Design and Study of Grain Dryer

Design & Study of Grain Dryer
CHAPTER - I
INTRODUCTION
I) HISTORY & IMPORTANCE OF DRYING
India produces about 150 million tonnes of food grains per year. The major
components of production are 47 million tonnes of wheat, 64 million tonnes of rice, and 13
million tonnes of pulses (Anon. 1987). Due to technological advances in agriculture and the
introduction of high-yielding varieties, this may increase. From this production, an average
10% is lost during postharvest operations between the field and consume. This means that
about 15 million tonnes of food grain, valued at about $A240 million (Indian Rupees 10,800
million) goes to waste. The major share of the loss occurs during storage of surplus stock.
Among the various causes of losses, the most important one is improper drying before
storage.
The preservation of agricultural produce by drying is a long-established
technique. Sun drying in the open, on mud-plastered or concrete floors, is the conventional
method of drying grain and also cash crops like chillies, and plantation and horticultural
crops. The drying time required in the open sun for these crops ranges from 5 to 45 days
depending upon the crop to be dried. Unfavourable weather conditions are likely to occur
during the drying period and degradation in quality of the final produce therefore becomes
unavoidable.
It is well-known that deterioration in quality caused by improper drying cannot
be eliminated until improved drying systems based on mechanical dryers have been adopted.
However, for many reasons, these systems have not been adopted. The main reason that is
encountered is a lack of organizational or government incentive to the farmer to deliver a
quality product that might command a premium price. This results in not only a negative
attitude, but also leads to the overall quality of the product gathered at market points being
alarmingly poor.
C.O.E.&T.,Akola 1
A second important reason for not using dryers is their high initial costs. Most
of the commercially available dryers are designed to suit the needs of the processing industry
and their output capacity is therefore far above the needs of individuals, or even of farmer
groups. An awareness of availability of dryers and of their use and advantages in drying food
grain for better storage and marketing is lacking among crop growers. The main reason for
this is inadequate extension programs. So far, extension agencies have concentrated on
increasing production. The time has now come to see that grain saved is equivalent to grain
produced. High technology has led to production targets being achieved, but much less
attention has been given to minimising losses, which have remained constant since the
beginning of the 'Green Revolution'. Annual postproduction losses by crop in India, expressed
as a percentage of total production, are estimated to be as follows: wheat, 8%; paddy, 11%;
pulses, 9.5%; and all food grains, 9.3%.
Commercial use of dryers
Dryers are used extensively in grain processing industries such as rice milling,
pulse milling, and oil extraction. Here the need for dryers has been realised not only for
proper storage of stock but also for timeliness of subsequent operations where wetting of
grain and redrying are involved.
In the case of the rice milling industry, parboiling of rice is a common practice.
The population of the coastal belt of the country consumes parboiled rice and about 70% of
production is processed in this manner. The paddy is soaked in water for variable lengths of
time depending on the process used and is then steaming.
High moisture content (m.c.) paddy is dried to 12-14% m.c. for milling. There
are about 100 000 rice mills with a total installed capacity of about 40 000 tonnes of paddy
per hour. About 30000 dryers of 1-2 t/h drying capacity are in use in the industry. The most
commonly used dryer is the LSU type in which air is heated for drying by burning rice hulls.
The steam requirement for drying is 21.3% of the total steam produced in the boiler, which
consumes about 4% of the total power required by the mill. In this type of dryer, the grain is
C.O.E.&T.,Akola 2
tempered for 30 minutes after every hour of drying so to equilibrate the moisture and avoid
stress cracking in further milling operations.
Dryers are also used in the pulse milling industry. Here both LSU-type and
flat-bed perforated-floor dryers are well, ranging in capacity from 1-4 t/h. There are about
4000 pulse mills in India having an average processing capacity of 10-20 t/day. Dryers are
required in industry for the following reasons:
 To dry the stock purchased from market before storing it; and
 To dry the grain which has become wet during processing.
In the LSU-type dryer, steam is used as the heating source, while in the flat-
bed dryers, light diesel oil is used, fuel consumption being 7-12 lt/h One such commercial
dryer. It consists of a drying tray or platform, an oil-fired burner, and an air blower. The cost
of a 3 t/h dryer is about SA13 500.
Use of dryers at farmer level
About 70% of total grain production in India is retained at farmer level: only
30% is sold on the open market. This means that a sizeable quantity of about 105 million
tonnes is kept by farmers. The losses here, though perhaps not felt by individuals, on a
collective basis have a substantial impact on the country. It is therefore essential that drying
technology be disseminated to this group which is a major custodian of the nation's grain.
To promote the use of dryers in rural areas, the concept of a community drying-cum
storage system was put forward by T.P. Ojha in 1984. He suggested that changes in ecological
balances and the introduction of high- yielding varieties of field crops necessitated the use of
mechanical dryers and other devices to protect the food grains from spoilage due to untimely
rains. If rain-soaked food grains are not dried properly, farmers have to sell their excess stocks
at low prices to meet urgent financial needs. A community drying-cum-storage centre would
therefore serve them well by way of protecting the grain from spoilage and also by advancing
temporary loans on their grain deposits. As soon as grain prices stabilise, stocks can be sold
and payments can be made to the farmers after deducting dues such as rental and service
C.O.E.&T.,Akola 3
charges, loans paid, and interest on advances. Such a system would no doubt benefit farmers.
They would not be required to make forced sales of their produce and, as a result, storage
losses would be minimised.
For such complexes, selection of a dryer of the correct design is very
important. The large capacity dryers used in grain-processing industries are not economical or
feasible for most farmer groups. In India, the average village has a population of about 1000
and the small amount of surplus grain available for drying at this level suits dryers of 2-4
t/day capacity operating for 60 days per year. In India, many research organizations have
developed, or are currently developing dryers for village groups, but so far with little success.
The main considerations for selection of a grain dryer suited to this level are:
 The dryer should be of a size that matches the amount of grain available in a village or
a cluster of villages;
 The dryer's cost should be within the reach of users;
 It must be simple in construction and operation and easily understandable to users;
 The dryer should be simple in design so that it is easy for local artisans to repair, and
 The dryer should be suitable for drying a range of crops.
Specific Problems
Why there is a tremendous need of dryers ?
To Farmers :
In year 2002 near about 80% loss of crops like black gram, green gram etc. due to
heavy rain at the time of harvesting. If there is a facility of dryers in every village may be at
Grampanchayat level, this heavy loss may be eliminated.
Sorghum crop :- After total maturity period of sorghum crop. is not harvested for near about
one month due to presence of moisture. Normally the problem faced by farmer is that rain
comes during this period and sorghum is affected, which results in bad quality as it turns
black. Due to this reason, the cost in market is reduced. This loss can be recovered if the
dryers are used at this stage.
C.O.E.&T.,Akola 4
After drying farmers can store the grains for a long period and it will send in
market at the highest rate.
To Dal Mill:
In the Dal mill the pulses are dried at different stages. The drying is done on the
platform by using solar energy, which is time consuming and large manpower required. So to
avoid this the dryers are used in the Dal mills.
To Food Corporation of India (FCI)
In foreign countries the grains are stored in Silos where there is on line drying of
grains but in India grains are stored in bags which is unhealthy. So, by applying dryers, the
problems of storage should be overcome.
To Industries
Different types of dryers are used in following industries
1) Textile industries, paper mills.
2) Plastic and polymer industry.
3) Chemical industries.
4) Food storage plants.
II) CHEMICAL COMPOSITION OF GRAIN:-

Grain is a living biological product, which germinates and respires also. The
grain is composed of both organic and inorganic substances, such as carbohydrates, proteins,
vitamins, fats, water, mineral salts and enzymes.
III) EFFECT OF TEMPERATURE ON QUALITY OF GRAIN.
Proteins: - At temperature above 500C denaturation and even coagulation of proteins takes
place. As a result, the water absorbing capacity of proteins and their capacity for swelling
decreases.
C.O.E.&T.,Akola 5
Starch: - At temperature above 700C and especially in presence of high moisture in the grain,
gelatinisation and partial caramelisation of sugars with the formation of caramel may take
place which causes deterioration in colour of the product.
Fats: - At temperature above 700C, fats may also undergo a partial decomposition resulting in
an increase of acid numbers.
Vitamins: - The heat sensitive B - vitamins present in the germ and aleurone layer are
destroyed at high temperature.
IV) PHYSICAL PROPERTIES: -

The knowledge of physical properties such as shape, size, volume, surface
area, density, porosity, colour etc. of different grain is necessary for design of various storing
and drying systems.
Porosity: - It is the percentage of volume of inter grain space to the total volume of grain
bulk.
Sphericity: - Sphericity is the ratio of surface area of sphere having same volume as that of
particle to the surface area of particle.
Coefficient of friction: - The coefficient of friction between granular materials is equal to the
tangent of the angle of internal friction and depends upon grain shape, surface characteristics.
Angle of repose: - Angle of repose is the angle between base and slope of cone formed on a
free vertical fall of the grain mass to a horizontal plane.
V) THERMAL PROPERTIES: -
The raw foods are subjected to various types of thermal treatment namely,
heating, cooling, drying etc. for processing. The change of temperature depends on the
thermal properties of the product. Therefore, knowledge of thermal properties namely,
specific heat, thermal conductivity, thermal diffusivity is essential.
C.O.E.&T.,Akola 6
Resistance of grain bed to air flow:

In the design of blowers for grain dryers, it is necessary to know resistance
exerted by grain bed to the air current blown through it. The resistance is dependent upon i)
bed thickness ii) air velocity iii) orientation of the grains and iv) type of grain.
VI) CHANGES IN STORED PRODUCTS -

There are many changes, which occurs to a product during transportation,
handling, storage and preserving.
Chemical Changes - The effect of canning upon the minerals, proteins and vitamins of
various food products is a large scientific field in itself. In stored hay and grains, changes
occur in fat acidity, enzymes, color and vitamins. These changes are influenced greatly by
moisture content and temperature, which are often used as a means of indicating the quality of
stored products.
Respiration and Heating: - In hay, grains, fruit and vegetable products respiration or
breathing continues after storage. Heat is produced by respiration process. The quantity of
heat produced is greatly influenced by moisture content and temperature of product. Loss of
viability or germination often occurs after heating. Movement of air through the products
helps to prevent excessive temperature by removing heat and excess moisture.
Microorganism: - Changes occurs in the amount of mold and yeast growth in stored product.
The changes largely depend upon temperature and moisture.
Insects and Rodents: - The population of insects is affected by moisture and temperature of
environment of stored product. Ventilation presents a method of controlling growth of insects,
but after they get out of control, chemical means are commonly used.
VII) LOSSES OF FARM CROPS: -
The losses of farm crops can be used to indicate the importance of proper
harvesting, storage and drying.
C.O.E.&T.,Akola 7
Table 1.1 : Estimated loss of production during harvest and storage.
Product Harvesting % Storage %

Wheat, oat, rice, barley 5% 4.5%
Corn 4% 6%
Cotton 2.5% 0.25%
Potato 7% 8%
Soyabean 5% -
Prevention: _
Maximum loss occurs because of an accumulation of moisture in grain, even
though dry when placed in the storage. Two terms are used for preservation of grain through
moisture control, drying and aeration.
Drying is the procedure used to remove excess moisture from the grain to
reduce the moisture to a level acceptable for safe storage or for commercial sale. Drying may
be accomplished by using either heated or unheated air.
Aeration refers to moving a small amount of air through the grain to cool and
ventilate the grain at frequent intervals. The reverse operation, turning refers to moving the
grain through the air by transferring the grain from one bin to another.
***
C.O.E.&T.,Akola 8
CHAPTER - II
THEORY OF GRAIN DRYING

Generally the term refers to the removal of relatively small amount of moisture
from a solid or nearly solid material by evaporation. Therefore, drying involves both heat and
mass transfer operations simultaneously. In convective drying the heat required for
evaporating moisture from the drying product is supplied by the external drying medium,
usually air. Because of the basic difference in the characteristics of grains in thin layer and
deep bed, the whole grain drying process is divided in to thin layer drying and deep bed
drying.
I) MOISTURE CONTENT: -
Usually the moisture content of a substance is expressed in percentage by
weight on wet basis. But the moisture content on dry basis is more simple to use in
calculation, as the quantity of moisture at any time is directly proportional to the moisture
content on dry basis.
The moisture content, m per, wet basis -
Wm
m= × 100
Wm + Wd
The moisture content, M, dry basis percent
Wm m
M= × 100 = x100
Wd 100 − m
Where Wm = weight of moisture.

