MOISTURE CONTROL OF COUNTER CURRENT FLOW DRYERS

Dr. D. E. Ventzas1
Professor of TEI Lamia
Control & Instrument Eng.

ABSTRACT: The paper presents a counter current

flow rotary dryer model for heat transfer and for humidity
control; dryer state variables functions and relations are given.
Control algorithms such as single or multiple control variables
and conventional or model-based and intelligent control
schemes are investigated. Simulation results are given.

KEYWORDS: Dryer, moisture, control, quality

model, turbulence, simulation.

INTRODUCTION: Drying and humidifying processes present a variety of

types (rotary, with fins and fluidized beds) that correspond to the control and
mechanical solutions, with or without moving parts (Milg K. M, 1964, Barber, M, et al,
1995, Brook, R.C, 1987, Wedel, G. L, et al, 1987).
A counter current rotary dryer consists of a heater, a stationary compartment
with its material feed and its sealing, the dryer with the cage, the dryer drive motor, a
hopper, a cyclone as dust collector, a fan unit, the discharge unit with an exhaust fan
and the material discharge exit, see fig. 1.
The paper presents the modeling, operation and control of a counter current
flow dryer and the case of moisture control. It takes into account variable drying
conditions and test control strategies(Morey, R.V, et al, 1979, Stroshine, R, et al 1992).

DRYER MODEL: Theoretical study of dryers is difficult, so the overall unit

drying efficiency and quality is derived experimentally (Allen R, et al, 1994), see fig. 2, 3,
4; combination of drying units and techniques (Lynch, B.E, 1989) results in higher
efficiency and minimal start-up time, under a wide range of drying conditions and
materials (Courtois F, et al, 1991). Heat transfer in rotary dryers is related to a power of
0.8 of the air mass velocity (Mykelestad, O, 1972). Heat and mass transfer relations are:

Uv  0.52. G 0.8 N Nu  0.2. N Re 0.83 where,

Uv = volumetric heat transfer [kcal/hr.m3.oC]

G = air mass velocity [kg/hr.m2]
NNu = Nusselt number NRe = Reynolds number

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D. E. Ventzas, Analipseos 124, Volos 382 21, Greece, Fax: 30-421 - 69787- E-mail:[email protected]

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 a. external view b. operational diagrams
Fig. 1. Rotary-linear dryer - cooler (longitudinal installation)

kg/hr mA
160 9

140 8 15%

120 7 12%

100 6 10%

80 5 9%
8%
60 4 7%
6%
40 sand mass flow [kg/hr] = 5%
= 18.2 * control signal + 18.0 2
20

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0 1 2 3 4 5 6 7 0 1 2 3 4 5 6
7
control signal [mA] sand control signal
[mA]
a. sand flow (vibration screw feeder) b. percentage moisture curves
Fig. 2. System parameters

volumetric coefficient
of heat transfer [kcal/hr.m 3.oC] time in dryer [min]
750

700 30

650

600

550 20

500

450

400 10
4000 5000 6000 7000 8000 9000 4000 6000 8000
mass air velocity (kg/hr.m 2) mass air velocity (kg/hr.m 2)
Fig. 3. Relations between dryer operating variables (Vikas Saksena, et al, 1997)

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air temperature [oC] solid moisture [%]

50 35

45 30

40 25

35 20

30 15
16 24 32 40 0 0.5 1.0 1.5 2.0
solid moisture [%] traveling length in dryer [m]

Fig. 4. Relations between dryer operating variables

Air out air in

dv

Solids in solids out

l dl
Fig. 5. Counter current rotary drying

The moisture as a function of dryer length, see fig. 5, is:

 k .U v . A  b  t s   k .U v . A  
X  X i . exp  . l  . exp  . l  1 where,
 . F  k   . F  
X = solids moisture at distance l from feed entrance [ kg/kg ]
Xi = solids moisture at distance feed entrance [ kg/kg ]
Uv = volumetric heat transfer coefficient [ kcal/hr.m3.oC ]
ts = solids temperature ta = air temperature
l = distance ta = k.X + b
F = feed rate [ kg/hr ] λ = latent heat at ts
[ kcal/kg ]
In case of multiple pass dryers higher efficiencies are possible.
There is a strong coupling between quality and drying models; models
complexity is simplified by equations assumptions, while model based control prevents
from quality degradation (destruction of fibers structures, etc).
The dryer measurements are:
1. drying medium temperature 2. cooling medium temperature
3. temperature / humidity of processesd material at the input / output
4. drum rotating speed 5. product quality
6. drying /cooling medium mass/velocity 7. turbulence
8. drying material particle size 9. tilt and oscillation frequency
10. operating monitoring (fans, collectors, etc)
The rotating drum has a length of 4 * D (D= drum diameter) ; apart of the
drum’s inclination there is also the drum’s tilt (left-to-right motion); during material
passage along the drum’s, the tilt and the varying width of the material under drying,

