Particle Drying Ressel Komp

Center for Wood Sciences
CASWoodBased Panels
Module1:Process Technology
Particle drying
Prof.Dr.JoergB.Ressel
September7 12,2015 Biel,CH
www.biologie.unihamburg.de/zentrumholzwirtschaft.html
Wood Based Panels
Content
Content
Particle drying - fundamentals
Additional Information
Particle drying dryer types
MOLLIER-h,x-Diagram for humid air
Drying plant components
emc of wood KEYLWERTH-Diagram
Flash tube pre-dryer

Drum dryer
Single pass drum dryer
Drum dryer for OSB strands
Indirect heated tube bundle dryer
Indirect heated rotary tube bundle
dryer
Fibre dryer
Superheated steam dryer for wood
fibres
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Particle drying
Particle drying process - fundamentals
mc
Continuous drying process

Combined heat transfer to particles by convection
(fluid = hot gas / air, steam) and conduction (contact )
Drying phases (simplified)
1. Particle mc FSP evaporation of free water, fast
increase of particle temperature up to constant level
(cooling limit temp.) below the boiling point of water
2. Particle mc < FSP desorption and evaporation of
capillary and bound water, increasing particle temperature up to gas temperature; fire hazard ! (self ignition
at approx. 240C)!
Drying curve
mcin
const. evaporation
( free water)
FSP
decreas. evaporation
( bound water)
mcfin
t
dmc/dt
Drying rate
1.
2. Phase
Drying parameters ( process parameters)

Material related : wood species, density, particle dimensions (thickness, width, length), mc (initial, final) ...
Process related : gas/air/steam temperature, partial
pressure of water vapour, gas velocity, retention time
FSP fibre saturation (point);

upper limit of hygroscopic mc-range
(0 emc approx. 28% mc FSP)
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Particle drying

Energy required for
(heat and electricity)
heating up wood particles ( wood substance & water!)

evaporation and desorption of free and bound water from wood
covering exhaust heat losses
covering transmission heat losses (drying plant)
electric power for fans, drum drive, servo-motors
Spec. energy consumpt. [MJ/kgwater]
Specific energy consumption is related to 1 kg water removed from wood particles

Spec. energy consumpt. [MJ/kgwater]
4,0
Heat of adsorption
(hv+hb)max = 3,6 MJ/kg
3,5
3,0
2,5
2,0
1,5
Heat of
evaporation
hv = 2,5 MJ/kg
1,0
0,5
0,0
2,70
Left:
Heat of evaporation
and heat of adsorption for flake drying
depending on mc
(May 1979)
2,65
2,60
Right:
Average specific energy consumption of flake drying depending
on initial mc (May 1979)
2,55
2,50
0
10
15
20
Initial moisture content [%]
25
25
50
75
100
125
Initial moisture content [%]

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Particle drying

Total energy consumption
o PB production
140.000 m/a
o PB coating
40.0000 m/a
Heat
2,69 GJ/m 84,6 %
Electricity 0,49 GJ/m 15,4 %

Ressel J B Energieanalyse der Holzindustrie der
Bundesrepublik Deutschland. BMFT-PS T 86-184.
1986. 161 pages
all figures in % of the total energy consumption

(http://sankeymatic.com/build/ 26.08.2015)
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Wood Based Panels
Particle drying

Energy consumption
entire PB production
Heat
2,95 GJ/m
82 %
Electricity
0,65 GJ/m
18 %
FAO Energy conservation in the mechanical forest

industries. FORESTRY PAPER 93. Rome, 1990
all figures in % of the total energy consumtion

(http://sankeymatic.com/build/ 26.08.2015)
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Particle drying
Particle drying process - basic dryer types

Scheme
Temp. range Drying time
Capacity
Rotary bundle dryer

( spinning tubes)
up to
200C
20 min
1 9 t/h
Tube bundle dryer

( spinning drum)
up to
160C
n.a.
10 18 t/h
Single-pass drum
dryer
up to
450C
20 - 30 min
40 t/h
Triple-pass drum
dryer
up to
400C
5 - 7 min
25 t/h
Flash tube pre-dryer
up to
500C
20 s
2 14 t/h
Jet tube dryer
approx.
500C
0,5 - 3 min
10 t/h
acc. Deppe, Ernst 2000 / Fig. 3.2-5
Dryer type
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Particle drying
Basic drying plant components
Heating system for drying medium (fluid = flue gas, hot air, superheated steam) boiler
Dryer - one or two stages pre-dryer optional
Material infeed systems material sluice/airlock cellular wheel
Material separators cyclones
Heating gas re-circulating system and fan(s) feed-back of flue gas etc.
Exhaust gas cleaning system filter systems reduction of VOC emissions !
Chimney stack
Heating systems direct heating indirect heating
Burner for natural gas, oil, dust

