INTRODUCTION

Industrial drying has been around for a long time, albeit in a crude form at first.

Drying goods and materials was soon committed to basic ovens, and as industrial needs
developed, so did drying technologies.

Rotary dryers have found their way into nearly every industry, from food and specialty
chemicals to minerals and fertilizers, and nearly everything in between, thanks to their
versatility

The rotary dryer also known as tumbling dryer is an equipment employed to minimize the
moisture content of a feed material

SCOPE OF THE PROJECT

Rotary drying is one of many drying processes used in chemical engineering unit
operations

cylindrical shell rotating on bearings and usually slightly inclined to the horizontal, are
used for drying

Wet feed is delivered into the dryer's upper end, where it moves through the drier

The parameters of the processed material determine the direction of gas flow through the
cylinder in relation to the solids

CHAPTER 1: INFORMATION ABOUT THE ROTARY DRYERS

1.1 Introduction:

Drying is the term applied to thermal processes for removing undesired moisture from a
product. Dryers utilize air to carry away the vaporized water and deliver the necessary
heat required for the process
 Figure 1.1. A simplified diagram of a direct-heat rotary dryer

1.2 Types of Rotary Dryers:

Rotary dryers are classified as direct, indirect–direct, indirect, and special types.

The main types of rotary dryers include:

Direct rotary dryer, Direct rotary kiln, Indirect steam-tube dryer, Indirect rotary
calciner, Direct Roto-Louvre dryer.

1.3 Working Principle:

 Fig 1.2 Working Principle of a rotary dryer
https://www.youtube.com/watch?v=v0EOvMFS9l0
https://www.youtube.com/watch?v=V3SBE41vJ64
1.4 . Implications:
1.4.1 Advantages:

Rotary dryer: strong overload resistance, large processing capacity, low fuel
consumption, low drying cost, and less sensitive to particle size.

Rotary Drum dryer: can change the operating parameters, and can accept the highest
flue gasses of any type of dryer, adopts new feeding and discharging device, Low
maintenance cost.

1.4.2 Disadvantages:
 Excessive entrainment losses in the exist gas stream is possible
 Dust removal equipment and dust recovery equipment are needed.
 1.5 Applications:
Rotary dryers can be used for any in any industry for drying such as:
 Building materials industry
 Agriculture
 Industrial industry
 Mineral processing industry

And some other industries:

 Food and Dairy Industry.

 Chemical and Pharmaceutical Industry.
 Ceramic Industry.
 Sand Industry.
 Rubber Industry.
 Foundry Industry.
 Wood and Paper Industry.
 Metal Industry

https://www.youtube.com/watch?v=V3SBE41vJ64

https://www.youtube.com/watch?v=djPvTJ5GVn8

Yến nói chiếu hai clip này trước khi vô chap 2

CHAPTER 2: DESIGN PARAMETERS

2.1 Fabricated Materials:

Rotary dryer shells can be constructed from a variety of materials, including:

 Carbon steel
 Stainless steel
 Hastelloy
 Inconel
 And other alloys
 Element Composition % SA 285 Gr C

Carbon, max 0.28

Manganese, max

Heat analysis 0.90

Product analysis 0.98

Phosphorus, max 0.025

Sulfur, max 0.025

Table 2.1 Chemical Requirements

 SA 285 Gr C
ksi (MPa)

Tensile strength 55-75 (380-515)

Yield strength, min 30 (205)

Elongation in 8 in. or (200 mm), min, % 23

Elongation in 2 in. or (50 mm), min, % 27

Table 2.2 Tensile Requirements

2.2 Rotational Speed (RPM):

It is found generally in practice that the speed of rotation irrespective of lifter shape
and spacing is inversely proportional to the retention time.

2.3 Flight Design:

Fig 2.1 Rotary Dryer Flights

Flights, also commonly referred to as "material lifters" or "shovelling plates" are used in
rotary dryers and rotary coolers to shower material through the process gas stream.

