Numerical and experimental study of dryer in forced convection

A numerical simulation model is developed to predict the forced convection performance of a dryer. This model takes into account the shrinkage phenomenon of the products during the drying process. The experimental results of the potato drying are obtained in climatic conditions similar to conditions found in natural open‐air drying when the dryer is fed by air heated by a solar air flat plate collector. After a study of the influence of parameters of the drying air on the product during the drying process, we expose the experimental results and compare them with those calculated by the theoretical model. Copyright © 2001 John Wiley & Sons, Ltd.     

Performance of a heat-pump assisted dryer

We present a simple mathematical model of a heat-pump-assisted dryer developed from psychrometric processes. A term ‘contact factor’ is used in the theoretical model to characterize the drying chamber. The experimental data of the drying rates of different types of products are used to predict the values of the contact factor of the dryers. We examine the effect of various parameters such as the contact factor, air inlet conditions, and the moisture removal rate on the performance of the heat-pump-assisted dryer. It has been shown that the non dimensional contact factor of a dryer is insensitive to dryer air inlet temperature. Finally, a performance chart to guide the selection of the heat-pump dryer components is proposed.     

Modelling of heat and mass transfer in a tunnel dryer

This work presents a numerical model for heat and mass transfer of granular products in a fixed-bed tunnel dryer. The drying process is simulated under real operating conditions based on a thin layer model and experimental drying kinetics. A simplified heat and mass transfer numerical model is developed based on the governing equations and the drying rate of a thin layer bed of granular products.The obtained system of non-linear partial differential equations is numerically solved by a finite volume method. The turbulent airflow and granular bed convection coefficient as well as the effective conductivity are estimated using the turbulent airflow over flat-plate correlations. Simulations are compared with experimental data from drying of grapes in a thin layer model.In order to study the effects of the air inlet conditions on the relative moisture content and the drying time and therefore to optimise the tunnel dryer operation, the influences of different parameters essentially the air flow characteristics and the fixed-bed dryer length are examined. The numerical code allows establishing the drying front propagation for several operating conditions.     

Computational fluid dynamic analysis of innovative design of solar-biomass hybrid dryer: An experimental validation

A solar-biomass hybrid dryer is designed and constructed for natural rubber sheet drying. The dryer consists of solar collector cum drying chamber, heat exchanger and biomass furnace. There is indirect heating of rubber sheet instead of direct exposure to smoke in ribbed smoked rubber drying. An attempt has been done to reduce consumption of biomass by introducing solar energy application. Computational fluid dynamics technique is used to simulate the temperature and air flow distributions in an innovative design of drying chamber. The simulation results for temperature are found very close to experimental values in terms of statistical parameters. CFD simulation is done for air flow distribution inside solar-biomass hybrid dryer to ensure the utility of air circulating fans. The solar-biomass hybrid dryer is tested for drying of 100 number of natural rubber sheets. Moisture content of rubber sheet is reduced from 34.26% to 0.34% (db) in only 48 h, a notable reduction in drying time as well as consumption of biomass. The color and texture of the natural rubber sheet were noticed better than the traditional smoke rubber drying.     

Simulation of a new concept of an indirect solar dryer equipped with offset rectangular plate fin absorber‐plate

A simulation code was developed to predict the indirect solar dryer performance of the thin beds of discs of potato, subjected to time‐varying air conditions. Two mathematical models are developed separately; the first allows the determination of the thermal performances of the solar collector with offset rectangular plate fin absorber‐plate and the second, allows to determine the kinetics of drying for the data input of the air at the exit of the collector. The latter takes into account calorific losses through the walls of the dryer and shrinkage of discs. Experimental results of the solar dryer thermal performances, using sunlight in Valenciennes (in the North of France), will be compared with the results obtained by the theoretical model suggested. Copyright © 2005 John Wiley & Sons, Ltd.     

