Chapter 1

THE PROBLEM AND ITS SETTING

1.1. Introduction

Rice agriculture have never failed to introduce new innovations and

improvements, and with the advent of mechanization, the problems

encountered by the industry before are now being solved one after the

other.

Continuous advancement in the field of science revolutionized

agriculture. Through this, engineering had been addressing the problems of

farmers from seed sowing to post-harvesting in order to build a smart and

more efficient farming system. Post-harvest operations include field drying,

stacking, threshing, procurement, and drying.

The main goal of drying is to reduce the moisture content present in the

paddies. As established by the International Rice Research Institute, the

moisture content of a rice grain upon harvesting ranges from 20%-25% and

for it to be safely stored, it should be at least be around 14% (IRRI,

2018).There are two methods of rice drying, Sun-drying and Mechanical

drying. Sun-drying is the traditional way of reducing the moisture content of

the rice paddy being spread out on the pavement under the sun. This

method requires a lot of labor and space. The laid-out rice paddy must be

turned over from time to time to ensure even dryness and to avoid excessive

drying that causes fissures on the paddies. On the other hand, Mechanical
 drying uses heated air to reduce the moisture content of the rice paddies.

Unlike in sun-drying, mechanical drying can be used regardless of the time

and weather since it doesn’t depend on the heat coming from the sun.

Mechanical drying can be performed in large or small-scale dryers. In

the Philippines, large scale dryers are widely used, however these can’t be

utilized efficiently and the cost is much higher if the farmers weren’t able to

reach the minimum capacity of large scale rice grain dryers. In this light, the

technology of the vertical dryer introduces a small scale variation of such

technology which would be able to assist and benefit local farmers who

harvest rice grains less than what is required on a large scale dryer.

1.2. Background of the Study

Rice production is one of the country’s lifeblood, ranking as the 9 th

largest rice producer globally (FAO Statistics, March 2011). Ironically, even

though the country produces 2.8% of the world’s rice supply, it is still one of

the world’s largest rice importers (Reuters, January 2011).

According to Gado of PhilRice, post-production and existing farming

practices accounts to 20% of rice paddy loss on 2014. The local government

has been educating and encouraging its farmers and millers on proper

drying techniques and recent technologies to more efficiently handle their

crops.

Martin Gummert, a Senior Scientist at IRRI declares that paddy

drying is one of the most challenging problems in agricultural mechanization

as it is important that these technologies are integrated into the established

system to be fully utilized. Furthermore, rice paddy drying falls on the

intricacies of biology, which requires extensive knowledge and

understanding of crop characteristics. As a result, so many engineers,

researchers and experts have been involved in seeking solutions and

creating various prototypes of the dryer which currently work only in

laboratory setting.

As an alternative for farmers using the roads for sun-drying, Dr.

Arnold Alepano expressed the National Post Harvest Institute for Research

and Extension (NAPHIRE) efforts by their allocation and construction of

multipurpose pavements for the farmer’s sun-drying.

Since the country is located in a tropical region, the Philippines is

highly subjected to rainy seasons. This is why sun-drying of paddy is

unreliable and space-wise inefficient, even more so when it rains

unexpectedly. These sudden changes in weather may cause fissured

grains or worse, the grain rots completely. On the other hand, a testament

of mechanical drying, a local of Laguna, said that the cost of rice grain

dryers is outweighed by the product loss that resulted when they sun-dried

(fao.org, 1998).

Grain dryers were introduced in the late 1950s. However, it wasn’t

that prevalent until in the 1980s, when successive plentiful harvests created

a large grain drying problem (Wang Hanbin, 1998). One of the three main

types of mechanical dryers is the tower or vertical dryers. Tower or vertical

dryers are widely used for drying large grains such as corn. This type is
 classified into two, namely direct or indirect dryers. In direct dryers, the

heated air makes direct contact with the grain resulting in a better drying

efficiency. While, indirect dryers employ heat exchangers. The capacities of

tower dryers using coal as fuel are around 10 to 20 tonnes per hour with a

moisture removal of about 10% for each pass. Vertical dryers also require

less floor area compared to flat-bed type dryers and even more so with the

sun-drying method.

1.3. Statement of the Problem

More than Php23 million daily or about Php8.4 billion annually of rice

are wasted by Filipinos, according to the International Rice Research

Institute (IRRI, 2018). With as much as 1 to 5 % of these losses comes from

unmilled grains through poor harvesting and post-harvest activities,

inefficient transportation, inadequate storage, wasteful processing and

market spoilage, according to a Food and Agriculture Organization report in

2011.

Since drying is the initial step in successful storage and handling of rice

grains, this is the part where the problem should be addressed first. Most of

the mechanical dryers used nowadays are flatbed type dryers because of

its capacity in handling tons of rice paddy in hours of drying, but flatbed

dryers take up about 4 meters long and 2 meters wide. Also, other farmers

still use the traditional sun-drying method which takes up almost a whole

basketball court that measures 28 meters long and 15 meters wide.

 Most rice farmers only have limited space for drying their harvests, so

they usually rent big spaces for sun-drying. Others are also required to have

a large space just to use a flatbed dryer. But with vertical dryers, less space

is required for operation.

