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DRYING OF WHITE SUGAR IN A FLUID BED: SIMULATION

AND DESIGN OF INDUSTRIAL SCALE DRYERS-COOLERS
a a
Z. Pakowski & J. Grochowski
a
Department of Heat and Mass Transfer Processes, Faculty of Process and Environmental
Engineering , d Technical University , d, Poland
Published online: 27 Apr 2007.

To cite this article: Z. Pakowski & J. Grochowski (1997) DRYING OF WHITE SUGAR IN A FLUID BED: SIMULATION AND
DESIGN OF INDUSTRIAL SCALE DRYERS-COOLERS, Drying Technology: An International Journal, 15:6-8, 1882-1892, DOI:
10.1080/07373939708917334

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 DRYING TECHNOLOGY, l5(6-8). 1881-1892 (1997)

DRYING OF WHITE SUGAR IN A FLUID BED'

SLMULATION AND DESIGN OF INDUSTFUAL SCALE DRYERS-COOLERS
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Z. P a k o d and 1. Gmchowski

Oeparunent of Heat and Mas T r a d e r Pmcares. Faculty of Pmoess and Environmental

Engineering, lddi Technical University. tMi Poland

Key mrrds: FB,WE, fluidization, model

ABSTRACT

In the late 60-ties fluid bed drying of sugar made a nep from m a r c h laboratories into
indusuial praaiar, dna then the pro- of sugar fluid bed drying technology has been
noticeable, however, the description of the drying proscss is still b a 4 on questionable models
and no reliable sugar drying w e is available. This paper presents nnv i n f o m t i o n on the
chmcIerisIic drying curve of while sugar and a cornpuler simulation model of a fluid bed dryer-
moler for sugar togelher with iU applistion for the design of indusuial wale dryemmolers. Thc
model has been used in Ihe development of a series of fluid bed dqeerramlen for sugar in Polish
sugar industry.

PREvlOUS WORK

Sugar is a crystalline solid mmpowd almost of p w sucrow. Sugar crystals form in the
proass of moking: their size range d l y from 3 lo 0.2 m. Predominant ranges are 1.6-0.71
mm which is called medium crystal and 0.71 to 0.28 called fine crystal. Cooking technology has a
decisive influence on the panicle size disuibution of raw sugar. Usually crystal sire range
produced m v e n both medium and fine crystal. Such sugar can be furlher separated by scmning
or sold as is.
M o i m mntcnt (m.c.1 after cenuifugation of the m s e c u i t e is as low as 1%. However.
during drying sugar m a i m wntenl mun be reduced to l a s than 0.03% in fypical applications

Copyright 0 1997 by Marcel Dekker. Inc.

 I882 PAKOWSKI AND GROCHOWSKI

(silo storage, packaging into plastic bags etc.). Even less (0.02%) is required for Mnsport of
sugar in bulk. The total m.c. is diRributed beOKen the one contained in the s d x e film ofthc
samVd sucmw solutioh the one contained in internices beOKen crynal debris and the one
embedded in the sugar crystal defcns. The f i m lypc is asumcd to wmrpond to mc. greater lhan
0.05 lo 0.1 %. Below these valuer the hw other l y p of bound moisturr have to be removed. The
value of 0. I % i s lhcrcfore commonly accepted as the "critical moirmre mnsnt".
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Sugar being soluble in Hater exhibits a fypical sorplion isotherm lorn with a plateau
wmsponding to uater advily ca. 0.88 as explained in the paper by Breyan and Mathlouthi.
1994. This plateau extends from ca.1% m.c. wer a side range of moisture wntenL Werner.
1966 shorn detailed sorption isotherms in the range below 1% m.c. As shown by Zaborsin,
Dmiu)ulr. I982 sorption i s o t h e m of sugar depend on crynal size and wntent of impuritia.
Hygroscopicity of sugar increases with incrcaring impurities content and dsrcasing crynal s i x .
Sugar tempcraturc alter centrifugation is close to 70'C. The initial temperature at dryer entry
depends on h e distance of UanspoR route from cenIriFuges to h e dryer. If the dinan= is t w far.
sugar temperame may dmp considerably which is a m e of encrgv h c h olhmvirc can be uscd
for drying and clun can form on a sugar layer which may lead to lump formation in a dryer.