Flue gas from energy system (e.g., grate firing systems)
Turbine exhaust gas
Combination of heating systems mentioned above
Particle movement / particle transport through the dryer

Pneumatic transport, particles carried by fluid (gas velocity approx. 525 m/s)
Mechanical transport by built-in devices (paddles), e.g., rotating with the drum
Combined transport (fines pneumatic transport, coarse particles mechanical transport)
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Particle drying
Flash tube pre-dryer Type VT (Buettner 2015)

Used for material with high initial moisture content
Separate pre-dryer or combined a downstream drum
dryer
Increase capacity of existing dryer
Water evaporation from 115 t/h
Material throughput: 170 t/h (dry) resp. 185 t/h
(wet material)
Fresh air or re-circulating air operation
Heating systems
Direct heating flue gases from gas, dust, oil
burner or grate firing, exhaust gas from turbine
Indirect heating heat exchangers with steam,
thermal oil
Infeed of material with different moisture content and
bulk densities at the same time
Power and control switch plant including PLC and
visualization
Flash tube pre-dryer (Buettner 2015)
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Wood Based Panels
Particle drying
Flash tube pre-dryer Type VT (Buettner 2013)

Optional re-circulation gas
approx. 25% of thermal
energy saving
Stack / to exhaust gas

cleaning system
Wet material
Fan
Heating system
Cyclone / separator
Direct heating
flue gases
Indirekt heating
heat exchanger
Rotary valve
Rotary valve
Oversized
material
Emergency Dry material to
material production
discharge
(Buettner 2013)
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Wood Based Panels
Particle / Flake drying
Drum dryer Type NH (Buettner 2013)

Material throughput: 570 t/h (dry) resp.
10120 t/h (wet material)

Heating systems:
Burner for natural gas, oil, dust ( heat exchanger)
Flue gas from energy plant (e.g., grate firing systems)
Turbine exhaust gas ( heat exchanger)
Combination of above mentioned heating systems
Possible combination with flash tube pre-dryer and
discharge of coarse particles
Drum diameter 30006200 mm
Drum dryer Type NH with
without
material
discharge
material
discharge
boxbox
Material discharge via cyclones
(Buettner 2013)
Individual exhaust gas cleaning system (e.g., high
efficiency cyclones, filter systems (EFB, WESP, RTO)
visualization, also for conveyors in front and behind the
dryer
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(Flash-Dryer) Pre-dryer and Drum dryer
(http://www.wbpionline.com/uploads/newsarticle/853739/images/210594/large/vanachai1.jpg / 24.08.2015)
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Wood Based Panels
(Flash-Dryer) Pre-dryer and Drum dryer
(http://www.instalmec.it/images/stories/settori/orig/01.jpg / 24.08.2015)
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Wood Based Panels
Drum dryer Type NH without discharge box (Buettner 2013)

Material discharge directly via cyclone
cleaning system
Swivel
damper
Recirculation duct
Fan
Pre-dryer
Wet
material
Pre-dried
material
Material separators or
high efficiency
cyclones
Drum dryer
Heating
system
Oversized material

material production
discharge
(Buettner 2013)
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Wood Based Panels
Drum dryer Type K (Buettner 2013)

Material discharge via outlet box
Fine material discharge via cyclone

cleaning system
Swivel
damper
High efficiency cyclones
Recirculation duct
Pre-dryer
Wet
material
Heating
system
Pre-dried
material
Fan
Mixing
chamber
Drum dryer
Discharge
box
Reversible
srew feeder
Oversized
material
Emergency Dry material

material to production
discharge
Emergency Dry material

material to production
discharge
(Buettner 2013)
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Pre-dryer and single pass drum dryer (SPE 2005)
Flash tube pre-dryer and single pass drum dryer ( 5200 mm, length 28 m, 30 t h-1; Buettner 2005)
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Single pass drum dryer (SPE Dieffenbacher Group 2007)