Wd = weight of bone dry material.
C.O.E.&T.,Akola 9
TABLE 2.1 Approximate moisture content for safe storage % (w.b.)
FOR SAFE STORAGE

CROP
FOR ONE YEAR FOR TWO YEAR
Corn 13 11
Wheat 13-14 11-12
Barley 13 11
Sorghum 13 10-11
Pea beans 17 -
Rice 13 -
Soyabeans 13 10
II) EMC: - Most of agricultural products, specially the food grains absorb moisture from
environment or loose moisture. At a particular condition the moisture content of grain
depends upon the temperature and relative humidity of environment. If the vapour pressure of
water present in grains is more than the vapour pressure of water vapours in the air, the water
present in grain vaporises and diffuses in the atmosphere. Alternatively, if the vapour pressure
of water present in grain is less than the atmospheric vapour pressure, grain will absorb
moisture from atmosphere. This property of gaining or loosing of moisture as per the
atmosphere condition is known as hygroscopicity.
The moisture content attained by a grain with respect to a set of atmosphereic
temperature and relative humidity is called the EMC. In such condition, the grain moisture is
in equilibrium with surrounding air.
Methods for determination of EMC. There are two methods for determination
of EMC -
i) Static Method: -
In the static method, the grain is allowed to come to equilibrium with the
surrounding still air without any agitation. This method is time consuming; at high relative
humidities mould growth in the grain may take place before equilibrium is reached.
ii) Dynamic Method: -
In the dynamic method, the air is generally mechanically moved. The dynamic
method is faster and is thus preferred. The EMC is to be determined under constant relative
C.O.E.&T.,Akola 10
humidity and temperature conditions of air. Generally, a thermostat is used to control the
temperature and aqueous acid or salt solution of different concentrations are used to control
the relative humidity of air.
TABLE 2.2 : Grain equilibrium moisture content, %, Wet basis, Relative humidity, %
Humidity
GRAIN 10 20 30 40 50 60 70 80 90 100
Temp0C
1
Paddy 23 4.9 7.3 8.7 9.8 12.4 13.5 15.9 19 -
0.9
1
Paddy 30 - 7.1 8.5 10 11.9 13.1 14.7 17.1 -
0.9
Paddy 44 - - - - - 10.3 12.3 14.3 16.5 -
1
Wheat white 25 5.2 7.5 8.6 9.4 11.8 13.7 16 19.7 26.3
0.5
1
Wheat 32 - 5.3 7 8.6 11.5 12.9 14.3 - -
0.3
Wheat 49 - - 6.2 7.4 9.6 10.4 11.9 13.6 - -
Shelled corn
25 5.1 7.2 8.5 9.8 11.2 12.3 13.9 15.5 18.9 24.6
(WD)
Shelled corn
32 - - 5.3 6.6 8.3 10.2 12.1 13.9 - -
(YD)
Shelled corn
49 - - - 5.3 6.5 7.8 9.3 10.7 - -
(YD)
Shelled corn 1
70 3.9 6.2 7.6 9.1 11.9 13.9 15.2 17.9 -
(YD) 0.4
Sorghum 25 4.4 7.3 8.6 9.8 11 12 13.8 15.8 18.8 21.9
1
Sorghum 32 - 7 8.7 11.8 12.2 13.1 14.8 - -
0.2
1
Sorghum 70 - 6.6 8 9.4 11.6 12.7 14.3 - -
0.7
1
Oats 25 4.1 6.6 8.1 9.1 11.8 13 14.9 18.5 24.1
0.3
1
Barley 25 4.4 7 8.5 9.7 12.1 13.5 15.8 19.5 26.8
0.8
1
Rye 25 5.2 7.6 8.7 9.9 12.2 13.5 15.7 20.6 -
0.9
C.O.E.&T.,Akola 11
III) DETERMINATION OF DRYING CONSTANT: -

There are two methods of determination of drying constant -
i) Graphical Method: -
The drying constant, K can be worked out easily by finding out the slope of the
straight line.
1
.1
Moisture Ratio ,M-Me / M0Me
y
.01
.001
20 40 60 80 100 120 140 160 180 200 210 220
Drying Time, Min

Graph to calculate drying constant
ii) Half life period method: -
If the time of one - half response in a drying process be defined as the Number
of hours necessary to obtain a moisture content ratio of one-half, then drying equation.
M − Me
= Exp [- Kθ] can be written as -
Mo − Me
1 In 2
= exp[−Kθ1 / 2 ] or θ1 / 2 =
2 K
1 In 4
and = exp [−Kθ 1 / 4 ] or θ 1 / 4 =
4 K
Therefore, by knowing the values of θ1/2 or θ1/4, K can be found out.
C.O.E.&T.,Akola 12
IV) DRYING EQUATION:-

Based on Newton’s equation for heating or cooling of solids, a simple drying
equation is derived as follows-
dt
The Newton’s equation is- = −K ( t − t e )
dθ
If the temperature term t is replaced by the moisture term M, then

dM
= − K (M − M e ) ......................... (1)
dθ
where M = Moisture content (d.b), %

θ = time, hr,
Me = EMC, (d.b), %
K = drying constant , 1/hr
Rearranging the equation (1)
dM
= −Kdθ
M − Me
Integrating the above equation within proper limits, we get

M − Me
= exp[−Kθ]
M0 − Me
1 Mo − Me
or θ= In
K M − Me
Mo − Me
is known as the moisture ratio, M.R.
M − Me
V) THIN LAYER DRYING: -

Thin layer drying refers to the grain drying process in which all grains are fully
exposed to the drying air under constant drying conditions. i.e. at const air temperature and
humidity. Generally, up to 20 cm thickness of grain bed (with a recommended grain ratio) is
taken as thin layer. All commercial flow dryers are designed on thin layer drying principles.
i) Constant rate period: -
C.O.E.&T.,Akola 13
Some crops including cereal grains at high moisture content are dried under
constant rate period at the initial period of drying. Falling rate period follows subsequently.
As for example, wheat is dried under constant rate period when its moisture content exceeds
72%.
In the constant rate period the rate of evaporation under any given set of air
condition is independent of the solid and is given set of air condition is essentially the same as
the rate of evaporation from a free liquid surface under the same condition. The rate of drying
during this period is dependent upon.
 Difference between the temperature of air and temperature of the wetted surface at
constant air velocity and relative humidity.
 Difference in humidity between air stream and wet surface at constant air velocity and
temperature.
 Air velocity at construction air temperature and humidity.
Under adiabatic and controlled drying air conditions, the temperature of wetted
surface attains the wet bulb temperature. In the constant rate period drying takes place by
surface evaporation and moisture moves by vapour pressure difference. The moisture content
at which the drying rate ceases to be constant is known as the critical moisture content of the
solid. The average critical moisture content Xc for a given type of material depends upon the
surface moisture concentration, bed thickness, rate of drying and characteristics of solids such
as shape, size and the drying conditions.
ii) Falling - rate period: -
Cereal grains are usually dried entirely under falling - rate period. The falling -
rate period enters after the constant drying rate period and corresponds to the drying cycle
where all surface is no longer wetted and the wetted surface continually decreases until at the
end of this period the surface is dry.
The falling rate period is characterised by increasing temperature both at the
surface and within the solid. Further more, changes in air velocity have a much smaller effect
C.O.E.&T.,Akola 14
than during the constant rate period. The falling rate period of drying is controlled largely by
the product and is dependent upon the movement of moisture within the material from the
center to the surface by liquid diffusion and the removal of moisture from the surface of the
product.
The falling rate period of drying can be divided into two stages -
(a) Unsaturated surface drying.
(b) Drying where the rate of water diffusion within the product is slow and is the controlling
factor.
Practically all cereal grains are dried under falling rate period if their moisture
content is not very high.
iii) Remarks on thin layer Drying: -
None of the theoretical equations represents the drying characteristics of grains
accurately over a wide range of moisture and temperature, on account of the following
limitations -
 The theoretical drying equations are based on the concept that all grains in thin layer
are fully exposed to the drying air under constant drying conditions and dried
uniformly. Therefore, there is no gradient in thin layer of grain, which is not true for
finite mass depth.
 The grain drying equation developed from diffusion equations are based on the in
correct assumptions that Dv and K are independent of moisture and temperature.
 It is not possible to choose accurate boundry conditions and shape factors for drying of
biological materials.
 Drying equation developed from Newton equation for heating or cooling does not take
into account of the shape of the material.
Therefore, the uses of theoretical drying equations are limited. However, if
accurate results are not desired and the values of Dv and K are known then the theoretical
drying equation can be used and give fairly good results within a limited range of moisture.
C.O.E.&T.,Akola 15
Many empirical drying equation for different cereal grains are found to be
useful and frequently used as they give more accurate results in predicting drying
characteristics of a particular grain for a certain range of moisture, temperature, air flow rate
and relative humidity. A few empirical drying equation are presented below: -
Becker (1959) proposed the following equation for wheat: -
MR = 1 - 8.78 (Dv θ)1/2 + 13.22 (Dv θ )
For (Dv θ )1/2 < 0.0104
MR = 0.509 x exp [- 58.4 Dv θ]
For (Dv θ)1/2 ≥ 0.0104
where, Dv = 7.135 e-19944/T
Dv = m2/hr, θ = hr and T = 0K
Based on drying equation for planar symmetry Pabis and Henderson (1961)
developed the following expression for diffusivity for thin layer drying of corn
D v corn = 5.853 x 10-10 exp [-12502/T] on the basis of drying equation for
sphere, the following expression for drying constant K corn has been developed -
K corn = 5.4 x 10-1 exp [- 9041/T]
Where k = 1/sec, T = 0K
VI) DEEP BED DRYING: -
Moisture content of paddy (%)
In deep bed drying all the grains in the dryer are not fully exposed to the same
condition of drying air. The condition of drying air at any point in the grain mass changes
with time and at any times it also changes with the depth of the grain bed. over and above the
rate of overflow per unit mass of grain is small compared to the thin layer drying of grain. All
on farm static bed batch dryers are designed on deep bed drying principle. The condition of
drying in deep bed is shown in figure.
C.O.E.&T.,Akola 16
Drying time in hr.
Fig.2.1
The drying of grain in deep bin can be taken as the sum of several thin layers.
The humidity and temperature of air entering and leaving each layer vary with time depending
upon the stage of drying, moisture removed from the dry layer until the equilibrium moisture
content is reached. Little moisture is removed, rather a small amount may be added to wet
zone until the drying zone reaches it. The volume of drying zone varies with the temperature
and humidity of entering air, the moisture content of grain and velocity of air movement.
Drying will cease as soon as the product comes in equilibrium with the air.
i) Time of advances of drying front
The time period taken by the drying front to reach the top of the bin is called
the max drying rate period.
The time taken by the drying front to reach the top of the bed can be calculated
by -
Wa (M 1 − M x )
= A G ( H s − H 1 ) θ1
100
OR
Wa (M 1 − M x )
θ1 =
A G (H S − H1 ) 100
Where - M1 = Initial moisture content of grain ( d.b) %

Mx = Ave moisture content (d/b) % at the end of the drying front advance at the top.
θ1 = Time of advance, hour.
A = C/s area of dryer, through which air passes, m2
C.O.E.&T.,Akola 17
G = Mass flow rate of dry air, Kg/hr m2

Hs = Humidity of the saturated air leaving the dryer Kg./kg.
H1 = Humidity of the air entering in to the dryer, Kg/Kg.
wd = Weight of dry grain in the bin, Kg.
ii) Decreasing rate period: -

As soon as the drying front reaches the top of the bin, the rate of drying. Starts
decreasing and is termed as decreasing rate period. The time of drying for this decreasing rate
period can be expressed by -
1  Mx − Me 
θ2 = In 
K  M − Me 
where, θ2 = Time of drying during decreasing rate period, hr.

