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FORCED DRAFT TRAY DRYER

INTRODUCTION:

Drying a solid means the removal of relatively small amounts of water or other liquid from
the solid material to reduce the content of residual liquid to an acceptable low value. Drying
is usually the final step in series of operations, and the product from a dryer is often ready for
final packaging.

Water or other liquids may be removed from solids mechanically by presses or centrifuges or
thermally by vaporization. This manual is restricted to drying by thermal vaporization. It is
generally cheaper to reduce the liquid content as much as practicable before feeding the
material to a heated dryer.

The liquid content of a dried substance varies from product to product; occasionally the
product contains no liquid and is called bone – dry. More commonly, the product does
contain some liquid. Dried table salt, for example, contains about 0.5 % water, dried coal
about 4 %, and dried casein about 8 %. Drying is a relatively term and means merely that
there is a reduction in liquid content from an initial value to some acceptable final value.

The solid to be dried may be in many different forms – flakes, granules, crystals, powders,
slabs, or continuous sheet – and may have widely differing properties. The liquid to be
vaporized may be on the surface of the solid, as in drying salt crystals; it may be entirely
inside the solid, as in solvent removal from a sheet of polymer; or it may be partly outside
and partly inside. The feed to some dryers is a liquid in which the solid is suspended as
particles or is in solution. The dried product may be able to stand rough handling and a very
hot environment or it may require gentle treatment at low or moderate temperatures.
Consequently a multitude of types of dryers are on the market for commercial drying. They
differ chiefly in the way the solids are moved through the drying zone and in the way heat is
transferred.

CLASSIFICATION OF DRYERS:

There is no simple way of classifying drying

equipments. Drying equipment can be
classified according to the following design
and operating features:

1. Batch or Continuous
2. Physical state of the feed: liquid,
slurry, and wet solid.
3. Method of conveyance of the solid:
belt, rotary, fluidized.
4. Heating system: conduction, Figure – 1: Simple Batch Dryer
convection, radiation.

Except foe a few specialized applications, hot air is used as the heating and mass transfer
medium in industrial dryers. The air may be directly heated by the products of combustion of

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the fuel used (oil, gas, or coal) or indirectly heated, usually by banks of steam heated finned
tubes. The heated air is usually propelled through the dryer by electrically driven fans.

Batch dryers are normally used for small – scale production and where the drying cycle is
likely to be long. Continuous dryers requires less labor, less floor space; and produce a more
uniform quality product.

When the feed is solids, it is important to present the material to the dryer in a form that will
produce a bed of solids with an open, porous, structure.

For pastes and slurries, some form of pretreatment equipment will normally be needed, such
as extruction or granulation.

The main factors to be considered when selecting a dryer are:

1. Feed condition: solid, liquid, paste, powder, crystals

2. Feed concentration, the initial liquid content
3. Product specification: dryness required, physical form
4. Throughput required
5. Heat sensitivity of the product
6. Nature of the vapor: toxicity, flammability
7. Nature of the solid: flammability (dust explosion hazard), toxicity.

The basic types used in chemical process industries are: tray, band, rotary, fluidized,
pneumatic, drum and spray dryers.

When wet sample is placed in contact with air, water evaporates from its surface and diffuses
as vapor through the air film that covers the surface. The concentration of moisture at the
surface is decreased, a concentration difference is setup and moisture then diffuses from the
interior to the surface of the slab or it moves to the surface as rapidly as it can vaporize from
the surface, the rate of drying is independent of the moisture content of the slab and is
constant providing that the air velocity, temperature and humidity do not change.

During this constant rate period the rate of drying is controlled by the rate of vapor diffusion
through the air film and is, therefore, dependent upon the humidity difference across the film
and the thickness of the film.

However, when the moisture content becomes less than a certain value known as the critical
moisture content, moisture can no longer move to the surface as rapidly as it could be
vaporized from the surface. The drying rate begins to fall and continues to fall with
decreasing moisture content until the equilibrium moisture content is reached and no further
drying is possible under the particular drying conditions.

