ROTARY DRIER

Initial temperature of wet feed = 26 ℃

Initial moisture content = 43 %

Final moisture content = 3 %

Q = 1100 kg/hr

Hot air enters at 180 ℃ , humidity 0.015

Temperature of solid leaving the drier not to exceed 74 ℃

Air velocity must not exceed 1.5 m/s

Cp of coconut = 2.312 kJ/kg.K

Let basis of operation be 1 hr of operation

Mass of dry solid = 1100(1-0.43)

= 627 kg/hr

Moisture in the wet solid = X1 = 43/57 = 0.75

Moisture in the dry solid = X2 = 3/97 = 0.03

Water evaporated, mw = Ms(X1-X2)

= 627(0.75-0.03)

= 451.44 kg/hr

TS1 = 26℃, TG2 = 180 ℃, Y2 = 0.015

Let exit temperature of gas = 50 ℃ and for solid TS2 = 65 ℃

Enthalpy of different streams (suppose reference temperature = 0 ℃

HS1 = [cps + (4.187)X1](TS1 – 0)

= [2.312 + (4.187)(0.75)](26-0)

= 141.76 kJ/kg dry solid

HS2 = [cps + (4.187)X1](TS2 – 0)

= [2.312 + (4.187)(0.03)](6-0)
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 = 158.44

HG2 = [1.005 + (1.88)0.015](180 – 0) + 0.015(2500)

= 223.476

HG1 = [1.005 + (1.88)Y1](50 – 0) + Y1(2500)

= 50.25 + 2594Y1

Overall Mass Balance

Gs(Y1 - Y2) = Ms(X1 - X2)

Gs(Y1 - 0.015) = 451.44

451.44
Gs = 𝑌 −0.015
1

Ms(HS2 – HS1) = GS(HG2 – HG1)

451.44
627(158.44 – 141.76) = 𝑌 −0.015(223.76 – (50.25 + 2594Y1)
1

Y1 = 0.066
451.44
GS = 0.066−0.015

= 8851.76 kg/hr

Shell Diameter

Volume of humid inlet gas (180 ℃ and Y2 = 0.015)

V/m = RT/P = 287.08(180+273)/101325

VH2 = 1.28 m3/kg dry air

Volume of humid exit gas (50 ℃ and Y1 = 0.044)

VH1 = 0.91

Max volumetric gas flow rate = GsVH2

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Design of the Drying Chamber

The material used to construct the drier should withstand the high temperature. The material used
to construct the drier is mild steel. Since mild steel can withstand temperature of about 200ºC.

Working Pressure in the drier = 101.3 KPa = 0.1013 N/mm2

Design pressure = 1.5 x WP = 1.5 x 0.1013 = 0.152 N/mm2

Permissible Stress of the material used = 124 N/mm2

Inner Diameter of the drier = 1.5 m = 1500 mm

Length of the Drier = 10m

To find the thickness of the drier shell:

𝑝𝐷
𝑡𝑠 =
2𝑓𝐽+𝑝

p – Design pressure, N/mm2

D – Diameter of the drier, mm

F – Permissible stress, N/mm2

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J – 0.85

0.152 × 1500
𝑡𝑠 = = 1.1 𝑚𝑚
2 × (0.85)( 124) + 0.152

But the minimum thickness is 8 mm for the shell

Therefore including corrosion allowance the thickness can be taken as 10 mm

Therefore the outer Diameter = 𝐷𝑖 + 2 x 10 = 1500 + 2 x 10 = 1520 mm = 1.52 m

To Find the Thickness of the insulation:

To limit the heat loss, an insulation is to be given to the drier. The insulating material can be
chosen as asbestos.

Density of asbestos = 577 Kg/𝑚3

Thermal Conductivity of asbestos = 681.4 x 10-3 W/𝑚3 K

Material of the drier is mild steel

Thermal Conductivity = 147.6 W/𝑚3 K

Convective Heat transfer Coefficient = 56.78 W/𝑚3 K

Limiting Heat Loss from the Drier = 50 KW

𝐷1 = 1.5 m

𝐷2 = 1.52 m

𝑡1 = 10 mm

Let ‘y’ be the thickness of insulation

𝐷3 = 𝐷2 + 2𝑦

𝑇1 = 122 ℃ , 𝑇2 = 76 ℃

We have from the Continuity equation

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 (𝑇1 − 𝑇2 )
Q= 𝑡1 𝑡 1
+ 2 +
𝑘 1 𝐴 1 𝑘 2 𝐴 2 𝐻𝑐 𝐴 3