1.4. Theoretical Framework

This paper treats the design and construction of a vertical rice dryer

using propane gas burner to achieve the desired temperature as a solution to

the problem in rice drying. This system uses lesser floor space than the typical

rice dryer and has a simple design but can efficiently use the heat produced

by the heating assembly. The system also produces enough heat to achieve

the necessary moisture content in less than twenty-four hours after

harvesting. The fuel's heating value will affect the performance of the rice

dryer because it will determine the heat to be transferred in the air. Another

factor to be considered is the heat loss in the surroundings; the design should

minimize the heat loss to have better efficiency.

𝑞 = ℎ𝑐 𝐴 𝑑𝑡

𝑄 = 𝑚 𝐻𝐻𝑉
𝑊1 ( 𝑀1 − 𝑀2 )
𝑊2 = 𝑊1 −
100 − 𝑀2
where:

𝑊1 = weight of undried grain (kg)

𝑊2 = weight of dried grain (kg)

𝑀1 = moisture content of undried grain (percent)

 𝑀2 = moisture content of dried grain
1.5. Objectives

General Objective

The researchers’ main objective is to design and fabricate an efficient

vertical rice paddy drying machine.

Specific Objectives

1. To fabricate mechanical rice dryer that will reduce the moisture

content of rice paddy from 20-25% to 14-15% moisture content.

2. To dry 200 kilograms of rice paddy within an operation using a

vertical rice dryer.

3. To produce marketable rice, dried and milled, comparable to

products already in the market, in terms of quality (color and texture).

1.6. Significance of the Study

Same as other mechanical rice dryers, this research will ease the

process of drying and will be used to reduce moisture from wet grains by

forcing heated air through the grains. It is also an alternative to sun-drying

which may have been the most used method in provinces but it is too limited

in its operation and is less efficient. This research can be used at any given

time, unlike sun-drying which is dependent on the time of the day and the

weather. This research also largely shows the advantages of applying

mechanical concepts intro agriculture which leads to more efficient farming

 methods that will benefit not only the farmers but the entire country

economically.

1.7. Scope and Limitations of the Study

The prototype will strictly have a capacity of 150 to 200 kg of rice paddy

per operation. The prototype is for drying rice paddies only, and any further

application to other agricultural items haven’t been tested and adjusted by the

researchers. Various heating elements have been considered theoretically,

however, the prototype makes use of propane burners as their heating element.

1.8. Definition of Terms

1. Drying - a mass and heat transfer process consisting of the removal of water

or moisture by evaporation from a solid matter.

2. Furnace - refers to a directly fired heater, commonly used in in chemical

industries or for providing heat.

3. Gasification - refers to producing combustible gases from a dry biomass

without the combustion of the said gases.

4. Germination - is the budding of a seed after it has been planted in soil or

after it has retained enough moisture for a certain period of time.

5. IRRI – International Rice Research Institute. An international agricultural

research and training organization with its local headquarters situated in

Los Baños, Laguna which focuses on technologies in relation to rice

farming.
6. Milling - is to remove the husk and the bran layers, and produce an

edible, white rice kernel that is sufficiently milled and free of impurities.

7. Moisture - a small amount of a liquid (such as water) that makes something

wet or moist.

8. Recirculating Rice Dryer - is a mechanical device or machine that removes

the water from wet grains by forcing either ambient air or heated air through

the grain bulk. The same quantity of grain is recycled through the dryer until

the final moisture content is reached.

9. Rice paddy – recently harvested rice. Rice still with husk.

10. Tempering – intermittent pause on drying of rice paddies.

 Chapter 2

REVIEW OF RELATED LITERATURE AND STUDIES

This chapter presents the review of related literature, studies, and

technologies in relation to the framework of the study. It includes the important and

vital details of the research.

2.1 Related Literature

2.1.1 Drying

According to the study of Waewsak, J., et al. entitled Hot Air Drying for

Some Agricultural Product, one way of preserving agricultural products is by

drying. Drying is mainly implemented to prolong shelf life. In the Philippines,

traditional drying is sun-drying. It has been for a very long time due to very few

and limited alternatives. Compared to recent technologies in mechanical

drying, sun-drying's efficiency falls short. This is due primarily at its

dependence on weather and season, which results in a decrease in the quality

of rice and on the amount of rice usable as well.

2.1.1.1 Moisture Content (MC)

The moisture content of a substance is usually referred in

percentage by on wet basis. Wet basis moisture content (MCwb) is the

ratio of the weight of water to the total weight of the substance while dry

basis moisture content (MCdb) refers to the ratio of the weight of water

to the weight of dry matter. In terms of agricultural materials and food

 products, wet basis is predominantly used. The dry basis is normally

used in research.

Moisture content calculations:

Wi − Wf
MCwb = x 100
Wi

where ∶

MCwb = wet basis moisture content in percent

Wi = Initial weight

Wf = Final Weight

Due to the decrease in moisture content through evaporation

process, rice grains will decrease its weight.