The direct-heat rotary dryers are studied more extensively. The flights are usually offset
every 0.6- 2 m and their shape depends upon the characteristics of the solids.

Fig 2.2 Commom flight profiles

2.4 Residence Time:

2.4.1 Cascade motion:

the result of the lifting action of the flights and the slope of the dryer

2.4.2 Kiln motion:

the motion of the particles as they slide either over the metal surface in the lower half of
the shell, or over one another

2.4.3 Bouncing

This motion occurs when a falling particle rebounds from the shell surface or from the
settler layer of particles, instead of come to rest, and results in the particle progress
because of the dryer slope.

The average residence time (or, time of passage) τ is defined as holdup H divided by the
H
solids feedrate F, thus τ= (Equation 2.1)
F
Johnstone and Singh proposed the equation
1/ 2
0.0433(ln )
τ= ( Equation 2.2)
DN tanα

‘‘Bureau of Mines,’’ proposed by Sullivan et al

0.0310(ln)1/ 2
τ= (Equation 2.3)
DN tanα

by Prutton et al.

kL mu
τ= + ( Equation2.4)
DN tanα 60

Perry and Chilton

0.23 L
τ= ( Equation2.5)
D N 0.9 tanα

2.5 Diameter:

dryers of the same length with all other factors held constant, production will vary in
direct ratio to shell cross sectional area

a dryer with a 50% more cross sectional area will provide a 50% increase in production if
the supplied heat and gasses are proportionally increased
 Fig 2.3 Production capacity vs shell cross sectional area

2.6 Length

In comparing dryers with the same diameter or cross sectional area and with the same gas
velocity, the production capacity may be increased with added length, but on less than a
direct ratio

Fig 2.4 Effect of dryer length on production capacity

 2.7 Thickness

Dryer shells can also be tailored in many ways, depending on the material and process
requirements of the customer. For example, shell thickness can be fine-tuned to improve
heat retention via the addition of insulation.

2.8 Loads

accurate estimation of the design load is critical to the analysis of performance and the
optimal design of flighted rotary dryers

2.9 Power requirement

According to a research about Design of Rotary Dryer for Sand Drying using Biomass
Energy Sources, it is known that the faster the rotary dryer rotation, the rotary dryer
capacity, and the required motor power will increase, but the traveling time will decrease.

CHAPTER 3: DESIGN PROCEDURE

3.1 Design Criteria:
3.1.1 Form of Feed: Wet Filter Cake

Wet Cake Filtration is a key method in solid-liquid separation and plays an important role
in many industrial processes

3.1.2 Mode of Operation: Continuous Operation

Operating mode is a phase of operation during the operation and maintenance stages of
the life cycle of a facility. Operating modes include start-up, normal operation, shutdown,
product transitions, equipment cleaning and decontamination, maintenance, and similar
activities.

Chemical manufacturing is a subsector of the manufacturing industry. In most situations,

it is performed using one of two methods: continuous processing; and batch processing.
Continuous production is a flow production method used to manufacture, produce, or
process materials without interruption

3.1.3 Heating System: Steam-heated Air

A heating system is a mechanism for maintaining temperatures at an acceptable level.

The gas stream is most commonly heated with a burner using gas, coal or oil. the hot gas
stream is made up of a mixture of air and combustion gases from a burner, the dryer is
known as "directly heated". Where burner combustion gases do not enter the dryer, the
dryer is known as "indirectly-heated".

Steam-atmosphere drying is much more efficient than the most common drying
technique, convection drying.

In a rotary drum steam-atmosphere dryer, steam and wet feed flow through a rotating
drum

3.1.4 Gas Flow Pattern in Dryer: Continuous Flow

The stream of hot gas can either be moving toward the discharge end from the feed end
(known as co-current flow), or toward the feed end from the discharge end (known as
counter-current flow). The direction of gas flow combined with the inclination of the
drum determine how quickly material moves through the dryer

Many factors are taken into consideration when designing a rotary drum dryer that can
both efficiently and effectively dry a material.

