Design of a One Ton Pineapple Solid Waste Direct-Heat

Countercurrent Rotary Dryer

Ray H. Malonjao

Engr. Joey S. Pastoril

Pineapple solid waste consists of residual pulp, peels, cores and leaves. The post-harvest
processing of pineapple fruits can leave a lot of pineapple waste which can cause environmental
problems. The volume of pineapple produce generated from the farms in the Philippines annually
(approximately 2.198 million metric tons in 2009), results to a large amount of pineapple solid
waste that needs to be disposed. Another problem is the conventional methods of drying are not
cost efficient specifically during rainy or wet season.
Recently, there have been studies and investigations on recycling pineapple waste into
animal feed (Makinde 2011). Particularly, there is a large amount of early research and
experience supporting the use of pineapple wastes in beef cattle, dairy cattle, sheep, goat and
tilapia (http://www.trc.zootechnie.fr/node/676). One of the ways to reprocess it into other
products with commercial value like animal feed is through drying. Difficulty in the conversion
of high-moisture by-products according to Makinde and Sonaiya, (2010), arises from high cost
of drying equipment and lack of simple and appropriate alternatives. For this, the researcher
designed a counter-current rotary dryer with a capacity of one metric ton per hour for pineapple
solid waste.
This research aims to simulate the effect of changing the values of the parameters of heat
and mass transfer equations adapted from Mujumdar (2006) to the diameter of the pineapple
solid waste peel direct heat countercurrent rotary dryer drum; simulate the effect of changing the
values of the parameters of residence time equations adapted from Kemp (2004) to the length of
the pineapple solid waste peel direct heat countercurrent rotary dryer drum; and develop a
detailed design of a direct heat countercurrent rotary dryer for pineapple solid waste peel using
Solidworks after determining design values which yield reasonable dryer performance.

In this process, the researcher simultaneously applied the three (3) types of design
calculations. One design was design of a new dryer using heat and mass transfer in getting the
diameter, using residence time equation in getting the length, determining the lifting flight design
using Solidworks, derived an hourly local climatic design condition based from ASHRAE
Handbook 2009. Also, one design type was performance data calculations for an existing dryer at
a new set of operating conditions. And the other design type was fabrication of a scale-down
laboratory-scale dryer using scoping design level, Solidworks for design drawings, Symprosys
2.2 for dimension simulation.
Then the simulation results from the three design types of calculations were gathered and
evaluated according to the design range or limits used by the books and related literatures. Then
the reasonable values of the diameter and length of dryer and the appropriate flight design were
used in making the drawings using Solidworks for the new dryer design. Detailed design
drawings including small parts like bolts and washers were included to fully conceptualize the
actual size of the dryer.

The researcher used the design methodology by Kemp (1999) in selection process. The
calculation process principle of a fully structured approach to dryer modeling that was used is
described by Kemp and Oakley (2002). The researcher used forced convection heat and mass
transfer in getting the diameter, residence time equation for the length, application of design
climatic conditions (based from ASHRAE Handbook 2009) for feed temperatures and moisture,
and using Solidworks in the design of flights.

First, what was done was to provide the information on the physical and thermal properties
that will be used for numerical calculation. The useful data were taken from the selection guide
table which already contained the preliminary information on the dryer design.
5.1.2 PROCESS PARAMETERS
The results in the preceding computation were organized and presented in Table 5.2. The
results showed different calculated output parameters implemented in Microsoft Excel.

Table 5.2 Results of Process Design Calculations

Overall inlet material

1072.5

Overall exit material

715

Evaporating water

357.5

Overall heat consumption

1023018

Heat for evaporation

840125

Heat for vapor

16802.5

Heat for liquid

22415.25

Heat for product solid

45240

Heat for product water

5434

Air mass rate

10662

Diameter

1.216055

Volume

3.787363

Length
Number of heat transfer units

1.5

Heat load of exchanger

1432226

Thermal efficiency

0.649351

5.2 DRYER LENGTH CALCULATION USING RESIDENCE TIME KEMPS EQUATION

The residence time equations are sourced from the different related literatures and studies
about rotary dryers. The equations were used to determine the length of the dryer after heat and
mass transfer calculations. Then, evaluation is done to determine which is appropriate.
The calculations using the different equations are tedious, and highly repetitive therefore
time consuming. This is the reason why the researcher believes that using Microsoft Excel or any
programming software that facilitates in evaluating the equations. Using any of the commercial
software, it is easier to simulate or get results using different input values. These results gave
basis for the selection of right residence time equation in determining the length of the dryer
drum.
It was found out that Kemps equation is most appropriate in determining the length of the
dryer drum since it includes sliding, lifting and falling mechanism of solids movement inside a
countercurrent, cascading and direct-heat rotary dryer. The schematic diagram of Kemps
equation is shown in Figure 5.1.

1 Accelerating 2 Sliding 3 Lifting 4 Fluidizing/Falling backward due to drag 5

Bouncing/Dispersing 6 Rolling/Sliding

Also, the researcher designed a dryer with the use of performance data calculations for an
existing dryer at a new set of operating conditions. And the other design type was fabrication of a
scale-down laboratory-scale dryer using scoping design level, Solidworks for design drawings,
Symprosys 2.2 for dimension simulation. Simulation was also done in Microsoft Excel and
Visual C Sharp. The results were analyzed and evaluated with the design limits for optimization.
The computed dimensions were designed in different detailed drawings and illustrations using
Solidworks.
DETERMINATION OF FLIGHT DESIGN AND HOLD UP VOLUME
The Solidworks design constraints were used in determining the areas of hold up in the
flights. The sum of the areas was used as basis to determine if the dryer performance efficiency
is within the range of benchmark for that is 10 to 15 percent of the total volume of the dryer as
mentioned by Mujumdar (2006). Difficulty is experienced using the conventional computation

method since computations would take considerable time. This was where the use of Solidworks
is maximized in differentiating the different types of flight designs, different numbers of flights,
and different hold up mechanisms sourced from the book and handbooks (used as reference in
this research). All these data were used in the analysis for determining the best specification of
flight design that will be used in designing the new dryer.
With the different designs of flights drawn in Solidworks, the holdup volume of dyer on a
particular design of flights and hold up volume with different and varying number of flights were
determined. The purpose was to determine the quantity of flights and their design that can hold
the maximum volume of material inside the drum. In some cases, what was done was to conduct
experimentation wherein the different designs of flights were attached and installed inside the
drum, then the drum will be rotated, then stopped to see which quantities and types of flights
have accumulated the biggest volume of material inside the drum. In this case, the computed
hold up volume is for 6.5 meters length of the drum taken from length calculation. The actual
computed length of the drum is 7.5 meters, which means the remaining 1 meter length of the
drum is divided into two, for spiral flights of both ends which is serves only as material
accelerator.

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