Weight loss:

100 − MCi
Wf = Wi x
100 − MCf

where:

Wi = Initial weight

Wf = Final Weight

2.1.1.2 Rice Grain

At harvest season, rice grain contains a moisture content of 20-

25% according to International Rice Research Institute (IRRI). Due to its

high moisture content, the grain is still exposed to germination which may

cause deterioration of the rice. Also, this much moisture contributes to the

development of molds and discoloration.

 To safely store the rice grains after harvesting, the moisture

content should be lowered first to avoid losses.

Table 2.1: Required moisture contents for safe storage. (IRRI Rice Bank Knowledge)

2.1.1.3 Rice Equilibrium Moisture Content (EMC)

Rice paddy will eventually reach its equilibrium moisture

content in the drying process. Equilibrium moisture content is an event

where rice will not lose any moisture content with the ambient air. Moisture

content in the rice paddy is the same with its environment. It is important to

monitor the rice paddy’s moisture content and compare it with the EMC to

achieve an efficient drying process.

Table 2.2 Equilibrium Moisture Content Table (IRRI Rice Bank Knowledge)
2.1.1.4 Equilibrium Relative Humidity

When the grain is in an enclosed or isolated storage where

the air surrounding the grain does not circulate, the relative humidity of the

air reaches the equilibrium relative humidity.

If the moisture content of the stored grain is high, it will result

in a high equilibrium of relative humidity. High equilibrium of relative

humidity promotes mold development or loss of germination. According to

the International Rice Research Institute, 65% or less of the equilibrium of

relative humidity is considered safe and may hinder the development of

molds or infestation of insects.

2.1.1.5 Heat Transfer

Drying using in high temperature required hot air to be blown

or forced in the rice grains. Heat transfer can be in the mode of conduction,

convection, and radiation.

q = UA( Tf − Ti )

where:

q = heat transfer rate

U = over − all heat transfer coefficient

( Tf − Ti ) = change in temperatures
 2.1.2 Conveying

Vertical screw conveyors have proven its efficiency for conveying

materials; however, due to the speed limitations and presence of gravity, they

are somewhat stalled in which types of products in can be used for. Vertical

screw conveyors are most effective when applied in agriculture, most

commonly granular.

2.1.2.1 Capacity, Sizing, and Speed

Table 2.3 Recommended Maximum Capacity for Vertical Screw Conveyors. (CEMA)

Vertical Screw
Maximum Recommended Recommended Speed
Conveyor Diameter,
Capacity (ft3/hr) Range (RPM)
in
6 400 200-215
9 1300 200-215
12 3000 165-180
16 6000 135-150
2.1.2.2 Total Horsepower

2.1.2.2.1 Friction Horsepower Calculations

Horsepower required to drive the conveyor empty
𝐿 𝑥 𝑁 𝑥 𝐹𝑑 𝑥 𝐹𝑏
𝐻𝑃𝑓 =
1,000,000

2.1.2.2.2 Material Horsepower Calculations

Horsepower required to move the material

𝐶𝑤 𝑥 𝐿 𝑥 𝐹𝑣 𝐶𝑣 𝑥 𝑊 𝑥 𝐿 𝑥 𝐹𝑣
𝐻𝑃𝑣 = OR 𝐻𝑃𝑣 =
1,000,000 1,000,000

2.1.2.2.3 Total Shaft Horsepower Calculation

(𝐻𝑃𝑓 + 𝐻𝑃𝑣 + 𝐹𝑖)

𝐻𝑃𝑡 =
𝑒
 where:

L = height of lift (vertical)

N = conveyor speed
Fd = diameter factor
Fb = bushing factor
Cw = conveyor capacity, lb/hr
Cv = conveyor capacity, ft 3 /hr
W = density, lb/ft 3
Fv = factor for material horsepower (From Materials Table)
Fi = incline factor
Fo = overload factor (correction for calculated hp of less than 5hp)
e = motor efficiency
2.2 Related Technologies

2.2.1 Established Dryers

Rice drying already came a long way from simply laying the paddy to dry in

the sun up to the introduction of mechanical dryers. The first appearance of the

flatbed type of rice dryer was before World War II occurred; grains are placed on

top of the chamber and then dried from below by having heated air forced through

the grains from below. This method introduced the most basic concept of drying

utilized by the modern mechanical dryers invented today.

2.2.1.1 Flatbed Dryers

At the University of the Philippines in Los Baños, a 6 ft x 12 ft floor above a

plenum, with a grain depth of 18 inches. An 18-inch fan was used to supply 3500

cubic feet of air per minute. A vaporizer heated by a kerosene burner is the used

to bring the drying air from ambient temperatures to a maximum of 110°F. In this
method, the moisture removal rate of the grain is 1% per hour. Grain with an initial

moisture content of 24% wb decreased to 14% wb after 10 hours. There was a 1%

moisture variance between the top and bottom layers, for instance, the top layer

was 14% wb and the bottom layer was 13% wb. This type of grain dryer results in

uneven drying. Heated air passes through the rice bulk from bottom to top. Most

of the heat from the air is transferred to the bottom layer, decreasing in temperature

as it rises to the top. These results in a more dried paddy at the bottom compared

to the paddies at the top.