Standard installation
Options
Direct discharge to
cyclons
Discharge via dropout box
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Wood Based Panels
Pre-dryer and single pass drum dryer (Binos 2011)

Single-pass drum dryers are either
direct or indirect heated. The dimensions of the dryer drum are similar to
the three-pass drum dryer; gas inlet
temperature is lower (< 500C).
Cyclone battery
Emergency stack
The moisture is removed more gently, retention time is longer (> 20 min).
The system is suitable for drying material with various mc and dimensions.
Discharge
box
Stack
Wet mate
rialinlet
Mixing
chamber
Dry mat. discharge

Pre-dryer
Drum dryer
Combustion
chamber
Bison ( o. J.)
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Single pass drum dryer (SPE 2007)

Particle discharge
Dust separation
Sand / ash
separation
Dust separation
Discharge
box
Particles
Particles
Drum dryer datails (SPE 2007)
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Design details for the flake dryer
Drum ( 27 m, thick drum shell,
rigid concept)
Trunnion assembly
Variable speed drive
with friction, chain
or rack ring
Drum dryer datails (SPE 2007)
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Flake / Strand drying

Specific drum internals for PB (left) and OSB (right)
Omega
supports
Cross
internals
Support
discs
Drum dryer datails

(SPE 2007)
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Strand drying
Drum dryer Type NH for OSB strands

Particularly developed for strand drying requirements
Material throughput: 540 t/h (dry) resp.
1080 t/h (wet material)

Heating systems:
Burner for natural gas, oil, dust ( heat exchanger)
Flue gas from energy plant (e.g., grate firing systems)
Turbine exhaust gas ( heat exchanger)
Drum dryer for OSB strands (Buettner 2013)
Combination of above mentioned heating systems
Single-pass drum dryer for OSB
strands (Metso panelboard 2004)
Particularly designed internal strand transport system
inside the drum
Material discharge via cyclones
Individual exhaust gas cleaning system (e.g., high
efficiency cyclones, filter systems (EFB, WESP, RTO)
Power and control switch plant including PLC and visualization, also for conveyors in front and behind the dryer
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Wood Based Panels
Particle drying
Drum dryer Type NH for OSB strands (Buettner 2013)

cleaning system
Swivel
damper
Recirculation duct
Fan
Material separator
Heating
system
Mixing
chamber
Wet
material
Drum dryer
Grate
firing
system

material production
discharge
(Buettner 2013)
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Particle drying
Drum dryer Type LS (Buettner 2013)

cleaning system
Recirculation duct
Fan
Material separator
Wet
material
Direct
heating
system
Drum dryer
Emergency
material
discharge
Dry material to
production
(Buettner 2013)
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Wood Based Panels
Particle drying
Triple pass drum dryer for flakes (Binos 2011)

Pre-drying in the centre tube of the dryer drum
Final drying during the second and third pass of the drum after
turning back of flow direction with decreasing temperature and

flake mc
(Binos 2011)
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Particle drying
Triple pass drum dryer (Binos 2011)

Pre-drying in an upstream flash tube dryer
Final drying during the passage of the nested tubes
within the drum: Particles are carried through the

dryer by the flowing hot gas; temperature and flake
mc decrease with transport distance
(Binos 2011)
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Wood Based Panels
Particle drying
Indirectly heated tube bundle dryer (Buettner 2013)

Material throughput: 8>30 t/h (dry) respectively
16> 55 t/h (wet material)

Heating systems:
Steam - combination with flue gas optional
Rotating drum, stationary tube bundles
Indirect heated tube bundle dryer (Buettner 2013)
Exhaust gas cleaning by filter system no cyclones

visualization, also for conveyors in front and behind

the dryer
Preferred in combination with cogeneration
( coupled heat & electricity generation)
Tube bundle (Buettner 2013)
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Wood Based Panels
Particle drying
Indirectly heated tube bundle dryer (Buettner 2013)
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Wood Based Panels
Particle drying
Indirectly heated rotary bundle dryer (Buettner 2015)

