increased by changing the operating conditions although the heat recovery must be enhanced for practical application of CHPDs.     

EXPERIMENTAL STUDIES ON A NOVEL CHEMICAL HEAT PUMP DRYER USING A GAS–SOLID REACTION

The authors have been studying Chemical Heat Pumps (CHP) from the viewpoints of energy saving and environmental impact. The CHP can store thermal energy in the form of chemical energy by an endothermic reaction, and release it at various temperature levels during heat demand periods by exo/endothermic reactions. The authors have proposed in an earlier study a novel chemical heat pump (CHP) system for environmentally-friendly effective utilization of thermal energy in drying as a chemical heat pump dryer (CHPD). In this exploratory study, we test the effectiveness of operating the proposed CHPDs experimentally. Basic experiments on the CHPDs such as hot dry air production for convective drying are performed on lab-scale CHPD apparatuses using gas–solid reactions in calcium oxide/calcium hydroxide reactant beds. The proposed CHPDs are found to produce hot air by CHP operation for drying. The temperature levels of the produced hot air and the reaction rates/conversions are as good as in the case of hot water supply system using basically same CHP operation. The cold heat for air dehumidification is also found to be generated/recovered by the same CHPD system. The generated heat amounts can be increased by changing the operating conditions although the heat recovery must be enhanced for practical application of CHPDs.     

Enhancement of Energy Efficiency of a Chemical Heat Pump-Assisted Convective Dryer

In earlier studies we have shown by simulation and experimental studies that the proposed chemical heat pump (CHP) unit can be used to recover waste heat from dryers and reuse it by storing and releasing heat with upgrading the temperature or by dehumidification. However, the final thermal energy production efficiency of the CHP for drying was found to be low. In this paper we present experimental results to demonstrate the potential for improved heat-recovery/storage and the heat-release/production of hot dry air for batch drying applications using the heat enhancement mode of the CHP. A new laboratory scale experimental CHP dryer system was built utilizing the calcium oxide/calcium hydroxide hydration/dehydration reversible reaction. The aim of this study is to improve the efficiencies of the heat recovery from heat source in the heat-storage step and the hot dry air production in the heat-release step of the CHP for heating up the air to around 100°C. The results of this experimental study utilizing a new reactor design showed that the shallow reactor/heat exchanger could accomplish 94% chemical heat storage and produce 100°C air at better than 75% efficiency for the reaction heat by controlling the preheating condition. The reaction conversion reached 90% in these experiments. The proposed CHP-assisted convective dryer system is found to be energy-efficient over a wide temperature range of industrial interest.     

SIMULATION OF HYDRATION/DEHYDRATION OF CaO/Ca(OH)2 CHEMICAL HEAT PUMP REACTOR FOR COLD/HOT HEAT GENERATION

ABSTRACT

A chemical heat pump (CHP) utilizes reversible reactions involving significant endothermic and exothermic heats of reaction in order to develop a heat pump effect by storing and releasing energy while transforming it from chemical to thermal energy and vice versa. In this paper, we present a mathematical model and its numerical solution for the heat and mass transport phenomena occurring in the reactant particle bed of the CHP for heat storage and cold/hot heat generation based on the CaO/Ca(OH)₂ reversible hydration/dehydration reaction

Transient conservation equations of mass and energy transport including chemical kinetics are solved numerically subject to appropriate boundary and initial conditions to examine the influence of the mass transfer resistance on the overall performance of this CHP configuration. These results are presented and discussed with the aim of enhancing the CHP performance in next generation reactor designs.     

Saffron Drying with a Heat Pump–Assisted Hybrid Photovoltaic–Thermal Solar Dryer

Saffron is the most expensive spice and Iran is the largest producer of this crop in the world. Saffron quality is profoundly affected by the drying method. Recent research has shown that hybrid photovoltaic–thermal solar power systems are more efficient in comparison with individual photovoltaic and thermal systems. In addition, heat pump dryers are highly energy efficient. Furthermore, they are suitable for heat-sensitive crops such as saffron. Therefore, in the present study, the performance of a hybrid photovoltaic–thermal solar dryer equipped with a heat pump system was considered for saffron drying, in order to obtain a high-quality product and reduce fossil fuel consumption. The effect of air mass flow rate at three levels (0.008, 0.012, and 0.016 kg/s), drying air temperature at three levels (40, 50, and 60°C), and two different dryer modes (with and without the heat pump unit) on the operating parameters of the dryer was investigated. The results of the investigation showed that total drying time and energy consumption decreased as air flow rate and drying air temperature increased. Applying a heat pump with the dryer led to a reduction in the drying time and energy consumption and an increase in electrical efficiency of the solar collector. The average total energy consumption was reduced by 33% when the dryer was equipped with a heat pump. Maximum values for electrical and thermal efficiency of the solar collector were found to be 10.8 and 28%, respectively. A maximum dryer efficiency of 72% and maximum specific moisture extraction rate (SMER) of 1.16 were obtained at an air flow rate of 0.016 kg/s and air temperature of 60°C when using the heat pump.     

