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Abstract
In this thesis, an overall review of rotary dryer design is performed and an optimization path for different scenarios is given for an existing rotary dryer. The two scenarios examined in this thesis are maximum throughput and minimum energy. The rotary dryer analyzed and optimized is a Bartlett Snow Countercurrent Rotary Dryer and is used in a manufacturing facility.
This analysis was accomplished through the creation of an analytical model. The model equations are solved in MATLAB. This optimized model was improved and modified through comparison against observed operating conditions of the analyzed rotary dryer.
The results of the maximum throughput operating conditions indicate that a throughput increase of 84% is possible when increasing the power supplied by 60 kW, bringing the overall power supplied to the heaters to 300 kW. To accommodate this change in feed rate, it was necessary to reduce the residence time to roughly 30 minutes. This reduction of residence time was accomplished by increasing the drum slope to approximately 3°.
The results of the minimum energy operating conditions indicate that a power reduction of 16 kW is possible, bringing the overall power supplied to heaters to 224 kW, while still maintaining the existing feed rate of 2604 kg/hr. This represents an energy usage decrease of 7%, with an annual cost savings of $15,300. This existing feed rate and residence time combination is actually overloading the dryer beyond the design capacity; therefore it was necessary to reduce the residence time once again. The ideal residence time was found to be 55 minutes and can be achieved by increasing the dryer slope to 1.6° for the minimum energy operating conditions.
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