Me = Equilibrium moisture content of grain (db)
K = Drying constant, 1/hr.
M = Average moisture content (db) at the end of decreasing rate period.
Mx = Average initial moisture content (db) at the beginning of decreasing period.
∴ The total drying time for grains in the bin is -
Total drying time , θ = θ1 + θ2
iii) Remark on deep bed drying: -
(1) If drying air at high relative humidity and relative low temperature is used, then the total
drying time will be very long due to slow rate of drying which may cause spoilage of grains.
(2) The correct choice of air flow rate is very imp.
(3) Drying air at high temperature cannot be used due to the development of moisture
gradients within the grain bed. It leads to non - uniform drying of grain. In general an air
temperature of 400C ( 150C rise) is recommended for deep bed drying.
C.O.E.&T.,Akola 18
VII) EFFECTS OF DIFFERENT FACTORS ON THE DRYING PROCESS: -

The drying rate is depend upon many factors, namely air temperature, air flow
rate, relative humidity, exposure time, types, variety and size of grain, initial moisture content,
grain depth, etc. of them, first four factors are imp. They are -
i) Effect of air temperature: -
The rate of drying increases with the rise of air temperature. But the
equilibrium moisture content falls as air temperature increases.
ii) Effect of air velocity: -
Henderson and pabis found that air rate has no observable effect on thin layer
drying of wheat when air flow was turbulent. A/c to them, air flow rate varying from
10cm3/sec/cm2 to 68 cm3/sec/cm2 had no significant effect on the drying rate of wheat. But in
case of paddy and corn it has been found that air rate has some effect on rate of drying.
iii) Effect of air humidity: -
When the humidity of air increases the rate of drying decreases. The effect is
much smaller in comparison to the effect of temperature changes.
iv) Effect of air exposure Time: -
In the case of intermediate drying, drying rate of grain depends on its exposure
time to the drying air in each pass. Total drying time, which is the sum of all exposure times,
is dependent upon exposure time. Total drying time reduces as exposure time decreases.
***
C.O.E.&T.,Akola 19
CHAPTER - III
METHODS OF GRAIN DRYING

So far, drying systems have not been classified systematically. However,
drying methods can be broadly classified on the basis of heat transfer to the wet solid.
According to mode of heat transfer, drying methods can be divided in to :
(a) Conduction drying (b) Convection drying and (c) radiation drying. There are other
methods of drying also, namely dielectric drying, chemical or sorption drying, vaccum drying,
freeze drying.
Of them, convection drying is commonly used for drying of all types of grain.
Conduction Drying: - When the heat for drying is transferred to the wet solid mainly by
conduction through a solid surface (metallic) the phenomenon is known as conduction or
contact drying. In this method, conduction is the principal mode of heat transfer and the
vaporised moisture is removed independently of heating media. Conduction drying is
characterised by -
a) Heat transfer to the wet solid takes place by conduction through a solid surface, usually
metallic. The source of heat may be hot water, steam, flue gases, hot oil, etc;
b) Surface temperature may vary widely;
c) Dust and dusty materials can be removed very effectively. Conduction drying can be
carried out either continuously or batch wise.
Convection Drying :- In this drying, the drying agent ( hot gases ) in contact with wet solid
is used to supply heat and carry away the vaporised moisture and the heat is transferred to the
wet solid mainly by convection. The characteristics of convection drying are -
a) Drying is dependent upon the heat transfer from drying agent to wet material.
b) Steam heated air, direct flue gases of agricultural waste, etc. can be used as drying agent ;
c) Fuel consumption per kg of moisture evaporated is always higher than that of conduction
drying.
C.O.E.&T.,Akola 20
Convection drying is most popular in grain drying. It can be carried out either
continuously or batch wise.
Convection drying further classified as -
Natural air drying: - The unheated air as supplied by nature is utilised.
Supplemental heat drying: - drying with supplimental heat just sufficient amount of heat
(temperature rise 50 to 100 C) only is supplied to drying air.
Heated air drying:-
In heated air drying air is heated to a considerable extent. The natural air
drying and drying with supplemental heat method which may require one to four weeks or
even more, heated air drying is most useful when large quantity of grain is to be dried within a
short time.
Radiation drying :-
Radiation drying is based on the absorption of radiant energy of the sun and its
transformation in to heat energy by the grain, sun drying is an example of radiation drying.
The effectiveness of sun drying depends upon temperature and relative humidity of the
atmospheric air, speed of the wind, type and condition of the grain, etc.
Sun drying: -
Sun drying is the most popular traditional method of drying. A major quantity
of grain is still dried by the sun in most of the developing countries.
Infra - Red Drying: -
Infra-red rays can penetrate into the irradiated body to a certain depth and
transformed into heat energy, special infra red lamps used as generators in infra red radiation.
Radiation dryers have been used in many countries for drying the painted surfaces of
machinery, textile industry and food industries.
Dielectric drying :-
In dielectric drying, heat is generated within the solid by placing it in a fixed
high frequency current. In this method, substance is heated at the expense of dielectric loss
C.O.E.&T.,Akola 21
factor. The molecules of the substance, placed in a field of high frequency current are
polarized and begin to oscillate in accordance with the frequency. The oscillations are
accompanied by friction and thus a part of the electric energy is transformed into heat. The
main advantage of this method is that the substance is heated with extraordinary rapidity.
Chemical drying :-
Various chemicals such as sodium chloride, calcium propanate, copper
sulphate, ferrous sulphate, urea etc have been tried for the preservation of wet paddy of these,
common salt has been proved to be effective and convenient. The common salt absorbs
moisture from paddy but it cannot penetrate in to endosperm through husk layer. This is
unique property of paddy.
Sack drying: -
This method is particularly suitable for drying of small quantity of seed. The
grain bags are laid flat over holes cut on the floor of a tunnel system so that heated air can be
forced up through the grain from an air chamber underneath.
***
C.O.E.&T.,Akola 22
CHAPTER - IV
GRAIN DRYERS
Grain dryers can be divided in to two broad categories, unheated air dryers and
heated air dryers. Different types of grain dryers of both groups have been discussed in this
chapter.
I) UNHEATED AIR DRYERS: -
Unheated or natural air-drying is usually performed in the grain storage bin.
Natural air-drying is commonly used for on farm drying for a relatively small
volume of grains. Either full bin or layer drying system is employed in natural air drying.
The period of drying for either system may be as long as several weeks depending on the
weather. In layer drying, the bin is filled with a layer of grain at a time and drying, is begun.
After the layer is partially dried, other layers of grain are added periodically, perhaps daily
with the continuation of drying until the bin is full and whole grain mass is dried. In full bin
drying a full bin of grain is dried as a single batch. Then the drying bin is used for storage
purposes. The air flow rate provided is relatively low. Though natural air is supposed to be
used, an air heating system should be kept so that supplemental heat may be supplied to
natural air during rainy seasons. Grain containing moisture more than 20 % should not be
dried with natural air. As in natural air drying the grain is aerated and stored in the same unit,
the complete installation simply consists of a storage unit equipped with ducts for air
distribution and devices for air exhaustion and a blower.
II) HEATED AIR DRYERS :-

Heated air dryers of different types are as follows.
i) Deep bed dryers :- These batch in bin dryers are of large capacities to several hundred
tonnes. The most common shapes are round or rectangular. To operate deep bed dryers
efficiently following rules may be followed :-
C.O.E.&T.,Akola 23
 An air flow rate of 2.94 - 3.92 m3/minute per tonne is

recommended. Rates above 3.92 m3/minute per tonne may
result in uneven drying and is expensive in operation.
 If the moisture content of grains is up to 18% the layer
depth of grain should be limited to 3 m and for above 18%
moisture depth recommended is 2.5m.
 The net perforated are of the floor should be 15% of total
floor area. Air velocity of 300 m/minute through opening
is preferable. Fig. Deep bed dryers.
1. Exit air 2.Wet grain 3. Drying
ii) Flat bed dryer :- zone 4. Dry grain 5. Blower
In the flat bed batch type dryer

surface area of dryer is more and depth of drying
layer is less. These dryers are of usually 1 - 2 tonne
capacity. Grains are spread 0.6 to 1.2 m deep over
the perforated floor and dried. The main
advantages are
Fig. Flat bed dryer
 The whole batch is dried quickly. 1. Exit air 2. Plenum chamber 3. Blower
 There is less likehood of over drying.

 Lower air pressure is required to force the drying air.
iii) Continues flow dryers :-
These dryers are columner type in which wet grains flow from
the top to bottom of the dryers. These dryers are of two types.
1) Mixing and 2) Non - mixing.
1) Mixing type continuous flow dryers :- When the grains are
diverted in the dryer, it is called a mixing type dryer. Drying is
Fig. Continuous flow dryer (mixing)
accomplished by forcing heated air across the falling 1.feed hopper2.exit air
3.plenum chamber 4.dry material outlet
layers of grains.
C.O.E.&T.,Akola 24
In mixing dryers, baffles are provided to cause the grains to mix during their
downward flow. These dryers use low air flow rates of
50-95m3/min tonne and high drying temperature of
650C Zig-Zag columns enclosed by screens on both
sides are used primarily to achieve mixing action during
drying process.
2) Non-Mixing dryers :- Baffles are not provided in
the column and drying takes place between two parellel
screens, 15-25 cm apart. In these dryers high air flow
rates of 125-250 m3/min - tonne can be used. Drying
Fig. Continuous flow dryer (non mixing)
air temperature of 540C used in non mixing dryers. 1.feed hopper2.plenum chamber 3.exit air
4. dry grain outlet 5.screened grain column
iv) Recirculating dryers :-
In this type, a multipass
procedure is used to avoid excessive drying stress.
During each pass, the grain are exposed to the
heated air for short time ( 15-30 minutes ) and
about 1 - 3 % of moisture is removed. Drying
temperature is 60 - 800C is used. Drying is faster
and effective because of continuous movement of
grains during short drying times.
Fig. Recirculatory dryer's
1.elevator 2.tempering bins 3.wet material
4.semidried material 5.conveyor
v) L. S. U. dryer :- The design of this continuous dryer was developed at the Lousiana State
University called LSU dryer. It is a mixing type continuous flow dryer. The layers alternate
between hot air intake and exhaust air outlets and are staggered to provide mixing. The LSU
dryer is of high capacity and being used in big commercial rice mills.
C.O.E.&T.,Akola 25
Fig. LSU dryer

A' 1.garner 2. duct 3. dry material outlet 4. hopper 5.continuous flow 6.door 7.roof
B' 1. Cross section of drying chamber 1. air exhaust 2. air intake
vi) Fluidized bed dryer :-