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TERMS USED IN DRYING - DEFINITIONS:

 MOISTURE CONTENT, WET BASIS:

The moisture content of a solid or solution is usually described in terms of weight percent
moisture, and unless otherwise qualified this is ordinarily understood to be expressed on
the wet basis, i.e. as
(kg moisture / kg wet solid) 100 = [(kg dry solid + kg moisture)] 100 = 100 X / (1+X).

 MOISTURE CONTENT, DRY BASIS:

This is expressed as kg moisture / kg dry solid = X.
Percentage moisture, dry basis = 100 X.

 EQUILIBRIUM MOISTURE X*:

This is the moisture content of a substance when at equilibrium with a given partial
pressure of the vapor.

 BOUND MOISTURE:
This refers to the moisture contained by a substance, which exerts an equilibrium vapor
pressure less that of the pure liquid at the same temperature.

 UNBOUND MOISTURE:
This refers to the moisture contained by a substance, which exerts an equilibrium vapor
pressure equal to that of the pure liquid at the same temperature.

 FREE MOISTURE:
Free moisture is that moisture contained by a substance in excess of the equilibrium
moisture: X – X*. Only free moisture can be evaporated, and free – moisture content of a
solid depends upon the vapor concentration in the gas.
Relative Humidity of Gas

Equilibrium Moisture
Curve
1.0

Bound Unbound
Moisture Moisture

Equilibrium
Moisture Free Moisture

0 X* X
Moisture
FORCED DRAFTContent,
TRAY kgDRAYER
moisture / kg dry solid

Figure – 2: Types of Moisture

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THEORY OF DRYING:

There are various modes of drying a material in various types of dryers. In the present
experiment, we study the cross – circulation drying in an adiabatic or direct dryer. In this
case, hot gas (air) is blown over a bed of wet solid (brick particles wetted with water) under
constant drying conditions by maintaining the temperature, humidity and the velocity of the
air across the drying surface constant. A drying curve is then obtained by plotting drying rate
against moisture content of the solid. In drying, it is necessary to remove free moisture from
the surface and also moisture from the interior of the material. Thus there is interplay of the
surface evaporation, inter - -particle and intra – diffusion processes during the drying of a
material. This gives rise to several distinct periods in the drying curve as the moisture content
of the solid is reduced from the high value to its final value, as given below:

Period – I0:
An initial period during which the drying rate may increase or decrease rapidly drom an
initial value and the drying conditions are adjusting themselves to the steady state condition,
which is the next period. This period is of relatively short duration and in some experiments
may be unobservable. Therefore, this period is neglected in the mathematical analysis of the
process.

Period – I:
An early stage of drying during which drying rate remains constant value, that is, is
independent of thye moisture content. This period may be absent if the initial moisture
content of the solid is less than a certain minimum.

Period – II:
During this period, the drying rate decreases more or less linearly with continued decreases of
water content.

Period – III:
This stage immediately follows period – II but is not always clearly distinguishable from it.
The drying rate in this zone decreases further, but generally in a non - -linear fashion with the
moisture content.

The moisture content at which the drying rate falls for the first time is the first critical
moisture content, and the moisture content at which the drying rate falls, for the second time
is the second critical moisture content. In case of non – porous solid, due to the absence of
intra – particle moisture and hence intra - particle diffusion, the constant - rate period is
followed by only one falling rate – period. So that there is only one critical moisture content.

Drying continues until equilibrium moisture content in the solid is attained. Nature of the
drying curve depends on the nature of the solid (porous / non – porous), and the temperature,
humidity and flowrate of the drying medium.