𝐿
𝐴1 = 𝜋 (𝐷1 + 𝐷2 ) ×
2
10
= 𝜋 (1.5 + 1.52) × 2

= 47.43 𝑚2

𝐿
𝐴2 = 𝜋(𝐷2 + 𝐷3 ) ×
2
10
= 𝜋 (1.52 + 1.52 + 2𝑦) × 2

= 47.752 + 31.416y 𝑚2

𝐴3 = 𝜋 𝐷3 L

= 𝜋 (1.52 + 2𝑦) × 10

= 47.752 + 62.832 y 𝑚2

(122−76)
50× 103 = 10 ×10−3 𝑦 1
+ +
47.6 ×47.43 681.4 ×10−3 (47.752 + 31.416y) 56.78 (47.752 + 62.832 y )

y = 0.02 m

𝐷3 = 5.132 𝑓𝑡

Therefore the thickness of the insulation should be 80mm.

To find the power to drive the Drier:

From Eqn (20- 44) Perry.
r ( 4.75 d w + 0.1925 D W + 0.33 W)
Power = 100000

Where r – rpm of the drier

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d – shell diameter, ft
W – total rotating load, lb
w – live load, lb
D – riding ring diameter, ft (d+2)

To calculate the live load and the rotating load:

Density of mild steel = 480 lbs/ft3
We have D2 = outer diameter of the drier shell
D1 = inner diameter of the drier shell
(𝜋𝐷2 2 −𝜋𝐷1 2 )𝐿
Volume of Shell Material = 4

((𝜋(5)2 −𝜋(4.92))32.8
= 4

= 20.44 𝑓𝑡 3

Weight of the drier = volume of the shell material x density

= 20.44 x 480
= 9811.2 lbs

Assume Hold up = 0.1

𝜋𝐷1 2 𝐿×0.1
Volume of the Drier filled with material = 4

𝜋(4.92)2 (32.8)×0.1
= 4

= 62.36 𝑓𝑡 3

Weight of the material in drier at any time = Volume × density

= 62.36 × 25 𝑙𝑏𝑠/𝑓𝑡 3

= 1560 lbs

(𝜋𝐷3 2 −𝜋𝐷2 2 )𝐿
Volume of the insulating material = 4

(𝜋(5.132)2 −𝜋(52 )))32.8

= 4

= 34.45 𝑓𝑡 3

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Weight of the insulating material = volume x density
= 34.45 x 36
= 1240.2 lbs

W = weight of the drier + weight of the insulation + weight of the material

= 9811.2 + 1560 + 1240.2 = 12611.4 lbs

w = weight of the material

= 1560 lbs
D=d+2
= 4.92 + 2 = 6.92 ft
r = 20 rpm
20x(4.75x4.92 x 1560 + 0.1925 x 6.92 x 12611.4 + 0.33 x12611.4 )
BHP = 100000

= 11.5 BHP

= 8.6kW

To calculate the power required by the blower:

Temperature of inlet air = 30 ºC

Humidity = 0.002 kg/kg
Total Quantity of air handled = 32734.68 Kg/hr

32734.68 x 22.4 x 303

Volume of the inlet air = 29 x 298

= 25.70 x 103 𝑚3 /hr

From equation (6 – 34a) Perry

Power = 2.72 x 10−5Qp
Q - fan volume, 𝑚3 /hr
p – fan operating pressure, cm water column
p = 20 cm water column
Power = 2.72 x 10-5 x 25.70 x 103 x 20
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 = 13.98 KW

To Calculate the power required by the Exhaust fan:

Temperature of the outlet air = 87 ºC
Humidity of the outlet air = 0.065 kg/kg
Total Quantity of air handled = 34862.43 Kg/hr

34862.43 x 22.4 x 363

Volume of the inlet air = 29 x 298

= 32.80 x 103 𝑚3/hr

Power = 2.72 x 10−5 x 32.80 x 103 x 20

= 17.84 kW

To Find the diameter of the feed pipe:

Feed Rate = 5 kg/s
Volumetric feed rate = 0.012 𝑚3 /𝑠 = 0.7 𝑚3 /hr
Assume the velocity of the feed to be 100 m/hr
Cross sectional area of the feed pipe = (0.7/100) = 0.07 𝑚2
Diameter of the feed pipe = 0.3 m

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