Experimental and simulated performance of a PV-ventilated solar greenhouse dryer for drying of peeled longan and banana

This paper presents experimental and simulated performance of a PV-ventilated solar greenhouse dryer for drying of peeled longan and banana. The dryer consists of a parabolic roof structure covered with polycarbonate plates on a concrete floor. Three fans powered by a 50-W PV module ventilate the dryer. To investigate the experimental performances of the solar greenhouse dryer for drying of peeled longan and banana, 10 full scale experimental runs were conducted. Of which five experimental runs were conducted for drying of peeled longan and another five experimental runs were conducted for drying of banana. The drying air temperature varied from 31 °C to 58 °C during drying of peeled longan while it varied from 30 °C to 60 °C during drying of banana. The drying time of peeled longan in the solar greenhouse dryer was 3 days, whereas 5-6 days are required for natural sun drying under similar conditions. The drying time of banana in the solar greenhouse dryer was 4 days, while it took 5-6 days for natural sun drying under similar conditions. The quality of solar dried products in terms of colour and taste was high-quality dried products. A system of partial differential equations describing heat and moisture transfer during drying of peeled longan and banana in the solar greenhouse dryer was developed and this system of non-linear partial differential equations was solved numerically using the finite difference method. The numerical solution was programmed in Compaq Visual FORTRAN version 6.5. The simulated results reasonably agreed with the experimental data for solar drying of peeled longan and banana. This model can be used to provide the design data and is also essential for optimal design of the dryer.     

New approach for thermal testing of solar dryer: Development of generalized drying characteristic curve

It is necessary to develop thermal test procedure that can assist performance comparison between various solar dryer designs on common basis. In order to achieve this objective, the laboratory model of mixed-mode solar dryer is specially designed to perform indoor drying experiments with cylindrical potato samples. Sixteen drying kinetic curves are obtained over a wide range of various drying process variables. The variables investigated are absorbed thermal energy, air mass flow rate, food sample thickness and loading density. Based on experimental data of moisture content ratio-drying time, new concept to develop standard test method for performance evaluation of a given dryer is proposed. The proposed methodology facilitates to generate single generalized characteristic curve representing 16 drying kinetics and dimensionless parameter called dryer performance index (DPI) characterising the effectiveness of dryer system is identified. Different solar dryers with potato, banana and wheat are also tested in real climatic conditions to validate the proposed methodology. DPI with consistent values for all test conditions, indicating high degree of independence of operating conditions and food product characteristics, can therefore be used as a test parameter for performance comparison between different dryer designs on equitable basis.     

Energy analysis in fluidized‐bed drying of large wet particles

Energy analysis of a fluidized‐bed drying system is undertaken to optimize the fluidized‐bed drying conditions for large wet particles (Group D) using energy models. Three critical factors; the inlet air temperature, the fluidization velocity, and the initial moisture contents of the material (e.g., wheat) are studied to determine their effects on the overall energy efficiency to optimize the fluidized bed drying process. In order to verify the model, different experimental data sets for wheat material taken from the literature are used. The results show that the energy efficiencies of the fluidized‐bed dryer decrease with increasing drying time and become the lowest at the end of the drying process. It is observed that the inlet air temperature has an important effect on energy efficiency for the material where the diffusion coefficient depends on both the temperature and the moisture content of the particle. Furthermore, the energy efficiencies showed higher values for particles with high initial moisture content while the effect of gas velocity varied depending on the material properties. A good agreement is achieved between the model predictions and the available experimental results. Copyright © 2002 John Wiley & Sons, Ltd.     