It is mainly used for granular material, it also applicable in the drying of
solutions, pastes and liquids sprayed on to the fluidized inert bed. The principle of operation
of fluidized bed dryer is to be provide sufficient air pressure to fluidize a thin bed of
grain/product giving excellent air/grain contact. The drying method is based on ventilating
hot air through the bed of product kept on the support grid. When the air velocity becomes
higher than the critical fluidization velocity, the bed progressively expands until it reaches a
state that of boiling liquid. This
phenomenon is called fluidization.
vii) Rotary Dryer :-
In commercial rotary
dryers the diameter of drum is between
1 to 3 m and length is from 3 to 6 m.
It is operated at slight inclination. The
drum rotates on its axis. The grain
Fig. Continuous flow heated sand medium rotary
flows downward through the rotating dryer
drum and is periodically lifted by
C.O.E.&T.,Akola 26
inclined flights, then dropped, ensuring good air/grain contact. In small scale rotary dryers,
the walls are heated by direct contact with flue gases.
viii) Tray dryer :-
In a tray dryer, many shallow trays are
kept one above the other with a gap between in the
drying chamber. Try dryer is generally used for drying
vegetables. If the heated air is coming from the sides of
drying chamber, the trays may not have perforated
bottom. Products are kept in thin layers in the trays.
Fig. Tray dryer
ix) Tunnel dryer :- 1. exit air 2.blower 3.heater 4. inter space
between trays 5.trays 6. plenum chamber
It is similar to tray dryer. When
the group of trays is moving in a tunnel, the
system becomes a tunnel dryer. The flow of
heated air in a tunnel dryer may be concurrent
or counter current.
Fig. Tunnel dryer
x) Grain drying in bags :- 1.blower 2. heater 3.trays 4.exit air chimney
This method is useful to dry grains in
small quantities. Method requires large number of unskilled labours and more space is
needed. The heated air is forced through the racks and
bags. During drying, the bags are inverted at least once to
accomplish drying on both sides of the bags.
xi) Solar dryers :- Solar drying of agricultural products
can be advantageous to sun drying for the farmers of
developing nations. Two basic principles are inherent in the
operation of solar dryers, firstly solar heating of air
Fig. Direct dryer (natural convention)
and secondly the removal of moisture from the wet 1.exit air2.chimney3.transferable
panel4.bamboo5.air intake 6.clear plastic sheet
material by the heated air.
C.O.E.&T.,Akola 27
CHAPTER - V
SELECTION OF GRAIN DRYERS
Many factors are to be considered before the final selection of the most
suitable type of dryer for a given application. The selection is little but made difficult by a
whole range of dryers in to days market.
The commercial dryers are not enough flexible enough to compensate design
factors and the problems associated with handling of different types of food materials, which
are not taken into consideration previously. For this reason, it is particularly important that all
pertinent points be considered and drying tests be conducted before the final selection for
particular operation.
I) PRELIMINARY DRYER SELECTION :
The important factors to be considered in the preliminary selection of a crop
dryer are as follows :-
i) Physico chemical properties of the crop being handled.
ii) Drying characters of crop.
(1) Type of moisture.
(2) Initial, final and equilibrium moisture content.
(3) Permissible drying temperature.
(4) Drying curves and drying times for different crops with different dryers.
iii) Flow of crop to and from the dryer.
Quantity to be handled per hour.
Continuous or batch generations.
Process during drying and subsequent to drying.
iv) Product Qualities
(a) Colour
(b) Flavour
(c) Shrinkage
C.O.E.&T.,Akola 28
(d) Contamination
(e) Uniformity of drying
(f) Decomposition or Conversion of product constituents.
(g) Overdrying
(h) State of subdivision.
(i) Product Temperature
(j) Bulk density.
(k) Case hardening and
(l) Cracking and other desirable qualities of the end products.
v) Dust recovery problems.
vi) Facilities available at the site of proposed installation.
a) Space
b) Temperature, humidity, cleanliness of air.
c) Availability of fuels.
d) Available electric power.
e) Permissible Norse, vibration dust or heat losses.
f) Source of wed feed
g) Exhaust gas outlets.
II) COMPARISON OF DRYERS :-

The dryers selected are to be evaluated on the basis of drying performance and
the cast data.
Various drying tests for various crops have to be carried out with the dryers
under consideration to determine product characteristics. An approximate cost analysis is also
useful for evaluation of dryers.
C.O.E.&T.,Akola 29
III) FINAL SELECTION OF DRYERS.

From the results of the drying tests and analysis the final selection of the must
suitable dryer can be made.
For successful introduction of any grain dryer at farm level, a few additional
parts are to be borne is mind in the section and design of grain drying system. They are as
follows :-
 The dryer should be of proper size matching with the demand of a farmer ;
 The price of the dryer should be reasonable.
 The design of layer should be simple and made of different cheap and locally available
materials so that it can be manufactured locality.
 It should be easy to operate.
 It should be possible to make the dryer portable if necessary.
 The operating cast should be minimum solar or furnance (i.e. fired with agricultural
waste like hustic shells etc.) air heating system should be introduced in grain drying to
minimise the cast of grain drying.
 The repair and maintenance requirement should be minimum.
 It should be possible to use the dryer for different grains and to be used as a storage bin
later for its maximum utilization.
***
C.O.E.&T.,Akola 30
CHAPTER - VI
DESIGN PROCEDURE OF GRAIN DRYERS
The heated air grain dryers can be divided into three major groups.
1) Static deep bed batch dryers.
2) Continuous - flow - batch dryers. (either mixing or non - mixing type) and
3) Continuous dryer.
Grain dryers mainly consist of
(a) Drying chamber.
(b) Air distribution system.
(c) Direct or indirect air heating system.
(d) Blower.
(e) Control system (if any) and
(f) Grain conveying system (for flow dryers)
The following important factors are taken into consideration in the design of
heated air grain dryers -
DRYER FACTORS: -
(a) Size, shape and type of dryer ;
(b) Grain feeding rate ;
(c) Total drying time ;
(d) Air flow pattern and air distribution system;
(e) Depth of grain bed in the dryer; and
(f) System of cooling grain (if any).
AIR FACTORS :-
(a) Velocity and air flow rate per unit mass of the grain.
(b) Temperature and relative humidity's of the heated air and exhaust air.
(c) Static pressure of the air at which it is blown and
(d) Average ambient conditions.
C.O.E.&T.,Akola 31
GRAIN FACTORS :-
(a) Type, variety and condition of grain.
(b) Initial and final moisture contents of grain.
(c) The usage of dried grain and
(d) Latent heat of evaporation of grain moisture.
HEATING SYSTEM: -
(a) Type of fuel and rate of fuel supply.
(b) Type of burner (for liquid fuel) or type of furnace (for solid fuel) and
(c) Type of heat exchanger (for indirect heating system)
IMP. DESIGN FACTORS: -
Following are some of the important design factors -
(1) Size, shape and type of dryer :-
Size or capacity of a dryer is decided by the amount and variety of grain to be
dried per day or for the whole season. The sizes of dryer are express either in terms of
holding capacity of amount of grain to be dried per unit time or the amount of grain passing
through the dryer per unit time.
Thickness of grain layer exposed to the heated air is generally restricted to
room for continuous flow dryers. The designs of the continuous flow dryer are based on thin
layer drying principles whereas static batch dryers are designed in deep bed drying principles.
Choice of a grain dryers largely depends on the situation. Continuous flow
dryers are normally used for commercial purpose whereas static deep bed batch dryers are
used for on farm drying. Farm level batch dryers can be made of locally available materials,
namely, wood, bamboo, etc. if necessary. But commercial big dryers are made of mild steel
sheet, angle iron, channel section supports.
C.O.E.&T.,Akola 32
(2) Calculation of air and heat for heated air dryers i.e. Mass and Heat Balance in grain
drying:-
The air flow rate required for heated air drying systems can be calculated as follows :
The rate of air flow required for drying may be calculated by making heat
balance. The heated air drying system is represented by :
X1.t.c1
AMB. AIR HEATER HEATER AIR EXHAUST AIR
C1V1t1H1,RH1 t2H1,RH2
DRYER t3,H3,RH3
Wd
X2,tG2
where
G = air flow rate, m3/min.
H1, H2 = humidities of ambient and heated air, kg/kg.
H3 = humidity of exhaust air, kg/kg.
RH1, RH2 & RH3 = relative humidities of ambient, heated and exhaust air,
respectively, per cent.
t1, t2 & t3 = dry bulb temperatures of ambient, heated
and exhaust air respectively, 0C.
Wd = total weight of bone dry grain in the dryer, kg.
X1, X2 = initial and final moisture contents of grain, kg/kg.
t G1 , t G 2 = initial and final grain temperatures, 0C.
v1 = initial humid volume, m3/kg.
Heat supplied by drying air, qa, kcals :
qa = (0.24+0.45 H1) G' (t2 - t3 ) θ
C.O.E.&T.,Akola 33
Where G' = rate of air supply, kg/min.

θ = total drying time, min.
Amount of heat required :
Heat required for evaporation of moisture from the grain, q1, kcals :
q1 = W d ( X1 - X2 ) λ
where,
λ = average value of latent heat of vaporisation of moisture from the grain
kcals/kg.
Sensible heat required to raise the temperature of the grain and its moisture, q, kcals :
q = Wd C g ( t G 2 − t G1 ) + Wd C w ( t G1 − t G1 )X1
where
Cg, Cw = specific heats of grain and water respectively,
K cal/kg 0C
Therefore
q a = q1 + q
or G' = (0.24+0.45 H1) (t2 - t3 ) θ

−
= Wd [(X 1 − X 2 )λ + C a ( t G 2 − t G 2 ) + C w ( t G 2 − t G1 ) X1 ]
Wd [(X 1 − X 2 )λ + C a ( t G 2 − t G1 ) + C w ( t G 2 − t G1 )X 1 ]
or G' =
(0.24 + 0.45 H 1 ) (t 2 − t 3 ) θ
∴ G = G' x v1
where v1 = humid volume.
(3) Calculation of fuel requirement:-
Fuel consumption :
The rate of fuel consumption can be calculated as follows :
q'a
f =− −
η.η b .η ex .C n
C.O.E.&T.,Akola 34
where f = fuel rate, kg/hr.

q'a = total heat required to heat the drying air, kcal/hr.
Cn = Calorific value of fuel, kcal/kg of fuel.
η = efficiency of the heating system.
ηex = efficiency of the heat exchanger.
ηb = efficiency of the boiler, if any.
(4) Design of fan and blowers:-
Selection/Design of a centrifugal blower
For a given set of airflow rate and static pressure, the impeller diameter and
width of blower may be calculated as below,
1 Calculate the specific speed (Ns) for the specific static pressure, air flow rate and designed
motor speed.
N Q
Ns = rpm
p S0.75
Where, N = speed of motor, rpm
Q = air flow rate, cfm
ps = static pressure, inches water gauge.
2. From Fig. 6.1 determine the type of air moving unit which would operate at high efficiency,
at or near peak efficiency at the calculated specific speed. If more than one type of air moving
unit has good efficiency, make the final selection on other factors involved in the application
such as relative cost, size and shape of space available and the characteristics of the air flow
path.
3. From Table 6.1 find the typical value of pressure coefficient Ψ by interpolation, for the type
of fan or blower selected and the value of Ns.
4. Calculate the diameter of the impeller.
C.O.E.&T.,Akola 35
2.35 × 10 8 p S
ψ=
N 2d 2
where Ψ = pressure coefficient

d = diameter of the impeller, inch
5. Find out the typical value of flow coefficient φ from table and then calculate the width.
175Q
W=
φNd 2
Where, φ = flow coefficient
W= width of the impeller, inch
C.O.E.&T.,Akola 36
Table 6.1 Values of specific speeds, typical pressure co-efficient, typical flow co-
efficient and dimensions of centrifugal blowers
Dimension Specifi Typical Typical

c Speed pressure flow
coeff. coeff.
A B C Ns Ψ φ
13,000 1 0.15
1.7(D) 1.5(D) 1.25W+0.1D 20,000 2.0 0.5
40,000 1.0 0.75
4,000 1.4 0.002