Flvidimbiliry of we1 sugar

In the mean crystal sirc range of 0.6 to 0.8 mm white sugar with moimrn mntent of I to 0.1 ./.
will not fluidim well in a plug flow fluid bed type. Due lo nickinerr wct sugar when loaded into a
fluid bed dryer will tend to lump and form channels until il will loow fluidity. Even the
increasing of air vclocitia in ex- of 10 umfwill not help much. Typically bmethods are

.
uscd to overcome Ulis problem:
Am d o n is a deep bed of perfslly-mixed fype. Sugar fed into it will be dissolved in a large
mass of dry sugar so the averagc m.c, drops below 0.1 % (this method uas uscd in the firn

. dryer designs).
the whole dryer is vibrated (COMESSA. STORK. OMMKON) or gas is p d s d (Gawqmki
el. 01.. 1989). Oscillations help in sugar flow, they dolroy channels and assist fluidization.
Handling of sugar is gcntlc and attrition of crystals is low but Imw lumps of m t sugar that
may enter with the feed will tend to harden so a spccial feeder. comb-like devices immersed in
the bed (Hoks. Elfrink. 1993) or screening of the lumps from the Iced is required.
slow speed mixers with horizontal @MA) or vertical (ALLGAIER OMNIKON) sha& am
They denmy lumps and channels and facilitate sugar flow.
d.
Gas diNibutor plays an important role in making sugar fluidim. It has lo have enough
pressurr dmp (0.1 to 0.4 of lhe bed prcrsure dmp) lo caw Fvsn air distribution and provide
stablc fluidization (no channels and dead mner) without d n g t w much energy for pumping.
 DRYING OF WHITE SUGAR IN FLUID BED 1883

b i d e s providing a uniform gas distribution it should p x i b l y produce gas jeu of high

momentum to dcsVoy son lumps. U air jeu arc inclined towards thc exit end of the dryer a
pmpclling f o m is additionally obtained. Gas disuibutor p l a t s designed Hith thc abovc in mind
arc d l e d 'gill plates" and are commonly uscd in modern fluid bcd dryers. Availabilily of "gill
plate" gas distributors allowed for notimblc redunion of pumping mrts mmparcd to drillcd
platcs used in carly designs (Pako& el. 01.. 1988) and made them less ~ v e p l i b l elo clogging.
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Models of a g a r dving

Numerous models of sugar drying either assume that drying rate can be calculated from the
hcat uander ratc divided by latent hcat of vaporisation at adiabatic saturation tempcralurc
(Douglas el. ol.. 1993). from the rate of crynallisation of sucrow in the syrup film surrounding
lhe crystal Vail el, oL. 1994). from experimentally established exponent n in thc csponcntial
d m y of drying rate (KTcll el. a/., 1884) or from mass transfer mefticient in gas phase calculalcd
on lhe basis of diliisional resislana of pores in the crun snrrounding the crystal (Trichaiyapom.
1991). None of lhcsc models seems to adequately describe the drying ratc of crystalline sugar.

A workhorn for NgaI drying and cmling is still a mlary dryer Data compiled by us from various
s o w a s (e.g. Bosse, 1991) allow for comparison of the fluid bed vs. rotary dryers in a 10 point
scale shown in Figun 1. The cornparisan is made for a dryer-cooler of 480 tld throughput.

GAS-PARTICLE HEAT AND MASS TRANSFER IN A FLUID BED

Having @clc dewily of 1588 kglm3 and dominant panicle rim in the nnge 0.6 to 0.8 mm
dry NgaIklOngS to gmup B of Gcldan's classification. Such solids fluidize non-homogeneously
and bubbling stam at onscl of fluidilalion. For that reasan a ponion of gas leaves the bed
without adequately mnlacting the panicla. For such a bed an equilibrium model of solid and gas
mnraa is inadequate since drying or cmling rates Qlculated arc mmiderably larger than in
reality.
Non-homogenwus bcd models that include the bubbling-bcd (BE) model of Kunii and
L n e q i c l and ihc eBmive t h e r mefticicnt (FTC) model mponed by Kekhof. 1994 can be
uscd. U n f o n u ~ t c l yboth modds rvongly depend on nructrral parameters of the bed The BB
model uscs the ratio of volumc of panicles in bubbles to the volume of bubbler g. This parameter
 1884 PAKOWSKI AND GROCHOWSKI
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Figure I. Comparison of fluid bed and r o w dryers for sugar

varies from 0.01 to 0.001. On the other hand the FTC model nmngly depends an k d voidage c.
It was found that using Ule formula for e formerly ured by Kcrkhof. 1994 yields wucalistic rcrulU
for sugar.
It was also found that when using Mori and Wen mrrchlion for bubble size in the BB m&
(as rcmmmcnded by Cicsidczyk, 1996) and the following Todcs formula for bed voidage

at g = O.W3 both models give mmpamble d U .For practical applications x,hormcr, suggest
using the ETC model with voidage calculated form the Todes equation.
Comparison of heat Vansfer cocficicnts calculated for sugar of mean crystal s i n 0.7 mm in
(he air of 90C is s h o w in Figure 2.
Mass &er mcficicnu am calculated on a basis of a suitable hcat and mass &er
analogy.
. %

