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To cite this article: M. K. Krokida , Z. B. Maroulis & C. Kremalis (2002) PROCESS DESIGN OF ROTARY DRYERS FOR OLIVE CAKE,
Drying Technology: An International Journal, 20:4-5, 771-788
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ABSTRACT
*E-mail: maroulis@chemeng.ntua.gr
771
INTRODUCTION
and test empirical equations from the literature, concerning the residence
time calculation.
PROBLEM DEFINITION
drying cost. Thus, the design problem of a rotary dryer for olive cake can be
dened as follows:
1. Process Specication
Solids ow rate Fs (kg/h db)
Input material moisture content Xo (kg/kg db)
Output material moisture content Xs (kg/kg db)
2. The Characteristics of the Rotary Dryer are as Follows:
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. Size:
D: dryer diameter (m)
. Geometric characteristics:
the length to diameter dimensionless ratio (L/D)
the total hold-up to volume dimensionless ratio (H/V)
the number of blades to diameter dimensionless ratio
(nf/D)
3. Drying Conditions
Inlet temperature TAC ( C)
Velocity u (m/s) at temperature TA
The cylinder slope s (%)
PROCESS MODEL
I. Burner
Based on Eq. (1) the total balance and the moisture balance over the
burner are given by the following equations that describe the combustion
process:
FAC 1 YAC FA0 1 Yo Z 2
II. Dryer
The following equations describe the mass and the energy balances of
the dryer:
FAC YA YAC FS Xo XS 5
where YAC and YA are the air moisture content (kg/kg db) at the dryer input
and output, respectively, Xo and Xs are the material moisture content (kg/
kg db) at the dryer input and output respectively.
where CPA (kJ/kg K) is the specic heat of airvapour mixture and HV is
the latent heat of vaporization of water at reference temperature (kJ/kg) and
TA is taken as mean airvapour temperature at the dryer output.
2. Drying Kinetics
kM T, Y, u k0 T k1k2k3 8
where u (m/s), Y (kg/kg db), T ( C) are the velocity, humidity and tempera-
ture of the drying air. Parameters k0, k1, k2, k3 express the eect of various
factors on the drying constant.
The equilibrium moisture content of olive cake as a function of water
activity and temperature of the surrounding air, can be computed by using
the following equation:
3. Residence Time
4. Geometrical Constraints
5. Cost Estimation
The process unit cost of wet product ($/kg wb) has to be minimized:
Cp CT =t
op Fs 1 XS 19
where top is operation hours per year, Cp is the cost of the product due to
the process of drying, the total annual cost CT of the plant can be expressed
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2002 Marcel Dekker, Inc. All rights reserved. This material may not be used or reproduced in any form without the express written permission of Marcel Dekker, Inc.
CT eCeq Cop 20
where e is the capital recovery factor, eCeq is the yearly capital cost ($/y) and
Cop is the operating cost ($/y).
The capital recovery factor is given by the following equation:
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i1 iN
e 21
1 iN 1
Ceq aD AnD aZ Z nZ 22
where aD, aZ are unit costs and nD, nZ are scaling factors of dryer and burner
respectively.
The operating cost concerns electrical energy and fuel cost:
where Ce and Cz are the electricity and the fuel cost respectively. The elec-
trical power hp for cylinder rotation is given as follows (Kelly, 1995):
hp qNDM W 24
where dx (m) is the dryer wall thickness and M is the metal density (kg/m3).
A degrees of freedom analysis suggests that ve design variables are
available for the design problem described in the previous paragraphs. It
can be proved that an eective solution algorithm could be based on the
following selection of design variables: TAC, u, L/D, H/V, nf/D, where TAC
and u express the operating conditions and L/D, H/V, nf/D the dryer
shape.
MARCEL DEKKER, INC. 270 MADISON AVENUE NEW YORK, NY 10016
2002 Marcel Dekker, Inc. All rights reserved. This material may not be used or reproduced in any form without the express written permission of Marcel Dekker, Inc.
Figure 2. Drying constant versus temperature for various air velocities and
humidities.
MARCEL DEKKER, INC. 270 MADISON AVENUE NEW YORK, NY 10016
2002 Marcel Dekker, Inc. All rights reserved. This material may not be used or reproduced in any form without the express written permission of Marcel Dekker, Inc.