Table 2.4 Effects and Purpose of Moisture (IRRI Rice Bank Knowledge)

Possible
Moisture Range on IRRI
Purpose Problems during
Content moisture meter
storage
Unsafe, dry within
Greater than 14% 24h after Rapid temperature red
increase
harvesting
Molds,
Less than 14% Weeks to a few discoloration, green
months of storage respiration loss,
insect damage
13% or less 8 to 12 months of green
Insect damage
storage
12% or less Loss of yellow
Farmers Seeds
Germination
9% or less Storage for more Loss of seed
than 1 year viability
 Figure 2.1 Schematic Diagram of Flatbed rice dryer

2.2.1.2 Reversible Flatbed Dryer

However, a recent innovation on flatbed types is the Reversible Airflow

Flatbed Dryer, with the partnership of Nong-Lam University from Vietnam and the

Philippine Rice Institute. The components of the reversible airflow flatbed dryer are

similar to the flatbed dryer, the only difference presence of a Reversible Air

Chamber. In the reversible airflow flatbed dryer, once it reaches 2/3 of the

operation, the reversible air chamber changes the flow of heated air from the

regular bottom to top flow into forcing the heated air to flow from the top the bottom.

This innovation results into a more even drying on the paddy compared to a

standard flatbed.

The concept of reversible airflow flatbed rice dryer started in Taiwan. In

Taiwan, they designed a reversible-air dryer, with a rectangular drying bin and a

central box for reversing the air from the fan (Din-Sue-Fon, 1981).
 Figure 2.2 Reversible Airflow Flatbed Dryer

Figure 2.3 Operation of Reversible Airflow Flatbed Dryer

Figure 2.4 Change the airflow and covering the bin for even drying.
2.2.1.3 Recirculating Batch Dryer

These types of mechanical rice dryer were only used by medium-scale

rice industry while the large scale rice industry commonly uses Recirculating

Batch Dryer. The process of a recirculating batch dryer is done by feeding rice

in a silo where a screw conveyor or a bucket elevator is positioned vertically

and travels the fed rice grain up to the uppermost part then distributes it again

in the silo. Once the grains enter the drying section of the system, drying air is

focused directly into the silo. After the dryer is loaded, a suction fan above the

silo is engaged as to keep the circulation of the rice grain inside the drying area.

When the grain reaches 14% moisture content, the dryer then shuts off and the

grain is unloaded.

Figure 2.5 Recirculating Batch Dryer, Rice Knowledge Bank IRRI

Table 2.5 Comparison of Established Drying Techniques (IRRI)

DRYING TIME PROS CONS

 environment-
Days to weeks,  difficult to control the
friendly
depends on temperature
A. Sun-drying  cheaper than
how often  exposures to dirt and
mixed mechanical
microbes
drying
 even drying
 automatic
 Wear of mechanical
operation
B. Recirculating 6-8hr per components
 cost-efficient
Batch Dryer 4-10ton  Not suitable for small
 used in
scale rice farmers
cooperatives and
rice mills
 labor intensive
 cheap, simple
process, improper
C. Fixed Bed 6-8hr per  availability of
drying of top and
Batch Dryer 1-10ton local versions
bottom layer

 high capacity
 automatic
 Capital intensive,
D. Continuous operation
10ton/hr requires large volumes
Flow Dryer  established 1-2%
moisture drop

2.2.1.4 Louisiana State University (LSU) Dryer

A study conducted by Louisiana State University introduced what is now

well known as an LSU Dryer, which is a continuous mixed flow dryer for grains.

The design aims to maximize the amount of rice paddy making contact with the

heated air by having inverted v-ducts that focus the heated air through the

grains. The v-duct alternate layers are air inlet & outlet channels which are

arranged offset from one below the other. Because of the alternate

arrangement, each intake duct is surrounded by exhaust ducts or vice-versa,

as a result, the heated air travels through paddy towards all these exhaust
ducts. This forces the air to move against or across the paddy stream. Hence,

this has given the dryer its name 'mixed flow' (Fa, Loo Kau, 1996). This dryer

type was made to ensure a greater grain to air contact resulting in a more

uniformly dried product. (Tamil Nadu Agricultural University, 2011).

Figure 2.6 Working Drawing of the first LSU Dryer, Rice Drying and

Storage in Louisiana by WG. Taggart (1947)

2.2.1.5 Fluidized Bed Dryer

Fluidization of grain material has also been widely used on agriculture. The

principle is that when a solid particulate is placed under appropriate conditions, the

solid-fluid mixture will behave wholly as a fluid. In application, fluidized bed rice

dryers suspend the rice grains on the heated air almost all of the time to make sure

that every part of the grain is heated. This technology is already fully established

and commercialized on greater parts of Asia like China, Thailand and Vietnam,

although usually for large scale operations (IRRI, 2018). The drying rates of

fluidized bed dryers are very fast compared to other methods which raise the issue

of rice quality. Research by Wiset last 2011, compared two fluidized drying

methods. Single stage drying, which is drying the paddy from 27% down to 14%

as opposed to two-stage, which is drying to 18% followed by in-store drying to

14%. Wiset found that the two-stage method has the best head rice yield compared

to single-stage.

