DESIGN, FABRICATION AND PERFORMANCE

EVALUATION OF MULTIPURPOSE DRYER

(ROOM HEATER)
Submitted to

Department of Mechanical Engineering

G.B Pant University of Agriculture and Technology

Pantnagar-263145, Uttarakhand, India

Submitted by

Kalpana Pandey (50698)

Abhishek Singh (50703)

Sakshi Khetwal (50720)

Pinki (52326)

Guided by

Dr. Neeraj Bisht

Assistant Professor, Department of Mechanical Engineering
FOR THE DEGREE OF

BACHELOR OF TECHNOLOGY

(MECHANICAL ENGINEERING)

25th July 2020

 ACKNOWLEDGEMENT
The completion of any project depends upon the co-operation, coordination, and combined
efforts of several resources of acknowledging inspiration, and energy.

We would like to express our heartfelt gratitude and regards to the people, who would be directly
or indirectly responsible for the completion of this dissertation work.

We would like to express our deep reuse of profound gratitude towards our esteemed guide Mr.
Neeraj Bisht, Department of Mechanical Engineering, College of Technology, for providing
invaluable suggestions and enthusiastic encouragement, who also gave us innovative ideas and
guidance throughout this dissertation work. The discussion held with him has brought this work in
this present shape.

Finally, we express our gratitude towards one and all those who helped us in achieving the final
stage of this dissertation work.

Kalpana Pandey (50698)

Abhishek Singh (50703)

Sakshi Khetwal (50720)

Pinki (52326)
 CERTIFICATE

This is to certify that the project work entitled “Design, Fabrication and Performance
Analysis of Multipurpose Dryer And Room Heater” which is submitted by:

Name Id. No.

Kalpana Pandey ID-50698

Abhishek Singh ID-50703
Sakshi Khetwal ID-50720
Pinky ID-52326

Is a record of a students work carried by them in partial fulfilment of requirements for the award of
degree of Bachelor of Technology in the Department of Mechanical Engineering, College of Technology,
G.B. Pant University of Agriculture and Technology, Pantnagar.

PANTNAGAR (Prof. Neeraj Bisht)

Date: 21 July 2020 Project Guide
Design, Fabrication and Performance Analysis of Multipurpose Dryer(Room Heater)

ABSTRACT

This report focuses on the Design, Fabrication, and Performance evaluation of Multipurpose
Dryer(Room heater). Based on the preliminary investigation under controlled conditions of drying
experiments, a forced convection dryer to be used exclusively to dry agricultural products and
domestic purposes (laundry), was constructed. The design was done in Solidworks while analysis
was performed using ANSYS FLUENT. The analysis was done to analyze temperature
distribution, pressure, airflow, and kinetic turbulence in the system at various temperatures
ranging from 40°C, 50°C and 60°C. At 40°C, 50°C and 60°C the average temperature
distribution in the system are 33.2365°C, 42.8425°C, and 52.7850°C. The fan speed was kept
constant at 26m/s throughout the analysis, the average air velocity within the cabin remained
1.96517 m/s while exhaust air velocity was also constant at 48.7444 m/s. The maximum air
pressure in the system was found to be 6453.32 Pa.

Department of Mechanical Engineering4 | P a g e

Design, Fabrication and Performance Analysis of Multipurpose Dryer(Room Heater)

Table Of Content
1. Introduction
1.1. Need Of Multipurpose Drying and Room Heating
2. Methodology
2.1. Forced Convection
2.1.1. Mechanism Of Force Convection
2.2. Description Of Dryer
2.2.1. Material Selection
2.2.1.1. Mild Steel
2.2.1.1.1. Properties
2.2.1.2. Insulating Material
2.2.1.3. Industrial Paint
2.3. Design
2.3.1. Layers
2.3.1.1. Outside Layer
2.3.1.2. Insulating Woolen Fiber
2.3.1.3. Inside Wall For Collecting Condensate
2.3.2. Thermocouple
2.3.3. Temperature Controller
2.3.4. Need For Thermocouple and Temperature
3. Design And Development
4. Performance Evaluation and Application
4.1. ANSYS Analysis
4.2. Application
4.3. Cost Evaluation
5. Conclusion
6. References