During the constant rate period, the rate of drying can be expressed by the following
equation.
dW / d = KgA (pa - pg) (1)

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Where,
dW/ d = Rate of diffusion, kg/ hr
Kg = Film coefficient of diffusion, kg / hr m2 atmosphere
A = Area of drying surface, m2
pg = Partial pressure of water vapor in the air atmosphere
pa = Partial pressure of saturated air at the water air interface

Since H = 18 p / (29 * (1 - p))

Where H = Humidity kg water / kg dry air

p = Partial Pressure, atm
18, 29 mol. wt. of water and air respectively

H  (18 / 29) p

Then (1) may be written,

dW / d = KgA (Ha - Hg)

The drying time during the falling rate period can be calculated from the general diffusion
equation
dW / d = - Dg A dC/ dX
Where,
Dg = Diffusivity of water in air
C = Concentration of moisture subject to diffusion in wt. Per unit volume

When the experimental drying curve is available, the time required to dry a slab from one
moisture content to another during the falling rate period can be calculated by graphically
integrating the equation

f F
W 1 dF
0 d  
A F2 f ( F )
f

Where,
f = time of drying, hr
W = weight of dry solid, kg
A = drying area, m2
F1 = free moisture content at the beginning of drying period, kg water/ kg dry solid
F2 = free moisture content at the end of drying period
f(F) = ordinate of the drying rate curve where free moisture content is F kg/ kg dry
solid

The total time of during tT, is determined from the following equation:

ms  Xc 
tT   X 1  X c   X c ln 
A * Rc  X2 
Where,
ms = mass of bone – dry solid

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A = area of drying
Rc = rate at first critical point
X = free moisture content, mass of water per unit mass of dry solid
Xc = free – moisture content at first critical point
X1 = initial free moisture content
X2 = final free moisture content

Inderiving the above equation, the entire falling rate period is assumed to be adequately
represented by a singe straight line passing through the origin of the drying curve.

Free moisture content, X, is given by

X = XT = X*

Where,
XT = total free – moisture content
X* = equilibrium free – moisture content

The equilibrium moisture content of a non – porous insoluble material is practically zero so
that the whole moisture content is free moisture.

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AIM:

To find the rate of drying for given porous / nonporous material.

UTILITY:

230 v AC power supply, dryer assembly, water, brick particles ( or sand or CaCO 3 powder),
physical balance,

DESCRIPTION OF APPARATUS WITH TECHNICAL SPECIFICATIONS:

The equipment consists of a drying chamber (400*300*300 mm), MS insulated with glass
wool (25 mm thick) and cladded with SS sheet in which tray rack (SS, Nonmagnetic,
rustproof) & tray (1 Nos., SS (Nonmagnetic, Rustproof) is to be hanged. The drying chamber
is provided with toughened glass door and handle.

Hot air to the drying chamber is drawn with the help of a blower (1 FHP) and before entering
it is heated by 6 kW heaters of Nichrome wire (input to the heaters could be vary with the
help of controller). Flow control valve is provided for varying the Flowrate of air through the
heating chamber.

Wet and Dry bulb thermocouples types are mounted at either ends of the drying chamber to
measure the humidity of the entering and leaving air. Wet bulb thermocouple is provided with
proper water storage facility in the back portion.

The loss of moisture shall from the material to be dried is continuously monitored with the
help of an electronic balance (1 kg cap.  1 gm accuracy, LED display, 230 V AC power
supply) and is to be mounted directly over the heating chamber.

The control panel consists of Digital Temperature Controller, Temperature Indicator, On/ Off
starter switch for blower and MCB for heater with Indictor lamps (mains) & fuse. Space for
manometer mounting,

PROCEDURE:

1. Switch on the power supply to the unit and press the ON/OFF key provided on the
digital weighing scale. The scale will indicate the weight of the trays and tray cage.
Press TARE switch.
2. Open the drying chamber and take out the tray. Measure the surface area of the trays.
3. Prepare the sample whose drying characteristics are to be determined by taking about
2-3 kg of material (usually fine sand) and adding about 10 % of solvent (usually
water).
4. Fill the tray and spread the material evenly throughout the cross section of the tray.
5. Fill the bulb provided on the back of the tray dryer with water upto topmost level to
provide continuous water (wetting agent) to the wick of wet bulb thermocouples
provided at either ends of the drying chamber.
6. Connect the respective tappings to the Manometer,

