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Study of the performance of the rotary dryer with fluidization

Article · January 2004

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Drying 2004 – Proceedings of the 14th International Drying Symposium (IDS 2004)
São Paulo, Brazil, 22-25 August 2004, vol. C, pp. 1668-1675

STUDY OF THE PERFORMANCE OF THE ROTARY DRYER

WITH FLUIDIZATION

M. H. Lisboa, M.C.Alves, D.S.Vitorino, W.B.Delaiba, J.R.D.Finzer and M.A.S. Barrozo

School of Chemical Engineering, Federal Univerity of Uberlândia, P.O.Box 593, 38400-

902, Fax: 55-34-32394188- Uberlândia-MG, Brazil, email: masbarrozo@ufu.br

Keywords: rotary dryer, fertilizers, fluidization

ABSTRACT

The drying of granulated fertilizers is, most of the times, done industrially in rotary drum
dryers. In this work, the behavior of a non-conventional rotary dryer, called roto-fluidized
dryer, has been studied. A rotary dryer with an internal fluidization system constitutes this
equipment. The purpose of this work is to compare the performance of the roto-fluidized
dryer with the conventional rotary dryer, through drying tests with phosphate fertilizers. An
experimental design has been developed, trying to compare the performance of both dryers
and to study the influence of the air flow rate and temperature, and of the solids flow rate,
relating to the drying behavior. The obtained results showed that, for the same experimen-
tal conditions, the roto-fluidized dryer presented outlet solid temperature, heat transfer
global coefficient and drying rates higher than the conventional equipment.

Key words: drying, roto-fluidized, fertilizers

INTRODUCTION

Last year, the fertilizers sales in Brazil have reached 16.5 million tons. Those sales have increased con-
tinuously, mainly due to more profitable prices of soybean, sugar cane and orange. In 2002, the fertilizers
sales were 20% higher than in 2001. For the current year, it is estimated an increase of 5% (Anda, 2004).
The fertilizers’ drying is done industrially in rotary dryers. They are made of a long cylindrical shell that is
rotated. The shell is usually slightly inclined to the horizontal to induce solids flow from one end of the
dryer to the other. In direct heat rotary dryers, a hot gas flowing through the dryer provides the heat re-
quired for the vaporization of the water. To promote gas–solid contact, most direct heat dryers have
flights, placed parallel along the length of the shell, which lift solids and make them rain across the sec-
tion of the dryer (Revol et al., 2001).

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The air movement through the dryer is influenced by three different mechanisms (Foust et. al., 1982). In
first place, as soon as the drum rotates, each particle is elevated by the flights and then falls from a certain
height. Each fell, the particle advances a certain distance. The solids movement is attributed to the action
of the flights. Besides that, when the particles reach the lower part of the drum, they bounce; some others,
as they hit other particles that have not been raised by the flights, move forward, rolling over one another.
These effects, all together, constitute the “rotary drum action” and they affect significantly the residence
time for a particle in the dryer. Finally, the drying gas, blowing through the dryer, helps or complicates the
advance of the solids, according, respectively, to the concurrent or countercurrent configuration (Sherrit
et. al., 1993).
The amount of wet solids, from the rotary drums, affects the entire operation. A small amount of solids
makes the production insufficient. A very large amount will promote an irregular and incomplete ascend-
ing action, with part of the solids simply rolling in the bottom of the drum. The resulting product will
probably show moisture higher than expected. This fact increases the energy use in this type of dryer
(Keey, 1978).
As general rule, high gas velocities are needed in drum dryers. This way, using this dryer with solids con-
stituted by fine particles will probably result in excessive losses due to the dragging in the gas stream.
Trying to overcome some of the rotary drum limitations, it has been proposed, in this work, a non-
conventional configuration of this equipment: The roto-fluidized dryer. In this dryer, the air is fed in a
central duct, and then distributed to many smaller tubes in direct contact with the solid. The conception of
this non-conventional equipment has had, as motivation, a better fluid-particle contact, provided by the
fluidization system. It increases the heat and mass transfer coefficients and, as a consequence, allowing
the energy consumption reduction.
This way, the purpose of this work was to study the performance of the rotary dryer with fluidization and
to compare it to the conventional rotary dryer, operating in the same experimental conditions.
Due to the large utilization of the rotary dryer in the fertilizer industry, this material has been chosen to be
utilized in the experimental tests.

