BAHIR DAR INSTITUTE OF TECHNOLOGY

FACULTY OF CHEMICAL AND FOOD ENGINEERING

DEPARTMENT OF CHEMICAL ENGINEERING IN SUGAR STREAM
ADVANCED SUGAR THECNOLOGY AND APPARATUS DESIGN II
ASSIGNMENT - DRYING
NAME OF STUDENTS ID NO.
1. ARAGAW MISGIE BDU 1315054
2. LAMI GUTU BDU 1315061
3. ZEWELDI TEKA BDU 1315062
. 4. BERHANU BALTA BDU 1315055
SUBMITED TO: Dr. MULUGETA A.
 Presentation outline

❖ Introduction
❖ Types of dryer Mr. ARAGAW MISGIE

❖ Drying mechanisms
❖ Dryer selection

❖ Standard Specification of dryer Mr. LAMI GUTU

❖ Dryer design and size

❖ Dryer operation
❖ Basic parameters for maximum efficiency Ks. ZEWELDI TEKA

❖ Dust collector
❖ Advantage and Disadvantages of dryer
❖ Trouble shooting Mr. BERHANU BALTA

❖ Conclusion
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 Introduction

➢ Drying is the final unit operation in the production of sugar.

➢ Drying is a process of removal of a liquid from a material by the applications of heat and is accomplished by
the transfer of a liquid from a surface into unsaturated vapor phase.

➢ Drying is governed by the principles of heat and mass transfer.

➢ Sugar dryer provides heated air in counter flow to a sugar stream to drive the moisture out of the sugar to the
desired level. A dryer consists of a drying section followed by a cooling section.
➢ Factories having capacities less than 5000 TCD are generally using multi tray hopper with hot and cold air
blower, but factories having capacity more than 5000TCD are using Fluidized bed type driers for effective
drying of sugar.

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 Types of Dryer
➢ Dryers may be classified according to the following categories:
1. Method of operation:
A. Continuous dryer
Where the feed material is continuously flowing though a dryer without stopping.
❖ Rotary Cascade direct or indirect dryers
❖ Fluidized bed dryer
❖ Spray dryers
❖ Continuous tunnel dryers
❖ Pneumatic dryers
❖ Flash dryer

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Rotary Cascade dryer :

➢ The Cascade dryer is largely utilized in the sugar industry.

➢ It has a rotating drum mounted at a small angle with the horizontal with drier designed to pick up the sugar and
drop it from top to bottom all along the dryer, uniformly spread.

➢ Due to the inclination with the horizontal, sugar travels down the length of the dryer to the exit point.

➢ Warm (heated) air is drawn in to travel counter-current to the falling sugar and is exhausted at the end of the dryer.

➢ Used as sugar coolers by eliminating the air heater or even employing an air chiller.

➢ In fact, drying will certainly take place in both the dryer and the cooler, but due to both the higher initial sugar
moisture and the higher temperature operation, that share of the moisture removal will take place in the dryer.

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Fluidized Bed Dryers:

✓ The purpose of FBD to dry & cool the sugar received from the hopper.
✓ The fluidized bed dryer separated into two compartments by a perforated plate containing gas distribution nozzles.

✓ Part of the lower compartment (wind box) receives hot air for drying , which is produced by a steam heat exchanger
mounted in the main fluidizing air duct. The other section of the wind box receives cold air.

✓ Sugar from centrifugal is fed into the upper compartment expansion chamber at the desired feed rate and forms a
bed about 300 mm deep in the perforated plate, where the hot air passing through the plate fluids the sugar while
drying it.

✓ The nozzles in the perforated plate are specially designed to distribute air evenly through the sugar and keep it
uniformly fluidized.
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✓ In the fluidized condition, sugar behaves like a liquid and flows out through the dryer discharge outlet, where the
discharge rate is controlled by means of a vibrating feed.

✓ Waste gases leave the dryer at the top of the expansion chamber and pass to the dust catcher or collectors.