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7. Switch ON the blower and adjust the predetermined flow rate of air using the flow
control valve. When a steady state is reached, record the manometer reading
calculates the flowrate of air.
8. Switch ON the heater. Adjust the temperature of air by using digital temperature
controller provided for heater on control panel.
9. After achieving a fairly high & stable temperature note down the decrease in weight
displayed on the digital weighing scale after an interval of 5 minutes. Also note down
the wet & dry bulb temperatures of air entering and leaving the drying chamber on
digital temperature indicator.
10. After certain time no loss of weight is observed for prolonged period of time, switch
OFF the heaters as well as weighing scale. Take out the trays after it is cooled.
11. Switch OFF the Blower. Remove the sample from the trays and clean them with the
help of cotton cloth first and then with water. Allow them to get sun dried. Also clean
the drying chamber with the cotton cloth, if there is any spillage of material while
operation.
12. Repeat the experiment by either varying the flow rate for the same sample or take
different sample with the same conditions of air flow rate and compare them with the
initial results.

Setting of Drying Chamber Temperature by Digital Temperature Controller:

 Press SET key for 2 seconds.

 You are in SET MODE.
 Display 1 will show SEt.
 Display 2 will indicate current value of set point.
 You can change current value of set point by following PROCEDURE.
 Increase the parameter by  key.
 Decrease the parameter by  key.
 Press ENT key to store it in memory or press SET key for next step.
If no key is pressed for 5 seconds previous value of parameter is retained and controller goes
in control mode.

PRECAUTION:
 Never run the equipment without blower ON for more than 1 minute, immediately
after switching on the MCB provided for the heaters, switch ON the blower.
 While shutting down the tray dryer, we need to keep the blower on to cool down the
drying chamber and heaters so as to minimize the damage to the heaters and drying
chamber.
OBSERVATIONS:

Cross sectional area of the trays = m2

Drying Chamber Temperature = C

Weight of the material (fine sand) taken = gm (1)

Weight of the solvent (water) added = gm (2)

Total initial weight of the sample = gm (1) + (2)

Density of Air Air = 1 kg/m 3


Density of Manometric Fluid M = 1000 kg/m3

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OBSERVATION TABLE:

Time Wt. Loss in Inlet Air Temp. Outlet Air Temp.

Indicated weight of
Sr.
on the Material (C) (C)
No.
LED
(min) (Gram) (Gram) Dry Wet Dry Wet

CALCULATION:

 Manometer Reading = Ho = h1 – h2
= _____________ mm

Area of orifice =AO =12mm=(3.14/4)*(0.012)2 m =1.1304 * 10 -4 m2

Cd = 0.64

Q
COEFFICIENT OF DISCHARGE = Cd  = Q = kg/m3
A0 2gH 0

 Velocity of Fluid at the Orifice (V) = Q / AO

= ______________ m/s

Air flow rate over the trays
= Air velocity over the trays * C/s area of the dryer

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=

Loss in weight with time
= (Wt. of the sample at the time of previous reading – Wt. of the sample at given time)
=
= ___________

Plot the weight of the sample against time. Graphically differentiate this curve (draw
tangents to the points of interest and find their slopes) to obtain the drying rate.

dw Free
Time Wt. of  w w
d Drying Free Water
sample 
gm . Rate Water
Sr. No () (w)
min gm/ hr gm/ gm
gm
(from m2 gm dry
min gm min gm min
plot) stock
(1) (2) (3) (4) (5) (6) (7) (8) (9)


Free water content (gm / gm dry stock)
= (Wt. Sample - wt. of dry material) /wt. of dry material
=
= ___________

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
Plot the drying rates (column (7)) against the free water content (column (9)) & also
drying rates (column (7)) against time () (column (1)).