Drying Kinetics of Tomato by Using Electric Resistance and Heat Pump Dryers

Drying kinetics of tomato was studied by using heat pump dryer (HPD) and electric resistance dryers with parallel and crossed airflow. The performance of both systems was evaluated and compared and the influence of temperature, air velocity, and tomato type on the drying kinetics was analyzed. The use of HPD showed to be adequate in the drying process of tomatoes, mainly in relation to the conversion rate of electric energy into thermal energy. The heat pump effective coefficient of performance (COP_HT,EF) was between 2.56 and 2.68, with an energy economy of about 40% when compared to the drying system with electric resistance. The Page model could be used to predict drying time of tomato and statistical analysis showed that the model parameters were mainly affected by drying temperature.     

Energy and Cost Estimation for Application of Chemical Heat Pump Dryer to Industrial Ceramics Drying

Abstract

In this article we estimate the potential of a new chemical heat pump dryer (CHPD) application to an industrial ceramics drying process from the viewpoints of energy and cost saving. A CaSO₄/H₂O/CaSO₄·1/2H₂O hydration/dehydration CHPD system and a CaO/H₂O/Ca(OH)₂ hydration/dehydration CHPD system were examined. The CHPD systems store heat and simultaneously release the increased amount of heat at different temperature levels by using two chemical heat pumps (CHP) in their heat-enhancement mode. Furthermore, we propose enhanced systems using chemical heat pipes (CHPipe) for their environmental and cost merits. As a result, the consumed energy and the cost of using the CHPD systems in the industrial ceramics drying process are found to decrease to less than half of the conventional drying process using gas-fired boilers. For example, the energy efficiency and the cost of the present drying process are 28.4% and 604 × 10³ (JPY/month) (JPY: Japanese Yen), respectively. The energy efficiency and the cost of the proposed CHPD system are found to be 79.7% and 216 × 10³ (JPY/month), respectively, based on our experiments.     

Drying Kinetics of Tomato by Using Electric Resistance and Heat Pump Dryers

Abstract

Drying kinetics of tomato was studied by using heat pump dryer (HPD) and electric resistance dryers with parallel and crossed airflow. The performance of both systems was evaluated and compared and the influence of temperature, air velocity, and tomato type on the drying kinetics was analyzed. The use of HPD showed to be adequate in the drying process of tomatoes, mainly in relation to the conversion rate of electric energy into thermal energy. The heat pump effective coefficient of performance (COP_HT,EF) was between 2.56 and 2.68, with an energy economy of about 40% when compared to the drying system with electric resistance. The Page model could be used to predict drying time of tomato and statistical analysis showed that the model parameters were mainly affected by drying temperature.     

低温热泵干燥装置的技术方案分析

低温热泵干燥装置在化学品、食品、药品、农副产品的干燥中具有广泛需要。给出了基本型、真空型和吸附剂型三类低温热泵干燥装置,对其结构、工作原理和特性进行了简要分析。分析表明,在初投资方面,基本型最低,真空型最高;在能源效率方面,真空型最高,基本型最低;吸附剂型在初投资和能源效率方面均居中。上述工作可为低温热泵干燥装置的设计提供较好的参考。     

Calculation Steps for the Design of Different Components of Heat Pump Dryers Under Constant Drying Rate Condition

Heat pump–assisted dryers are an alternative method for drying heat-sensitive food products at low temperature and less relative humidity with lower energy consumption. The mathematical models of a heat pump dryer consist of three submodels; namely, drying models, heat pump models, and performance models. Heat and mass balance of both refrigerant and air circuits in all components of the system are used for development of mathematical models. The models are used for design of different components of heat pump dryers operating under constant drying rate condition. A simple stepwise design procedure for batch-type, closed-loop heat pump dryer is also presented.     