Volumetric meflicients arc calculated an the basis of the total bed a m calculated as the
swiacc area of a11 sugar crystals in 1m3 of (he dynamic M.Sphericity of a sugar crystal
n e m s v y for calcvlation ofthe equivalent diameter is 0.81.
 DRYING OF WHITE SUGAR IN FLUID BED
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Figure 2. Comparison of thc bubbling-bed model and lhc effeclive axficient model for hEa1
uansfer efficient in a fluid bcd of sugar

In M B s there is no need lo modify transfer d ~ c i e n f obtained

s by the above methods if air
velocity is larger than 3 umf.

CALCULATION OF DRYING KINETICS IN A FLuID BED

Calculation of (he drying rate presents the greatest difiiculty when modeling lhc drylng
process. The pmoas is governed both by heat and mass uansfer in the fluid bed and by drying
kinctic properties of the crystal itwlf including the sorptional propelties of the sugar. Wc suggest
the following semi empirical characlcrinic dqing curve equation uwd by us for dryer design for
lhe OMNIKON mmpany

Values of equilibrium m.c, and humidity can be calculated fmm sorption isotherm available
in Werner. 1966 modified to reach the plateau of RH. = 0.88 at 1% m.c.
 PAKOWSKI AND GROCHOWSKI
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Figure 3. Schematic of a single ccll

Further wrk is required to depen the undemanding of evaporation fmm sucmw film
covering the c w .

Plug-flow fluid bed h% a form of rrctangular layer supponed by the gas distributor. Blow
box= supply air to (hc bed. Each bowbox supplies air of ddinsd parameters. A portion of thc bcd
w u a blowbox is d e d a &on. Each d o n unrally has an adjumble wcir to keep (hc bcd
depth m m l in the d o n . Drying senions supplied with hot air are followd by moling
d o n s supplied with ambient air. Asrwning tbat air is evenly diaributcd over ihs whole d o n
the following bcd model can k used (originally appeared in Suumillo. PaLowski. iylla, 1986).
The &on is divided into n-cclls of equal lhickncrr shown whcmatically in Figure 3. Assuming
a profile of sugar moisture mntent and temperahue in the d o n (it \rill k verified later) an
average sugar m.c. and temperahue are calculated. Thcy arc used in (hc calculations of bcd
voidage, bcd prrrsun dmp, heal and masr uansfer d ~ c i c n t s .
 DRYING OF WHITE SUGAR IN FLUID BED 1887

u d y ca 100-300 cells are used per d o n to pmvidc nable calculations. Due to a m u m

of nonquilibrium model shown below a wt ofnon linear algebraic equations must be solved in
each cell to calculate the exil parameten of sugar and air.
The model of heat and mass uander in a single cell is composed of the following balance
equations:
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overall mass balance

overall energy balance

( i i - l i i )
S m
(. .i)
m - - A W ~ lgl-lg

mass balance for solid phase

W~(X'-~-X')=-~,.AV.~
energy balance for solid phase

~~(ik'-i,)=-(~+w~h~~)~V.a

Conaihltive equations have the form of Equation (3) for mass uander and the following
equivalent equation for heat lnnsfer

Conran heat uander from gas distributor and heal lows by outer Halls are usually neglected.
Solid enthalpies are calculated using the heat of sorption of sugar which is derived from the
sorption isotherm equation during mmpuI+ation.
Axial dispersion of sugar flow is also inmrponted in the model as explained in PaLoHski.
Mujumdar. 1995. H m e r , formulas for axial dispersion wefficient scattered in literature
strongly depend on the bed width to depth ratio and produce values diaering by an order of
magnitude. T h e d o n in these amputations axial dispersion was neglened.
b u l l s of calculations of a dryeraoler for I8 lh are shown in Figure 4 (on the Salin chart)
and in Figure 5 (profiles along dryer - note that the moirmre antent axis is logarithmic). Thc
unit is 12 m long and 1.4 m wide and has tw drying d o n s and two moling Sections. In
 1888 PAKOWSKI A N D GROCHOWSKI