Stationary dryer case (drum or trough) rota-
ting tube bundle (designed as single or double rotary bundle dryer), tube bundle size up to
3.600 mm
Water evaporation from 2 10 t/h
Material throughput: 2 10 t/h (dry)
respectively 420 t/h (wet material)
Heating systems:
Steam thermal oil hot water
Dust cleaning by cyclones
Individual exhaust gas cleaning systems, e.g.,
cyclones, EFB, WESP, RTO
Power and control switch plant including PLC
and visualization, also for up- and
downstream conveyors
Preferred in combination with cogeneration
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Particle drying
http://www.buettner-energydryer.com/en/dryingsystems/drying-systemsindirectly-heated-tube-bundledryers/ / 24.08.2015
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Wood Based Panels
Particle drying
Indirectly heated rotary tube bundle dryer (Bison o.J.)

Fully insulated rotary
bundle dryer
(Ponndorf 2005)
Heat pipe arrangement in rotary

tube bundle dryers
type RK (top)
type RS (bottom)
(Ponndorf 2005)
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Particle drying
Indirectly heated rotary tube bundle dryer (Buettner 2013)

Wet electrostatic precipitator
Cyclone
WESP
Thermal oil
heater
Fresh
air
Fuel
Combustion air
Fan
Pump
Ash
Wet material
Fresh air
Heat
exchanger
(Buettner 2013)
Rotary tube bundle dryer

Dry material to production
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Fibre drying
Fibre dryer (Buettner 2013)

Particularly designed for drying fibrous materials
Water evaporation from 5> 60 t/h
Material throughput: 5> 60 t/h (dry) respectively
10> 90 t/h (wet material)
Fresh air or re-circulating air
Heating systems:
Indirect heating via heat exchanger steam, hot
water or thermal oil
Direct heating burner for natural gas, LPG, oil,
dust, flue gas from energy plants (grate firing
systems) or turbine exhaust gas
High efficiency radial fans
Dryer duct diameter 800> 3.000 mm
Cyclone (diameter 3.0006.500 mm) for material
discharge and dust removal
visualization, also for subsequent fibre sifter
Dryer for fibrous materials heating system (Buettner

2013)
Dryer for fibrous materials (Buettner 2013)
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Fibre drying
Flash dryer types for fibrous material

Steam recovery
Two stage
flash dryer
Single stage
flash dryer
Fibre inlet
Fibre inlet
Fibre inlet
Single stage flash dryer

(Deppe / Ernst 1996)
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Fibre drying
One stage fibre dryer

Simple process solution and control
Low capital cost
High level of temperature and therefore over-drying or
fire hazard
High pre-curing rates of resins
Direct flue gas from energy plant
Low electrical energy consumption
Wet
material
from refiner
Fresh
air
dry
material
(SPE 2005)
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Fibre drying
Dryer for fibrous material (Buettner 2013)

cleaning system
Flue gas
Dryer duct
High efficiency cyclone
Fan
Fresh air
Heating system
(Buettner 2013)
Wet material
from refiner
Emergency
material discharge
Dry material to
production
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Fibre drying
Two stage fibre dryer

Lower gas temperature level
Advanced process control

High capital cost (more construction space)
Higher electric power consumption
Good control of final mc, less overdrying

low pre-curing of resins
1. stage
2. stage
Fresh
air
Wet
material
Fresh
from
air
refiner
Fibre bin
dry
material
Sifter
(SPE 2005)
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Fibre drying
Two stage fibre dryer

180
160
Temperature [C]
Advantages compared to single-stage fibre drying

Increased fibre quality and more uniform final mc
Reduced resin consumption with blow-line blending
Reduced energy consumption; 15 % compared to onestage drying, 25 % with RAS
Smaller ducts and cyclones, particularly at high
capacities
One-stage dryer
140
120
100
80
60
Two-stage dryer
40
20
0
Return air system (RAS)
0,0
0,2
0,4
0,6
0,8
1,0
1,2
1,4
Relative drying time [-]
1. stage
2. stage
Fresh
air
Wet
material
from Fresh
refiner air
Fibre bin
Sifter
(Metso panelboard 2002)
Advantages of RAS
lower energy consumption
decreased emission of particles
lower exhaust gas flow and
lower investment costs for
environmental control technology
(Metso panelboard 2002)
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Wood Based Panels
Fibre drying
Superheated steam dryer for wood fibres (SPE Dieffenbacher 2005)