CASE STUDY
Process specications
Solids owrate Fs 5000 kg/h
Input material moisture content Xo 1.00 kg/kg db
Output material moisture content X 0.10 kg/kg db
Fresh air characteristics
Temperature To 25 C
Humidity Yo 0.01 kg/kg db
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Thermophysical properties
Water to air molar fraction m 0.622
Air specic heat CPA 1.18 kJ/kg C
Water specic heat CPV 1.98 kJ/kg C
Heat of combustion Hf 15 MJ/kg
Latent heat of vaporization of water Ho 2500 kJ/kg
Porosity " 0.48
Empirical constants
Empirical constant in Eq. (14) k 0.003
Empirical constant in Eq. (24) q 1
Economic data
Dryer unit cost aD 8 k$/m2
Dryer scaling factor nD 0.62
Burner unit cost aZ 200 $/kg
Burner scaling factor nZ 0.4
Life time N 10 yr
Interest rate i 8 %
Operating time top 2000 h/y
Electricity cost Ce 0.07 $/kWh
Fuel cost Cz 0.05 $/kg
and each time all other variables are calculated. It must be noted that as air
drying temperature increases the fuel consumption increases and thus the
operating cost increases, while the size of equipment and consequently the
cost of equipment decreases. For a given air velocity the total unit cost (CT)
reaches a minimum at a specic air temperature (Figure 5).
In Figure 6 the total unit cost is presented as function of air tempera-
ture for dierent air velocities. Eect of air temperature on fuel and elec-
tricity cost is presented in Figure 7. As temperature increases it is evident
that the electrical cost decreases, while the fuel cost increases and is the most
important part of operating cost.
The model was adapted to an industrial rotary dryer 2.5 m in diameter
and 22 m long which has 24 blades. The drying conditions are 650 C input
MARCEL DEKKER, INC. 270 MADISON AVENUE NEW YORK, NY 10016
2002 Marcel Dekker, Inc. All rights reserved. This material may not be used or reproduced in any form without the express written permission of Marcel Dekker, Inc.
Design variables
Input air temperature TAC 700 C
Mean airvapour velocity u 2.4 m/s
Total holdup to volume fraction H/V 15 %
Length to diameter fraction L/D 20
Number of blades to diameter fraction nf /D 10 1/m
Drying air characteristics
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Mean air temperature TA 298 C
Humidity outlet Y 0.37 Kg w/kg db
Operating characteristics
Residence time t 0.3 h
Total holdup H 8.4 m3
Rotating velocity N 8.6 rpm
Dryer characteristics
Diameter D 1.5 m
Length L 30.6 m
Blade number nf 15
Utilities
Fresh air owrate FA0 15 048 kg/h
Fuel rate Z 1066 kg/h
Economics
Electricity cost Ce 6286 $/y
Fuel cost Cz 106 606 $/y
Operating cost Cop 112 891 $/y
Cost of equipment Ceq 55 619 $/y
Total cost CT 168 510 $/y
Unit cost Cp 0.00843 $/kg wb
drying air temperature, 2.4 m/s mean air-vapour velocity, while the fuel rate
is 1500 kg/h. It must be noted that the operating conditions obtained from
process design calculations are close to the real ones.
CONCLUSIONS
A design procedure for a concurrent olive cake rotary dryer has been
developed. A simple mathematical model for the rotary dryer was used,
while material thermophysical properties have been calculated experimen-
MARCEL DEKKER, INC. 270 MADISON AVENUE NEW YORK, NY 10016
2002 Marcel Dekker, Inc. All rights reserved. This material may not be used or reproduced in any form without the express written permission of Marcel Dekker, Inc.
Figure 6. Total unit cost as function of air temperature, at various air velocities.
MARCEL DEKKER, INC. 270 MADISON AVENUE NEW YORK, NY 10016
2002 Marcel Dekker, Inc. All rights reserved. This material may not be used or reproduced in any form without the express written permission of Marcel Dekker, Inc.
tally. A sensitivity analysis of the process unit cost has been achieved by
varying drying conditions (air temperature and velocity). It is noted that air
temperature aects signicantly products cost, while the eect of air velocity
is less signicant.
NOMENCLATURE
REFERENCES
Vant Land, C.M. Selection of Industrial Dryers. Chem. Eng. 1984, 91,
53.
Vant Land, C.M. Industrial Drying Equipment. Marcel-Dekker:
New York, 1991.
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