1.4(D) 1.35(D) W+0.1D 8,000 1.0 0.01
20,000 0.8 0.10
15,000 1.0 0.08

2.0(D) 1.6(D) W+0.16D 30,000 0.75 0.3
45,000 0.5 0.5
Fig.6.1 Specific speed vs. static

efficiency of various impellers
C.O.E.&T.,Akola 37
A review of manufacturer's literature is done to see that whether blower wheel

of calculated dimensions is available. If it is not available, then slightly smaller or larger
wheel is selected and the performance requirement is revised.
Blower housing:-
The configuration of the housing considerably affects the performance of a
centrifugal blower and thus is as important as the blower wheel. The size of the housing must
be considered keeping in view the space available. The standard housing dimensions
recommended by the blower manufacturers may be followed to maximise performance of a
particular blower wheel. These dimensions are generally given as proportions of wheel
diameter and width and so can be determined after the selected procedure is completed.
The purpose of
centrifugal blower housing as shown in
Fig. 6.2, is to control the air flow from
intake to discharge, and in the process,
to convert the velocity head into the
static pressure head. Pressure conversion
is accomplished as the cross-section of
the air stream increases in the increasing
annular space on the periphery of the Fig. 6.2 Housing of centrifugal blower
blower wheel from cutoff to discharge.
Since the amount of pressure conversion is determined by the scroll configuration, the shape
of the housing considerably affects air performance. The cutoff eliminates almost all free
circulation of air within the housing.
Diffuser angle:-
The increase in annular cross-section in the scroll around a blower wheel is
proportional to the developed length of the wheel periphery (Fig 6.3). The angle between the
C.O.E.&T.,Akola 38
developed scroll surface and blower wheel periphery is called the diffuser angle. Wheel
diameter and diffuser angle determines the shape and dimensions of the scroll.
Fig. 6.3 Scroll development of a centrifugal blower
The diffuser angle can be determined graphically and expressed in terms of

impeller diameter and either the maximum height or maximum width of the housing. Diffuser
angle may be given as,
H 
α h = 12 M − 1 .................................. (1)
 d 
W 
α w = 12 M − 1 .................................. (2)
 d 
As shown by above equations, the diffuser angle decreases if either dimensions

AE or CG decreases. However it is less sensitive to change in AE.
As the diffuser angle increases, the flow rate increases significantly at any
particular static pressure. Diffuser angle also affects performance of the blower in a particular
system.
The diffuser angle generally used as the basis for blower performance data is
10°. Although large diffuser angle improve performance, the relative amount of improvement
gradually diminishes and the size of the housing with respect to the diameter of the blower
wheel becomes too large.
C.O.E.&T.,Akola 39
The housing width may be determined by the following equation

M=1.25 W + 0.1 d .................................. (3)
where, M = housing width
W = impeller width
d = impeller diameter
The optimum diameter is based on a blower wheel mounted close to the inlet
ring and minimal clearance between the wheel back plate and side of the housing.
If the width of the housing recommended for the standard blower wheel is too
large, a narrower housing should be selected. If either dimension AE or CG of the
recommended housing is too large for the space available, a housing with a smaller diffuser
angle should be selected. The resulting reduction in air flow rate should then be determined
and compared to the original requirement.
Calculating diffuser angle:-
The diffuser angle, αh, equation (1) may be calculated with dimensions AE
equal to the maximum dimension Y of the space available (Fig. 6.3).
The diffuser angle, αw, equation (2) may be calculated with dimension CG
equal to the maximum dimension X of the space available.
The smaller of two diffuser angles corresponds to the housing that will fit into
the space available for blower. If the calculated diffuser angle is 4° or less, the housing is too
tight. If possible, a smaller blower wheel that produces the required air performance at a
higher operational speed should be selected.
(5) Drying air temperature :-
Correct choice of drying air temperature for a given type of grain is very imp.
as it has effects on the quality of dried product. The highest allowable air temperature for
drying of grain depends on the type and condition of grain and the usage of dried grain.
The upper limit of drying air temperature for different grain to be used for food, feed and seed
purpose are different and are given in following table.
C.O.E.&T.,Akola 40
(6) Grain parameters :-

The grain factors which affect the rate of drying are as follows :-
 Type, variety and condition of grain.
 Initial harvest moisture content, final moisture and equilibrium moisture content of
the grain.
 Structure and chemical composition of the kernel, seed, coat, husk etc. and
 Foreign materials present in the grain.
The above stated, factors are therefore to be considered in the design of grain
dryers.
Table 6.2 : Bulk densities of grain at different moisture contents
Grain Moisture content % (w.b.) Density Kg/m3

Paddy 14.0 587.9
18.0 615.2
Wheat 11.0 789.8
14.1 756.1
Corn (Shelled ) 13.0 736.9
16.2 720.9
Barley 16.8 592.7
10.8 576.7
Sorghum 12.0 752.9
14.3 752.9
Table 6.3 : Latent Heat of vaporization of grain moisture
Grain Moisture content Temperature 0C Heat of vaporisation
C.O.E.&T.,Akola 41
%(w.b.) Kcal/kg
Wheat 13 38 629.4
13 65 611.6
17 38 589.9
17 65 573.8
Corn 13 38 698.8
13 65 679.4
17 38 644.4
17 65 626.1
Sorghum 13 38 624.4
13 65 606.2
17 38 593.3
17 65 576.6
Water - 38 576.1
- 65 560.0
Table 6.4 : Specific gravity of cereal grains
Grain Moisture content % (w.b.) Specific gravity of kernel

Rice 8.6 1.36
Wheat 8.5 1.41
Corn 6.7 1.29
Barley 7.5 1.42
Millets 9.4 1.11
Oats 10.33 0.99
Table 6.5 : Thermal properties of cereal grains.
Grain Moisture Temperature Specific heat Thermal Thermal

content range 0C kcal/kg 0C conductivity diffusivity
%(w.b) kcal/m hr 0C m2/hr
Paddy 12 - 0.3934 - -
15 - 0.4255 - -
17 - 0.4469 - -
Wheat 9.2 - 0.370 0.1198 0.000414
11.7 26.50 to 31.0 - 0.128 -
Wheat, hard 12 - 0.367 - -
C.O.E.&T.,Akola 42
white
15 - 0.391 - -
Wheat, soft 14.4 9.0 to 23.0 0.5 0.116 0.000295
white
Corn, yellow 9.8 8.3 - 23.2 0.438 0.1308 0.000338
dent
13.2 26.6-31.1 - 0.102 -
Oats 12 - 0.380 - -
15 - 0.415 - -
17 - 0.439 - -
(7) Air flow pattern and air distribution :-
Any one of the three systems of airflow namely crosses flow; counter flow and
co-current flow can be adopted in flow type grain dryers. Generally cross flow of air is
preferred. Double screen and baffle type of columnar dryers have a plannum chamber and
L.S.U dryer has inverted V shaped air channels for uniform distribution of air throughout the
drying chamber. The deep bed batch dryer has the plenums at the bottom of the graindrying
chamber.
Aeration system
Both propeller and centrifugal types of blowers are used for aeration.
Centrifugal blowers may have cither forward-curved or backward-curved blades.
The airflow and static pressure requirements for different types of grains and
for different depths of grains are given in Table.
Air distribution system
Sufficient care should be taken in selecting and designing the air distribution
System so that .air is uniformly distributed throughout the grain bulk and void pockets are
avoided. There are five major systems of air distribution :
(a) Perforated floor,
(b) Central horizontal duct,
(c) Main duct and laterals, and
(d) Vertical slatted duct.
C.O.E.&T.,Akola 43
(a) Perforated flow

The circular storage bin can be fitted with the perforated false floor through
which unheated air is blown. Though the system is suitable for small and medium sized round
bins and for small depths of grain, it is used for large rectangular bins and for higher grain
depths as well.
(b) Central horizontal duct
This system is used in the quonset type units. This type of duct with openings
in the wall can distribute air more uniformly through the grain bulk.
(c) Main duct and laterals
The system -of main duct and laterals is most commonly used and is adopted
in ground, square and rectangular bins. The laterals are open at the bottom and raised off the
floor of .the bin so that the air can flow through the mass. The literals are inverted V or U or
rectangular in shape and are made of wood or steel or concrete or ferro-cement. The laterals
are spaced in accordance with the size of the storage unit, quantity of grain to be aerated or
dried and depth of the grain (Figs. 6.4 to 6.6). In round bins the ducts can also be placed in the
Fig 6.4
form of a ring on the bin floor.
Fig. 6.7
Fig 6.5
Fig. 6.6 Four common floor layouts for the Fig. 6.8
main duct and lateral in bins
C.O.E.&T.,Akola 44
Fig 6.9
(d) Vertical ducts

This system consists of either a vertical slatted duct or a central vertical
perforated tube (Fig.6.7). The air is blown, through the slots or perforations and is spread
laterally through the grain mass.
(8) Conveying and Handling System :-

Bucket elevators, vertical screw lifts for feeding, hopper bottom with proper
inclination for grain discharging are commonly used. Forced discharge mechanism with
slowly rotating fluted rolls are used for better control of the feed rate and drying rate. Dried
grain from the dryer is usually conveyed to different place by belt conveyor or screw
conveyor and bucket elevator.
(9) Air Heating System :-

Generally direct firing system are used for gaseous and liquid fuels and
indirect heating system using heat exchangers is employed for solid fuels. But direct flue gas
from the husk fired furnace can also be efficiently used for the grain drying. The drying cost
can be further reduced by introducing solar - cum - husk fired grain drying system.
Table 6.6 : Approximate Net Heating Values of Various Fuels
C.O.E.&T.,Akola 45
Fuel Density Heating Value
kg/m3 lb/ft3 Kcal/kg kJ/kg Btu/lb
Agricultural Crop residues
Bagasse, dry 4443 18,600 8,000
Corn stalks, dry 3965 16,600 7,150
Cotton batting 3953 16,550 7,114
Cottonseed hulls 4778 20,000 8,600
Newspaper 4378 18,330 7,880
Pecan shells 4940 20,680 8,890
Straw 3332 13,950 6,000
Wheat (Straw) 45 4167 17,445 7,500
Alcohol – gas
Ethyl (C2H5OH) 1.965 0.122 6625 27,750 11,930
Methyl (CH3OH) 1.363 0.085 5043 21,115 9,080
Alcohol - liquid (pure)
Ethyl (C2H5OH) 815.3 50.9 6268 26,240 11,280
Methyl (CH3OH) 796.1 49.7 4677 19,580 8,420
Coal
Anthracite 7112 29,772 12,800
Bituminous Specific Gravity=1.12- 7500 31.401 13,500
1.35
Semi-bituminous 8112 33,960 14,600
Manufactured briquets 7251 30,355 13,050
Fuel oil lb/gal
No.1 813.6 6.79 10384 43,473 18,690
No.2 863.9 7.21 10173 42,590 18,310
C.O.E.&T.,Akola 46
No.4 932.2 778 9856 41,263 17,740
No.5 938.2 7.83 9800 41,030 17,640
No.6 964.2 8.05 9545 39,960 17,180
Gasoline 736.9 6.15 10500 43,960 18,910
Kerosene 817.2 6.82 10367 43,403 18,600
Gas ( CnH2n+2) lb/ft3
Natural, methane (CH4 ) 0.680 0.0424 11956 50,055 21,520
Ethane (C2H6) 1.287 0.0803 11343 47,488 20,416
Manufactured 0.769 0.048 5878 24,610 10,580
Propane (C3H8) 1.924 0.120 11081 46,390 19,944
Butane (C4H10) 2.532 0.158 10934 45,775 19,680
Wood dry 5000 20,934 9,000
10) Safety features

Safety Features of Burner
Farmers, insurance companies, equipment manufacturers, and equipment
dealers are interested in the safe operation of burners used for heated air drying systems.
Important considerations of an installation designed for safe operation include the following:
(1) a flame control to shut off the fuel supply in the case of ignition failure, (2) a high
temperature limit switch which will stop the burner but allow the fan to continue to operate,
(3) a temperature control on the bonnet of the burner to prevent overheating of heater, (4)
proper electrical wiring connecting the fan and burner to the electric circuit (Fig. 7.3). All
units should be designed to "fail safe."
C.O.E.&T.,Akola 47
Fig. 6.10 Automatic control system for a portable dryer heater
There is a tendency to overemphasize the danger of starting a fire from

particles of trash getting into the open flame of a heated air dryer operated outside. The
velocity of the air passing the flame is so great that straw, chaff, and even cotton lint carried
into the airstream do not remain in contact with the flame long enough to ignite, although
such a circumstance is not recommended.
Safety Features of Installation
A properly designed heater can be used in an unsafe manner. Safety features of
an installation should include the following: (1) fuel pump and piping located a safe distance
from the flame of the burner, (2) the fuel feed line from the tank to the fuel pump protected
from mechanical injury, (3) the fuel tank located at least 5 m (16 ft) from the bin and other
buildings, (4) oil drums refilled a safe distance from the drying unit or the drying unit shut
down when the drums are refilled, (5) separate drying and storage installations provided for
safe and efficient grain drying by heated air, (6) if the crop is dried in batches, on wagons, or
in a batch bin, drying equipment separated from the main building by 3 m (10 ft), (7) the
C.O.E.&T.,Akola 48
drying unit connected to the bin by a duct of flameproofed canvas or other noncombustible
material. Insurance companies may require that a special permit be obtained to install and use
a heated air crop dryer. The insurance company representatives will determine if the
installation is reasonably safe, and if approved, a permit may be purchased.
CHAPTER - VII
DRYER PERFORMANCE & TESTING
Dryer performance can be expressed in terms of various efficiency factors
which are given below :-
(a) Thermal efficiency :-
Thermal efficiency can be defined as the ratio of the latent heat of evaporation
credited to the heat energy of the fuel charged.
Thermal efficiency can be expressed mathematically as follows :-
 dM 
 Wd
 dθ 
q
C.O.E.&T.,Akola 49
where
60VA
q= (h 1 h 0 )
v
dM
= drying rate, Kg / hr Kg
dθ
Wd = weight of dry material, Kg.

