Fundamentals of Drying

What effect does the design have on the three critical factors?
1. Uniform Process Time 2. Uniform Process Airflow 3. Uniform Process Temperature Non-uniformity in any, or all of these key variables will result in non-uniform drying.

(the Software)

Dryer Summary Costs

Aquatic Food System (12 mt / hr)
Electricity 5.9% Interest 5.9% Depreciation 12.1%

Dryer Maintenance 5.2% Gas 62.9%

Gas Costs determined assuming an efficiency of 1420 btu / lb (856 cal / g) of water removed

Labor 6.9%

Example: 12 Mt/h Dog Food

Drying / Cooling
System Configuration
Various components of dryers

Drying Theory
How does a dryer work?

Processing Conditions
What parameters effect drying?

Conveyor Dryers / Coolers

Gentle handling of product Air flow
Through Over On

Positive conveying
Uniform drying time

Primary Components
Spreader Conveyor Beds Fans Heat Source Makeup Air Inlets Exhaust Outlets Optional Devices

Spreaders
Purpose: Deliver product uniformly to conveyor bed
Across Conveyor Bed Along length of Conveyor Bed
Uniform spreading is essential to good product drying

Spreaders
Oscillating Spout
Advantages
Sanitation, versatile, cost, length

Disadvantages
Sticky / fragile products, low bed depth / short retention time products, height

Conveyor Beds

Purpose: Transport product through heated air flow Establish product retention time
Higher speed on upper bed - shallow depth Lower speed on lower bed - deeper bed

Conveyor Design
Trays
Hinged Overlapping Slotted or perforated
Galvanized or stainless steel

Screen
Wire mesh Polyester Screen PEEK Screen

Tray Openings
Perforations:
9/64 (3.6 mm) - 31% net open area 3/32 (2.4 mm) - 23% net open area

Slotted:
3/32 x 1/2 (2.4 x 13 mm) - 23% net open area

Polyester:
1,000 micron - 45% net open area 300 micron - 36% net open area

Recirculation Fans

Purpose: Provide uniform heated airflow to the dryer

Across the bed Through the bed (up and down) Uniform airflow is essential to product quality

Heat Source

Purpose: Produce heated process air

Uniform air temperature is essential to product quality

Heat Source
Direct Heat
Advantages
Energy exchange, high temperature, efficiency, economics

Disadvantages
Combustion by-products, limited to clean burning fuels required

Indirect Heat
Advantages
No combustion by-products, non-clean burning fuels

Disadvantages
Temperature, energy exchange, efficiency, heat exchanger

Makeup Air Inlets

Purpose: Replace spent exhaust air in dryers Replace cooler exhaust air

Exhaust Air Outlets

Purpose: Remove spent process air in dryer

Optional Devices
Brushes
Remove product clinging to conveyor

Fines system
Improve sanitation

Product breaker / agitator

Break up product clumps / stir product

Spray wands
Clean conveyor beds - extend process time

Humidity control
Artificially lower the drying rate

Product Cooling
Eliminate moisture condensation during storage
90C air - holds 454 g water 20C air - holds 8 g water

Normally cool 5 - 7C above storage temperature High ambient temperature

Mechanically cool process air

Conveyor Dryer with Attached Cooler

Product Inlet

Cooler

Dryer

Counter Current Coolers

Product discharges continuously Reduced bridging
Trays push up into product Product constantly moving

No moving conveyers Air flow

Through

Products
Coated Feeds

Vertical Dryers
(Wenger Cascade) Continuous turning of the product No moving conveyers No fines system needed Allows for efficient use of floor space Continuous batch operation Air flow

Drying Theory

"Black Box" approach to drying

PRODUCT AIR

Effects on Product
Moisture level decreases Product temperature
Increase Decrease Remain constant PRODUCT AIR

Effects on Air
Moisture level of air increases Temperature of air decreases Energy content of the air may or may not change