Figure 2.7 Effects of High-Temperature Drying on Rice Quality, Wiset et al

(2011)
2.2.1.6 Microwave Vacuum Dryer

At first thought of as a novel idea, microwave vacuum drying has been

made into reality due to advancements in technology. The Department of Science

and Technology (DOST) along with the Food and Nutrition Research Institute

(FNRI) developed a Microwave Vacuum Dryer. The technology was taught of as a

solution to uneven grain drying, specifically for material prone to scorching such

as rice paddy (Rogelio, 2014). The technology integrates microwave heating and

vacuum environment. It decreases the moisture content by directly transferring

heat to the material with the use of waves affecting the molecules in the material.

Further research and testing of this technology shows promise as it has several

advantages over traditional ways of processing as it reduces drying time, lowers

drying temperature, lowers energy consumption, and comes up with high-quality

products (Dizon, 2015).

Figure 2.8 Microwave Vacuum Dryer as launched by DOST.

2.2.2 Alternative Heating Elements

Past researches often make use of alternative heating elements to gasoline

and electric heaters for them to have an economic advantage over other dryers.

2.2.2.1 Rice Hull Furnace

In the Philippines, a commercial flatbed dryer made by the collaboration of

PhilRice and University of Agriculture and Forestry (UAF) which is now called

Nong-Lam University (NLU) on 1994, the PhilRice-UAF or Maligaya Flat Bed

Dryers utilizes by-products like rice hulls or ground coffee brews as fuel for heating

drying air.

The International Rice Research Institute (IRRI) also commercialized and

introduced the “semi-automatic” downdraft Rice Hull Furnace (dRHF). Its feed

system boasts its electronic timer which measures how much and when the next

batch of rice hull fuel goes into the combustion chamber. This auto feed function

eliminates the tedious and manual loading of rice hull into the furnace.

Figure 2.9 Initial version of IRRI’s semi-automatic rice hull furnace, Agrimag
2.2.2.2 Belonio Gasifier

Another furnace available is the Belonio gasifier, invented by agricultural

engineer Alexis Belonio. It also uses rice hull gas to produce heat. Initially, the the

rice hull undergoes pyrolysis which then converts it to combustible gas. This gas

results in a smokeless and clean flame, similar to LPG in heating value and

appearance. This furnace was already incorporated into a recirculating paddy

dryer at the Abordo-Portaje Rice Mill, resulting in a decrease in fuel cost to 30php

from aconsumption of 2065php per hour compared to using diesel.

Figure 2.10 Belonio Rice Husk Gasifier, from Rice Husk Gas Stove

Handbook
 Chapter 3

METHODOLOGY

This chapter comprises the methods applied by the researchers to the

study. It is consist of the stages undergone by the proponents to come up with the

said project such as problem identification, design conceptualization, and project

assessment. Multiple testing was done to achieve a satisfactory result of the

project. This comprises a series of testing the different components of the project

and adjustments were made according to the result. Subsequent sections

explicate the conducted experiments and analyses to investigate the effectiveness

of the study and to come up with recommendations for future development.

3.1 Research Design

The researchers used the well-known research method of prototyping as

a means of having a “proof of concept” in testing a concept and to ascertain if the

design is possible and can be implemented in the field of agriculture.

The researchers designed and developed a recirculating-continuous-

mixed flow vertical rice dryer that utilizes a screw conveyor for continued circulation

of the rice paddies in the system. The design follows the concept of mixed flow,

wherein the flow of paddy is against the flow of heated air. The researchers

designed the chamber with alternating exposed airways. Hot air entering

horizontally from the inlets will rise until it reaches an outlet above it. The hot air

will meet the rice paddies falling from the conveyor above. Utilizing the rise of hot

air made the design more efficient as it doesn’t counter the hot air’s natural flow.
Figure 3.1 Air-Grain Flow (Isometric)

Figure 3.2 Air-Grain Flow (Front)

 The researchers devised the system as a response to the end user's

request of developing a space-saving rice grain dryer for small scale farmers of

their community. This design is then consulted extensively with existing related

researches and studies that were developed throughout the history of rice drying

to assure its performance and feasibility.

 Background Research on Heating
Processes of Rice Grains
3.2 Project Development

Design of Machine Assembly for Process

Mechanization

No

Did the design

pass the
evaluation?

Yes

Construction of the Prototype

Preliminary Adjustment and Testing

No

Is the performance
acceptable?

Yes

Inspection and Quality

Control

Final Adjustments, Testing

and Data Collection

Deployment of the Machine to the

Benefactors
3.2.1 Problem and Investigation analysis

The researchers have contacted the people of Sto. Tomas, Isabela

where traditional sun-drying is still practiced in the vicinity due to limited

available technologies. The cooperatives in the area used to have a

recirculating bin rice dryer which has a capacity of 4 to 5 tons of rice paddy per

operation. The municipality of Sto. Tomas was unable to meet the minimum

required rice paddy leaving the Department of Agriculture no choice but to turn

the dryer over to other municipalities that may utilize it more efficiently. This left

the area with no other means of drying aside from traditional sun-drying. Upon

opening up the topic of designing and developing a rice dryer, the cooperative

in the area gave some insights that would satisfy and resolve their problem.