τ = latent heat of evaporation, K cal/Kg
q = rate of heat flow, K cal /hr
V = air rate, m3/min m2
A = area, m2
v = humid volume of air ( at the point of rate measurement ) m3/Kg.
h1 and h0 = enthalpy of drying and ambient air K cal/Kg.
(b) Heat utilization factor :- (HUF)
HUF may be defined as the ratio of temperature decrease due to cooling of the
air during drying and the temperature increases due to heating of air.
Heat utilised t 1 − t 2
HUF = =
Heat applied t1t 0
HUF may be more than unity under certain drying conditions.

(c) Coefficient of performance :- ( C.O.P.)
The COP of a grain dryer is express mathematically as follows :-
t −t
COP = 2 0
t1 − t 0
where :- t2 = dry bulb temperature of exhaust air, 0C

t0 = dry bulb temperature of ambient air, 0C
t1 = dry bulb temperature of drying air, 0C
(d) Relation Between HUF and COP :-
HUF = 1 - COP
C.O.E.&T.,Akola 50
Testing of Grain Dryers

No generalized test procedure can be adopted for all types of grain dryers. The
testing method for static deep bed batch dryer cannot be same as that of continuous flow thin
layer dryers. It is always preferable that test procedure for each type of dryer be designed
separately.
However, for convenience, the dryer testing method can be broadly divided
into two major heads : simple method and rigorous method. Either of these two methods can
be adopted in accordance with the objectives of the test.
a) Simple Method
A simple test procedure is so designed as to determine the approximate
performance of the grain dryer.
The simple test procedure for a batch dryer is tabulated as follows :
Table 7.2 : Test Procedure for the Performance of the Static Deep Bed Batch dryer
Type and model No. of dryer :
Type of grain and variety
Grain 1. Initial weight of wet grain (kg)
2. Final weight of dried grain (kg)
3. Initial moisture content (per cent)
4. Final moisture content (per cent)
5. Dryer loading time (hr)
6. Dryer unloading time (hr)
Air 1. Air flow rate (maximum) (m3/min)
2. Air flow rate (minimum) (m3/min)
3. Max. static pressure (mm water)
4. Min. static pressure (mm water)
5. Average ambient d.b. temp. ( 0C )
6. Average ambient w.b. temp. ( 0C)
7. Average heated air d.b. temp. ( 0C )
8. Average heated air w.b. temp. ( 0C )
C.O.E.&T.,Akola 51
9. Average exhaust air d.b. temp. ( 0C )

Drying capacity 1. Total drying time (hr)
2. Cooling time (if any) (hr)
3. Total moisture evaporation (kg)
4. Rate of moisture evaporation (kg/hr)
5. Rate of dried grain productions (tonnes/hr)
Heater and Fuel 1. Air heating method (oil fired burner/husk fired furnace/steam heat
exchanger)
2. Type of air heating (direct/indirect)
3. When oil fired burner/husk fired furnance is used
(a) type of fuel and cal. value
(b) total fuel consumption (kg)
(c) rate of fuel consumption (kg/hr)
4. When steam heat exchanger is used
(a) incoming steam pressure (kg/cm2)
(b) rate of condensate outflow (kg/hr)
(c) Temperature of condensate ( 0 C)
Power 1. Power consumption for blowing air to burner (KW)
2. Power consumption for pumping oil to burner (KW)
3. Power consumption for blowing heated air (KW)
4. Power consumption for loading and unloading grain (KW)
5. Power consumption for running feed rolls (KW)
Quality of dried 1. Germination of grain before drying (per cent)
grain
2. Germination after drying (per cent)
3. Head yield before drying (per cent-for paddy)
4. Total yield before drying (per cent)
5. Head yield after drying (per cent)
6. Total yield after drying (per cent)
7. Other quality factors
The simple test procedure for continuous flow dryer
Besides the test items tabulated in the above. Table, the following items are to
be taken into consideration for continuous flow dryers :
(1) Moisture content after each pass ( per cent )
(2) Residence time in the dryer for each circulation (hr) ;
(3) Number of passes ;
(4) Tempering time (hr) ;
C.O.E.&T.,Akola 52
(5) Average rate of moisture reduction or rate of moisture evaporation in each circulation
(kg/hr) ;
(6) Rate of grain recirculation (tonnes/hr) ;
(7) Drying air temperature at each pass ( 0 C) ;
(8) Weight of remaining grain in the dryer, elevator, etc.(kg).
b) Rigorous method
Rigorous test procedures for some batch and continuous flow dryers are given
as follows. The whole test procedure can be grouped into the following major heads :
(1) Checking of construction ;
(2) Drying performance test ;
(3) Fan/blower performance test ;
(4) Control system performance test ;
(5) Handling equipments performance test ; and
(6) Checking of different dryer-parts after disassembling (after the drying tests).
(1) Checking of Construction
The purpose of this test is to ascertain the major dimensions, material of
construction and other necessary specifications of the dryer and its accessories.
Investigation items: Specifications of : (a) dryer as a whole, (b) drying chamber with air
distribution system, (c) blower, (d) heating system and (e) conveying units such as bucket
elevator, grain distributor, screw conveyor, belt conveyor, etc. The specifications of the above
items have already been discussed earlier.
(2) Drying Performance Test
The objectives of this test are to determine the drying performance of a dryer
on the basis of rate of drying, rate of consumption of fuel and electricity, heat utilisation,
quality of the dried grain and other operating conditions.
The investigation items have already been tabulated.
(3) Blower Performance Test
C.O.E.&T.,Akola 53
The objective of this test is to determine the performance of the fan/blower

attached with the dryer.
Investigation items : Power input, kw, (b) air flow rate, m3/min., (c) static and total pressure,
mm water, (d) static pressure efficiency and (e) vibration, noise and other working conditions
of the blower.
CHAPTER VIII
SUGGESTED MODELS
DESIGN OF SUGGESTED MODELS FOR DAL MILLS:

Case:- Pulses
Design a rectangular bin batch dryer having hole capacity of 2.5 tonnes of pulses with 12%
w.b.
Solution :- Assume the following data.
Ambient air temperature = 300C
Relative humidity of ambient air = 70 %
Initial moisture content of pulses = 17% w.b.
Final moisture content of pulses = 12% w.b.
Grain inlet temperature = 300C = tG1
Grain Outlet temperature = 700C = tG2
Heated air temperature = 850 = t2
Exhaust air temperature = 400C = t1
Latent heat of water vapour = 600 K cal/Kg (from grain parameters table 6.3)
Thickness of grain bed to be dried = 45 cm
Bulk density of pulses at 12% w.b.m.c. = 770 kg/m3 (from grain parameters
table 6.2)
Dimensions of plenum chamber = 8 x 7 = 56 ft2
Drying time = 1 hr
C.O.E.&T.,Akola 54
Assumption – specific heat of grain = 0.3934 Kcal/Kg0C (from grain

parameters table 6.5)
Height of the dryer
H = height of bin + height of plenum chamber + 3
H = 2.5 + 0.75 + 3 = 6.25 ft
Volume of plenum chamber
V = 8 x 7 x 0.75 = 42 ft3
Volume of drying chamber
2500
V = = 3.247 m 3
770
= 3.24 × 10 9 mm 3
Air requirement :-
- Bone dry paddy = 2500 ( 1 – 0.12 )
= 2200 Kg
m
- Initial moisture content = 17% w.b = × 100 d .b
100 − m
17
= × 100 = 20.482 d.b
100 − 17
m
Final moisture content = 12% W.b.= × 100 d .b
100 − m
12
= × 100 = 13.64 d.b
100 − 12
Weight of moisture evaporated

= Weight of bone dry paddy x ( x1 – x2)
= 2200 ( 0.20482 – 0.1364 )
= 150.604 Kg
From psychrometric chart ( Appendix 1) :-
Absolute humidity of ambient air = 0.019 Kg/Kg
- Humid heat of ambient air
C.O.E.&T.,Akola 55
S = 0.24 + 0.45 H
S = 0.24 + 0.45 x 0.019
S = 0.24855 Kcal/Kg0C
Let G be the rate of air supply in Kg/min
Heat supplied by the air in 60 min
= G. S. ( t2 – t1 ) θ
= G (0.24855) (85-40) x 60
= 6.71.085 G
Heat Utilised :-
i) As sensible heat of grain
= B. D. grain x Sp. Heat of grain x temperature rise
= Wd x Cp9 x ( tG2 – tG1 )
= 2200 x 0.3934 x ( 70 – 30 )
= 34,619.2 Kcal
ii) As sensible heat of water
= total weight of water x sp.heat of water x temperature rise
= Wd (X1) x CPW ( tG2 – tG1 )
= 2200 x 0.20482 x 1.0 x ( 7.0 – 30 )
= 18024.16 K cal
iii) As latent heat of water vapour
= Water evaporated x latent heat of water
= 150.604 x 600 = 90,362.4 Kcal
- Total heat utilized = sum of above heats
= 34,619.2 + 18,024.16 + 90,362.4
= 143005.76 K cal
Suppose heat loss = 10%
Net heat required = 143005.76/0.9 = 1,58,896 Kcal.
C.O.E.&T.,Akola 56
Hence,
671.085G = 1,58896
G = 236.774 Kg/min
- From psychrometric chart humid volume of the ambient air = 0.88 m3/Kg
So air required = 236.774 x 0.884
= 209.308 m3/min
= 209.308 x 35.34
= 7396.94
= 7397 cfm
Static pressure drop
- Surface area of plenum chamber = 8 x 7 = 56ft2
- Since maximum 50% area is perforated area through which air passes = 28 ft2
7397
Air requirement per ft = 264.18 cfm / ft 2
28
from shedd’s curve ( Appendix 2)