Optimization of mixed-mode and indirect-mode natural convection solar dryers

This paper presents a comparison of optimized mixed-mode and indirect-mode natural convection solar dryers for maize. The mixed-mode and indirect-mode solar drying simulation models were validated against results from a laboratory solar dryer with experiments carried out under a solar simulator at the University of Newcastle upon Tyne, UK. The models are now run under variable solar conditions in order to optimize the dryers and compare their performance. The inputs to the simulation models were Zambian weather conditions and materials. The solar drying simulations are combined with the cost of the dryer materials and a search technique that finds the dryer dimensions at the minimum drying cost. Optimization gave a shorter collector length for the mixed-mode solar dryer (1.8 m) than for the indirect-mode dryer (3.34 m) of the same grain capacity (90 kg). The drying cost, annual cost and initial cost of the mixed-mode dryer are lower than those of the indirect-mode although the quantity of dry grain obtained from the mixed-mode for the whole year is less than for the indirect-mode; the drying costs are 12.76 and 16.05 US$/ton for mixed-mode and indirect-mode dryers, respectively.     

Silk cocoon drying in forced convection type solar dryer

The thin layer silk cocoon drying was studied in a forced convection type solar dyer. The drying chamber was provided with several trays on which the cocoons loaded in thin layer. The hot air generated in the solar air heater was forced into drying chamber to avoid the direct exposure of sunlight and UV radiation on cocoons. The drying air temperature varied from 50 to 75 °C. The cocoon was dried from the initial moisture content of about 60–12% (wb). The drying data was fitted to thin layer drying models. Drying behaviour of the silk cocoon was best fitted with the Wang and Singh drying model. Good agreement was obtained between predicted and experimental values. Quality of the cocoons dried in the solar dryer was at par with the cocoons dried in the conventional electrical oven dryer in term of the silk yield and strength of the silk. Saving of electrical energy was about 0.75 kWh/kg cocoons dried. Economic analysis indicated that the NPV of the solar dryer was higher and more stable (against escalation rate of electricity) as compare to the same for electrical oven dryer. Due to simplicity in design and construction and significant saving of operational electrical energy, solar cocoon dryer seems to be a viable option.     

Performance of indirect solar cabinet dryer

In this paper, the development and testing of a new type of efficient solar dryer, particularly meant for drying vegetables and fruit, is described. The dryer has two compartments: one for collecting solar radiation and producing thermal energy and the other for spreading the product to be dried. This arrangement was made to absorb maximum solar radiation by the absorber plate. In this dryer, the product was loaded beneath the absorber plate, which prevented the problem of discoloration due to irradiation by direct sunlight. Two axial flow fans, provided in the air inlet, can accelerate the drying rate. The dryer had six perforated trays for loading the material. The absorber plate of the dryer attained a temperature of 97.2 °C when it was studied under no load conditions. The maximum air temperature in the dryer, under this condition was 78.1 °C. The dryer was loaded with 4 kg of bitter gourd having an initial moisture content of 95%, and the final desired moisture content of 5% was achieved within 6 h without losing the product colour, while it was 11 h for open sun drying. The collector glazing was inclined at a particular angle, suitable to the location, for absorption of maximum solar radiation. A detailed performance analysis was done by three methods, namely ‘annualized cost method’, ‘present worth of annual savings’ and ‘present worth of cumulative savings’. The drying cost for 1 kg of bitter gourd was calculated as Rs. 17.52, and it was Rs. 41.35, in the case of an electric dryer. The life span of the solar dryer was assumed to be 20 years. The cumulative present worth of annual savings over the life of the solar dryer was calculated for bitter gourd drying, and it turned out be Rs. 31659.26, which was much higher than the capital cost of the dryer (Rs. 6500). The payback period was calculated as 3.26 years, which was also very small considering the life of the system (20 years). So, the dryer would dry products free of cost during almost its entire life span. The quality of the product dried in the solar dryer was competitive with the branded products available in the market.     