PRODUCT AIR

Aquatic Food Drying Curve

120 110 Measured Temperature (C) 100 90 80 70 60 50 40 0 5 10 15 20 Drying Time (Minutes) 25
Product Moisture

30 Product Moisture Content (MCWB)

25

20

15

10
Product Temperature

0 30

Basic Factors Controlling Drying

Temperature Airflow Time Bed Depth Spreading Product Characteristics

Temperature
Defined by product characteristics Rule of Thumb: Lower Always Better Reality: Run to the maximum the product will allow

Water Holding Capacity of Air

Temperature
(Deg. C)

Moisture in Air
(kg H2O / kg dry air)

25 30 40 50 60

0.020 0.028 0.049 0.087 0.150

Air heated to 1350C has 70X water holding capacity of 200C air

AIRFLOW
Most Important Factor Rule of Thumb:
Last Variable to be Adjusted

Reality:
Instant Experts Make Life Interesting

Effect of Air Velocity on Drying Time

30 25 Drying Time (min) 20 15 10 5 0 0.5 0.7 0.9 1.1 1.3 1.5 1.7 Air Velocity (m/s)

Effect of Air Velocity on Drying Time

Low Air Velocity

High Air Velocity

Time
Defined by product characteristics Rule of Thumb: Longer Always Better Controlled by:
Conveyor Speed Bed Depth

Bed Depth
Increasing bed depth decreases dryer size Deeper beds affect air flow Bed depth limited by
Soft or fragile products Sticky products Very wet products Product Size

Spreading - Across the Bed

A commercial case study was undertaken to examine the cost benefits associated with decreased moisture variation.
The following slides are the results of the study which directly compared the Wenger Series III and Series VII.

The two dryers tested were in commercial production, equally sized, and running like products at similar evaporative loads.

Case Study of Moisture Variation in Series III Single Plenum Dryer

Case Study of Moisture Variation in Airflow II Dual Plenum Dryer

Case Study of Moisture Variation Overlaying Series III and Airflow II Data

A lot of data, so what does it mean?

What is the 3.8% Moisture Loss Costing the Operation? This cost is in two forms:
1. The loss in profit potential from not having the ability to market moisture at Finished Product Value. 2. The additional energy cost needed to remove the excess moisture.

What is the 3.8% Moisture Loss Costing the Operation?

1. Lost Profit from Excessive Drying

Interactive

What is the 3.8% Moisture Loss Costing the Operation?

2. The additional energy cost needed to remove the excess 668 lb of moisture.
668 lb / hr X 1450 BTU / lb evaporation = 968,000 BTU / hr 968,000 BTU / hr X 5.0 6 $ / BTU** = 4.84 $ / hr

** assumption of $ 5.00 / MCF natural Gas Cost

The Silent Thiefs Annual Reward.

Is a dryer replacement justifiable?

Interactive

Payback Period
Definition
The minimum period of time required for the benefits to equal the cost of the investment.

Payback Period

Depreciable Fixed Capital Investment = Avg. Profit / year

Dryer Replacement Expenses (based on 8 ton / hr system)

* Depreciable Item ** Non-Depreciable items Interactive

Actual Payback Period

Payback (Period in Years) = Depreciable Fixed Capital Investment** Avg. Profit / year

For this example Depreciable and Non-Depreciable costs are included ** Interactive

What is your Moisture Uniformity?

Extreme Left Left Center Center Right Center Extreme Right High Reading Low Reading

Time 1

% % % % %

% % % % %

% % % % %

% % % % %

% % % % %
Date: _____________________ Product: ___________________

2 3 4 5

Dryer Process Trouble Shooting

TROUBLE SHOOTING Two Basic Areas:

Process Issues Maintenance / Hardware Issues

TROUBLE SHOOTING
Guidelines:
Remember Primary Factors
Time Temperature Airflow

Effect of Retention Time One At A Time

ONE AT A TIME
Most process corrections will involve multiple steps Make one process change at a time
Any change made to the process will take the retention time of the process to be noted at the dryer discharge