Rotary dryers are available in two types of air-flow configurations: co-current and counter
current. Co-current kilns work best with materials that do not need a gradual temperature
increase for a controlled transformation

3.1 Data Sheet:

 ROTARY DRYER DESCRIPTION: Reduce the moisture
DATA SHEET content of filter cake from 25.0% to 0.9%
Dimensions
Material of Construction Carbon Steel (SA 285, Grade C)
Inclination (degrees) 5
Inside Diameter (m) 1.31
Total Diameter (m) 1.39
Length (m) 8.02
Shell Thickness (mm) 8.17
Insulation Thickness (mm) 32.30
Technical Data
Rotational Speed (rpm) 4.60
Number of Flights 13
Flight Depth (m) 0.16
Motive Power Requirement (kW) 3.23
Blower Power Requirement (kW) 3.97
Dryer Power Requirement (kW) 1.61

3.2 Design Data:

Feed
Air
Component CaHPO4 .2 H 2O Ca( H 2 P O4 )2 H 2O

Mass Flow
407.41 kg/hr 5.51 kg/hr 137.64 kg/hr 6712.60 kg/hr
Rate
Inlet
30℃ 170℃
Temperature
Outlet
105℃ 105℃
Temperature
CHAPTER 4: DESIGN CALCULATIONS
4.1 Calculation of heat duty:

Using Ambient Temperature of 30oC and RH = 93% (based on the weather in Manila,
Philippines, 2015).

From Psychometric chart of Perry’s Handbook: Humidity = 0.0252 kg of water per

kg of dry air.

Taking the humid heat of Air:

kJ
Cs = 1.005 + 1.88H = 1.005 + 1.88 x 0.0252 = 1.0524 ( )
kg . K

Calculating for the amount of air needed:

kJ
382642.7525( )
Q h
ma = C ΔT = = 5593.83 (kg/h)
s
1.0524 (
kJ
kg . K )
× ( 443.15−378.15 ) ( K )

Humidity of outlet air:

mvapor
H= + H 30 Co
mair

1338868(kg water) kg water

H= + 0.0252 ( )
5593.83(kg dry air ) kg dry air

kg water
=> H = 0.05 ( )
kg air

Relative humidity of outlet air:

Po at 105oC = 120701.0447

1 kmol
0.0419 ( kg water ) × ( )
18.02 kg
PH O =
( 1
(kmol
)) ( 1
(
kmol
))
2

0.0491 ( kg water ) × + 1 ( kg dry air ) ×

18.02 kg 28.84 kg
=> P H O = 7387.04 (Pa)
2

PH O 7387.0354 ( Pa)
=> RH = 2
× 100 % = × 100 % = 6.12%
P o
120701.0447(Pa)

Thus the outlet air does not exceed the capacity of the air to carry vapor since
RH<100%.

Allotting an allowance of 20%, for the possible heat losses and due to startup,
shutdown and cleaning (van’t Land, 2012).

kg kg
ma = 1.20× 5593.83 ( ¿ = 6712.60 ( ¿
h h

4.1 Calculation of inside diameter and length:

kg kg
The allowable mass velocity of the air ranges from 2000
2 up to 25000
h.m h . m2
kg
(Mc. Cabe, Harriot & Smith, 1993). Assuming that the mass velocity of air = 5000 2.
h.m
Then, the area of dryer:

A=
6712.60 ( kgh ) = 1.34 (m ) 2

5000
( hkg. m ) 2

√
2
Di = 4 ×1.3425(m ) = 1.31 (m)
π

Drying diameter ranges from 1 to 3m (Mc. Cabe, Harriot & Smith, 1993), thus the
computed drying diameter is accepted.

