Overview of Dryers and The Drying Process
Overview of Dryers and The Drying Process
Overview of Dryers and The Drying Process
A dryer is a machine that reduces the moisture content of bulk solids, manufactured parts,
and other valuable materials. It is a complex system consisting of a drying chamber, heaters,
materials handling equipment, forced convection equipment (if applicable), and others.
Vacuum Dryers
Vacuum dryers operate at a low (vacuum) pressure to hasten the vaporization of
moisture or solvent absorbed by the material. The decrease in operating pressure
depresses the boiling point of the absorbed liquid; hence, these dryers operate at a lower
temperature than other industrial dryers.
The materials to be dried are loaded in trays. The dryer is equipped with a vacuum
pump to reduce the pressure inside the chamber. Heat is transferred from the chamber
walls to the material by conduction or radiation. Some vacuum dryers have a steam
jacket. The vacuum pump draws the vapor; the vaporized solvent may be recovered by
condensation and reused if necessary.
Vacuum dryers are used for heat-sensitive, hygroscopic, combustible, and
granular products. They are used in food and pharmaceutical products to keep nutrients
from degrading in high temperatures. They remove large quantities of moisture
efficiently and have fast drying times.
Pan Dryers
Pan dryers are equipped with an agitator or a mill that stirs wet materials inside a
jacketed vessel. The agitator or mill revolves slowly to increase drying rate (i.e., moisture
removed per unit time per unit area), ensure uniform heat distribution, and avoid products
sticking on the vessel walls. Pan dryers may be operated in an atmospheric or vacuum
pressure.
Pan dryers are used in drying heat-sensitive, viscous, and sticky products.
Freeze Dryers
Freeze-drying (or lyophilization) involves freezing the material to be dried and
subjecting it under vacuum pressure. It is employed for products that drastically degrade
or change at high temperatures. It preserves the material’s biological activity and
chemical properties. It is used in food and pharmaceutical products to preserve their
nutrient content and active ingredients. It is also used in biological specimens such as
blood, tissues, and proteins. However, freeze-drying takes a long time to complete.
Freeze dryers consist of refrigeration equipment, a drying chamber, holding trays,
and a vacuum pump. The sample is first frozen to at least its melting temperature to
convert the moisture and solvent within the material into a solid phase. The vacuum
pump is then activated to decrease the pressure inside the chamber. Heat transfer under
low pressure causes the solidified moisture or solvent to transform into vapor. The
vacuum pump draws the vapor sublimed off the material. The freeze dryer will continue
to run to drive off the moisture or solvent bound to the material.
Bin Dryers
Bin dryers consist of a holding tank or bin with a perforated plate at its bottom. A
fan blows ambient or preheated air through the perforated plate vertically upward. Air
surrounds the moist material, causing it to dry. The material may be arranged on shelves,
with the wettest material at the bottom. The moisture-carrying air leaves at the top of the
bin. Bin dryers are used in drying agricultural and forest products such as wood, fruits,
vegetables, grains, bamboo, and others. However, bin dryers may lack drying controls
and be used as a pre-dryer.
TYPES OF CONTINUOUS DRYERS
Tunnel Dryers
In tunnel dryers, the materials to be dried are loaded in trays attached to a trolley.
The trolleys enter at one and move slowly through the drying tunnel, wherein a stream of
hot air or gas is blown. The material dries as it moves through the tunnel. The trays may
move in either of the following directions with the air stream:
Concurrent Configuration The material movement and the airflow are in the
same parallel direction. This configuration is the least efficient.
Countercurrent Configuration The material movement and the airflow are in
opposite parallel directions. It is the most efficient configuration as the
temperature gradient across the chamber is more uniform — the hottest and driest
air contacts with the materials with the highest moisture content.
Cross-Flow Configuration The airflow is perpendicular to the material
movement, thereby maximizing contact. The screen conveyor dryer is a type of
tunnel dryer that utilizes this configuration. The materials are placed in a
perforated screen through which hot air is vertically blown. Moisture is removed
from the materials as it passes through the tunnel.
The settings of the heater zones and the trolley speed may be optimized according
to the type and quantity of materials being loaded and final moisture or solvent content.
Tunnel dryers are considered as an enhancement to tray dryers. Materials
continuously enter and exit throughout their operation. The material is steady on the
trolley as it traverses the tunnel. Hence, these dryers are suitable for products sensitive to
damage or deformation, such as automotive components, electronic parts, construction
materials, glass materials, and large fruits, vegetables, and food products. Tunnel dryers
are operationally efficient in processing materials requiring long drying times.
Rotary Dryers
Rotary dryers consist of a slightly inclined metal cylinder with internal flights.
The material is fed from the upper end of the cylinder. The cylinder slowly rotates to lift
and cascade the product. Hot air or gas enters in a concurrent or countercurrent direction
with the material. The agitation caused by the rotation and internal tumbling action
results in rapid and uniform drying. The product is collected at the lower end of the
cylinder.
Rotary dryers may be classified as direct-fired or indirect-fired. In direct-fired
rotary dryers, the hot gas directly contacts the material inside the cylinder. High-
temperature air may be used to roast food products. In indirect-fired rotary dryers, heat is
conducted from the cylinder walls to the material being dried.
Rotary dryers are suitable for drying granular and non-sticky materials. They are
commonly used in drying products from a crystallization process. They are suitable for
drying salts, minerals, grains, nuts, and animal feeds.
Flash Dryers
Flash dryers dehydrate wet granular materials by conveying them across a drying
duct. A high velocity hot gas stream flows through the duct that keeps the particles
suspended. The heat from the gas stream removes the moisture or solvent from the
product. After passing through the duct, the particles are separated from the gaseous
stream by a cyclone and a bag filter. A portion of the exhaust gas is recirculated to the
duct in order to increase energy efficiency. Flash dryers are used in drying minerals, salts,
starches, dyes, and other granular products.
Drum Dryers
Drum dryers or roller dryers dehydrate liquid feed in order to produce powders,
flakes, or granular materials. They consist of one or two internally heated drums that
rotate about their axis. Steam is flowing inside the drum, and heat is conducted through
the walls. The feed is sprayed onto the surface of the rotating drum or between the two
rotating drums. A thin film of the liquid feed sticks and dries on the hot surface. The
product's initial and final moisture contents determine its residence time on the drum
surface. A scraper removes the dried particles once the desired moisture content is
obtained.
In vacuum drum dryers, the drums are placed in a chamber with vacuum pressure.
The low pressure inside the chamber decreases the boiling point of the moisture or
solvent, causing it to evaporate at a lower temperature. Hence, vacuum drum dryers are
suitable for drying heat-sensitive products.
Disc Dryers
Disc dryers consist of multiple vertical discs mounted on a shaft, which are all
contained in a horizontal cylinder. The shaft is internally heated by steam or hot oil; heat
is conducted from the shaft to the mounted discs. The discs provide the area for indirect
drying. The wet feed in the form of slurry or sludge enters on one side of the cylinder.
Moisture or solvent from the feed evaporates as it touches the discs. The materials are
transported axially throughout the cylinder. Scrapers are installed inside the cylinder to
ensure uniform mixing and prevent the materials from sticking onto the discs. Finally, the
products are collected at the bottom of the other cylinder end.
Source:
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