Department of Mechanical Engineering5 | P a g e

Design, Fabrication and Performance Analysis of Multipurpose Dryer(Room Heater)

List Of Figures

2.3. Designs

2.3(a) CAD Wireframe Model

2.4(b) CAD Model Depicting Inside Layers

2.4. Thermocouple Wires

3. Solidworks Model Of Dryer Exposing The Inside Without Trays

4.1. Pictorial View Of The Temperature

4.2. Pictorial View Of Air Velocities

4.3. Temperature Profile In Symmetry Of Cabin

4.4. Pressure Profile In Cabin

Department of Mechanical Engineering6 | P a g e

Design, Fabrication and Performance Analysis of Multipurpose Dryer(Room Heater)

Chapter 1

INTRODUCTION

Drying is an essential operation having commercial importance in almost all industrial areas,
as drying is one of the most energy-intensive operations in the industry. A variety of dryers are
available with specific purposes like cloth drying, drying of edibles like grains and fruits. Dryers
consist of a rotating drum through which heated air is circulated to evaporate the moisture, while
the drum is rotated to maintain air space between the articles. Using these machines may cause
clothes to shrink or lose softness. A simpler non-rotating machine may be used for delicate fabrics
and other agricultural products not suitable for rotating dryers.

1.1. NEED OF MULTIPURPOSE DRYER (WITH ROOM HEATING)

Though there are many dryers and room heaters available in the market, they all have specific
purposes. Like crop and clothes, dryers are solely used for crop and clothes drying only and the
room heater only provides heat inside the room. So for different purposes, different machines are
required which increases the cost and occupies more space. Thus, a multipurpose model is
proposed which can perform all these work efficiently and effectively. This can run on solar as
well as direct electricity as per the availability. It has a simple construction and is easy to fabricate.
It operates without any noise. Also, instead of a motor unit, four coils at the bottom will be used.
These heating coils are very much efficient than a motor unit. This is because 1hr consumption of
a clothes dryer motor will consume 4kWh while 4 heating coils will use only .32kWh. It can dry
various items more quickly and provide heating inside the room by its exhaust gas simultaneously.
This drying technique can also be used for the preservation of agricultural, food products such as
fruits vegetables, medicinal plants, etc for a longer period while maintaining their nutritional value.

Department of Mechanical Engineering7 | P a g e

Design, Fabrication and Performance Analysis of Multipurpose Dryer(Room Heater)

CHAPTER 2

METHODOLOGY

2.1. Forced Convection

It is a special type of heat transfer in which fluids are forced to move, to increase the heat
transfer. This forcing can be done with a ceiling fan, a pump, a suction device, or other. people
are familiar with the statement that "heat rises". This is a simplification of the idea that hot fluids
are almost always less dense than the same fluid when cold, but there are exceptions (see the layers
of the atmosphere and thermohaline circulation for exceptions).

This difference in density makes hotter material naturally end up on top of cooler material due to
the higher buoyancy of the hotter material.

Natural Convection can create a noticeable difference in temperature within a home. Often this
becomes places where certain parts of the house are warmer and certain parts are cooler.

Forced convection creates a more uniform and therefore comfortable temperature throughout the
entire home.

2.1.1. Mechanism of Forced Convection

Convection is a complex heat transfer method, but can be expressed by Newton's Law of
Heating and Cooling: which simply says that the rate of convection heat transfer, expressed in the
units is proportional to the difference between the initial temperature of the material (t1) and the
final temperature of the material (t2) through a proportionality constant. The rate of heat transfer
is also strongly dependent on the roughness and shape of the material being heated. Newton's Law
of Heating and Cooling changes depending on whether or not the convection is forced. For natural
cooling, the value is equal to a certain number. However, by forcing convection and pushing heated
or cooled air from one place to another one can change this proportionality constant and heat or
cool an object more quickly.