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optimizes the overall drying / cooling. Drum’s construction materials are stainless steel
for sewage, aluminium for erosion strength, Monel for further resistance. The rotating
mechanisms are chains with minimum service requirements. In fin dryers the transfer
efficiencies of 200 BTU / hr / sq.ft / o F in a total surface of 10 ¸ 15 m2 have been
measured. Sometimes the processed material is enriched by salts in inert atmosphere.
The dryers with fins are vulnerable to corrosion in sewage treatment, while cooling is
achieved by water mixed or heat exchangers.
Fluidization results in fluids like materilas, that present properties similar with
the fluids; suitable air flow velocity achieves optimal fluidization and drying, under
mild turbulence and for suitable flue gas temperature; excess turbulence leads to non
economic pumping operating characteristics of the system. Minimal drying material
loss, is achieved by a cyclone for material accumulation.
Due to high temperatures, local operators protection barriers are needed. Short
drying time and low drying temperatures avoid material thermal shock. Industrial
drying examples, are sugar drying at 38 ο C, municipal wastes and lignite drying.

DRYER CONTROL: Α model-based moisture sensing and control algorithm

(Maier, D.E, et al, 1994) and the differential temperature method for dryer control
senses and controls moisture inside dryers(Mittal, G.S, et al, 1981), are considered. The
influence of design parameters and operating conditions and parameters (global,
intermediate and local), including control laws on the products qualities are examined.
For continuous dryers it is based on the mathematical model:

M = K1 . ΔT . p - K2 / S . q where,

M = product moisture
ΔT = temperature drop of hot air after contact with the wet product
S = production rate or dryer speed
K1 ,K2 = constants unique to a system and product
p, q = exponents unique to a system and product
Dryers are continuous, semi-continuous or batch; for batch dryers, dryer speed is
converted to drying time, Δt, and the model becomes:

M = K1 . ΔT . p - K3 . Δt . r

The differential temperature method (Moreira, R.G, et al, 1992) uses only two
temperature probes for sensing moisture inside-the-dryer, resulting in unit energy
savings by automatically adjusting the hot side temperature to an idle when there is no
product in the dryer. By automatically adjusting the hot side temperature with varying
incoming moisture the differential temperature method also narrows the moisture
content distribution (quality improvement), thus eliminating overdrying. The energy
savings could reach 35% reduction in fuel consumption per ton of dry product (Watson,
S. B, 1997).
Drying control operation presents various types of dryer control schemes
(Ventzas, 1997) and should be able to handle temperature and relative humidity control
in various types of dryers, initiating typical procedures for starting up and shutting
down a dryer. Dryer is an excellent example for research and training in control theory
state de-coupling.
Single-loop controller does not automatically adjust the heat to save energy, it
is unable to adjust heat when product is absent (or changed) and to handle variations in

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incoming product moisture, wasting energy due to inadequate control while it does not
eliminates the possibility of wet product.

Fig. 6a. Dryer simulation scheme

material humidity [ % ] material temperature

15 % 40 oC

0 1 2 3 4 5 0 1 2 3 4 5 min
(b) (c )

Fig. 6b, c. Dryer simulation results output responses

The non linearities involved in drying are dryer saturation (i.e. part of the dryer
volume is unused), drying air saturation (i.e. part of the drying ability of the air is lost),
variance in moisture distribution of the material under drying processing, etc. Relative
errors in flow measurements are minimized (Ventzas, 1997), while experimental
uncertainties are difficult to evaluate.
Model robustness is proved by control simulation, where control parameters do
not require drastic correction during experimentation. Simulation predicts dryer
degradation.

CONCLUSIONS: The paper presented the modeling, operation and

moisture control of a counter current flow dryer. A heat transfer and moisture model
were given. Model-based and differential temperature control schemes are proposed.

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Modern dryers with air recirculation present tempering zones, i.e. drying stages with
different temperatures. Multi-stage techniques allow moisture to diffuse to the surface,
thus increasing the drying rate, while resting at high temperatures strongly influences
quality. CAD techniques assist in dryer design, selection and operational simulation.

