The document discusses drying, which involves removing liquid, usually water, from a wet solid using thermal energy. Drying is a complex process that involves simultaneous heat and mass transfer through porous media as moisture is transported internally and evaporated from the surface. There are over 200 types of industrial dryers that employ various modes of heat input and drying conditions. Drying is highly energy-intensive, accounting for 8-25% of industrial energy usage. Improving dryer efficiency and developing new drying technologies has potential to significantly reduce energy consumption and greenhouse gas emissions.
The document discusses drying, which involves removing liquid, usually water, from a wet solid using thermal energy. Drying is a complex process that involves simultaneous heat and mass transfer through porous media as moisture is transported internally and evaporated from the surface. There are over 200 types of industrial dryers that employ various modes of heat input and drying conditions. Drying is highly energy-intensive, accounting for 8-25% of industrial energy usage. Improving dryer efficiency and developing new drying technologies has potential to significantly reduce energy consumption and greenhouse gas emissions.
The document discusses drying, which involves removing liquid, usually water, from a wet solid using thermal energy. Drying is a complex process that involves simultaneous heat and mass transfer through porous media as moisture is transported internally and evaporated from the surface. There are over 200 types of industrial dryers that employ various modes of heat input and drying conditions. Drying is highly energy-intensive, accounting for 8-25% of industrial energy usage. Improving dryer efficiency and developing new drying technologies has potential to significantly reduce energy consumption and greenhouse gas emissions.
Consepts Product size: m ten of cm Product porosity: 0 99% Drying times: 0.25sec (tissue paper) to 5months (hard woods) Production capacities: 0.10kg/h - 100t/h Product speeds: 0 (stationary) - 2000m/min (tissue paper) Drying temperatures: < triple point - > liquid critical point Operating pressures: < 1millibar - 25atm Heat supply: continuously, intermittently; convection, conduction, thermal and microwave radiations Patents granted each year: 250 (US), 80 (European) Some Statistics and Factoids on Drying Papermaking - massive dehydration operation - more energy-intensive than steel making! Industrially developed nations: 12-25% national industrial energy consumption - thermal dehydration Drying in some stages of all industrial opp. - controls the quality and market value or products marketability Excluding petrochemical refining, drying is by far the most energy-intensive Improper drying of the most expensive drugs may form polymorphs (no therapeutic value) mil$$$ of losses Improper design & operation - can be a hazardous operation - fire/explosion damage (organic products) Most thermal energy comes from combustion of fossil fuels, a major environmental impact Some Statistics and Factoids on Drying 8% of total industrial energy consumption for drying (Low?) Approx. 27 million tons water removed / year in drying processes An efficient dryer consumes about 1 ton of oil equivalent (TOE) to remove 8 tons of water (inefficient ones are as low as 1:3) Assuming average ratio of 1:6, 4.5 million TOE of fossil fuel energy is consumed annually in the U.K. for industrial drying emitting 13 million tons of CO 2 ! Significance of Drying: Figure for the U.K. (1990) 230 x 10 15 J/year used for drying 17.1 million tons / year CO 2 emission Current efficiency levels 15-35% (EDRL) 5% improvement in energy efficiency will decrease CO 2 emission by 3 - 4 million tons / year Improving existing dryers and developing new drying technologies have potential to reduce CO 2 emission by 1.2 and 9 million tons / year Significance of Drying: Figures for Canada World production ~ 2 billion tons 35% worlds cereal crops need drying (25% to 15% water, w.b.) Post-Harvest Drying of Grains (source: FAO, 1996) Pharmaceutical Industry Drying / energy costs negligible component of market price of products Over $190 billion worth pharmaceutical products are freeze dried around the world Complexity of Drying Liquid Semi-solid Solid Physical & thermal properties vary with moisture, temperature Enormous variety Various modes of heat input Various flow configurations 2-phase flows; transient, 3-D effects Dwell times vary widely Temperature Pressure Steady, unsteady Affect properties of product Affect micro- structure Material Properties Equipment