PROCESS ISSUES
Consistent Occurrences
Under-drying (Product too wet) Over-drying (Product too dry)

Random Occurrences Case Hardening

CONSISTENT UNDER-DRYING
Factors:
Temperature Retention Time Bed Depth Incoming Product Moisture Air Flow

CONSISTENT UNDER-DRYING
Temperatures Too Low:
Verify temperatures for all zones Confirm operation of all burners Check steam pressure Plugged filters or steam coils

CONSISTENT UNDER-DRYING
Retention Time Too Short:
Confirm speed of both conveyors
Based on previous runs Based on pre-set levels Upper beds are designed to travel faster than lower beds
35 percent of total time on top pass 65 percent of total time on bottom pass

CONSISTENT UNDER-DRYING
Bed Depth
Too Deep:
Conveyor speed too slow for incoming feed rate Increased feed rate into dryer Reduced product density at same production rate.

Bed Depth
Increasing bed depth decreases dryer size Deeper bed depths affect air flow Bed depth limited by
Sticky products Very wet products Soft or fragile products Product size

CONSISTENT UNDER-DRYING
Feed Product Moisture Too High:
Same Feed Product Outside Moisture Specification Change in Feed Product:
Product Size small pieces dryer more quickly than large pieces due to the surface to volume ratio Product Density increase in density results in an increase in drying time

Recipe change

CONSISTENT UNDER-DRYING
Insufficient Exhaust Volume
Excess Spent Process Air
Exhaust Fans
Belts Rotation Louvers

Ducting
Additional equipment Rusted or damaged duct

Major Seasonal Change

NEED FOR SEPARATE EXHAUST

Majority of water removed occurs in first half of top pass - Maximum Exhaust needed. Zone 2 Exhaust handles balance
30 25 Moisture 20 15 10 5 0 0 5 10 15 20 Drying Time 25 30

CONSISTENT UNDER-DRYING
Insufficient Make Up Air
Dryer is Starved for fresh air
Louvers Filters / steam coils plugged Recirculation Fans Belts Rotation Product buildup on wheels

CONSISTENT UNDER-DRYING
Improper Air Flow
Air short circuits the product bed
Missing or damaged air locks or air curtains Missing Panels Missing or Damaged Flashing Door seals

CONSISTENT OVER-DRYING
Factors:
Temperature Retention Time Bed Depth Incoming Product Moisture

CONSISTENT OVER-DRYING
Temperatures Too High:
Verify Set Points for all temperature zones Recently Cleaned Conveyors Major Season Change (wet to dry)

CONSISTENT OVER-DRYING
Retention Time Too Long:
Confirm Speed of both Conveyors
Based on previous runs Based on Pre-Set levels Upper Beds are designed to travel faster than Lower Beds
35 percent of total on top pass 65 percent of total on bottom pass

CONSISTENT OVER-DRYING
Bed Depth Too Shallow:
Retention Time Too Short Decreased Feed Rate into Dryer
Lower Temperature Decrease Fan Speed

CONSISTENT OVER-DRYING
Incoming Product Moisture
Moisture Too Low
Change in Feed Product:
Product Size small pieces dryer more quickly than large pieces due to the surface to volume ratio Product Density increase in density results in an increase in drying time

Recipe change

RANDOM UNDER / OVER DRYING

Factors:
Non-Uniform Spreading Inconsistent Incoming Product Unbalanced Airflow Blocked perforations on conveyor Product Clumping

RANDOM UNDER / OVER DRYING

Non-Uniform Spreading:
Across the Bed:
Hump pattern most common Edge Overflow second most common Adjust Oscillation Frequency

Along the Bed:

Ocean Wave, or S pattern Accelerate oscillation frequency

Spreading - Across the Bed

Spreading - Along the Bed

RANDOM UNDER / OVER DRYING

Inconsistent Incoming Product
Density Moisture

RANDOM UNDER / OVER DRYING

Unbalanced Airflow:
Equal time exposure Top and Bottom Equal time exposure Right to Left Majority of Exhaust from Zone 1