The following empirical equation is used to calculate for the overall heat transfer
coefficient from Perry’s Handbook with the index n=0.67 (Mc. Cormick, 1962). The k
value falls in the range 3.75≤k≤5.25 as suggested by AICHE for SI unit (van’t Land,
2012). Assuming k=4.75:
 kg 0.67
kG
n
4.75 ×5000( ) kJ
Ua = = h . m2 = 1092.92 ( )
D h . m3 . K
1.3074 (m)

For the calculation of wet bulb temperature, the most economical operation of
rotary dryer can be achieved for Nt is in general between 1.5 and 2.5 (Mujumdar, 2014).
Assuming the value of Nt = 2.

( )
T A −T
Nt = ln
¿ w

T A −T
out w

2 = ln ( 443.15−T w
378.15−T w )
=> Tw = 367.98 (K)

Calculating the logarithmic mean temperature difference:

( T A −T w )−( T A −T w ) ( 443.15−367.98 )−(378.15−367.98)

¿ out

(ΔT)lm = ( T A −T w ) = (443.15−367.98) = 32.5 (K)

ln ¿
ln
( T A −T w ) (378.15−367.98)
out

Calculating the length of the dryer:

Q = UaAL(ΔT)lm

=> L =
Q
=
382642.7525 ( kJh ) = 8.02 (m)
U a A (∆ T )lm
(
1092.92
kJ
3
h.m .K)×1.3425(m2)× 32.5(K )

Checking the L/D ratio:

L 8.0242(m)
=
Di 1.3074(m)
= 6.14

L/D ratio is most efficient between 4 and 10 for industrial dryers (Mujumdar,
2014), therefore the above diameter and length can be accepted.
 4.2 Calculation of RPM, flight design and residence time:

Speed values ranges 0.1 to 0.5 m/s (van’t Land, 2012). Assuming the peripheral
speed of rotation to be 0.1 m/s.

Calculating the speed of rotation of dryer:

RPM =
peripheral speed 0.1
diameter
= s
× ( ) ( )
m 60 s
1 min = 4.59 (rpm)
1.3074( m)

The revolution of a dryer varies between 2 and 5 rpm. Therefore the above value
can be accepted.

Fight design:

(
Number of flights = 3D (D in feet) = 3× 1.3074 ( m ) × )
1 ( ft )
0.3048 ( m )
= 12.87 ≈ 13

Flight Depth:

D 1.3074(m)
Fd = = = 0.16 (m)
8 8

Using the following empirical equation for the residence time (in minutes) in dryer
as recommended by AICHE (van’t Land, 2012):

B = 5 d p−0.5 =5 ×210−0.5=0.4350

0.23 L 2 BLG 0.23 × 8.0242 2 ×0.3450 × 8.0242×5000

+ = + =89.28(min)
F
( )
0.9 0.9
τ = SN D 5 ×4.5892 ×1.3074 416.67
1.3425

Residence time of rotary dryer typically ranges at 5 to 90 minutes (Couper,

Penney, Fair & Walas, 2005). Therefore the computed value is acceptable.
 4.3 Calculation of shell dryer thickness and outer diameter:

Considering the material to be used is Carbon Steel (SA 285, Grade C) because it
can withstand up to 343.33˚C. For operating pressure of 0 psig (14.7 psia), the design
pressure is 10 psig (24.7 psia) or 170 253.5714 Pa (Hesse & Rushton, 1975)

Using the following formula for working stress:

Sw =S u × F m × F a × Fr × F S

Where Su : minimum specified tensile strength, 380 MPa (ASME SA285 Grade C, n.d.)

F m : material factor, 0.92 for Grade C material

F a : radiographing factor, 1.00 since radiographing is not employed

F r : stress relieving factor, 1.00 since relieving is not employed

F S : factor of safety, 0.25 for temperature less than 315.56˚C

Sw =380 MPa × 0,92× 1.00× 1.00× 0.25=87.4 MPa

Using the following equation to calculate shell thickness with corrosion allowance
of 6.35 mm (Hesse & Rushton,1975) and efficiency of the joint 0.7 for double-welded
butt joint since radiographing is not employed (Sinnot, 2005):

PD
t s= +C
2 S w e−P

N 1000 mm
170 253.5714×1.3047 m ×
m 2
1m
t s= +6.35 mm=8.17 mm
( N
)
2× 87 400 000 2 × 0.70 −170 253.5714 2
m
N
m

The minimum shell thickness of equipment vessel with 1.0668 – 1.524m diameter
is 8.128 mm (Couper, Penney, Fair, & Walas, 2005), therefore above value can be
accepted.