60 cfm = 0.7 inch of water per 1 ft grain depth
∴for 264.18 cfm/ft2 = 3.0821 per 1ft grain depth
Depth of grain = 1.5 ft
3.0821
So pressure drop = × 18 = 4.62315 inch of water
12
Packing of grain in bin may cause 50% higher resistance air flow than the values shown
∴Total pressure drop = 6.934725 in of water
Add the static pressure drop from the duct and floor, usually about ¼ in water if the air
velocity is kept at 1,000 fpm or less
∴Total pressure drop = 6.935 + 0.25 = 7.184725 in
= 7.185 x 2.54 = 18.25 cm
- Density of air = 1.13 Kg/m3
C.O.E.&T.,Akola 57
18.25 1000
Pressure drop in terms of air column = ×
100 1.13
= 161.5 m
H.P. required
Height of air column (m) × air flow rate ( kg / min)
=
4500
161.5 × 236.774
=
4500
= 8.49 ≈ 9 hp ≈ 10 hp
Heating System :-
Fuel consumption :-
Diesel
q' a
F=
η, η b η ex C n
158896
=
1 × 1 × 41263 / 4.1865
= 16.12 ≈ 17 Kg / hr
Same as above
Petrol = 15.13 ≈ 16 Kg/hr Bagase dry = 35.76 ≈ 36 Kg/hr
Kerosene = 15.32 ≈ 16 Kg/hr Cotton batting = 40.19 ≈ 41 Kg/hr
L.P.G. = 14.33 ≈ 15 Kg/hr Wheat straw = 38.13 ≈ 39 Kg/hr
Wood = 31.77 ≈ 32 Kg/hr
Selection/Design of a Centrifugal blower :-
1) Specific speed (Ns)
N Q
Ns = rpm Where Q = cfm ; Ps = inch
Ps 0.75
C.O.E.&T.,Akola 58
1440 7397
=
7.185 0.75
= 28220.85 ≈ 28221 rpm
= 28221 rpm
2) Figure 6.1 indicates that two types of air units are quite efficient at Ns = 28,221 rpm a
forward curved. Centrifugal blower and a backward curved (wide) centrifugal blower. While
the forward curved centrifugal blower seems to have a substantially higher static efficiency
Table shows that both the pressure and flow coefficient of forward curved centrifugal blower
are high. Therefore, a forward curved unit is selected.
3) from Table 6.1 ψ = 1.5
2.35 × 108 Ps
4) Since ψ=
N 2d 2
2.35 × 10 8 × 7.185
d2 =
(1440) 2 1.5
d = 23.29 ≈ 24” = 609.6 ≈ 610 mm

5) from table 6.1 φ = 0.62
Q
W = 175
φ Nd 2
7397
W = 175 ×
0.62 × 1440 × ( 23.29) 2
W = 2.67” = 67.89 ≈ 68 mm
Blower housing
Width of housing = M
M = 1.25 W + 0.1 d
M = 1.25 x 68 + 0.1 x 610
M = 146 mm
Diffuser angle
C.O.E.&T.,Akola 59
 146 
αw = 12 − 1
 610 
αw = 9.12 ≈ 10 0 C
Table 8.1 :- Air, fan, heat, fuel, Blower and H.P. requirements for Drying pulses with
heated air from different percentage of m. c. & different grain depths
Pulses Capacity 2.5 tonnes/hr
Grain mois- Practica Static Recomm- Heat Fuel Blower H.P.

ture cont-ent l grain pressure ended required consumption requirement Required
% w.b depth, ft drop water minimum air Kcal/hr , Kg/hr
inch/mm flow rate,
of water cfm or
m3/min
Ini Final
17 12 1.5 7.19/183 7397/210 158896 Diesel-17 Ns=28221rpm 10
Kerosene-16 d=610mm
LPG-15 W=68mm
15 12 1 4.079/104 5328/151 114497 Diesel-11 Ns=36620rpm 3-5
Kerosene-10 d=446mm
LPG-9 W=82mm
Suggested Drawing
C.O.E.&T.,Akola 60
Technical Specification
Model 1 Model 2
Heat output Kcal/hr 1,60,000 1,15,000
Drying capacity kg/hr 2,500 2,500
Moisture removing %/hr 5 3
capacity (from initial
moisture content of
17)
Fuel consumption
1) Diesel Kg/hr 17 17
2) Kerosene Kg/hr 16 10
3) L.P.G. Kg/hr 15 9
Power Supply 415 V 50 Hz 3 phase 4 wire
Electric loading
Blower motor HP 10 3.5
Fuel pump motor HP 0.5 0.5
Cost Estimation
Particulars Cost Rs. Reference

Burner ( Diesel fired) 40,000 Quotation (attached )
Heat Exchanger 10,000 Local made
Blower (centrifugal) 5,000 Local made
Blower motor 15,000 Standard
Dryer structure fabrication 30,000 Local made
considering 25% labour cost
Unforeseen cost 5000
Prod. cost 1,05,000
Profit 20% 21,000
Selling price 1,26000
C.O.E.&T.,Akola 61
CATALOGUE
C.O.E.&T.,Akola 62
C.O.E.&T.,Akola 63
C.O.E.&T.,Akola 64
C.O.E.&T.,Akola 65
DESIGN OF SUGGESTED MODEL FOR DRYER FOR FARMERS
Case I : SORGHUM
Design a rectangular bin batch dryer having holding. Capacity of 2.5 tonnes of
paddy with 10% moisture content w.b.
Solution: - Assume the following data.
Relative humidity of ambient air = 70%
Initial moisture content of paddy = 15% w.b.
Final moisture content of paddy = 10 % w.b.
Grain outlet temperature = 700C = tG2
Heated air temperature = 850C = t2
Latent heat of water vapour = 600 Kcal/kg (from grain parameter tables 6.3)
Buck density of paddy grain at 10% moisture = 752.9 kgm3 (from grain
parameter tables 6.2)
Drying time = 1 hrs.
Assumptions: -
Specific heat of grain = 0.3934 Kcal/kg0C (from grain parameter tables 6.5)
Height of the dryer: -
H = height of bin and height of plenum chamber
H = 1.5 + 0.75 +3
H = 2.25 ft + 3 = 5.25 ft
C.O.E.&T.,Akola 66
Volume of plenum chamber: -

V = 8 x 7 x 0.75 = 42 ft3
Volume of drying chamber: -
2500
V= = 3.32049409 m 3
752.9
= 3320494cm 3
= 3.32 x10 9 mm 3
Air requirement: -
Bone dry paddy = 2500 ( 1 – 0.10 ) = 2250 kg
m
Initial moisture content = 15%, w.b. = x 100
100 − m
15
= = 17.65 d.b
100 − 15
Final moisture content = 10%w.b. = 11.111db

Weight of moisture evaporated: -
= wt. of bone dry paddy x (x1-x2)
= 2250 (17.65 % - 11.11%)
= 2250 (0.1765 – 0.1111)
= 147.06 Kg
From psychrometric chart: - ( Appendix 1)
Humid heat of ambient air
S = 0.24 + 0.45 H
S = 0.24 + 0.45 x 0.019
S = 0.24855 Kcal/Kg0C
Let, G be the rate of air supply in Kg/min
C.O.E.&T.,Akola 67
= G.S. ( t2 - t1 ) Co
= G (0.24855) (85-40) x 60
= 671.085 G
Heat Utilised: -
= S.D. grain x Sp. Heat of grain x temperature rise
= Wd x CP9 x (tG2 -tG1)
= 2250 x 0.3934 (70-30)
= 35406 Kcal
ii) A = sensible heat of water
= total Wt of water x sp.heat of water x temperature rise
= Wd (X1) x CPw (tG2 – tG1)
= 2250 x 0.1765 x 1.0 x (70-30)
= 15885 K cal
= 147.06 x 600
= 88236 K cal
Total heat utilized = sum of above heats
= 35406 + 15885 + 88236
= 1,39,527 K cal
139527
Net heat required = = 1,55,030 Kcal
0.9
If heat loss = 20%

139527
Net heat required = = 1,74,08.75 K cal.
0.8
C.O.E.&T.,Akola 68
Hence, 671.085G = 155030

G = 231.013955 kg/min
From psychrometric chart humid volume of the ambient air
= 0.88 m3/Kg
So air required = 231.013955 x 0.884
= 204.22 m3/min
= 205 m3/min = 205 x 35.34 = 7244.7 cfm.
Static pressure drop:-
Surface area of plenum chamber
= 8 x 7 = 56 ft2
Since maximum 50% area is perforated, area through which air passes = 28 ft2
7244.7
Air requirement per ft2 = = 258.74 cfm/ft2
28
From shedd’s curve ( Appendix 2 ) static pressure drop

For 260 cfm/ft2 = 3 inch of water per 1 ft grain depth.
Depth of grain = 1.5 ft.
3
So pressure drop = x18 = 4.5 inch of water
12
- Packing of the grain in bin may cause 50% higher resistance to airflow than the values
shown
∴ Total pressure drop = 6.75 inch of water
- Add the static pressure drop from the duct and floor, usually about ¼ in water if the air
velocity is kept at 1,000 fpm or less.
∴ Total pressure drop = 6.75 + 0.25 = 7 inch of water = 17.78 cm
Density of air = 1.13 Kg/m3
17.78 1000
100 1.13
= 157.345 m
C.O.E.&T.,Akola 69
H. P. required: -
Height of air column ( m) × air flow rate (Kg / min)
=
4500
157.345 × 231.013955
=
4500
= 8.077
≈ 9 hp = 10 hp
Heating System: -
q'a
Fuel Consumption: - F=
η.ηb ηex C n
1,55,030
f=
1 x 1 x 41263 / 4.1865
f = 15.729 ≈ 16 Kg/hr
Using Net heating value
155030
F=
1 x 1 x 40785 / 4.1865
F = 15.91 ≈ 16 Kg/hr
Calculated same as above ----

Petrol = 15 Kg/hr Bagass (dry) = 35Kg/hr
Kerosene = 15 Kg/hr Cotton batting = 40Kg/hr
L.P.G. = 14Kg/hr Wheat = 38 Kg/hr
Wood = 32 Kg/hr
Selection/Design of a Centrifugal blower: -
1) Specific Speed (Ns)
N Q
Ns = rpm
Ps 0.75
Where N – speed of motor rpm = 1440
C.O.E.&T.,Akola 70
θ - Air flow rate m3/min or cfm

Ps = static press m wake gauge or inch.
1440 7245
Ns =
7 0..75
Ns = 28481.19
2) Fig 6.1 indicates that two types of air units are quite efficient at Ns = 28451.19 a forward
curved centrifugal blower. While the forward curved centrifugal blower seems to have a
substantially higher static efficiency Table 6.1 shows that both the pressure and flow
coefficient of forward curved centrifugal blower are high. Therefore, a forward curved unit is
selected.
2.35 × 108 Ps
4) Since ψ =
N 2d 2
2.35 × 103 Ps
d2 =
N 2ψ
2.35 × 10 3 × 7
d2 =
(1440) 2 1.5
d = 22.99 ≈ 23”
d = 584.2 ≈ 585 mm
5) From Table 6.5 φ = 0.62
Q
W = 175
φ Nd 2
175 × 7245
W=
0.62 × 1440 × (22.99) 2
W = 2.687”
W = 68.246 ≈ 67 mm
C.O.E.&T.,Akola 71
- A review of manufacturer’s literature is done to see that whether blower wheel of

calculated dimensions is available. If it is not available, then slightly smaller or larger
wheel is selected and the performance requirement is revised.
Blower housing: -
- Width of housing = M
M = 1.25 W + 0.1 d Where M = housing width
M = 1.25 x 67 + 0.1 x 585 W = impeller width
M = 142.25 ≈ 143 mm d = impeller diameter
Diffuser angle
 143 
αw = 12 − 1
 585 
αw = 9.067 ≈ 10 0
TABLE : Air, Fan, Heat, Fuel, blower and H.P. Requirement for drying sorghum grains
with heated air from different percentage of M.C. and different grains depths.
Sorghum Capacity
Grain mois- Practical Static Recomm- Heat Fuel Blower H.P.
ture cont-ent grain depth, pressure ended required consumption, requirement Required
% w.b ft drop water minimum air Kcal/hr Kg/hr
inch/mm flow rate, cfm
of water or m3/min
Ini Final
17 10 2 8.256/2 20 9323/264 200402 Diesel -21 Ns-2762 13
L.P.G. -20 d-640 mm
Wood - 40 W-69 mm
15 10 1.5 7/178 7245/205 155030 Diesel -21 Ns -28482 10
Wood - 40 rpm
cotton d-585 mm
Batting -40 W-67 mm
17 10 1 7/178 5201/148 111771 Diesel -12 Ns -24132 5-7.5
Petrol -11 rpm
Cotton d-585 mm
Batting -29 W-49 mm
Case II : Udid or Mug or soyabean
C.O.E.&T.,Akola 72
Design a rectangular bin batch dryer having holding capacity of 2.5 tonnes of
Udid or Mug or soyabean with 13% w.b.
Solution: - Assume the following data.