Department of Mechanical Engineering8 | P a g e

Design, Fabrication and Performance Analysis of Multipurpose Dryer(Room Heater)

2.2. Description Of The Dryer

The multipurpose dryer is a batch convective dryer using heated air as the drying medium and
operating in batch-wise mode. The dryer is a direct heat tray-type achieving heat exchange through
direct contact between the hot air and the material to be dried. The dryer is designed to operate
under an adiabatic condition. The gas/solid contacting pattern in the dryer is parallel flow in which
the direction of airflow is parallel to the surface of the yam bed. Contacting is primarily at the
interface between the air phase and yam bed, with possibly some penetration of air into the voids
among the sliced yam near the surface. The yam bed is in a static (stationary) condition. The
multipurpose dryer has a metal frame structure that holds the four trays in position. The design is
so flexible that it can be operated by one person. The dryer dimensions are 1.0 × 0.6 × 1.2 (m). It
is fabricated from a metal sheet and the inside is made of composite material with an insulator
made of fiberglass of thickness 20mm.

2.2.1. MATERIAL SELECTION

I. MILD STEEL

The outer frame of the model will be fabricated with mild steel which consists of iron
alloyed with less than 0.3% carbon, mostly between 0.1 to 0.25%. The building industry frequently
uses mild steel in construction because of its ductility and malleability. Mild steel plates are made
by using high-grade raw material which provides them properties like resistance from corrosion
and high durability. These mild steel plates are available in various sizes in the market.

I.I PROPERTIES OF MILD STEEL

1. High strength due to the low amount of carbon present.

2. High resistance to breakage.

3. Provides corrosion resistance.

4. Rust free.

5. Long life.

Department of Mechanical Engineering9 | P a g e

Design, Fabrication and Performance Analysis of Multipurpose Dryer(Room Heater)

6. Abrasion resistant.

II. INSULATING MATERIAL

Thermal insulation is based on the use of substances with very low thermal conductivity and
low surface emissivity. These materials are known as insulation materials. Common insulation
materials are wool, fiberglass, rock wool, polystyrene, polyurethane, and goose feather etc. These
materials are very poor conductors of heat and are therefore good thermal insulators. It is important
to note that the factors influencing performance may vary over time as material ages or
environmental conditions change. In all types of thermal insulation, evacuation of the air in the
void space will further reduce the overall thermal conductivity of the insulator.

III. INDUSTRIAL PAINT

Ordinary paint when applied at the inner walls of the dryer can burn at such a high temperature
but industrial paint, on the other hand, doesn’t burn at a very high temperature of about 700C.
Solar drying refers to a technique that utilizes solar radiation to convert it into thermal energy
required for drying purposes. To reduce the amount of direct electricity being used, we can also
connect it with the solar panel to make use of solar energy for drying the clothes.

Department of Mechanical Engineering10 | P a g e

Design, Fabrication and Performance Analysis of Multipurpose Dryer(Room Heater)

2.3. DESIGN:

2.3.1 Layers Inside The Dryer

This dryer has one box having a size of about 1.0*0.6*1.2 (m) approximately. This consists of
4 heating coils at the bottom, with an exhaust fan at the top

Figure 2.3(a)CAD wireframe model

This model consists of 3 layers:

I. OUTSIDE LAYER This layer is made up of mild steel, which will protect the device from
breakage by imparting strength to the model.

II. INSULATING FIBRE SHEET

This layer is used to provide insulation to the device to prevent any heat loss to the surroundings,
thus making it more efficient.

III. INSIDE WALL FOR COLLECTING CONDENSATE

These walls are used for collecting condensate from the sidewalls and the roof, inside the box.

Department of Mechanical Engineering11 | P a g e

Design, Fabrication and Performance Analysis of Multipurpose Dryer(Room Heater)

Figure 2.3.(b )CAD model Depicting inside layers

2.3.2. Thermocouple :

The basic principle- A Thermocouple is a sensor used to measure temperature.