Verify Internal Doors in place Confirm Make-up Air louver settings Confirm Exhaust Damper settings

RANDOM UNDER / OVER DRYING

Blocked Conveyor:
Restricts uniform airflow Fines and Fat will plug bed slots
May require more frequent bed cleaning

RANDOM UNDER / OVER DRYING

Product Clumping:
Product agitator
Use only if clumping is an issue

Clumps of product act the same as large diameter pellets

CASE HARDENING
Outside of product dries too rapidly which closes all pores in skin and blocks moisture transfer from interior of pellet Reduce initial heat exposure If random search for airflow restrictions

Maintenance List
1. 2. 3. 4. Improper spreader adjustment Improper gas pressure Unbalanced exhaust and make up air Combustion blower fan wheels clogged with dust. 5. Combustion air duct rusted out.

Maintenance List
6. Steam coils clogged with fines. 7. Missing air panels 8. Side flashings not secure. 9. Missing/damaged air locks / curtains. 10. Internal filters clogged.

Dryer Air Flow Design

Dual Plenum Cross Air Flow Balances airflow throughout dryer Fans isolated by zone Airflow UP or DOWN by zone
+/- 0.5% Moisture Variation

Wenger Airflow II Dryers

What is this new dryer?
Dual Plenum Dryer That is NOT a Series VI or VII. Airflow is same as ET Air Flow II although construction is NOT.

New Dryer Utilizes a Center-Airflow

Center-Airflow Design Advantages

Balanced Airflow Increased Process Airflow Sub-floor between conveyors Temperature Profiling Process Air to Product Bed Fresh Make-up Air Exhaust Air

Process Airflow Control Sub-floor

Materials of Construction:
Unchanged from previous models: Mild Steel (w/304 SS in high corrosion areas) Mild Steel (w/304 SS in product contact areas) Complete 304 SS

sub-floor 304 SS

Time Temperature - Airflow

Heat Source Options:

Direct fired gas note unlike the Series VI dryers -- heat unit is mounted exterior to dryer. Indirect steam heat coils inside heat plenum include removable / air filters for dust removal.

Factory assembly & testing dryer access / insulation

Unchanged from previous models:

Factory assembly & testing dryer access / insulation

When compared to the North Carolina company Wenger offers unparallel dryer access for sanitation / maintenance.

Polyester Screen in the Dryer

Special Inlet Spreaders

Leveling Auger
Advantages
Bed depth variation, height, depth, great for small products

Disadvantages
Cost, more mechanism

Wenger or Extru-Tech AFII Dryers

-Guarantee +/- .5% Moisture Variance. -Watch the Water and Increase profits. -Calculations can show that this may equal depending on capacity upwards of 250,000.00 US each year in increased profits.
10MT/hr over 5000 hours is 50,000 tons @.5% Moisture variance lost 250 tons of water sold @ 2.5% Moisture variance lost 1250 tons of water sold ( difference is 1000 tons) @500 US per ton feed sold at 1000 tons is a loss of 500,000.00 US @ 250 US per ton feed raw material cost loss is 250,000.00 US

An efficient and modern dryer can increase profits on this example by 750,000.00 US per year not including the loss if energy over drying when drying to a variance of 2.5%

ASR System will Automatically Sense and Control the Humidity in the Exhaust to a Pre-Set Level

$ 26.21 Exhaust Air Values

Total Gas Cost @ Highest Evaporative Load Total Gas Cost @ Moderate Evaporative Load Unnecessary Gas Cost
$ / hr $ / hr $ / hr

$ 10.13

36.34 26.21 10.13

Time Temperature - Airflow

Side fines auger connecting to cross auger at Return section

Normal side plenum floor under fan side of Dryer

Cross auger with extension for side auger inlet

Midpoint of Dryer length

Floors not used, trough and auger inserted. Side of Dryer opposite fans.

Protective grate