Advances in Organic Liquid‐Gas Chemical Heat Pumps

Compared with inorganic chemical heat pumps (CHPs), organic liquid‐gas CHPs are more amenable to be run as a continuous process because the reactants and products can be fed or removed continuously. Therefore, increasing attention has been paid to investigations of CHPs using the organic liquid‐gas reaction system. Relevant research topics involved reaction catalyst, chemical reaction kinetics, reactive distillation, energy efficiency evaluation, economic analysis, etc. Nevertheless, the research on an organic liquid‐gas CHP system is still in the elementary stage. A detailed review on the current research status of catalyst‐assisted CHPs employing an organic liquid‐gas reaction system has been performed. Existing problems are identified and future research directions are proposed.     

The Application of Heat Pump in Drying of Biomaterials

The UN estimates that 6.4 billion people will be living on Earth by the year 2000. As a consequence, dried biomaterials demand will rise and equipments will have to be built or redesigned to accomadate changes. The design and innovations on industrial dryers require fundamental knowledge conceived in laboratory units. The new heat pump dryer operates at a wide relative humidity and the air temperature is adjustable from -20 to 100'C. Above and belw freezing point drying modes are done in the same plant which allows the control of biomaterial properties. The technique consists of two stages, unbound weakly held water removal by freeze drying. and tightly bound moisture desorption by medium temperature drying. The fluidized and shelf heat pump dryers have the required features to dry heat sensitive biomaterials. The dryers were built and extensive research on biomaterials has been conducted at The Norwegian Institute of Technology. Many emeriments were done on effect of heat pump drying conditions on-enrime and biological active bacteria solutions, fruits, cod fish, fish feed and shrimps. At optimum heat drying conditions, the bacteria Rhodococcus reached 100% viability and dried biomolecules attained full biolosical activity. The heat pump dryer allowed adjustment of the bio-mterial properties and quality according to its phase, shape and size. Dried samples showed improvements on survival rate. rehydration, colour, hardness and mono-multimolecular sorption isotherms over poorly dried products. Beneficial results were achieved for nearly all tests. This indicates that the heat pump dryer application has high potential in processing heat sensitive biomaterials.     

The Application of Heat Pump in Drying of Biomaterials

ABSTRACT

The UN estimates that 6.4 billion people will be living on Earth by the year 2000. As a consequence, dried biomaterials demand will rise and equipments will have to be built or redesigned to accomadate changes. The design and innovations on industrial dryers require fundamental knowledge conceived in laboratory units. The new heat pump dryer operates at a wide relative humidity and the air temperature is adjustable from –20 to 100'C. Above and belw freezing point drying modes are done in the same plant which allows the control of biomaterial properties. The technique consists of two stages, unbound weakly held water removal by freeze drying. and tightly bound moisture desorption by medium temperature drying. The fluidized and shelf heat pump dryers have the required features to dry heat sensitive biomaterials. The dryers were built and extensive research on biomaterials has been conducted at The Norwegian Institute of Technology. Many emeriments were done on effect of heat pump drying conditions on–enrime and biological active bacteria solutions, fruits, cod fish, fish feed and shrimps. At optimum heat drying conditions, the bacteria Rhodococcus reached 100% viability and dried biomolecules attained full biolosical activity. The heat pump dryer allowed adjustment of the bio–mterial properties and quality according to its phase, shape and size. Dried samples showed improvements on survival rate. rehydration, colour, hardness and mono–multimolecular sorption isotherms over poorly dried products. Beneficial results were achieved for nearly all tests. This indicates that the heat pump dryer application has high potential in processing heat sensitive biomaterials.     

Drying of biofuels from the forest—A review

The literature during 2000–2016 about drying of biofuels from the forest has been reviewed. Biofuels constitute a low-cost energy resource that is likely to continue to increase and the dryers for such products should be simple, robust, and easy to operate. In 1970s and 1980s, rotary dryers and flash dryers were the most common types, and in 1990s, superheated steam (SHS) dryers became common. Maintenance costs and use of medium pressure steam for the SHS dryers are important topics to consider and one drawback for the rotary dryers is that high-temperature heat sources are used. The development during the last 15 years has moved toward moving bed dryers because of the possibility to use cheap low-temperature energy sources, robust design, and direct capacity control that is achieved by controlling the air temperature in the dryer. A price for the dry biofuel of 15–20 Euro/MWh has been indicated to make a dryer installation profitable based on no cost for the thermal energy and 40 Euro/MWh as the cost for the electrical energy. Shrinkage and the internal transport of moisture and heat in large particles of biofuels will need more considerations in the future. Fractionation of the biofuels, codrying with other products, the total cost for the drying process, environmental issues, and development of drying processes operating at high dew points are the other things to consider.     