3.2.2 Design Concept and Criteria

Rice grains must be kept dry for long-term storage. Drying is typically

done by forcing hot air in the rice grains. Knowledge in airflow resistance in the

bulk grains will help in designing and selection of appropriate methods. In

reducing the moisture content of a material, hot or cold air must be forced in

the bulk rice grains. Rice resistance develops pressure-drop when the air is

forced in the rice grains. It is important to predict the resistance of bulk grains.

Design Concept

The vertical rice dryer is composed of 3 major components, the drying

chamber, the mixing and transporting component, and the heat generating

components. The Drying Chamber is composed of an inverted V-Ducts that will

 focus the drying air onto the subjected rice paddy. The drying chamber will

consist of discharge and an inlet chute, located at the bottom and at the top,

respectively. The initial feed of paddy of rice is also located at the top. The

discharge chute located at the bottom is specifically designed to let all rice

paddies circulate all over again the chamber.

The mixing and transport component of the system is a vertical screw

conveyor. Since the dryer has a vertical orientation, it is required to consider

an appropriate type of conveying system.

3.2.3 Fabrication and Assembly

The fabrication and assembly involves the following:

1. Canvassing and selection of the fabricating shop that will meet the

specification of the project.

2. Purchasing the materials needed.

3. Fabrication and assembly of each component.

a. Drying Chamber

b. Screw Conveyor

c. Heating Assembly

d. Feed and Discharge Chutes

4. Assembly of all the parts.

5. Initial testing and modifications.

3.2.4 Testing

Testing the prototype is a necessary procedure to know the efficiency and

capability of the said project. For the process of testing, the researchers provided

testing procedures to prevent any mishap from happening.

Various tests were done for the assessment. The results of the tests were

tabulated and so with the observation on the performance of the machine.

3.2.5 Project Assessment

Depending on the gathered result of the testing procedure, the researchers

assessed if the result were satisfactory, if not, minor adjustments were necessary.

The prototype was presented to a panel and evaluations of the study were given

with some additional recommendations

3.2.6 Testing Procedure

Chute Efficiency Testing:

1. Start pouring the rice paddy into the chamber.

2. Check if the chute feeds all of the rice paddies into the screw. Tabulate the

results.

3. Repeat step 1 and 2 using the second and third design of chute.

4. Compare the results.

Screw Conveyor Motor RPM

1. Turn on the screw conveyor.

 2. Pour rice paddy into the system. Check how much time passed until it

circulates into the drying chamber.

3. Time the operation and repeat step 1 and 2 with different motor rpm.

4. Compare the time it takes for the rice paddy to recirculate.

Reducing Moisture Content in the Rice Bulk

1. Measure the initial moisture content of the paddy of rice.

2. Start the operation by starting the screw conveyor.

3. Pour the rice paddy into the chamber.

4. Once circulation on the paddy starts, light the high-pressure burners.

5. Turn on the fan to supply air to be heated.

6. Every 30 minutes, measure the moisture content of the rice bulk until it

reaches the desired moisture content.

Assessing Rice Quality

1. Make sure that the dried rice satisfies the standard 14-15% moisture

content.

2. Proceed to rice milling proper.

3. Assess the output rice. Compare its color and texture to commercially

available rice.
3.3 Evaluation Procedure

The procedure for the evaluation involves measuring the time passed and the

decrease of the rice paddy’s moisture content. This parameter will dictate the

efficiency of the dryer. Proper testing results must be achieved and tabulated

results for each process must be shown.

3.4 Dryer Evaluation Criteria

The machine will be evaluated based on the following criteria:

 The time consumed in drying

 The decrease in moisture content of the rice paddy

 The quality of the milled rice

 Chapter 4

RESULT AND DISCUSSIONS

4.1 Gathered Facts and Information

Different research points have been identified by the researchers in

exploring the various areas and parts of the project, specifically:

1. The established drying parameters

Dryers in the market have a standard of 38-40°C Drying Temperature. The

moisture content of freshly harvested rice paddies reaches 22-24% and 14% is set

as standard moisture content for safe storage of rice grains.

2. The vertical screw conveyor design

The researchers used one-half of the diameter for the pitch. The vertical

screw conveyor must also have very little clearance between the screw and the

case to avoid the rice paddies from falling or ground at the sides.

3. The burner parameters

Heating mechanisms usually used are electric heaters for accurate control of

the temperature. However, other researches that strive for efficiency often used

furnaces that run on biogas and similar concepts. It is also vital that the fuel must

not affect the smell or color of the rice.