Drying coefficient during the constant rate period:

dw  1 
Kg’ =  
Ad  Hw  Hg 

Where,
dw/ Ad = Drying rate, gm water evaporated per hour per cm2
Kg’ = Drying coefficient, gm water evaporated per hr per cm2 per unit humidity
difference
Hw = Saturation humidity of air at the wet bulb temperature, gm water per gm
dry air
Hg = Humidity of the drying air, gm water per gm dry air

The humidity diff. (Hw - Hg) is calculated from the eqn. = 0.26 (tg - tw) / w

tg = Dry bulb temperature, C (average value)

tw = Wet bulb temperature, C (average value)
w = Latent heat of evaporation of water at tw

OBSERVATIONS:

Cross sectional area of the trays = 0.0968 m2

Drying Chamber Temperature = 53 C

Weight of the material (fine sand) taken = 500 gm (1)

Weight of the solvent (water) added = 500 gm (2)

Total initial weight of the sample =1000 gm (1) + (2)

Density of Air Air = 1.29 kg/m 3

OBSERVATION TABLE:

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Time Wt. Loss in Inlet Air Temp. Outlet Air Temp.

Indicated weight of
Sr.
on the Material (C) (C)
No.
LED
(min) (Gram) (Gram) Dry Wet Dry Wet
5 2126 21 48.6 44.3 48.1
58.9
10 2105 14 54 38.1 50.5
53.7
15 2091 13.5 55 38.2 51.1
54.2
20 2077.5 14.5 54.3 37.2 50.8
53.9
25 2063 15 54.6 36.7 51
54.2
30 2048 15 55.2 38.1 54.3 51.4

CALCULATION:
Velocity of air: 4.2 m/sec.


Air flow rate over the trays
= Air velocity over the trays * C/s area of the dryer
= 4.2*0.0968
= 0.406 m3/sec

Loss in weight with time
= (Wt. of the sample at the time of previous reading – Wt. of the sample at given time)
= (2126-2105)
= 21

Plot the weight of the sample against time. Graphically differentiate this curve (draw
tangents to the points of interest and find their slopes) to obtain the drying rat

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dw Free
Time Wt. of  w w
d Drying Free Water
sample 
gm . Rate Water
Sr. No () (w) time Wg.
min gm/ hr gm/ gm
gm
(from m2 gm dry
min gm min gm min
plot) stock
(1) (2) (3) (4) (5) (6) (7) (8) (9)

4.8
1 5 2126 5 21 4.2 41.6 27.4
4
2 5 2105 5 14 2.8 34.6 24.6
4
3 5 2091 5 13.5 2.7 34.6 16.6
3.5
4 5 2077.5 5 14.5 2.9 30.3 16.3
3.2
5 5 2063 5 15 1.5 27.7 17.8
2.6
6 5 2048 5 15 1.5 22.5 18.8

7 5 2033 5 15 1.5 2.5 21.6 19.2


Free water content (gm / gm dry stock)
= (Wt. Sample - wt. of dry material) /wt. of dry material
= (2126-2105)/2105
= 0.0099

Plot the drying rates (column (7)) against the free water content (column (9)) & also
drying rates (column (7)) against time () (column (1)).

Drying coefficient during the constant rate period:

dw  1 
Kg’ =  
Ad  Hw  Hg 

Where, Kg’= 216.66

dw/ Ad = Drying rate, gm water evaporated per hour per cm2
Kg’ = Drying coefficient, gm water evaporated per hr per cm2 per unit humidity
difference
Hw = Saturation humidity of air at the wet bulb temperature, gm water per gm
dry air
Hg = Humidity of the drying air, gm water per gm dry air

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The humidity diff. (Hw - Hg) is calculated from the eqn. = 0.26 (td - tw) / w
=0.26*(58.9-48.1)/2260
=0.0012
tg = Dry bulb temperature, C (average value)
tw = Wet bulb temperature, C (average value)
w = Latent heat of evaporation of water at tw

RESULT:

CONCLUSION:

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