Thermocouples consist of two wire legs made from different metals. The wires' legs are welded
together at one end, creating a junction. This is the junction where the temperature is measured.
When the junction experiences a change in temperature, a voltage is created. The voltage can then
be interpreted using thermocouple reference tables to calculate the temperature. Types- There are
many types of thermocouples, each with its unique characteristics in terms of temperature range,
durability, vibration resistance, chemical resistance, and application compatibility. The most
common types of thermocouples are J, K, T, & E. They are “Base Metal” thermocouples. Type R,
S, and B thermocouples are “Noble Metal” thermocouples, which are used in high-temperature
applications In this project type K Thermocouple is used due to the following reasons-

1. Inexpensive

2. Accurate

3. Reliable

4. Wide Temperature Range

Department of Mechanical Engineering12 | P a g e

Design, Fabrication and Performance Analysis of Multipurpose Dryer(Room Heater)

Figure 2.4 Thermocouple wires

Thermocouple grade wire- –454 to 2,300oF (–270 to 1260oC)

Extension wire- 32 to 392oF (0 to 200oC) Accuracy- Standard: +/- 2.2oC or +/- .75% Special
Limits of Error: +/- 1.1oC or 0.4%

2.3.3. Temperature controller:

A temperature controller is a device that is used to control the temperature. The role of the
temperature controller is to measure the temperature on the thermocouple, compare it to the
setpoint, and to calculate the amount of time the heater should remain switched on to maintain a
constant temperature.

Figure 2.5 Thermocouple in use with Temperature Controller

Department of Mechanical Engineering13 | P a g e

Design, Fabrication and Performance Analysis of Multipurpose Dryer(Room Heater)

2.3.4. Need for thermocouple and temperature controller :

Since this dryer is used for multipurpose, so we require to regulate the temperature according
to the object being placed inside the box. This is achieved by connecting one end of the controller
to the thermocouple and the other to the heating element. Then, first, it measures the temperature
(process variable) and then compares it to the desired value (set value). The difference between
these values is known as the error (Deviation). Temperature controllers use this error to decide
how much heating or cooling is required to bring the process temperature back to the desired value.
Once this calculation is complete the controller will produce an output signal that effects the
change required. This output signal is known as the (manipulated value) and is normally connected
to a heater "final control element" which injects or removes heat from the process. Thus, with the
help of a temperature controller temperature inside the box can be set by giving input with the help
of buttons provided below the controller screen. This will prevent the objects from overheating
and make the dryer user friendly.

Department of Mechanical Engineering14 | P a g e

Design, Fabrication and Performance Analysis of Multipurpose Dryer(Room Heater)

CHAPTER 3

DESIGN AND DEVELOPMENT

The Cabin dryer was modeled in Solidworks and imported to ANSYS 14.0 for the analysis.
ANSYS Fluent was used for the Computational Fluid Dynamic (CFD) analysis. The inlet
temperature of 40 oC, 50 oC, and 60oC of air at the inlet and constant air velocity of 26m/s was
used, the minimum and maximum air temperature distribution in the cabin were monitored, also
investigated are the exhaust temperature and air velocity at various air inlet temperature.

Figure 3: Solid works model of the dryer exposing the inside without the trays

The above figure is showing the picture of the model if fabricated according to the given design.
With the help of trays, space is available for putting the items inside the box to be dried. Generally
in the market, individual devices are available for particular drying items, but with the help of this
proposed model, different types of items can be dried in a single device.