MATHEMATICAL MODEL DEVELOPMENT AND SIMULATION OF HEAT PUMP FRUIT DRYER

ABSTRACT

A mathematical model of a heat pump fruit dryer was developed to study the performance of heat pump dryers. Using the moisture content of papaya glace' drying, the refrigerant temperature at the evaporator and condenser and the performance, was verified. It was found that the simulated results using closed loop heat pump dryer were close to the experimental results. The criteria for evaluating the performance were specific moisture extraction rate and drying rate. The results showed that ambient conditions affected significantly on the performance of the open loop dryer and the partially closed loop dryer. Also, the fraction of evaporator bypass air affected markedly on the performance of all heat pump dryers. In addition, it was found that specific air flow rate and drying air temperature affected significantly the performance of all heat pump dryers.     

Gaseous Carbon Dioxide as the Heat and Mass Transfer Medium in Drying

Using available correlations for heat transfer, a comparative analysis of drying rates in CO₂ and in air was performed for several basic types of dryers. Higher heat transfer rates were found for dryers with active hydrodynamics, which translates into shorter drying time for materials dried in the first drying period. These results were validated by experiments on drying wheat kernels fluidized by air and by CO₂. Shorter drying times by about 20% were confirmed for CO₂, which offers energy savings of about 3% of the heat input to the dryer. Additional energy savings of 4% of the heat load can be expected for drying at temperatures below 100°C because of the lower wet-bulb temperature for CO₂ than that for air. The potential for CO₂ abatement was evaluated based on a case study for drying of distillers' spent grain.     

Convective Drying with Time-Varying Heat Input: Simulation Results

Intermittent drying aims to match the heat input rate to the drying kinetics of the material so as to avoid thermal degradation of heat-sensitive products in particular. This paper presents results of a liquid diffusion model to examine the effect of varying the rates of heat input by convection heat transfer. This is accomplished by varying the drying air velocity, varying the air temperature as well as its relative humidity over different periods of time in a sequential manner. One of the outcomes of this work is guidelines for use of a heat pump to dehumidify the drying air. While most heat pump dryers are designed to operate continuously, our results show that it is not necessary to use heat pump continuously over the entire drying period. This option saves running costs by reducing use of electrical power in the drying cycle. Furthermore, it is possible to save capital costs by utilizing a smaller heat pump for a given dry product output. Alternatively, a given heat pump system can be used to service two or more drying chambers that may dry the same or different products by simply switching the dehumidified and heated air from one chamber to the other sequentially. When the heat pump air is switched off, unsaturated ambient air maybe used to accomplish rest of the drying. It is shown that using heat pump air over only a part of the drying cycle does not increase the drying time appreciably.     

Modeling of heat pump tumble dryer energy consumption and drying time

The use of heat pump tumble dryers is nowadays more common because they offer huge energy savings compared to conventional tumble dryers. Earlier studies made on conventional tumble dryers have shown that parameters such as heater power, fan speed, drum speed, weight and initial moisture content of textiles and air leakage have a huge impact on the energy efficiency and drying time. In the present study, a modified commercial heat pump tumble dryer was evaluated for energy consumption and drying time by changing operating parameters including fan speed, drum speed, and mass load. The total energy consumption and drying time were measured and corrected for the initial and final moisture content in the textiles. The experimental results based on 27 drying tests were evaluated to develop linear regression models for energy consumption and drying time, which show a good agreement with the experimental data. The results show that a large mass load, a high drum speed, and a low fan speed give the highest energy efficiency, i.e. the lowest energy consumption per kg of drying load. Larger loads extend the length of the drying cycle while higher fan and drum speeds result in shorter drying time.     

A Control Strategy for a Chemical Heat Pump Dryer

This article presents results of an experimental investigation on the controllability of hot air production using a pair of chemical heat pumps (CHP). The objective of this study is to determine how a CHP-assisted batch dryer can be operated effectively. The CHP uses the well-known CaO/H₂O/Ca(OH)₂ hydration/dehydration reaction, which is reversible. The hot air temperature can be controlled by adjusting the reactor temperature, and pressure, as well as thermal power supplied to it. It is shown that hot air can be produced in both the heat storage and heat release steps of the CHP.