4. The quality of milled rice

The milled rice should be comparable to commercial rice in terms of color and

texture. The researchers milled a total of 20 kg of dried rice at Anabu Millers, Imus,

Cavite.
Table 4.0: Prototype Specifications

Prototype Specifications

Prototype Dimension 2m x 0.95m x 2.5m

Capacity 150 to 200 kgs of rice

Operation Time 2 hours and 15 minutes

Moisture Drop 8 to 10%

Screw Dimensions

Diameter 6 inches

Pitch 3 inches (1/2 diameter)

Angle 30°

Heating Assembly Specifications

Inlet Air Temperature 32°C

Outlet Air Temperature 58-60°C

4.2 Conceptualization of Design

The design conceptualization started with the end user's specification of a low

capacity, space-saving dryer that can be compared better than sun-drying or equal

to small scale commercialized dryers in terms of performance. The researchers

came up with a recirculating continuous mixed-flow vertical rice dryer utilizing a

screw conveyor to facilitate the recirculation element. The general concept behind

the vertical rice dryer is that heated air makes contact into every grain inside the

system to effectively lower the grain’s moisture content. To do so the researchers

start by knowing the proper way of drying rice paddies which results to a

satisfactory quality of rice grains. Time is also one parameter, the design should

take less time reducing moisture content compared to traditional sun-drying.

Figure 4.1 Conceptual Design of the Machine

 An efficient drying can be done when heating air is well allocated in the system;

the researchers make use of an inverted V-ducts to distribute the air inside the

chamber. Another factor that helps in the drying is the use of screw conveyor with

a well flowing discharge. With the installation of a screw conveyor, recirculation of

rice paddies is less tedious for the operators.

Figure 4.2 Actual Design Assembly

4.3 Design and Fabrication

The general design of the Vertical Rice Dryer consists of 3 components:

the drying chamber, heating assembly and the screw conveyor.

The main material for the dryer is made of stainless steel: 50.8x50.8 mm

square bar with 1.5mm thickness; 1mm steel plate; gear motor; bearings; screw

conveyor; 1.5 mm steel plate. Other materials utilized are propane burner, forced

draft fan, hygrometer and conductance moisture meter. The processes included
 on the fabrication of the project are: measuring the cutting dimension onto stainless

steel plates; bending the stainless steel plates to the planned dimensions and

proportion of the components; and assembling all the parts together. With the

assembly of the components, the researchers used bolt and nuts for easier

disassembly and maintenance for the project.

Construction of Vertical Rice Dryer

Conveyor to Chamber
Discharge

Side Cover

Drying Air
Inlet side Cover

Drying Air
Outlet side Cover

Stand Frame

Discharge Chute

Figure 4.3 Exploded View – Drying Chamber

 Figure 4.4 Drying Chamber Assembly

Figure 4.5 Outlet (Left) and Inlet (Right) Sides

The Stand Frame

The frame is composed of four square bars with a surface area of 50.8x50.8

mm and a total length of 8m each. Each square bar is 0.9m apart from each other

forming a square cross-section. Supporting bars are welded to place the inverted

V-ducts in position. The supporting bar is a 25.4x25.4 mm square bar and is

oriented horizontally. A total of 12 square bars are welded on the frame.

Figure 4.6 Chamber Frame

Air Outlet and Inlet Subassembly

The inverted V-ducts are incorporated within the drying chamber. The V-ducts

are categorized into two parts, the inlet and outlet. There are a total of 6 layers of

inverted V-Ducts positioned alternately. The inlet side is composed of three

inverted V-Ducts welded on two parallel supporting square bar that are 0.9m apart.
While on the outlet ducts, there are two whole inverted V-Ducts with an addition of

two half duct pieces which are all welded on two supporting parallel square bars.

The thickness of the stainless steel plate is 1mm, a height of 90mm and a base of

180mm.

Figure 4.7 Inverted V-Duct - Isometric

Side Covers

The project side covers can be classified into 3 types, the drying air inlet and

outlet side covers and the remaining side covers. The drying air inlet and outlet

side cover have triangular shapes cut onto them, this is to compliment the inverted

V-Ducts that are installed on each layer. The inlet side cover represents the three

inverted V-Ducts and this is also where the drying air will enter. The outlet side

cover represents the 2 complete and 2 other half of the inverted V-Ducts. The

attachment of side covers on the stand frame is welded precisely. The material for

the side cover is stainless steel plate with a thickness of 2mm. The remaining side

covers a cross-sectional area is 900mmx1000mm.

Discharge Chute

The required sizes for the four sides of the chute are measured and then cut

accordingly. Using a 2mm steel plate as the main material, the discharge chute

subassembly is composed of three different sizes with four of each size of steel

plate cut and welded together. The first component serves as the collector, the

second distributes the flow of the grains evenly, and the third directs the flow to the

conveyor. Multiple trials were made to find the most efficient design for the chute,

so that the flow of the rice paddies leading to the screw conveyor is continuous.

Figure 4.8 Discharge Chute

Conveyor to Chamber

Connected to the discharge line, it is built with a 2mm steel plate. The area of

the inlet of this discharge line is 101.6x101.6 mm while the discharge area is also

the same. The discharge line is positioned at a 45 o angle for smooth grain travel

and is pointed at the center of the cover to equally distribute the rice paddy for

recirculation.