,I 00 (150 ,200 \250 ,300\ \400 , i,k~kg

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Figure 4. Drying and cooling prccess trajectories on the Salin chan

Figure 5 ends of sections are marked with vcnical lines The air supplied to individual sections is
marked wilh a dark circlc in Figurc 3. Bcd depth is 0.3 m in the drying section and 0.2 in the
cooling sections. Note the diflcrenccs in thc solid and exit air tempcraturc resulting from the
non-equilibrium model.

DESIGN TRENDS

Modern fluid bed drycrdcoolers arc designed as elongated troughs ofplug-flaw lype. Length
lo width ratio of lhe whole bed is usually 6 to 10. Air is fed lo blow boxes of individual drying and
cmling =lions. Air lcmpcralures of 90 lo IW'C am uwd for drying and ambient air typically of
15Cis uwd for cooling. UNally the towl of 3 lo 10 sections is used BMA i n r n s a shon cooling
section k t w n drying sections I and I1 (Bosw. 1991). This is supposed lo induce the so called
"temperalure nring" believed lo incrcasc the drying ram. This aclion. hoxvcr. nus no1
conlimed in lilenorc.
 DRYING OF WHITE SUGAR IN FLUID BED

Calculated profiles of crossflow contact of white sugar

containing water with air
Y . p/ka X. 9( A v d t ~ ~ . 4 8 l O ~ C Avadgastanp.=15.78& T"C

- - . *
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Figure 5 . Calculated profiles of t e m p e r a m and humidity along the dryer-cmlcr

The range of gas supemcial velocities vary. With the minimum fluidization velocity of sugar
equal lo ca. 0.16 mls, velocities close lo I m h are uwd in the drying d o n s and 0.5 mls in the
cmling sections.Selmian of gas velocity influences the bed hood design. BMA using velocities
up 10.1.3 m h makes hoods as lall as 5 m with horimntal crorrwnion almoa 1W% larger lhan
h a t of the bed in ardcr to aparatc the entrained panicles (Bossc. 1991). STORK in their VFB
design uses apparently much louer gar velocities so their hood is ca. 1 m lall and has no
expansion (Hoks. Elfring. 1993). In our designs the hood is ca.2 m fall and has -ion of a.
50 %.
Dtyer design may be a s d on the basis of tm, indicators: elslric energy mnnunption in
kWhh and steam consumption in k g k For the required final sugar tcmpcrature c30Cand m.c.
C0.03 %the values of thsw parameters available in lilerahlre vs. ours are shown in Table I
Apparently the figurer obtained are a lrnrlt of several factors bed area and depth, air velocity.
initial sugar temperature Thorough optimistion studies are necessary lo find the optimum
design. They have to be based on a reliable model of thc pmc-s. SuEct to say h a t if the sugar is
overdried in the drying d o n s it will have higher temperaNIc which lhen l
m to be reduced in
 1890 PAKOWSKI AND GROCHOWSKl

Tablc I. Comparison ofperlormancc factors of selcsled dycrslcmlcn for sugar

Dryer ~ y p Initial Initial ~ h ~ Elmric

~ ~energy
~ h Steam
~ ~ ~ ,
sugar m.c.. sugar temp.. 11% mnsumption, mnsumption
OC kWhn kgh
BMA 1.2 70 20.0 3.8 19.8
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STORK 0.6 60 38.5 5.5 28.7

OMNLKON 1.0 60 18.0 4.4 29.4

lhe m l i n g sections. Fwther economies can be ob!aincd if (he air exiting &om the m l i n g
sections, which is dry and has t e m p e r a m of ca. 4OeC, can be recycled into the drying d o n s .
This. houevcr, q u i m musidcrably deep dun mmaval so (he air may passed though a seam
heater before reaming to the dryer or the ruyclcd air must bc mixed with air much hotter than
90Crequired for operation. So far the recyclc of air into drying section 11 without reheating is
uwd in a Rusrian made P S S l S unit as described by Tcmpcr er 01.. 1979.
"Gill plates" bemme nandard gas distributors in sugar dryers. Homver, their direclional
action c a w sugar to be m p n e d t w fan in Ulin beds. Weirs have to be placed aftcr each
sclion and d a p c r b d s uwd.The advantage of lhis actioq homver, can be uwd h e n designing
a side sugar exit instead of a svaight one.
With marc stringent qualify reguinmcnu (lower m.c. as required for vanspn in bulk and
lomr bancria munu) air uwd for drying and m l i n g will havc to be bcncr filtcrcd and
mnditioned to remove humidity fmm foggy autumn air. So far mnditioning of the cmling air has
not b a n found economically and technically justirted. Therefore to avoid sugar rehumidiiication
in some designs auxiliary air heaters we uwd (e.g. PSS-IS. OMNKOM. It is rmommcndcd to
k a p the sugar exit lcmpcrarure higher by 10 degrees than (he cmling air tcmperanuc to p m w
the sugar from rehumidhication.

