Dryer Problem 7.

A rotary dryer fired with bunker oil having a HHV 10,000 kcal/kg is to produce 20MT/hr of dried sand with 0.5%
moisture and from a wet feed containing 7% moisture, specific heat of sand is 0.21 Btu/lb-F. Temperature of wet sand is 30°C and
temperature of dried product is 115°C. Calculate : T ( P = C process)
a.) the weight of wet sand to be removed (in kg/s) Tb =115°C
b.) the weight of water to be removed (kg/s) (2257kj/kg)
c.) the heat (Q)required (kcal/s) (BPwater)T=100°C; QL=2257kj/kg
d.) L/ of bunker oil consumed if SG is 0.90, and the dryer operates 60% efficient.
Solution: {assumption wet basis of analysis} sat’n curve
Schematic diagram & given data: Ta=30°C (TS Diagram) S
FEED: 30°C, Xa = 7% moisture Waste Humid Air (Mair2) out; Xa = Mwa/Mta; Mwa= Xa(Mta)
(Mta; Mwa)
(FEED): Mwa = Xa(Mwa + Mds)= XaMwa + XaMds
(Wet Basis) Mwa-Xa (Mwa) = XaMds
Eq (2) Mwa [(1-Xa) /Xa] = (Mds)
Mwa =
Mair1 Fan (Rotary) DRYER PRODUCT: Mtb=20MT/hr (115°C, Xb = 0.5% Water)

Fuel: Bunker Oil 10,000 kcal/kg HHV Similarly(Wet Basis), Mwb = Xb(Mtb)=0.005(20,000)=100kg/hr
a.) Mass flowrate of feed material (Mta), Mds = Mwb[(1-Xb)/Xb]; Mwb = (Mds + Mwb)(Xb) Eq(2)
Mta = Mwa + Mds = Mtb (1-Xb)[(Xa/1-Xa)+1] Mwb = MwbXb + MdsXb
Mta =(20000/3600)(1-0.005){[0.07/(1-0.07)] +1} =5.9443kg/s(wet sand) = 21,397.8kg/hr Mwb-(Xb)Mwb = Mds(Xb)
b.) Amount of water to be removed, Mwb (1-Xb) = Mds(Xb)
Mwb = (Xb) (Mtb) = (0.005)(20,000)/3600 = 0.02778 kg/s water( in Product); Mds = Mwb(1-Xb)/Xb= Mtb(1-Xb) Eq(3)
Mwa = (0.07/1-0.07)(1-0.005)(20,000)/3600 = 0.416 kg/s (in Feed);. Checking: Mds = 20,000 (1-0.005) = 19,900 or Mds = Mtb-Mwb
Thus, Water to be removed = Mwa-Mwb = 0.416- 0.02778 = 0.3882 kg/s(water or moisture); Thus, Mds =0.02778(3600)=100kg/hr
c.) Heat required (q). Mds = 20,000-100=19,900kg/hr
For Tb<100°C, Spec.heats: Cpw= 1kcal/kg-C; Cpsteam= 1.863 KJ/kg-C/4.187KJ/kcal = 0.445 kcal/kg-C; Cpds = 0.21 kcal/Kg-C(given)
Qtotal = Qwa + Qwr + Qds
Checking: Mta = Mds + Mwa = 19,900 + 0.416(3600) =21,397.6kg/hr
For Tb>100°C, Latent Heat,
Qtotal = Qwa + Qwr + Qwb + Qds (Hfg)100 = 2257kJ/kg = 539.17KJ/kg; Mds= 5.556kg/s –(0.02778) = 5.528kg/s(drysand)
Where:
1.) Qwa = Sensible he at required to bring water to BP(100°C)
= (Mwa)(Cpw)(T100 -Ta) = (0.416)(1)(100-30)= 29.12Kcal/s
2.) Qwr = Latent Heat required to evaporate moisture removed (sat steam)
= (Mwa-Mwb)(Hfg)100 = (0.3882kg/s)(539.17Kj/kg) = 209.3 kcal/s
3.) Qwb = Sensible Heat required to heat Mwb (Moisture left in product) from T=100 to T=115°C
= Mwb(Cpw) (Tb-100) = (0.02778) (0.445)(115-100) = 0.185 kcal/s
4.) Qds = Sensible heat required to heat dry sand from Ta = 30°C to Tb = 115°C
= Mds(Cpds)(Tb-Ta)(5.528kg/s dry sand)(0.21kcal/kg-C)(115-30)C = 98.67kcal/s
Thus, Qtotal = 29.12 + 209.3 + 0.185 + 98.67 = 327.27 kcal/s
c.) Bunker Oil Consumption (Mf),
Eff Dryer = Heat Output/Heat Input x 100 = Qt/Qin => Qin = Qt/eff = (337.27 kcal/s)/0.6 = 562.11 kcal/s
But, Qin = Qadd = Mf (HHV) = 562.11kcal/s = Mf (10,000kcal/kg) ; thus, Mf = 0.056211kg/s(bunker oil)
Vf = Mf/(1000kg/m³ x m³/1000L)(SG)= 0.056211/0.90 = 0.0624Liters/s(Bunker Oil) consumed.
NB: Dryer derived equations (Wet Basis only).Always Assume Wet Basis if Not Specified in problem {commonly used in BoardExam}

Material: Mwa = Mds [Xa/(1-Xa)] subst Eq( 2), Mwa = (1-Xb)(Mtb) [Xa/(1-Xa)]
Mta = Mwa + Mds; or Mta = Mwa/Xa = [Xa/(1-Xa)] Mds/Xa = Mds/(1-Xa) Eq (4)
Mta = [Xa/(1-Xa)]Mds + Mds
Mta = Mds[(Xa/1-Xa) + 1] = Mtb (1-Xb) [Xa/1-Xa) + 1] ; where Mds = Mtb(1-Xb) Eq (5) & (6)
Checking:
Mtb = Mds + Mwb = Mds + Xb(Mtb) = 19, 900 + 0.005(20,000) =19,900 + 100 = 20,000 kg/hr (dried sand)
ddp2020/pme5272