Department of Mechanical Engineering15 | P a g e

Design, Fabrication and Performance Analysis of Multipurpose Dryer(Room Heater)

CHAPTER 4

Performance Evaluation and Application

4.1. ANSYS Analysis

Table1: parameters temp, fan speed(rpm)

Drying Min. Max. Avg. Fan speed Air velocity Exhaust air Exhaust
temperature tempt in tempt in Tempt. in cabin velocity air
0 cabin cabin In-cabin Tempt
40 25.1900 41.2830 33.2365 26.00 1.96517 48.7444 39.205
50 34.4180 51.2670 42.8425 26.00 1.96517 48.7444
60 44.2010 61.3690 52.7850 26.00 1.96517 48.7444 59.267

80 Temperatures Comparison
60

40

20

0
CFD at 40 deg CFDat 50 deg CFD at 60 deg

Drying Temp Min. Temp Max. Temp Exh. Air Temp

Figure4.1: Pictorial View of the Temperatures

Department of Mechanical Engineering16 | P a g e

Design, Fabrication and Performance Analysis of Multipurpose Dryer(Room Heater)

Ve 60 Comparison of Air Velocities

loc 50

ity 40

(m 30

/s) 20
10
0
CFD at 40 deg CFD at 50 deg CFD at 60 deg
Fan Speed Cabin Air Vel Exhaust Air Vel

Figure4.2: Pictorial View of the Air Velocities

This analysis shows that when the inlet temperature of the air is 60 oC and the control is set at 60
o
C the minimum and maximum temperature in the system are 44.2010 oC and 61.3690 oC with an
average of 52.7850 oC. At 50 oC inlet air and set temperature the minimum and maximum
obtainable are 34.4180 oC and 51.267 oC with the average air temperature distribution of 42.8425
o
C in the system. While at 40 oC inlet and set temperature the minimum temperature in the system
is 25.19 oC and a maximum of 41.283 oC with an air temperature distribution in the system of
33.2365 oC. In this investigation the fan speed was kept constant at 26 m3/s, the velocity within
the cabin remained 1.96517 m/s, and the air velocity at 48.744 m/s. The exhaust air temperature
increases correspondingly as shown

Table4.2. Pressure, Turbulence, Air velocity showing the stable flow

Drying Pressure Pressure Air velocity Min. Turbulence Max. Turbulence

temperature Min. max. (Pa) in K.E Kinetic Energy
(Pa) Cabin (J/kg) (J/kg)
(m/s)

40 6430.72 6453.32 1.96517 1.20784 42.2994

50 6430.72 6453.32 1.96517 1.20784 42.2994
60 6430.72 6453.32 1.96517 1.20784 42.2994
The lower the magnitude of the turbulence and kinetic energy the more stable the flow. The
maximum value obtained during simulation is 42.2994 J/kg which indicates that the flow is in
stable condition. The higher the turbulence, the greater will be the calorific loss inside the
device.The minimum and maximum pressure in the system are 6430.72 Pa and 6453.32 Pa.

Department of Mechanical Engineering17 | P a g e

Design, Fabrication and Performance Analysis of Multipurpose Dryer(Room Heater)

Figure 4.3: Temperature Profile in Symmetry of the Cabin

Figure 4.4:Pressure profile in the cabin

The temperature is evenly distributed in the cabin due to the strategic location of the fans. The
fans run continuously even if the automatic control switch off the air heater due to the

Department of Mechanical Engineering18 | P a g e

Design, Fabrication and Performance Analysis of Multipurpose Dryer(Room Heater)

temperature set. The pressure distribution in the system is shown in figure 4 above. The
maximum air pressure in the system is 6453.32 Pa.

4.2. APPLICATIONS:
Open sun-drying is a traditional drying method but the disadvantages outweigh the advantages of
this method. With non-conductive or inclement weather and the restriction of drying to day time
being prime disadvantages, it is essentially a very gradual and delicate process. Mechanical drying
on the other hand is an ingenious and very effective method to dry agricultural products as well as
clothes.

A multipurpose dryer along with drying of seeds and room heating purposes can also be utilized
for various domestic purposes. It can also be used for numerous applications in industries such as
textiles, food, fruits, and food processing papers, pharmaceuticals, and agro-industries. As the hot
air passes over agricultural products in the chamber, the drying process takes place.