To calculate the outer diameter of dryer.

 (
D o =D i+ 2t s=1.3047 m+2 8.1717 mm ×
1m
1000 mm )
=1.32 m

4.4 Calculation of insulation thickness:

To limit heat loss an insulation is to be given to the dryer. The chosen insulating
material is brick. From literature, its thermal conductivity equals to 0.72 W/m.K. Mil steel
however has a thermal conductivity of 51.9220 W/m.K.

2 πL(T 2−T 1 )
Q=
r r
ln ⁡( 2 ) ln ⁡( 3 )
r1 r2
+
kA kB

2 π (8.0242m)(443.15 K−303.15 K )
106 289.6535 W =
0.6619 0.6619+t i
ln ⁡( ) ln ⁡( )
0.6537 0.6619
+
W W
51.9220 0.72
m .K m.K

t i=0.0323 m=32.30 mm

To calculate the total diameter of dryer:

(
D t =Do +2 t i =1.3238 m+2 32.2966 mm×
1m
1000 mm)=1.39 m

Calculation of live load and rotating load:

To calculate the volume of shell material:

π ( Do −Di ) L π ( 1.32382−1.30742 ) m2 × 8.0242 m

2 2
3
V SM = = =0.27 m
4 4

To calculate the volume of insulating material:

 π ( D o −Di ) L π ( 1.38842−1.32382 ) m 2 × 8.0242 m
2 2
3
V ℑ= = =1.10 m
4 4

To calculate the weight of unloaded dryer using the density of mil steel 7850 kg/m3

kg
W dryer =0.2710 m3 × 7 850 3
=2 127.43 kg
m

To calculate the total weight of insulating material using the density of brick 2165
kg/m3
kg
W insulation =1.1040 m3 × 2165 =2390.26 kg
m3

To calculate the weight of the material in the dryer:

(
W material = 550.5535
kg
hr)×89.2775 min ×
1hr
60 min
=819.2 kg=1.806 lbs

To calculate the total weight of the loaded dryer:

W total =2127.4269 kg+819.2001 kg+2390.2589 kg

W total =5336.89 kg=11765.62 lbs

4.5 Calculation of blower power, motive power and dryer power:

Using the equation in (van’t Land, 2012) for the calculation of motor power for rotation
for rotary dryers:

0.3 π Di2 L 0.3 π 2

P m= = ×(1.3074) ×( 8.0242)=3.23 kW
4 4

To calculate the power requirement for blower:

( )( )( )
3
kg 1 kmol Pa. m
6,712.5950 8,314 (378.15 K )
nRT hr 28.5740 kg kmol . K
Qinlet air = =
P 101,325 Pa
 m3
Qinlet air =7,289.1505
hr
−5 −5
Pb=2.72×10 Qinlet air p=2.72 ×10 (7,289.1505)(20)=3.97 kW

Using the following equation proposed by CE Raymond Division, Combustion

Engineering Inc., to calculate the power to drive a dryer with flights (Mujumdar, 2014):

N (4.75 Di W material +0.1925 D' W total + 0.33W total )

P D=
100,000

Where:

N: expressed in rpm

D’: D + 2

Wmaterial, Wtotal: expressed in lbs

Di: expressed in feet

N (4.75 Di W material +0.1925 D' W total + 0.33W total )

P D=
100,000

4.75((4.75 × 4.29× 1,806)+(0.1925 ×6.29 × 11,765.62)+( 0.33× 11,765.62))

¿
100,000

0.75 kW
P D=2.52 bhp × =1.89 kw
1 bhp
CHAPTER 5: DISCUSSION