Testing method for thermal performance based rating of various solar dryer designs

A generalized methodology is developed for thermal testing of various solar dryer designs operated for natural and forced air flow conditions. The steady state mathematical model based on heat balance concept of solar dryer without load is applied to identify the dimensionless parameter called no-load performance index (NLPI). Laboratory models of direct (cabinet), indirect and mixed mode solar dryer are designed and constructed to perform steady state thermal tests for natural and forced air circulation. The dryers with no-load are operated with air passage between absorber plate and glass cover for the range of 300–800 W/m² and 0.009–0.026 kg/s of absorbed thermal energy and air mass flow rate respectively under indoor simulation conditions. The present study reveals that the forced convection operated dryer provides higher NLPI in contrast to that of natural convection. The comparative performance analysis of dryers indicates that the mixed mode dryer exhibits maximum value of NLPI followed by indirect and cabinet ones for both natural and forced air circulation. It is also found that for any dryer operating at given air flow condition, almost invariable NLPI values have been obtained for a wide range of absorbed energy and ambient air temperature data, thus facilitating performance comparison between different dryer designs on equitable basis. The results of statistical analysis showing low standard errors of mean further demonstrate good consistency in NLPI values for various dryer designs. The uncertainty in NLPI due to error in measurement of several parameters by instruments ranges from 0.79 to 1.96% for various dryer designs operated under different conditions.     

Experimental investigation of the performance of the solar tunnel dryer for drying bananas

The multi-purpose solar tunnel dryer was used to dry bananas under the hot and humid weather conditions of Thailand in order to investigate its performance. The dryer comprises a plastic sheet-covered flat plate collector and a drying tunnel. The dryer is arranged to supply hot air directly to the drying tunnel using three fans powered by a 53 W solar cell module. The products to be dried are spread in one layer on a plastic net in the drying tunnel to receive energy from both the hot air supplied by the collector and incident solar radiation. This dryer can be used to dry up to 300 kg of ripe bananas in each drying batch. In investigating the performance of the dryer, seven drying tests were conducted at the Royal Chitralada Projects in Bangkok during March–May 1995. Teh temperature of the drying air from the collector varied between 40 and 65°C during drying and the bananas could be dried within 3–5 days, compared to the 5–7 days needed for natural Sun drying. In addition, the bananas being dried in the solar tunnel dryer were completely protected from rain, insects and dust, and the dried bananas were of high quality in terms of flavour, colour and texture. As the fans are powered by the solar module, the dryer could be used in rural areas where there is no supply of electricity from grid. The pay-back period of the dryer is estimated to be about 3 years when the dryer is locally produced.     

Experimental and modelling performances of a roof-integrated solar drying system for drying herbs and spices

This paper presents experimental performance of solar drying of rosella flower and chili using roof-integrated solar dryer and also presents modelling of the roof-integrated solar dryer for drying of chili. Field-level tests for deep bed drying of rosella flower and chili demonstrated that drying in the roof-integrated solar dryer results in significant reduction in drying time compared to the traditional sun drying method and the dry product is a quality dry product compared to the quality products in the markets. The payback period of the roof-integrated solar dryer is about 5 years. To simulate the performance of the roof-integrated solar dryer for drying herbs and spices using hot air from roof-integrated solar collectors, two sets of equations were developed. The first set of equations was solved implicitly and the second set of equations was solved explicitly using finite difference technique. The simulated air temperatures at the collector outlet agreed well with the observed air temperatures. Good agreement was also found between experimental and simulated moisture contents.     

Simulation model of the thermal performance of a natural convection-type solar tunnel dryer

The basic objective of this paper is to develop a comprehensive simulation model of the thermal performance of solar tunnel dryer. The model is useful in system design as it is sensitive to the design parameters of air collector and dryer (like, length, radius, tunnel tilt, etc.). It is also useful in determining the drying behaviour of high-moisture products (vegetables, fruits, etc.) as well as low-moisture products (barely, wheat, etc.). The performance of the dryer has been estimated for a natural convection mode flow. A transient one-dimensional model was developed for the dryer and the numerical calculations were made for the climate of Delhi. It is observed that a large quantity of barley about 2135 kg can be dried in this dryer within two days of operation upto an equilibrium moisture content. © 1998 John Wiley & Sons Ltd.     