Thus it will prevent (or inhibit) the growth and activity of micro-organisms and hence preserve the
food to reduce the weight and bulk of food for cheaper transport and storage. When carried out
correctly, the nutritional quality, color, flavor, and texture of re-hydrated dried foods are only
slightly less than fresh food. However, if drying is carried out incorrectly there is a greater loss of
nutritional and eating qualities and, more seriously, risk of microbial spoilage and possibly even
food poisoning.

Department of Mechanical Engineering19 | P a g e

Design, Fabrication and Performance Analysis of Multipurpose Dryer(Room Heater)

4.3 Cost expenditure

S.no. Part Qty. Cost Net Cost
( per Rs.
Piece)
1. Mild Steel 10kg 40/kg 400
2. Insulating material 2 990 1980
3. Industrial paint 1 340/lt. 340
4. Heating Coils 4 850 3400
5. Exhaust fan 1 1000 1000
6. Temperature controller 1 560 560
7. Thermocouple 1 300 300
8. Switch 4 90 360
9. Others 1000 1000
Total 9340

4.3.1. Running cost(of heating coils)

load=320 watt.

Running hours per day= 3hours Daily consumption

= 3 X 320= 960 watt hour or .96 Kwh

Rate per unit= 3 Rs.

Daily Cost =.96x3=Rs2.88

Department of Mechanical Engineering20 | P a g e

Design, Fabrication and Performance Analysis of Multipurpose Dryer(Room Heater)

CHAPTER 5

Conclusion

The computational fluid dynamic (CFD) analysis for the tray dryer system is
presented. The air distribution was even and adequate at the design fan speed as
shown by the CFD which also translated to even and adequate temperature
distribution within the system. The maximum pressure in the system is 6453.32 Pa.
The pressure in the system is only affected by the air velocity and temperature
changes do not affect the pressure build upon the system. The temperature of the
outlet air is slightly lower than the cabin inside the temperature. The moisture
removed was substantial and significant showing our design is promising.

Economically sound farmers capable of moderate investments can choose dryers

according to their requirements. To encourage small and marginal farmers to use
dryers it is necessary to develop a more simple, effective, and economically forced
convection dryer which gives rise to the possibility of a better future.

Department of Mechanical Engineering21 | P a g e

Design, Fabrication and Performance Analysis of Multipurpose Dryer(Room Heater)

REFERENCES

1. Thoruwa, T.F.N., Johnstone, M.C., Grant, A.D., Smith, J.E., 2000. Novel, Low Cost CaCl2
based dessicants for solar crop drying applications. Vol.19, pp.,513-520
2. Basey. M.W. 1989, Development and use of solar drying technologies, Nigerian journal of
solar energy 89:133-64
3. Madhlopa, A.; Jones, S.A.; and Kalenga-Saka, J.D. 2002. A solar air heater with composite
absorber systems for food dehydration system. Renewable energy 27:27-37.
4. https://en.wikipedia.org/wiki/Grain_drying
5. https://www.coulton.com/Temperature_Controller.html
6. https://www.google.com/search?q=temperature+range+for+storing+different+grains&oq=tem
perature+range+for+storing+different+grains&aqs=chrome..69i57.19907j1j7&sourceid=chro
me&ie=UTF-8
7. Bin Xia and Da-Wen Sun, 2002. Applications of computational fluid dynamics (CFD) in the
food industry: a review. 2002 Elsevier Science B.V. PII: S0168-1699(01)00177-6
8. Süfer O., (Nov, 2014). An Emergent Technology for Modelling Drying: Computational Fluid
Dynamics (Cfd). 2nd International Congress on Food Technology; November 05-07, 2014
9. Cristiana B. M. et al (March, 2012). Simulation of The Airflow Inside A Hybrid Dryer.
International Journal of Recent Research and Applied Studies. Vol 10 Issue 3.
10. Shahab A. et al, 2011. Fruit drying process: Analysis, modeling and simulation. Scientific
Research and Essays Vol. 6(23), pp. 4915-4924, 16 October, 2011.
11. Marian V. et al, 2014. Prediction of Air Flow and Temperature Profiles inside Convective
Solar Dryer

Department of Mechanical Engineering22 | P a g e