➢ Now days two types of fluidized bed driers are in practice

1. Static fluidized bed drier, in which, tray remains static, both fluidization and shifting of sugar takes place with
air. E.g. Finchaa

2. Moving fluidized bed drier, in this type of drier tray is vibrating and sugar is fluidized by air.
Shifting/transporting of sugar takes place due to vibrating tray. E.g. Omo 2

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 Cont.…
11 1.Exhaust Hood
2.Cyclone Tank
3.I.D Fan
4.Hot Air Blower
5.Heat Exchanger
6.Primary Tank
4
7.Cold Air Blower
1 8.Centrifugal pumps
5
2
9.Drive Motor not seen
3
10.Feed & Discharge
6 Tray
8 10
11.Dust Duct collector
7

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 Cont.….
B. Batch dryer
Batch drying is a system at which a certain volume of grain is being dried at a time.
➢ Tray or shelf dryers
➢ Vacuum dryer
➢ Freeze dryer
➢ Microwave dryer
➢ Agitating dryers
➢ Turbo-shelf dryers
➢ Disc dryers
Tray dryer is the most common types of batch dryers.
✓ The dried product is spread thinly on the shelves dryers.
✓ Heating can be derived from the air flow across the tray, or the conduction from the heating tray, or radiation
from a hot surface, but generally by convection with the flow of hot air.
Under tray dryer air flow either
• Cross circulation
• Through circulation Sub 8/18/2022
 Cont. …..

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 Cont.……..

2. Method of energy supply

❖ Energy input may be supplied by the following ❖Moisture output comes out by the following
➢ Conduction ways

➢ Convection ➢ Vapor diffusion

➢ Radiation ➢ Surface diffusion

➢ Combination of above methods ➢ Combination of above

✓ Most of the dryers are the convection type with direct combustion gases or hot air as the drying
medium because water is the most common solvent removed in dryers

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3. Physical properties of material

➢ The design of the dryer is greatly influenced by the properties of the feed.
4. Conveyance
➢ The physical state of the feed dictates the method of conveyance of the material through the dryer.
5. Cost
When capacity is large enough, continuous dryers are more expensive than batch unit.
6. Special process features
Special characteristics of the drying material together with particular features of the product is carefully considered
in classifying of dryer and selection of dryer type.
• Hazardous
• heat sensitive
• quality sensitive products

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 Drying Mechanisms
The sugar discharged from centrifugal has basically two types of Moistures.
1) Inherent Moisture: is the water occluded within the crystal.
2) Surface Moisture: is the water on crystal surface and also known as free moisture.

Safety factor - A number designed to indicate the probable keeping quality of a fresh sugar having a pol of less than
99.00 Z0
As a guideline in preventing deterioration, sugar should be dried to below a threshold a moisture as determined by a
ratio known as the Safety Factor SF:

Safety factor SF = Moisture % Sugar

100 - Pol % Sugar

To keep the sugar satisfactorily, SF  0.23

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Dilution indicator ( DI ) – A factor used to predict the keeping quality of sugar, being the ratio of the moisture to the
solid non-sugars expressed as a percentage and calculated as follow.

DI = moisture % x 100
100 – (pol% + moisture%)

➢ If dilution indicator(DI) is less than 40% safety zone

➢ If dilution indicator (DI) 40 to 50 % doubtful zone
➢ If dilution indicator (DI) is greater than 50% zone of deterioration.
➢ Sugar of 98.5 Z0 Pol is generally dried to between 0.2 – 0.5 % moisture, and very high Pol sugar of 99.3 Z0 Pol to
less than 0.18 %. Refined sugar is dried to between 0.02 – 0.03 % moisture.

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 Dryer Selection

➢ The choice of the best type of dryer to use for a particular application is generally dictated by the following
factors:
a) Space requirements;
b) The nature of the vapor, (toxicity, flammability);
c) The nature of the solid, (flammability, dust explosion hazard, toxicity).
d) Size & density
e) Moisture content to be dried
f) Material handling
g) Production requirements
h) Efficiency & cost.
i) Temperature and pressure in the dryer
j) The means by which moist material is transported through the dryer

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k) Any mechanical aids aimed at improving drying

l) The method by which the air is circulated
m) The way in which the moist material is supported
n) The nature of the wet feed and the way it is introduced into the dryer
o) The nature of the product, both physical and chemical;
p) The value of the product;
q) The scale of production;
r) The available heating media;
s) The product quality consideration;

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 Standard Specification of Dryer

✓ Shell diameter……………………………….. 0.3 – 3m

✓ Length diameter …………………………….. 4 – 15D
✓ Shell speed ………………………………….. 4 – 5 rpm
✓ Radial flight height …………………………. D/12 – D/8
✓ The flight count per circle ………………….. 2.4 – 3D
✓ Inclination of the shell to the horizontal ……… up to 8cm/m
✓ Mass flow rate of the drying gas ……………… 1500 – 25000 Kg/h.m^2
✓ No. of heat transfer units in the dryer (NT) ……… 1.5 – 2
✓ Average solid retention time ………………………5 min – 2 h
✓ Drying capacity …………………………................6.4 – 40 kg moisture/h.m^3

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For Finchaa sugar industry dryer specification shows