MATERIALS AND METHODS

Materials

The drying experiments were accomplished with fertilizers (simple super phosphate) from FERTI-
BRAS, located in Uberaba – MG, Brazil.
The solids presented a Sauter diameter of 2 mm, initial moisture of 10.5% (dry basis), specific weight of
1.1 g/cm3 and specific heat of 0.245 kcal/kg ºC.

Experimental Apparatus
The drying experimental apparatus, used in this work, allows the utilization of the two rotary dryer
configurations and the accomplishment of tests in the same operational conditions, in both configurations.
Figure 1 shows an experimental apparatus scheme.
The experimental apparatus, presented in Figure 1, is constituted by a 4-HP blower (1). The air flow rate
was measured by a hot wire anemometer (2). The drying air passed by a 2-meter length duct and 0.2-meter
diameter (3) until it is heated by a system containing electrical resistances (4) linked to a voltage oscillator
(5); finally entering the dryer by a central duct (6) that contains several smaller tubes, which promote the
fluidization (roto-fluidized dryer). The air outlet is done by a metal peace (7) opened in the upper part.
The solid was feed by a storage tank (8), containing an auxiliary flow adjustment system, with a worm
gear in the lower part (9). The solid was withdrawn in the other side of the cylinder, by the lower part of
the metal peace (10). The dry bulb and wet bulb temperatures, in the air inlet and outlet, at the same time

1669
as the solids temperature were measured with the copper-constantan thermocouples linked to a digital
display (11). The diameter of the equipment cylinder was 25 cm and the length was 60 cm.

11
2
1
4

9
3
6
7

10
5

Figure 1 – Experimental apparatus scheme

Figure 2 shows a scheme of the conventional rotary dryer, with a solids flow in countercurrent with
the drying air. Figure 3 shows a rotary dryer with fluidization (roto-fluidized). In the roto-fluidized dryer,
the air is injected through a central tube, linked to many other smaller tubes fixed perpendicularly. The air
from the outlet flow of the smaller tubes reaches the solids flowing in the drum, promoting the “fluidiza-
tion”.
Solid inlet

Air outlet
Air inlet

Solid outlet
Figure 2 – Conventional rotary dryer

Solid inlet

Air outlet

Air inlet

Solid outlet
Figure 3 – Roto-fluidized dryer

1670
Experimental procedure

The experiments were accomplished with the adjustment of the operational variables (air flow rate and
temperature and solids flow rate) in the conditions determined by the experimental design. When the de-
sirable conditions were achieved, it was expected a time equivalent to a two-residence time period of the
solids in the bed to initiate to collect the solids designated to the moisture and temperature measures.
The air temperature, in the inlet and outlet streams of the dryer and the wet bulb temperature were
measured using copper-constantan thermocouple, previously calibrated in thermostatic baths with a stan-
dard thermometer with a 0.05ºC precision. The solid temperature was obtained by calorimetric tech-
niques.
The determination of the relative air humidity was accomplished through the dry and wet bulb tempera-
ture measures, assured by a thermo-hygrometer. The solids moisture was obtained by the stove method
(150±2ºC for 24 hours), once the mass was measured in the 1x10-4g precision digital analytical scale.
The drying air flow rate was measured by a hot wire anemometer. The solids flow rate was obtained by a
periodic sample collected in the outlet flow and measured in the 1x10-2g precision scale.
The probable errors of the variables measurements are listed in Table 1.

Table 1 – Expected deviations of the measurements

Variable Error
Air flow rate 4.0%
Temperature 0.25°C
Solids moisture 1.0%
Solids flow rate 1.0%

Experimental Design
In this wok, a factorial design of experiments in two levels (Box et. al.. 1978) was conducted, aiming
to verify the effects of the air flow rate and temperature, and the solids flow rate, in the solids outlet tem-
perature and drying rate, for both configurations studied in this work. Table 2 presents each variable lev-
els and its respective admensionalization (X).

Table 2 – Experimental conditions of the tests

Variable (unit) level Level

up down
Dimensionless
Flow rate of air, Qf (m3/min) 4,9 6,1
X1 -1 1
Temperature of the air, Tf (oC) 90 110
X2 -1 1
Flow rate of Solids, Gs 0,33 0,67
(Kg/min) X3 -1 1

According to the experimental design used, eight tests (with replicas) have been accomplished for each
dryer configuration. The order of experiments was conducted randomized. In this way, at the end of the
experiments, it was possible to compare the performance of both dryers under the same operational condi-
tions.