Experimental and simulation studies on the no-load performance assessment of a domestic solar dryer

Solar dryers have been tested with various simple and complex design modifications for better efficiencies. This article attempts to investigate the effect of a very simple design modification on the no-load performance of a natural convection domestic solar dryer (NCDSD). A direct-type domestic solar dryer has been developed with an air cavity surrounding the drying chamber. To compare the effect of air cavity, a domestic solar dryer without air cavity has also been developed and both the dryers were tested simultaneously under the climate of Hisar, India. The values of thermal efficiency were calculated along with convective heat transfer coefficient from absorber plate to the drying air. Both the dryers were also analyzed by developing finite element models in COMSOL multiphysics computer software. The no-load thermal efficiency for the domestic solar dryer without and with air cavity was found to be 22.68% and 34.08%, respectively. The values of coefficient of correlation for modeled and actual drying tray temperatures for dryer without and with air cavity were 0.980466 and 0.9833917, respectively. The proposed finite element model would be helpful in the design and development of NCDSDs.     

Development of a new type of solar dryer: Its mathematical modelling and experimental evaluation

A solar dryer fitted with a novel design of absorber having inbuilt thermal storage capabilities was designed, fabricated, simulated and also tested at Rajiv Gandhi College of Engineering Research & Technology, Chandrapur (MS) India. Thermic oil was used as a storage material. The main objective of the study was to reduce the drying period and enhance the quality of dried product mainly chillies and fenugreek leaves. The products were laid in a single layer. The dimensions of the dryer were arrived at using the well-defined procedure available in literature. The mass of thermic oil needed in the absorber and mass of product to be dried in trays were optimized using simulation techniques. The maximum drying air temperature required for drying agricultural products was around 65°C. The ambient conditions at the location were 25–40°C, 16–43% RH and solar radiation 105–1024 W m⁻². Experimental studies based on temperature and humidity measurements were performed on the dryer. The research concluded that the desired drying air temperature was achieved and maintained for a longer period. The length of operation of the solar air heater and the efficiency of the dryer were increased, and better quality of agricultural products in terms of colour value were obtained compared with open sun drying. Copyright © 2007 John Wiley & Sons, Ltd.     

Natural convection solar dryer with biomass back-up heater

A direct-type natural convection solar dryer and a simple biomass burner have been combined to demonstrate a drying technology suitable for small-scale processors of dried fruits and vegetables in non-electrified areas of developing countries. From a series of evaluation trials of the system, the capacity of the dryer was found to be 20–22 kg of fresh pineapple arranged in a single layer of 0.01-m-thick slices. The overall drying efficiency of the unit was calculated to be 9%. During the same trial, the drying efficiency of the solar component alone was found to be 22%. Other trials estimated the efficiency of the burner in producing useful heat for drying to be 27%. Key features of the biomass burner were found to be the addition of thermal mass on the upper surface, an internal baffle plate to lengthen the exhaust gas exit path and a variable air inlet valve. Further modifications to further improve the performance of both the solar and biomass components of the dryer are suggested.     

Mathematical modelling and experimental investigation of tropical fruits drying

A mathematical model has been developed to solve the heat and mass transfer equations for convective drying of tropical fruits. The model takes into account shrinkage of material and moisture content and shrinkage dependant effective diffusivity. Heat and mass transfer equations for the dryer, termed as equipment model, have also been developed to determine the changes of drying potential of the drying medium during drying. The material model is capable of predicting the instantaneous temperature and moisture distribution inside the material. The equipment model, on the other hand, describes the transfer process in the tunnel dryer and predicts the instantaneous temperature and humidity ratio of air at any location of the tunnel. Thus, the model is capable of predicting the dynamic behaviour of the dryer. The predicted results were compared with experimental data for the drying of banana slices dried in a solar dryer. Experimental results validated the model developed.