4 - Rotary Dryer

SELECTION AND DESIGN
OF DRYER
Zafar Abbas
2003-poly- 1061
What is a drying process ?
• Drying generally refers to the removal of
relatively small amounts of water or other
liquid from the solid material to reduce the
content of residual liquid to an acceptably
low value.
Principle of drying
In drying of solids, water or other liquids are
removed thermally by vaporization
Classification of Dryers
Drying equipment may be classified in several

ways. Two most useful classification are
based on
1).The mode of heat transfer to wet solid.
• Heat transfer by convection
• Heat transfer by conduction
2).The scale of operation
Cont’d
• Batch operation
• Continuous operation
3). Form of feed
• Free flowing granular or crystalline solids
• Slurries
• Fibrous solids
• Pastes
“ We select direct heated rotary dryer for our
application ”
Advantages of Rotary Dryer
• Best for slurries
• Maximum contact area
• Higher rate of heat and mass transfer
• Simplest in construction
• Most Economical
• Low operating Cost
• Efficiency Range is 55—99%
• Reference :1 Principles of unit operations 2nd edition By Foust
2: Perry’s Handbook for chemical engineers
Direct contact Rotary Dryer
• It consists of revolving cylindrical shell ,with
lifting flights, horizontal or slightly inclined
towards outlet.
• Wet feed enters one end of the cylinder; dry
material discharge from the other.
• In this dryer solids are directly exposed to hot
gas usually air.
Reference : Unit operations of chemical engineering by Warren L.

McCabe , Julian c. Smith
Rotary dryer
Direct contact Rotary Dryer construction
Ref: Chemical Process Equipment Selection & Design, Stanley M. Walas

Rotary dryer working
Ref: Chemical Process Equipment Selection & Design, Stanley M. Walas

Direct heated rotary dryer
1.Heat 2.Air
duty 2.Air
needed
needed
7.7.
Residence
Residence
time
time design steps 3.Diameter
3.Diameter
4.Dryer
6.Dryer volume
6.Dryer
speed
speed 5.Dryer
5.Dryer
Length
Length
Solid Feed Rate & Moisture Content
• Solid feed rate entering the dryer= ms
=2552 Kg/hr
• Inlet moisture content=Xa 0.29 =Kg of water/Kg
of dry solid =25%(wet basis)
• Outlet moisture content=Xb
.0025 = Kg of water/Kg of dry solid
=0.25%
Heating Medium & its Temperature
• Steam heated air is used which enters the

dryer at 175 C
• The outlet temperature of air is calculated
from energy balance that comes to be 90C
Temperature
Important temperature Details
Temperature of feed entering=T1

=70C (183 F)
Temperature of feed out =T2
=80 C (202 F)
Temperature of air in =Ta
=175 C (372 F)
Temperature of air out =Tb
=90 C (220 F)
Reference : Process drying Practice by Edward D Cook , Harman D. Dumont
1.Calculation of Heat duty
Heat duty is calculated as follows
• Qt = Q1 + Q2 ---------------------------------- 1
• Q1 =mscps∆T +mwlcpw∆T-------------------- 2
• Q2 =mw [cpw∆T+ λ+ Cpv∆T’] ----------------3
Where ∆T’ = Ta2 _Ts2
• Qt =1.6*106kj/h =1.4 *106Btu/h----------4
Reference :Dryer design hand book by Mujumdar

2. Amount of air needed
• ma = Qt /(cpa ∆T’’) ----------------------------5
Where ∆T’’ = Ta1 _Ta2

• ma = 18451kg/hr
Add 10% for possible heat losses
So ma = 20296.54skg/h -------------------6
Ref: Processes for Major Addition-Type Plastics and Their

Monomers Lyle F. Albright
3. Dryer diameter
• Area =ma/G -----------------------------------7
G =mass velocity selected on basis of particle size
and for 150 – 200 micron particles
• G=500 lb/ft2.h *
So by eq 7
• A = 7.53 m2
So
• D = 3m ---------------------------------------8
Reference: Perry’s Handbook for chemical engineers

4. Volume of dryer
• Qt = V Ua (LMTD) (BE units) ----------------10
• V= Qt/Ua (LMTD) -------------------------------11
• LMTD= ∆T2-- ∆T1/ln(∆T2/∆T1) --------------12
• LMTD = 40.40 C = 130 F
• Ua= 0.5*G0.67/D (in BE units )---------------------13
Putting values we get
• Ua = 3.27 Btu/ft3.hr------------------------14
So
• V= 3463.3 ft3 =97.98 m3 ----------------15
Reference: Perry’s Handbook for chemical engineers

5. Dryer length
• L = V/A ----------------------------------------16
Putting values of V and a we get
• L = 13 m = 45.23 ft ------------------------17
• L/D ratio = 4.33 < 6 * -------------------18
6. SLOPE **
It varies between 2 to 5 degrees. we take 3o for our
product
* Reference : Plant design and economics for chemical engineers by Peters and
Timmerhaus Klaus D
** Reference :Dryer design hand book by Mujumdar
7. Rotational speed
• Rotational speed of drum may be between 20 to 25
m/min for dryers diameter ranging from 1 to 3m .
Because the circumference of our dryer is 9.44 m so 20
m/min or 3 rev/min is taken. *
• 8. Drying gas direction **
Drying gas direction is taken as co-current with wet solid,
because in counter-current the polymer temperature may
suddenly rise to its degradation temperature
* Reference : unit operations of chemical engineering by Warren L.

McCabe , Julian c. Smith
** Reference : Process drying Practice by Edward D Cook , Harman D.
Dumont
No of flights
• No of flights = 3*D (D in ft)---------------19
• Nf =3*6.56= 19.68
So 20 flights are required using lip angle of 45 degrees
Radial height
• Radial height is taken as 1/8 of D (D in m )
So Radial height = 2/8=0.25 m
Reference : unit operations of chemical engineering by Warren L. McCabe , Julian c. Smith

Residence Time
Friedman and Marshall developed relation fo
residence time given as
• Tr = kL / NDtanΦ
• k = constant = 0.13
• N = rpm =3
• Φ = slope of dryer = 3 degrees
So Tr = 4.7 minutes ----------------------- 20
Reference :Dryer design hand book by Mujumdar

SPECIFICATION SHEET
Equipment Dryer
Feed Rate 2552 kg/hr
Moisture Content 25%
Product Moisture 0.25%
Diameter 3m
Length 13 m
Number of Flights 30
Material Mild Steel
Rotational Speed 3 rpm
Shipping Weight 39900 kg
Price $298933

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SELECTION AND DESIGN

Drying equipment may be classified in several

Reference : Unit operations of chemical engineering by Warren L.

Ref: Chemical Process Equipment Selection & Design, Stanley M. Walas

Ref: Chemical Process Equipment Selection & Design, Stanley M. Walas

• Steam heated air is used which enters the

Temperature of feed entering=T1

Reference :Dryer design hand book by Mujumdar

Where ∆T’’ = Ta1 _Ta2

Ref: Processes for Major Addition-Type Plastics and Their

Reference: Perry’s Handbook for chemical engineers

Reference: Perry’s Handbook for chemical engineers

* Reference : unit operations of chemical engineering by Warren L.

Reference : unit operations of chemical engineering by Warren L. McCabe , Julian c. Smith

Reference :Dryer design hand book by Mujumdar

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