1671
 RESULTS

Table 3 presents the experimental results for the outlet solids temperature, in both configurations
studied in this work.

Table 3 – Results for the outlet solids temperature

Exp. Qf Tf Gs Ts(°C) Ts(°C)

3 o Conven- Roto-
m /min C Kg/min
tional fluidized

1 6,1 110 0,67 46,1 74,2

2 4,9 110 0,67 43,7 70,3
3 6,1 90 0,67 42,2 66,4
4 4,9 90 0,67 38,3 65,2
5 6,1 110 0,33 49,8 85,0
6 4,9 110 0,33 44,5 75,8
7 6,1 90 0,33 44,3 72,3
8 4,9 90 0,33 43,2 66,0

It is observed that the results presented in Table 3, which, for the same experimental condition, the outlet
solid temperature in the roto-fluidized dryer is always higher than the outlet temperature of the conven-
tional rotary dryer. The average difference between these temperatures was 28ºC.
The results on the drying rate, defined by the relation between the water removed by the dry solid mass
and by time, are presented in Table 4 for the two rotary dryer configurations. This drying rate has been
calculated through a mass balance done with the conditions of inlet and outlet fluid and solid in the dryer.

Table 4 – Drying rate results

Rate Drying x103
Qf Tf Gs (min-1)
Exp o Conven- Roto-
3
m /min C Kg/min
tiona fluidized
1 6,1 110 0,67 4,93 14,59
2 4,9 110 0,67 3,69 11,88
3 6,1 90 0,67 3,06 10,60
4 4,9 90 0,67 2,92 9,51
5 6,1 110 0,33 5,80 18,41
6 4,9 110 0,33 4,88 16,98
7 6,1 90 0,33 4,20 15,18
8 4,9 90 0,33 3,86 13,49

The results presented in Table 4 show that, for the same operational conditions, the drying rate of the roto-
fluidized dryer was 3 (three) times higher than the conventional rotary dryer.
The results of Tables 3 and 4 confirm the higher heat and mass transfer rates in the roto-fluidized dryer.
As a consequence, it is possible to assume that this dryer has an energy consumption significantly lower

1672
than the conventional configuration. Another consideration to be done is the possibility of operating with
a lower air flow rate in the non-conventional dryer, allowing the use of this equipment to dry finer parti-
cles, which could be dragged in the conventional equipment.
The data presented in Tables 3 and 4 have been analyzed as the response surface technique (Myers, 1976).
Correlations were obtained to predict the drying rates to the conventional dryer (Equation 1) and to the
roto-fluidized dryer (Equation 2), as a function of the air flow rate and temperature, and the solids flow
rate. In these regressions, the Equations 1 and 2 explained 95.4% and 98.9% of the data variability, re-
spectively, (R2=0.954 and 0.989). These regression residues presented a random and normal distribution.
The parameters presented in these equations were those significant in a hypothesis test, using a t-Student,
with maximum probability of error equal to 5%. The remaining parameters, related to the interactions be-
tween the variables, were not significant.

Rateconv = 0,004+0,406X1+0,730X2-0,506X3 (1)

Rateroto = 0,014+0,300X1+0,568X2-0,759X3 (2)

In the Equations 1 and 2, the drying rate is presented in min-1 and the independent variables are placed in
non-dimensional form (Table 2).

When the parameters of Equations 1 and 2 are analyzed, it is observed that there was a decrease in the
values related to the air flow rate and temperature, when passing from the conventional to the roto-
fluidized dryer. It indicates a higher mass and heat transfer efficiency in the new dryer. It is also observed
an increase in the parameter related to the solids flow rate.