✓ Capacity …………………………………………. 40 t/h dry sugar
✓ Length …………………………………………..... 15.24 m [ 11m drying zone , 4.24m cooling zone]
✓ Diameter ………………………………………….. 2743.2mm
✓ Inclination …………………………………………. 1.79 degree
✓ Rotational speed …………………………………….7.9 rpm
✓ Retention time ………………………………………11 min
✓ Sugar feed condition ……………………………..…2% moisture content, 57.2 ℃
✓ Sugar discharge condition …………………………. 0.04% moisture content, 40 ℃
✓ Steam condition …………………………............... 650 kpa, 230 ℃
✓ Maximum steam consumption …………………….. 2300 kg/h
✓ ID fan speed ……………………………………….. 1349 rpm
✓ Dust catcher capacity ………………………………. 200 kg/h dust sugar

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 Design and Sizing

Rotary dryer
➢ The holdup of a rotary drier varies with the feed rate, the number of flights, the shell diameter and the air
rate.
A correlation for sugar holdup as a percentage of drier volume (for zero air flow) gives:

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 Cont.…..

the correlation arranged to calculate residence time as:

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Design of Drying system
q

Mass and energy balance

𝑚ሶ 𝑎 = air flow rate, Kg dry air/h
𝑚ሶ 𝑝 = product flow rate, Kg dry solids/h
W = absolute humidity, Kg water/Kg dry air
w = product moisture content, dry basis (Kg water/Kg dry solids)
q = energy loss in the drying system
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Mass balance
𝑚ሶ 𝑎 W2 + 𝑚ሶ 𝑝 w1 = 𝑚ሶ 𝑎 W1 + 𝑚ሶ 𝑝 w2

Energy balance
𝑚ሶ 𝑎 Ha2 + 𝑚ሶ 𝑝 Hp1 = 𝑚ሶ 𝑎 Ha1 + 𝑚ሶ 𝑝 Hp2 + q
Ha = Cs (Ta – To) + WHL
Cs = 1.005 + 1.88 W
Hp = Cp(p)(Tp – To) + wCp(w)(Tp – To)
Ha = thermal energy of air KJ/Kg dry air
Hp = thermal energy of product KJ/Kg dry solids
Cp(p) = specific heat of product
Cp(w) = specific heat of water
Cs = humid heat air
q = energy loss from the drying system
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➢ The drying stages of sugar :

1. constant rate stage:
✓ Due to understanding film of syrup exists on the crystal surface, and evaporation occurs at nearly constant rate.
2. Falling-rate stage:
✓ As the surface film becomes more concentrated due to moisture loss, evaporation is slowed by the influence of the
solutes, mainly sucrose.

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 Drier Operation

➢ In all drier types, performance depends on:

✓ Air flow rate (or more accurately, ratio), temperature, and relative humidity

✓ Sugar quality (including moisture content) and temperature

✓ Retention time

➢ Retention time may be varied in different ways, depending on the drier type:

✓ In fluidized-bed units, by adjusting the bed height

✓ In rotary drum units by adjusting the speed or adjusting the bed depth (modifying
the outlet ring weir)

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Operational Parameters

➢ Hot air temperature ………………………………...... 65 – 75 ℃

➢ Cold Ambient air temperature ……………………….. 30 - 35 ℃
➢ Inlet sugar moisture …………………………………. 1 - 2%
➢ Outlet sugar moisture content ………………………. 0.03% - 0.04%
➢ Feed temperature of sugar …………………………… 50 - 55 ℃
➢ Discharge sugar temperature ………………………… 30 - 40 ℃
➢ Normal sugar crystal size ……………………………. 0.6 - 1 mm
➢ Hot air heating media(steam) pressure ……………….. 4kg/cm2 (bar)
➢ Hot air heating media(steam) temperature …………… 140 – 160 ℃
➢ Handling capacity …………………………………….. 30 – 70 TPH

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 Basic Parameters for Maximum Efficiency
1. Draught
➢ It should be a negative pressure(5mmHg) in the exhaust hood at a height of 1.5 m form the sugar bed.
➢ The damper for FD&ID fan to be adjusted
➢ Sugar layer 4 to 5 inches entering the system
2. Air temperature for drying the sugar
➢ Temperature can be set 75℃ to 80 ℃ but if greater than 90 ℃ it leads to charring of sugar.
➢ Evaporation rate of moisture is directly proportional to the temperature of air in the given ambient condition.
➢ The input air temperature and quantity depend upon the output sugar moisture from the dryer.
➢ It operates automatically.
3. Air temperature for cooling the sugar
➢ Input air quantity depend on the output sugar temperature from the dryer, sugar input temperature and ambient
temperature
➢ Out put temperature of sugar is in the range of 42 to 45 ℃
4. Dust collection
➢ The FBD ensure reduction in generation of dust by gentle treatment sugar crystal, preventing crystal abrasion and
inter collision
5. Layer formation
➢ Directly affect the drying and cooling of the sugar in the FBD system
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 Dust Collectors
➢ The exhausted air from a sugar dryer is always contaminated by sugar dust. Dust collators are used to separate the sugar dust
from the air.