Fig. 7. Rotary dryer test Fig. 8. Dryer heat exchanger

REFERENCES
1. Allen, R. M., & Bakker, H. H. C, Spray Dryer Control Based on Online Particle Size
Analysis, Trans IChemE, 72(A2), 251-254, 1994
2. Barber, M. Kauppila, J-Ili, Ilvespaa, H, The Future of Drying, PITA Conference
"Water Removal '95", Conference Proceedings, 5/6 December 1995
3. Brook, R.C, A look at Control of in-bin Grain Drying Equipment. Paper No.
87-6037. ASAE, St. Joseph, MI, 1987
4. Colliver, D.G., Peart, R.M., Brook, R.C., and Barrett Jr., J.R, Energy usage for low
temperature grain drying with optimized management, ASAE Transactions. 26:
594-600, 1983
5. Courtois F., Lebert A., Duquenoy A., Lasseran J.C., Bimbenet J.J., Modeling of
Drying to Improve Processing Quality of Maize, Drying Technology, 9(4),
pp 927-945, 1991
6. Lynch, B.E. and Morey, R.V, Control Strategies for Ambient Air Corn Drying,
ASAE Transactions, 32(5):1727-1736, 1989
7. Maier, D.E., Dalpasquale, V.A., and Kallestad, D, High-Low Temperature Drying
plus Automatic Conditioning, Paper No. 94-6042. ASAE, St. Jospeh, MI, 1994
8. Milg K. M., A Study of the Dynamics in a Rotary Drum Dryer with Counter
Current Flow, Chr. Michelesen Institute, Norway, Bergen 1964
9. Mittal, G.S. and Otten, L, Evaluation of various Fan and Heater Management schemes
for Low - Temperature Corn Drying. Can. Agric. Engng. 23(2):97-100, 1981
10. Moreira, R.G. and Bakker-Arkema, F.W, Grain dryer control: A review, Cereal
Chem. 69(4):390-396, 1992
11. Morey, R.V., Cloud, H.A., Gustafson, R.J., and Petersen, D.W, Management of
Ambient Air Drying Systems, ASAE Transactions. 22(6):1418-1425. 1979.
12. Mykelestad, O, Heat and Mass Transfer in Rotary Dryers, Chemical Eng,
Process Symposium Series, pp. 129-137, No. 41, vol 59, 1972
13. Stroshine, R.L., Mc Kenzie, B.A., Sarwar, G., Thompson, T.L. and McFate, K.L.
Improving Management of Low Temperature Drying of Corn, Technical Report
TR-100445. EPRI, Palo Alto, CA, 1992
14. Ventzas, D, Control Theory, TEI Lamia, 1997 (in Greek)
15. Vikas Saksena, Mike D. Montross, Dirk E. Maier, Site Specific Natural Air/Low

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Temperature Drying Strategies for White Food Corn, Department of Agricultural &
Biological Engineering, Purdue University, West Lafayette, Indiana, The ASAE
International Annual Meeting, The American Society of Agricultural Engineers,
Minneapolis, Minnesota, August 10-14, 1997
16. Watson, S. B, Improving Dryer Section Efficiency - A Scientific Approach, Paper
Technology 37, 6 July/August 1996
17. Wedel, G. L. and Palazzolo, S Advances in dryer section runnability, Tappi Journal
September 1987

APPENDICES

APPENDIX I : SYSTEM SPECIFICATIONS

SYSTEM S PE C I FI CAT I O N S
Dryer temperature set point accuracy +/-5 °C
Ambient temperature controlled set points with a 40 °C maximum
Individual set point control for each dryer with a 45 °C maximum
Three system set point options Fixed, Ambient plus, Ambient Humidity/Temperature
low temperature and high temperature alarms customer selectable
Alarm output 12V
Controller communication lost alarms
Controls up to 192 produce dryers
Daily log files set points, ambient temperature, dryer temperature,
Log files importable into any database or spreadsheet
Customer response control frequency of temperature readings
Thermostat control independently configured for each dryer controller
Remote system control customer control of dryers
RS-485 interface bus computer/Network Controller yes

Dryer systems consist of a dryer controller, a weather station, a network controller and
the dryer control system software. The dryer controller is a microprocessor based
temperature controller used to control fan power and temperature of a produce dryer
for increased temperature accuracy; the unit is a self contained thermostat controller
that maintains the desired set point within +/- 10 °C. The weather station is a
microprocessor based temperature sensor that is used to sense the temperature and
humidity of the air being supplied to the produce dryer. The dryer control system
software reads the temperature of the weather station and calculates the set point for
the dryer controllers and monitors the controllers connected to the network. The
Network controller is a microprocessor based communication station; this allows the
dryer control system to support up to 8 networks of up to 24 dryer controllers (192
total). Energy savings and reduction in unit energy costs (Colliver, D.G, et al, 1983)
are achieved by reducing wasting energy due to poor control, reducing flue gases
going out the exhaust stack, stopping the dryer to run when no product is in the dryer,
and defining a consistent target product moisture content without over-drying or
wasting energy during startup or down times.

APPENDIX II : MATERIALS under PROCESSING (DRYING, COOLING, etc)

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 MATERIALS under PROCESSING (DRYING, HUMIDIFYING, COOLING, etc)
alumina blood glass salts biomass
foods cheeses rice soap flour
asbestos cocoa tobacco powders retines
medicine coffee lignite sewages cotton
boxite grains lime sand resins
bones detergents milk sugar popcorn
petfood grains plastics chemicals cement

APPENDIX II : DRYING - COOLING - HUMIDIFYING METHODS

EVALUATION of DRYING - COOLING - HUMIDIFYING METHODS

TYPE ROTARY with FINs FLUIDIZED BED
OPERATION D, H, D & H 1 D, H, C D, H, C
OPERATION warm, humid air fins/pipes exchange vertical, warm air
CAPACITY small - large small - large medium - very large
PROPERTIES of free flow, products and thin with grains small size
MATERIALS specifications
TYPICAL foods, plastics, food, sugar, coal, minerals, chemicals,
MATERIALS chemicals chemicals, etc coal, cock, etc
DRYING TIME constant, variable, dust constant, variable, short time, dust cyclones
removal dust collectors
CRITERIA drying quality, variable inert atmosphere, add large quantities, dry and
times, temperatures oil and salts cool simultaneous

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D = Dryer , H = Humidifier , C =
cooling