The following equation was used to represent the heat transfer in the rotary dryers:

Q = Ua V ∆Tm (3)

where: Q is the total heat transferred (kcal/min), Ua is the global volume coefficient of heat transfer
(kcal/m3minºC), V is the dryer volume (m3) and Tm is the temperature mean logarithmic differences be-
tween the hot air and the solid, considering a countercurrent configuration.
With the temperature measures and the remaining energy balance data, the heat transfer global coefficient
was calculated for each test done in both types of the dryers studied.
From the results obtained for Ua, this parameter was correlated to the variables studied. According to
Friedman and Marshall (1949), the global heat transfer coefficient in the rotary dryers may be expressed
by correlations such as:

Ua = K Gsa Gf n
(4)

Where: Gs and Gf are the solid and fluid mass flows, respectively. K, a and n are parameters.

Table 5 presents the results of the parameter estimation of Equation 4, for both dryers studied (Ua in
kcal/ºCmin m3, Gf and Gs in kg/min).
In the non-linear regressions to estimate the parameters of Equation 4 for both types of dryers, it was ob-
served that Equation 4 explained around 70% of the data variability. The residues were random and nor-
mally distributed.

1673
Table 5 – Parameters of Equation 4 for each type of dryer

Parameters Conventional Roto-

of Eq. 4 Fluidized

K 10,87 25,30
a 0,19 0,25
n 0,68 0,29

Figures 4 and 5 presented the relation between the values obtained for Ua from the experimental data and
those predicted by Equation 4, for the conventional and for the roto-fluidized dryer, respectively.
It is observed that, from the data presented in Figures 4 and 5, the values of Ua for the roto-fluidized dryer
were around 50% higher than those obtained in the conventional rotary dryer. This result confirms the ex-
pectation of a thermal exchange, more efficient in the non-conventional dryer, allowing a considerable
energy economy in the drying industrial processes, which use this kind of equipment.

45
Ua (kcal/C min m3) experimental - conventional

40

35

30

25

20

15
15 20 25 30 35 40 45
Ua (kcal/C min m3) predicted by the eq. 4

Figure 4 – Relation between Ua experimental and predicted by Equation 4 for the conventional dryer.

45
Ua (kcal/C min m3) experimental- roto-fluidized

40

35

30

25

20

15
15 20 25 30 35 40 45
Ua (kcal/C min m3) predicted by the eq. 4

Figure 5 – Relation between Ua experimental and predicted by Equation 4 for the roto-fluidized dryer.

1674
 CONCLUSIONS

Through the results obtained in this work, it was possible to conclude that the roto-fluidized dryer pre-
sented higher heat and mass transfer rates, than the conventional rotary dryer.
For the operational conditions studied, the drying rate was 3 times higher in the new equipment, and the
final solid temperature was around 28ºC above the obtained value for the conventional dryer. The global
heat transfer coefficient obtained for the roto-fluidized dryer was around 50% higher than the one related
to the conventional dryer.
Empirical equations were obtained for the drying rate estimation, as a function of the air flow rate and
temperature, and the solids flow rate, as well as the global heat transfer coefficient, relating to the air and
solids flow rate. These correlations were fitted for the roto-fluidized dryer and for the conventional rotary
dryer data.
Through the results obtained in this study, it was concluded that the roto-fluidized dryer has an energy
consumption significantly lower than the conventional configuration. The new equipment also allows the
operation of with a lower air flow, allowing its application in the drying of particles, finer than the usually
used, which could be dragged in the conventional rotary dryer.

REFERENCES

Anda (2004), Associação Nacional para Difusão de Adubos, www.anda.org.br,

Box, M. J., Hunter, W. G. and Hunter, J. S. (1978), Statistics for Experimenters. An Introduction to De-
sign, Data Analysis, and Model Building. John Wiley and Sons, New York.

Foust, A. S. et al. (1982), Princípios das Operações Unitárias, Guanabara Dois, Rio de Janeiro.

Friedman, S.J. and Marshal, W.R. (1949), Chemical Eng. Progr., 45, pp. 482-573.

Keey, R.B. (1978), Introduction to Industrial Drying Operations, Pergamon Press, Oxford.

Myers, R.H. (1976), Response Surface Methodology,Ann Arbor, Mich.: Edwards Brothers .

Sherrit, R.G., Caple, R., Behie, L.A. and Mehrotra, A.K. (1993), Movement of Solids Through Flighted
Rotating Drums, Journal of Chemical Engineering, Vol. 71, N. 3, pp. 337-346.

Revol, D., Briens, C.L. and Chabagno, J.M. (2001), The design of flights in rotary dryers, Powder Tech-
nology, 121, pp. 230–238

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