Biomass Dryers: Presented by Gencap Technologies Inc. 9/9/2010

2010
Biomass Dryers
Presented By
GenCap Technologies Inc.
9/9/2010
A Comparison of Biomass Dryers 2010

Table of Contents
List of Figures ........................................................................................................... 2
ROTARY DRYERS ..................................................................................................... 3
Companies ............................................................................................................ 3
FLASH DRYERS/PNEUMATIC DRYERS ................................................................... 4
Companies ........................................................................................................... 4
RING DRYERS (modified flash dryer) .................................................................... 5
Companies ........................................................................................................... 5
FLUID BED DRYERS ................................................................................................. 6
Companies ........................................................................................................... 6
SPRAY DRYERS ........................................................................................................ 7
Companies ............................................................................................................ 7
ARTICLES ................................................................................................................. 8
From Operating Ease to Operating Costs: Weighing Differences in DDGS Dryers 8

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List of Figures

Figure 1 GEA Barr-Rosin Flash Dryer ....................................................................... 4

Figure 2 Open system of a Fluid Bed Dryer ........................................................... 6
Figure 3 GEA Niro Spray Dryer diagram .................................................................. 7

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ROTARY DRYER

Purposes
Chemical
Pharmaceutical
Food
Maize germs
Powders
Crystalline materials
Cylinder shell inclined at angle (0-5 degrees)

Function: conveyor and heating device
Lifting flights inside to increase contact with surface area
$122 000 per year to maintain

74.8% capital
25.2% operational
Produce 150 kg/h db dried potato cubes
80-90% of moisture reduced

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Low maintenance
Large volume
Structure
Cost and Output
Advantages
Disadvantages
Can only dry certain volume at a time (not a continuous feed)

o Slow (10-20 minutes residence time)
Cannot dry sludge, wet waste, fine grains, any similar materials
Burns fossil fuel to create heat
Expensive because use of fossil fuel
Only 10-15% of cylindrical volume is filled
High energy consumption, low output
Companies
Whiting Equipment Canada Inc. (Swenson dryers)
Ambient air temp up to 350 degrees F

Direct heat dryer produced hot air- up to 1800 degrees F
143000 PPH water evaporation from 158000 PPH bone dry material
Teaford

P a g e | 3

GEA Barr-Rosin

Evaporate 30-40 tonnes/hour

FLASH DRYERS/PNEUMATIC DRYER

Purposes
Sludge
Wet cakes
Food
Minerals
Chemicals
slurries
Spin flash dryer

o Horizontal agitator disperses mass that comes in contact with heat to dry
Cage Mill flash dryer
o Vertical pin type rotary cages
o Wet mass fed through center for direct heat contact
o Rotation disperses feed while drying
Structure
Cost
Approx. Output of few hundred kg/hour hundreds of tons/hour

Approx temp 500-600 degrees C
0.5-2 seconds of residence time

Cylindrical shape and short time = high volume of mass that can be dried
Ideal for fine grained materials
Not ideal for heat sensitive materials

Only dries surface moisture
Advantages
Disadvantages
Companies
GEA Barr-Rosin
Use of scrubbers to clean exhaust gas to meet

emission requirements
Elevated drying temperature
o Flashes off surface moisture, drying gas is
instantly cooled w/o increasing product
temperature
20+ tons of water evaporation/hour
Inlet air temp 100-650 degree C
Figure 1 GEA Barr-Rosin Flash Dryer

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Airflow can exceed 120 000 cfm (200 000 m3/hour)
Available in carbon steel, stainless steel and other alloys

RING DRYERS (modified flash dryer)

Purposes
Sludge
Food (byproducts)
grains
Materials first heat contact is a flash of heat

Particles pass through rings for further drying (if larger/wet particle, conveyed back to dry again)
Materials are then conveyed to a second chamber column
Heated air is moved through column, drying particles
Particles pass through rings for further drying (if larger/wet particle, conveyed back to dry again)
Thorough and complete drying

Short residence time
o 2 seconds flash dry
o 4 minutes mixing recycle system
Structure
Cost
Advantages
Disadvantages

Many parts to machine and drying process
Companies
GEA Barr-Rosin
Presence of manifold or internal classifier

Centrifugal airstream and adjustable splitter blades move heavier, semi dried material back into
dryer
Lighter dryer continues through conveyor
Selective residence time
150 000cfm (250000 m3/hr)
Natural gas, steam, hot oil, flue gases used to operate

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FLUID BED DRYERS

Purposes
Food
Chemical
Mineral
Polymer
Powders/crystals/granules
Air supplied through perforated distributor plate