CONCLUSIONS

Fluid bed dryers for sugar synemalically rcp1a-x mrary dryen. Modeling of fluid bed dIying
in a plug flow dryer can be bawd an a Mn-equilibrium model of heal and mars vaodcr in Ihc bed
as cxplaincd abwe. Drying l a c of a single grain is still bawd on empirical functions Wrc the one
p r o p s 4 in this w r k . More wok is q u i d on the micmkinctia of drying single sugar cIystals
 DRYING OF WHITE SUGAR IN FLUID BED I891

to explain c.g, Ihe "temperam suing" action. Funher work is also quircd to optimize the
design having in mind possibly low elguiciry ansumption, steam ansumption and overall
capital msts wilhout sacrificing sugar quality.

NOTATION
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Archimedes number,
specific area of mntacl,
enthalpy of water vapor at interface temperature
cnthalpy calculated per kg of incn substance
gasbed mass transfer metficicnt
heal uansfer rate
panicle Reynolds number
temperam K
mass flourate kgh
drying rate kglmzs
air flowate per each cell
volume of each cell
sugar moirmre antent
absolute humidity

Greek lellers

a heal uander coefficient

e voidage of the fluid bed
j relative humidiry

I at gas inlet to a cell

2 at gas exit from a cell
C critical
i denotes a m n t cell
g hwnidgas
m wu solid

W G A I E R . BhiA. COMESSb. OMNMON,STORK arc wade names ofrrspenive mmpanies.

 PAKOWSKI AND GROCHOWSKI

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Bosse E. D.. 1991. Fluidid-bed drying and cooling of crystal sugar. Int. Sugar J.. 93, 1 15, pp.
229-23 1.237
Brcssvl C.. Malhloulhi M., 1994. Thermodynamic activity of uater and sucrose and the stability
of crystalline sugar. Zuckerind.. 119.8. pp. 652458
Ciesiclnyk W., 1996. Analogy of heat and mass Uansfer during wnnant rate period in f l u i d i d
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bed drying. 14.2. pp. 217-230

Douglas P.L.. Kwade A . LFe P.L.. Mallick S.K.. 1993, Simulation of a rotary dryer for sugar
crystalline. Drying Technology, 11. I. pp. 129-155
Gaw& 2.. Glaser R.. Z g o d e u i r z J, 1989. Drying of granular material in pulrofluidised
bed. Hung. J. Ind. Chem.. 17, pp. 245-255
Hoks D., Elfrink E., 1993. A new fluidizcd bed white sugar drierlcooler. Zuckerind.. 118, 6. pp.
465-468
Kerkhof P.J.AM., 1994, The role of thmretical and mathematical modeling in scale-up, Drying
Technology. 12, 1-2, pp. 31-45
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105-LO5
Pakowski Z., Iciek I.. Grochonski J., 1988, Les experiences d'expolilation ses sechoim
rdroidisseurs a lit fluidire vibre pour lcs sucre blanc. Ind. Alim. Agric.. 105. 7-8. pp. 655459
Pakomki 2.. Mujumdar A.S., 1995, Basic proces calculations in drying. in "Handbwk of
indusuial drying", AS. Mujumdar (ed.), vol. I, pp. 71 -1 11
Suumillo C.. Pakouski 2.. Zylla R, 1986, Computer aided design of fluid bed dryers, Zhum.
Prikl. Khim., 9. pp. 2108-2115
Tail P.J., Schinkel Al.. Greig C.R. 1994, The development and application of a g e n e d i d
modcl for sugar drying, Proc. IDS'94, Brisbane, pp. 203 - 21 1
Temper S.I.. Bamnik N.I.. Gorobiels V.I., 1979, Fhid bed dryer-aalcr with multiple use of h a t
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