Characteristics Operating Conditions Heat and Mass Exchangers Complicating issues Bottom line: Total cost of drying per kg product ! Complexity of Drying Variety of energy sources (continuous, intermittent) Physical / chemical transformations Multi-component transport Transient transport processes Varying moisture transport mechanisms Product quality interactions 6 Complexity of Drying Why is drying of solids so complex? Over 200 types of dryers in industrial use Diverse product physical, chemical properties vary widely for feeds and products Involves transient momentum, heat and mass transport through porous media, with phase change, with/without chemical/biochemical reactions No universal drying theory exists Minor changes of MC result in large changes in physical properties Basics of Drying Drying Removal of a liquid from a solid/semi-solid/liquid to produce solid product by thermal energy input causing phase change (liquid - vapor; solid - vapor) Needed for the purposes of preservation and storage, reduction in cost of transportation, etc. Most common and diverse operation with over 100 types of dryers in industrial use Competes with distillation as the most energy- intensive operation Drying Drying is an operation in which a liquid usually water is removed from a wet solid in equipment termed dryers. When a wet solid is subjected to thermal drying, two processes occur simultaneously: Transfer of energy (mostly as heat) from the surrounding environment to evaporate the surface moisture Transfer of internal moisture to the surface of the solid and its subsequent evaporation due to process 1
Schematic Diagram of Various Heat and Mass Transfer Modes and Moisture Transport Mechanisms in Drying Energy input by: Conduction Convection Radiation MW / RF Combination of the above concurrently or sequentially Moisture out by: Internal diffusion (liquid or vapor) Capillarity Surface diffusion Knudsen diffusion Combination of above Drying Particle 1. INTERNAL CONDITIONS: MOISTURE CONTENT 2. EXTERNAL CONDITIONS: PSYCHROMETRIC 3. MECHANISM OF DRYING 4. CLASSIFICATION AND SELECTION 5. ENERGY COSTS, SAFETY, AND ENVIRONMENTAL 6. DESIGN OF DRYERS 7. DRYER SELECTION Drying Drying Rate Heat and Mass Transfer Rate External Control Internal Control Energy Supply Convection Conduction Radiation Dielectric Affected by Pressure Temperature Humidity Gas flow Dryer Configuration Gas flow pattern Residence time Mass Transfer (Aroma/Shelf life*) Liquid / vapor diffusion Equilibrium MC Energy Transfer (Chemical/Thermal damage*) Temperature distributions Thermal/chemical degradation Momentum Transfer (Delamination/Cracking/Puffing*) Single phase Two phase Mechanical Effect (Cracking*) Deformation Strength Stresses INTERNAL CONDITIONS: MOISTURE CONTENT
sample of mass water of mass = c m . . solids of mass water of mass = c m . . Water of hydration: integral part of the material Bound water: water which is in some way bound to material so that it exerts a vapour pressure less than that of pure water Free water: Water which is bound by such minute forces, that its vapour pressure is equal to the vapour pressure of pure water INTERNAL CONDITIONS : Types of Water in Material Water Activity versus moisture content for different types of food INTERNAL CONDITIONS : Various types of moisture content INTERNAL CONDITIONS : INTERNAL CONDITIONS : (1) asbestos fiber, (2) PVC (508C), (3) wood charcoal, (4) Kraft paper, (5) jute, (6) wheat, (7) potatoes. Moisture Isotherms INTERNAL CONDITIONS : SorptionDesorption Hysteresis A typical isotherm Typical sorption isotherms INTERNAL CONDITIONS : INTERNAL CONDITIONS : Temperature Variations INTERNAL CONDITIONS : EXTERNAL CONDITIONS: Gas & Water Vapor
Vapor in Air: The ClausiusClapeyron Equation Reference Substance: EXTERNAL CONDITIONS: Gas & Water Vapor
Specific Humidity:
EXTERNAL CONDITIONS: Gas & Water Vapor
Dry Air & Water Vapor:
Relative Humidity:
EXTERNAL CONDITIONS: Gas & Water Vapor
Dry air & Water Vapor
Mole Fraction:
Y M M Y M m M m M m n n n G w w w G G w w w G w
Y Y
622 . 0
Dry Air & Water Vapor:
EXTERNAL CONDITIONS: Gas & Water Vapor
EXTERNAL CONDITIONS: Gas & Water Vapor
Humid Volume: Dry Air & Water Vapor:
EXTERNAL CONDITIONS: Gas & Water Vapor
Above a humidity of 0.05 kg/kgda:
Enthalpy EXTERNAL CONDITIONS: Gas & Water Vapor
EnthalpyHumidity Charts EXTERNAL CONDITIONS: Gas & Water Vapor
Adiabatic Saturation: Mass Balance: Energy Balance: EXTERNAL CONDITIONS: Gas & Water Vapor Wet Bulb Temperature EXTERNAL CONDITIONS: Gas & Water Vapor
Wet Bulb Temperature
EXTERNAL CONDITIONS: Gas & Water Vapor
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