Air flow velocity is sufficient to support mass weight
Air turbulence causes materials to become suspended on a cushion of air or gas
Solids behave like boiling liquid
Can hold high volumes

Optimum heat transfer efficiency
Good mixture
o Frequent collisions between
particles allow for
Structure
Cost
Advantages
Disadvantages
Not easily operated with all the

different parts
Companies
Whiting Equipment Canada Inc.
(Swenson dryers)
Stationary and upright

Use of feed chute or screw feeder
Fluidized by gas (nitrogen)
Niro Vibro-Fluidizer
o
Size 300 ft2
Temperature up to 1200 degrees C
High thermal capacity
o ensures accurate temperature control
o uniform heat treatment
90f heat supplied through steam or circulating fluid
o Reduction in airflow = reduction in emission, plant size and operating costs
GEA
Figure 2 Open system of a Fluid Bed Dryer

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SPRAY DRYERS

Purposes
Food
Pharmaceutical
Atomizes a wet solution into drop

lets
Gas/spray mixing chamber
Heated air is sprayed at top of cone-
shaped chamber
o Wet is mixture comes in
contact with heat
o Dried particles gather at
bottom
Structure
Cost
Advantages
evenly and thoroughly dried

particles
Disadvantages
only produces powder solids

requires adequate droplet and
spraying distance

Companies
GEA Filtermat
requires a longer drying time

includes conveyor for second stage
drying
air blows downward
Figure 3 GEA Niro Spray Dryer diagram

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ARTICLES

From Operating Ease to Operating Costs: Weighing

Differences in DDGS Dryers
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Summary:
Operability and Control
Rotary (good)
o continues to run even if there is process problem
Material is too wet, sugar content too high, too much material in machine
o Adjustable temperature for different volumes of mass
Ring (good)
o Small volume of material = Produces better quality product
Rotary (bad)
o Long residence time = long and hard recovery
Especially if volume of mass is high
Ring (bad)
o Short residence time = smaller processing size
Layout
Rotary
o Requires large floor space and concrete foundation, lots of foundation for all part
required
o Not much steel involved
Ring
o Steel structure
o Only fan needs substantial foundation
Material Handling and Recycling Systems
Rotary
o Long conveyor
Dry product deposited on one end, feeder 60-70 feet at other end
Ring
o Short conveyor
Assist of gravity in process
Energy Usage
Rotary
o Large diameter seals under suction = leakage
o Use 5-10% more heat
Electrical Usage

P a g e | 8
Rotary
o Rotation of drum to convey product
Ring
o Conveys pneumatically and at high velocity
Consumes more power
Cost of electrical power is much less

than heat
Maintenance
Rotary
o Mechanical systems on drum and extra conveyors require regular maintenance
Ring
o Only main fan needs maintenance

P a g e | 9

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2010

A Comparison of Biomass Dryers 2010

A Comparison of Biomass Dryers 2010

Figure 1 GEA Barr-Rosin Flash Dryer ....................................................................... 4

A Comparison of Biomass Dryers 2010

Cylinder shell inclined at angle (0-5 degrees)

$122 000 per year to maintain

80-90% of moisture reduced

Cost and Output

Can only dry certain volume at a time (not a continuous feed)

Ambient air temp up to 350 degrees F

A Comparison of Biomass Dryers 2010

Evaporate 30-40 tonnes/hour

Spin flash dryer

Approx. Output of few hundred kg/hour hundreds of tons/hour

0.5-2 seconds of residence time

Not ideal for heat sensitive materials

Use of scrubbers to clean exhaust gas to meet

A Comparison of Biomass Dryers 2010

Airflow can exceed 120 000 cfm (200 000 m3/hour)

Available in carbon steel, stainless steel and other alloys

Whiting Equipment Canada Inc. (Swenson dryers)

RING DRYERS (modified flash dryer)

Materials first heat contact is a flash of heat

Thorough and complete drying

Many parts to machine and drying process

Presence of manifold or internal classifier

A Comparison of Biomass Dryers 2010

Air supplied through perforated distributor plate

Can hold high volumes

Not easily operated with all the

Stationary and upright

Figure 2 Open system of a Fluid Bed Dryer

A Comparison of Biomass Dryers 2010

Atomizes a wet solution into drop

evenly and thoroughly dried

only produces powder solids

requires a longer drying time

Figure 3 GEA Niro Spray Dryer diagram

Whiting Equipment Canada Inc. (Swenson dryers)

A Comparison of Biomass Dryers 2010

From Operating Ease to Operating Costs: Weighing

Operability and Control

Material Handling and Recycling Systems

A Comparison of Biomass Dryers 2010

Cost of electrical power is much less

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