(I ) Dry Air Separator

➢ In dry air section, the sugar dust is separated from the air in a “Cyclone Separator”. The sugar dust collected can be used for
seeding purposes or sold as powdered sugar.

➢ Dry air collectors are simple in design but are less efficient than wet air separators.

(ii) Wet Air Separator

➢ In the wet air separators, a spray of water is used to trap the sugar dust.

➢ The sweet water can be recycled until a desired Brix is reached.

➢ This type of dust separator is very efficient but care should be taken to keep the systems clean and free of fermentation (the Brix
is generally maintained at 150).

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General the dust collectors are used for various purpose
➢ To avoid air pollution
➢ To avoid health hazard and ensure safety in industry
➢ To improve product quality
➢ To recover a valuable productive
➢ To collect product it self as dust

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 Advantage of Rotary Dryer
A rotary drum as sugar dryer has several advantages both mechanically as well as process wise:
• A robust and an uncomplicated process
• Non sticky behavior
• Efficient use of energy
• Available in stainless steel
• Ideal for bulk flows with variance in feed stock
• Rotary dryers are less sensitive to particle size.
• It can accept the highest flue gasses of any type of dryer.
• Low maintenance cost; thus economical.

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 Disadvantages of Rotary Dryer

➢ A rotary requires a large area, which is difficult to get in built-up/urban areas.

➢ pay more attention to check and maintain rotary drum dryer before operating.

➢ The driers is damage that may be done to crystals by the tumbling motion. There is unavoidably or at least

scratching, of the crystal surfaces in this type of drier, causing some loss of the or "luster" of the crystals and a

amount of dust formation.

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 Advantages of FBD
• Intimate contact of hot air and solids result in high heat transfer co-efficient. This makes the drying system compact
• Unique and thermally efficient design of embedded heat exchanger
• No Moving parts, stabilized operation and negligible maintenance
• Moisture reduction from 1.0% to 0.03-0.05%
• Sugar temperature is close to wet bulb temperature of air. This allows gentle drying without Caramelization of
sugar
• The gentle drying and cooling process brings an excellent product quality
• Efficient dust catching system

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 Disadvantages of FBD

➢ An reduction of strength may takes place between the particle resulting in the production of fine particles.
➢ many organize powders develop electrostatic charges during drying to avoid this efficient electrical grounding of
the dryer is essential.

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 Trouble shooting
Sr.no Problem(s) Probable reason(s) Remedy(ies)

1 Lumps formation in ➢ Grid plate holes are chocked ➢ Clean grid plate
Chamber ➢ excess moisture in wet sugar ➢ Check and set right
➢ Shortage of hot air ➢ Check ID fan and route resistance

2 Vibration in ID fan ➢ Disturbed alignment ➢ Check and align

➢ Dust deposition on blades ➢ clean blades

3 ID draft is poor ➢ Sugar dust solution level in wet dust ➢ Check and set right
collector is high ➢ clean it
➢ Chocking in ducts ➢ check supply voltage
➢ Fan rpm is low ➢ Belt tightening condition, if not directly connected

4 Air temperature not ➢ Steam pressure & temp is low ➢ maintain design pressure
increasing ➢ Condensate is not released properly
➢ Scaling of tubes (4bar line not coated) ➢ Release condensate

➢ Clean heater tubes

5 Moist sugar ➢ Excess under size sugar crystals (false ➢ Removing unwanted crystals during boiling
grain) ➢ Maintain desired steam pressure & temperature
➢ Low steam temperature & pressure

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 Conclusion

➢ Drying is a very energy intensive activity, thus it is important for drying to reduce energy consumption, in order
to save cost and decrease carbon footprint.

➢ The rapid transfer of heat and mass in the drying operation often leads to changes of product quality, such as
puffing, shrinkage and other physical. With out drying the type of product chemical and biochemical reactions
occur, which may or may not be desirable; these usually involve changes in color, odor and texture.

➢ Drying of sugar is necessary in most cases for two reasons:

1. To achieve the required handling characteristics of the sugar, i.e. to ensure that it becomes and remains
free-flowing and has the physical and aesthetic qualities demanded by the market.

2. To reduce the likelihood of loss of sucrose or color formation via microbiological or chemical
degradation.

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