Superheated steam as drying medium offers
considerable advantages compared to humid
air in conventional drying processes:
less energy consumption (heat & electric
power)
heat recovery up to 6080 %
closed loop system no exhaust gas, no
dust and other emissions (VOC); all emissions removed by condensate waste
water treatment required
almost oxygen-free gas circulation no
fire and explosion hazard
reduced drying time due to better heat
transfer less mass flow (fluid = steam),
less fan power
shorter drying duct
(SPE 2005)
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Fibre drying

Comparison of
mass flow
Conventional fibre
drying process
Superheated steam
fibre drying process
SPE 2005
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Wood Based Panels
Fibre drying

Comparison of
energy consumption
Conventional fibre
drying process
Superheated steam
fibre drying process
SPE 2005
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emc & humid air
Overview
Wood Based Panels

MOLLIER-h,x-Diagramme
... changes of humid air conditions, e.g., with convective
drying processes.
recommended literature
Fibre drying
(http://public.beuth-hochschule.de/~wseifert/lmr/thermo/BilderThermo/Theorie/HX_Diagramm4.jpg / 27.08.2013)
Wood Based Panels
Keylwerth-Diagramme
The KEYLWERTH-Diagram
how to determine emc
Psychrometertemperatures TDB
and TWB EMC und r.h.
Dry bulb Temperature TDB and
relative humidity r.h. EMC und
TDB = 60 C EMC = 8,7 %

TWB = 50 C r.h. = 58 %
WBT
Note: use of the psychrometer for

determination of r.h. and emc respectively requires an air flow of at
least vL 2 m/s at the wet bulb
thermometer to met the adiabatic
evaporation temperature !
TDB = 25 C EMC = 6,1 %

r.h. = 30 % TWB = 15 C
Wood Based Panels

EMC-Chart
Wood mc-determination EMC-Chart

TDB =
25C
WBD = (TDB-TWB)
= 5C
EMC 11,1 %
63 %
TDB =
60C
WBD =
10C
r.h.
EMC 8,7 %
r.h.
07.05.2008
58 %
46
07.05.2008
47
Overview / Intro
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Particle Drying Ressel Komp

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Center for Wood Sciences

Wood Based Panels

Particle drying dryer types

MOLLIER-h,x-Diagram for humid air

Drying plant components

emc of wood KEYLWERTH-Diagram

Flash tube pre-dryer

Wood Based Panels

Particle drying process - fundamentals

Continuous drying process

Drying parameters ( process parameters)

FSP fibre saturation (point);

Wood Based Panels

Particle drying process - fundamentals

heating up wood particles ( wood substance & water!)

Specific energy consumption is related to 1 kg water removed from wood particles

Initial moisture content [%]

Initial moisture content [%]

Wood Based Panels

Particle drying process - fundamentals

2,69 GJ/m 84,6 %

Electricity 0,49 GJ/m 15,4 %

all figures in % of the total energy consumption

Wood Based Panels

Particle drying process - fundamentals

FAO Energy conservation in the mechanical forest

all figures in % of the total energy consumtion

Wood Based Panels

Particle drying process - basic dryer types

Temp. range Drying time

Rotary bundle dryer

Tube bundle dryer

Flash tube pre-dryer

Jet tube dryer

acc. Deppe, Ernst 2000 / Fig. 3.2-5

Wood Based Panels

Basic drying plant components

Heating systems direct heating indirect heating

Burner for natural gas, oil, dust

Particle movement / particle transport through the dryer

Wood Based Panels

Flash tube pre-dryer Type VT (Buettner 2015)

Flash tube pre-dryer (Buettner 2015)

Wood Based Panels

Flash tube pre-dryer Type VT (Buettner 2013)

Stack / to exhaust gas

Wood Based Panels

Particle / Flake drying

Drum dryer Type NH (Buettner 2013)

10120 t/h (wet material)

Wood Based Panels

Particle / Flake drying

(Flash-Dryer) Pre-dryer and Drum dryer

Wood Based Panels

Particle / Flake drying

(Flash-Dryer) Pre-dryer and Drum dryer

Wood Based Panels

Particle / Flake drying

Drum dryer Type NH without discharge box (Buettner 2013)

Emergency Dry material to

Wood Based Panels

Particle / Flake drying

Drum dryer Type K (Buettner 2013)

Stack / to exhaust gas