Figure 4.9 Top Cover

Screw Conveyor

Implementing a vertical screw conveyor is used to achieve the needed mixing

and transportation of the paddy of rice throughout the system. The measurement

and spacing between each part are based on the size of the grain. There should

be 2mm spacing between the outer diameter of the thread and to the casing; this

is to prevent the grain from falling while it travels up. Another factor that is

considered is the pitch between each thread; thus the researchers decided to use

one-half diameter. Measuring a total shaft height of 2500mm, a 165.1 mm outer

diameter and a 25.4mm shaft diameter, the screw conveyor consists of 20 thread

rotations, requiring it to have 20 pieces of circular plate with a 127mm outside

diameter and 25.4mm inner diameter with a 3mm thickness. A circular steel plate

is used with the ends welded together to form the case. To align the screw to the

cover bearing, caps are positioned at both ends of the cover. To run the screw

conveyor, a gear motor with a 175rpm and 0.5hp is used. Gear motors are used

mostly for a concise speed-high torque process which is applicable for a vertical

conveyor. Shown below is the assembly of the conveyor.

The given statements above were the ideal design the proponents wanted but

given the current circumstances, where the spacing between the disc diameter and

the inside diameter of the casing exceeds 2-3 mm, the researchers tried to fix the

dilemma.

Figure 4.10 Screw Conveyor Assembly

Heating Assembly

This part consists of Fan, High Pressure Burner, and Hot Air Cylinder

exchanger. The flame or gas goes on a separate tube to that of the air supplied,

to make sure that flue gases from the combustion doesn’t mix with the heated air

and contaminate the rice paddies. Gases are burned in an enclosed steel box in

which the hollow cylinder is placed. Burned gases travel outside the hollow

cylinder, increases the temperature of the hollow cylinder which transfers heat to

the flowing air inside it. A Fan is installed before the burner to avoid damage to the

fan’s motor and capacity.

Figure 4.11 Heating Assembly

 Figure 4.12 Forced Draft Fan

4.4 Actual Findings

The actual drying test for the dryer held at Technological University of the

Philippines. The highest weight of paddy the drying chamber can hold is 200 kg

while the lowest is at 150 kg. Multiple tests were made to tabulate the performance

of each components.

Table 4.1 Initial Testing 20

Total Weight: 200 kg 20 19
Average Initial 19 18.5
20.125%
Moisture: 18 17.5
Average Initial 17 16.5
29.25°𝐶 16
Temperate:
16
Time Moisture Content
15
5 19%
14
15 18.5%
0 5 10 15 20 25 30 35 40 45 50 55 60
30 17.5%
45 16.5% Figure 4.1 Moisture vs. Time
60 16%
Observation: The measured moisture content in the five minute mark is the result

from the difference of moisture content of each sack in addition from the contact

with heated air. The constant drop in moisture content is observed in the next

minutes. The even distribution of heated air due to the v-ducts inside the drying

chamber is another factor.

Table 4.2 Final Testing

Total Weight: 200 kg
Average Initial
24%
Moisture:
Time Moisture Content
5 19%
15 18.5%
30 17.5%
45 16.5%
60 16%
90 16%
120 16%
150 16%
180 15%
210 15%
240 14.5

30%

25%

20%

15%

10%

5%

0%
0 30 60 90 120 150 180 210 240

Figure 4.2 Final Testing

 Chapter 5

SUMMARY OF FINDINGS, CONCLUSION, AND RECOMMENDATIONS

5.1 Summary of Findings

Gathered data from testing the prototype shows that the Vertical Rice

Dryer performs as expected. The dryer with a capacity of 200-kg rice paddy

successfully decreased the paddy's moisture content from 22% to 14.5% in

an operation of 3 hours. Tests also show the effectiveness of using a vertical

screw conveyor as well as the design of offset inlet and outlet v-ducts in

drying the paddies evenly, with a range of 1-2% moisture variation

throughout the entire batch.

5.2 Conclusions

Based on the data gathered after the testing and evaluation process, the

following generalizations were formulated:

1. The vertical rice dryer is perfect for assisting local small scale farmers

of Sto. Tomas, Isabela with its capacity of 150 up to 200 kg of rice per

operation.

2. The vertical rice dryer was able to decrease a 200-kg paddy of 22%

moisture content to 14% in a span of 3 hours.

3. The milled rice is very similar to commercially available rice in terms of

color and texture. However, the milled dried rice contains a lot more

broken grains compared to commercial rice.

 4. The performance of the vertical rice dryer is comparable to existing small

scale dryers and is visibly more efficient compared to the traditional sun-

drying method.

5.3 Recommendations

The vertical rice dryer is a preliminary model for an existing and

established application of mechanical concepts in the field of agriculture.

However, the researchers still believe that the prototype is still in the

process of improvement. The recommendations raised by the researcher's

panel includes but is not limited to, (1) utilizing a much more efficient heating

element other than propane burners, an example would be electric heaters

which would give the machine a controlled heat transfer and a much more

even drying, (2) consideration of another type of conveyor that can be easily

fabricated, with as little as to no sophistication, unlike the current screw

conveyor which requires precise measurements and clearance, and lastly

(3) the installation of a vibrating platform on the top of the drying chamber

to evenly distribute the rice paddies as it circulates the system.