Relative humidity of ambient air = 70%
Initial moisture content of paddy = 20% w.b.
Final moisture content of paddy = 13% w.b.
Grain outlet temperature = 700C = tG2
Heated air temperature = 850C = t2
Latent heat of water vapour = 600 K Cal/Kg (From grain parameters table 6.3)
Bulk density of paddy grain at 13% w.b.m.c.= 752.9 Kg/m3 ( From grain
parameters table 6.2)
- Drying time = 1 hr
Assumption – Specific heat of grain = 0.4469 Kcal/Kg0C (From grain parameters table 6.4)
- Height of the dryer
H = 1.5 + 0.75 + 3 = 5.25 ft
- Volume of plenum chamber
V = 8 x 7 x 0.75 = 42 ft3
- Volume of drying chamber
2500
V= = 3.320449409m 3
752.9
= 3.32 × 10 9 mm 3
C.O.E.&T.,Akola 73
Air requirement :-
- Bone dry paddy = 2500 ( 1 – 0.13 )
= 2175 Kg
m
- Initial moisture content = 20% w.b. = x 100 d.b
100 − m
20
= × 100 = 25 d .b.
100 − 20
m
- Final moisture content = 13% w.b. = × 100 d .b
100 − m
13
= x100 = 14.943 d .b
100 − 13
- Weight of moisture evaporated

= Weight of bone dry paddy x ( x1 – x2 )
= 2175 ( 0.25 – 0.14943 )
= 218.74 Kg
From psychrometric chart :-
Absolute humidity of ambient air = 0.019 Kg/Kg.
- Humid heat of ambient air
S = 0.24 + 0.45 H
S = 0.24 + 0.45 x 0.019
S = 0.24855 Kcal/Kg0C
Let G be the rate of air supply in Kg/min
Heat supplied by the air in 60 min
= G. S. ( t2 – t1 ) θ
= G ( 0.24855) (85-40) x 60
= 671.085 G
Heat utilised :-
C.O.E.&T.,Akola 74
= B D. grain x Sp. Heat of grain x temperature rise

= W d x Cp9 x ( t G2 – tG1 )
= 2175 x 0.4469 x ( 70 – 30 )
= 38,880.3 K cal
ii) As sensible heat of water
= total weight of water x Sp. Heat of water x temperature rise
= Wd (X1) x Cpw (tG2-tG1)
= 2175 x 0.25 x 1.0 x (70 –30)
= 21,750 K cal
= 218.74 x 600 = 13,1244 Kcal
- Total heat utilized = sum of above heats
= 38,880.3 + 21750 + 131244
= 1918743 ≈ 1,91,875 K cal
191875
Net heat required = = 2,13,194 Kcal
0.9
Hence 671.0854 = 213194

G = 317.69 Kg/min
- from psychrometric chart humid volume of the ambient air
= 0.88 m3/Kg
So air required = 317.69 x 0.884
= 280.834 m3/min
≈ 281 m3/min
= 281 x 35.34 = 9925 cfm
- Static pressure drop
C.O.E.&T.,Akola 75
- Surface area of pleneum chamber

= 8 x 7 = 56 ft2
- Since maximum 50% area is perforatged area through which air passes = 28 ft2
Which air passes = 28 ft2
9925
Air requirement per ft2 = = 354.46 cfm / ft 2
28
- from shedd’s curve ( Appendix)

for 100 cfm/ft2 = 1 inch of water per 1 ft grain depth.
∴ for 354.46 cfm/ft2 = 3.55 inch per 1 ft grain depth
- Depth of grain = 2.5 ft
3.55
So pressure drop = × 18 = 5.325 inch of water
12
- Packing of the grain in bin may cause 50% higher resistance to airflow than the values
shown.
∴Total pressure drop = 7.9875 inch of water
- Add the static pressure drop from the duct and floor, usually about ¼ in water if the air
velocity is kept at 1,000 tpm or less.
∴Total pressure drop = 7.98 + 0.25
= 8.2375 inch of water
- Density of air = 1.13 Kg/m3 = 8.2375 x 2.59 = 20.92325 cm
20.92325 1000
100 1.13
= 185.162 m
- H. P. required
Height of air column (m) x air flow rate (Kg / min)
=
4500
185.162 × 317.69
=
4500
= 13.07 hp
C.O.E.&T.,Akola 76
Heating System :-
Fuel consumption :-
Diesel
q'a 213194
f = =
η.ηb ηex C n 1 × 1 × 41263 / 4.1865
f = 21.63 ≈ 22 Kg / hr.
Same as above
Petrol = 20.30 ≈ 21 Kg/hr Bagase dry = 47.98 ≈ 48 Kg/hr
Kerosene = 20.56 ≈ 21 Kg/hr Cotton Batting = 53.92 ≈ 54 Kg/hr
L. P. G. = 19.23≈ 20Kg/hr Wheat = 51.16 = 51.16 ≈ 52 Kg/hr
Wood = 42.63 ≈ 43 Kg/hr
Selection/Design of a Centrifugal blower :-
1) Specific Speed (Ns)
N Q
Ns = rpm Where Q - cfm ; Ps - inch
Ps 0.75
1440 9925
Ns =
8.23750.75
Ns = 29,504.019 rpm
2) Figure 6.1 indicates that two types of air units are quite efficient at Ns = 29,504.019 rpm a
forward curved. Centrifugal blower and a backward curved (wide) centrifugal blower. While
the forward curved centrifugal blower seems to have a substantially higher static efficiency
Table shows that both the pressure and flow coefficient of forward curved centrifugal blower
are high. Therefore, a forward curved unit is selected.
2.35 × 108 Ps
4) Since ψ=
N 2d 2
C.O.E.&T.,Akola 77
2.35 × 10 8 × 8.2375
d2 =
(1440) 2 1.5
d = 24.94 ≈ 25"
d = 633.66 ≈ 634mm
5) from table φ = 0.62

Q
W = 175
φNd 2
9925
W = 175 ×
0.62 × 1440 × (24.94) 2
W = 3.1276" ≈ 80 mm
Blower housing
Width of housing = 14
M = 1.25 W + 0.1 d
M = 1.25 x 80 + 0.1 x 634
M = 163.4 ≈ 164 mm
Diffuser angle.
 164 
αw = 12 − 1
 684 
αw = 8.89 ≈ 9 0
Table : Air, fan, heat, Fuel, Blower and H.P. requirements for Drying Udid, Mug and
Soyabean grains with heated air from different percentage of m.c and different grain
depths.
ture cont-ent grain pressure ended required consumption, requirement Required
% w.b depth, ft drop water minimum air Kcal/hr Kg/hr
inch/mm of flow rate, cfm
water or m3/min
Ini Final
20 13 1.5 5.325/136 9925/281 2,1319 Diesel-22 Ns-29505rpm 15
4 Wood-43 d-634mm
Wheat W-80mm
straws-52
C.O.E.&T.,Akola 78
17 13 1 4.29/109 6605/187 142590 Diesel-15 Ns-39261rpm 5
Kerosene-14 d-458mm
Wood-29 W-102mm
15 13 0.667 2.392/61 4595/130 98749 Wood-20 Ns-50750rpm 2
Bagase-23 d-342mm
Wheat straws W-117mm
-24
Case III : Paddy
Design a dryer having holding capacity of 2 tonnes of paddy with 15%
m.c.(w.b.)
Solution :-
Assume the following data .
Ambient air temperature = 300 = t
Relative humidity of ambient air = 70% = H
Initial m.c. of paddy = 30% (w.b.) = m1
Final m.c. of paddy = 15% (w.b.) = m2
Grain inlet temperature = tG1 = 300C
Grain outlet temperature = tG2 = 700C
Heated air temperature = t2 = 850C
Exhaust air temperature = t1 = 400C
Latent heat of water vapour = 600 Kcal/kg (from grain parameter table - 6.3)
Angle of repase = 450
Thickness of grain bed to be dried = 45cm
Bulk density of paddy grain at 15% m.c. = 575 Kg/m3 (from grain parameter table - 6.2)
Drying time = 3 hrs
Assumption specific heat of grain = 0.4 Kcal/Kg0C. (from grain parameter table 6.5)
C.O.E.&T.,Akola 79
- Height of the dryer

H = 1.5 + 0.75 + 3 = 5.25 ft
- Volume of plenum chamber
V = 8 x 7 x 0.75 = 42 ft3
- Volume of drying chamber
2500
V= = 3.320449409m 3
752.9
= 3.32 × 10 9 mm 3
Air requirement :-
2000 x15
Weight Bone dry paddy = Wd = 2000 -
100
Wd = 1700 Kg
Initial moisture content = 30% W.b.
m
M (d.b.) = x100
100 − m
30
= x100
100 − 30
= 42.857 % d.b. (X1)
Final moisture content = 15% w.b.
= 17.647 % (d.b.) (X2)
Weight of moisture evaporated
= Weight of bone dry paddy x ( x1 - x2 )
= 1700 ( 0.42857 - 0.17647 )
= 428.57 Kg
C.O.E.&T.,Akola 80
From psychrometric chart (Appendix)
Humid heat of ambient air
S = 0.24 + 0.45 H
S = 0.24 + 0.45 x 0.019
S = 0.24855 Kcal/Kg0C
Let G be the rate of air supply in Kg/min.
Heat supplied by the air in 180 minutes
= G. S. (t2 - t1) θ
= G ( 0.24855 ) (85 - 40) x 3 x 60
= 2013.255 G
Heat utilised
= B.D. grain weight x specific heat of grain x temperature rise
= 1700 x 0.4 x ( 70 - 30 )
= 27200 Kcal
ii) As sensible heat of Water
= total weight of water x specific heat of water x temperature rise
= Wd x (x1) x CDW (+G2 - +G1)
= 1700 x 0.42857 x 1.0 x ( 70 - 30 )
= 29142.46 ≈ 29143 K cal
iii) As latent heat of water Vapour
C.O.E.&T.,Akola 81
= 428.57 x 600
= 2,57,142 K cal
∴Total heat utilised = Sutn of above heats
= 27200 + 29143 + 257142
= 3,13,485 KCal
313485
Net heat required =
0.9
= 3,48317 Kcal
∴from heat balance
2013.2554 = 348317
G = 173 Kg/min
from psychrometric chart (Appendix - 1) humid volume of the ambient air = 0.88m3/Kg
So air required = 173 x 0.884
= 152.94 m3/min
≈ 153 m3/min
Air required = 5404 CFM
Static pressure drop
Surface area of planum chamber
= 7 x 8 = 56 ft2
∴50% of the area is perforated, area through which air passes = 28 ft2
C.O.E.&T.,Akola 82
5404
Air requirement per m2 =
28
= 193 cfm/ft2
from shedd's curve (Appendix 2 )
Static pressure drop for 30 cfm/ft2 = 0.6 inch of water per 1 ft. grain depth.
∴for 193 cfm/ft2 = 3.86 inch per
1 ft grain depth.
But grain depth is 1.5 ft.
3.86
= x18
12
= 5.79 inch
Packing of grain in bin may cause 50 % higher resistance to air flow than the values
shown
∴Total pressure drop = 8.685 inch of water
Add the static pressure drop from the duct and floor, usually about 1/4 inch of water if the air
velocity is kept at 1000 fpm
∴Total pressure drop = 8.685 + 0.25
= 8.935 inch
= 22.6949 cm
Density of air = 1.13 Kg/m3
22.6949 1000
Pressure drop in terms of air column = x
100 1.13
= 200.84 m
C.O.E.&T.,Akola 83
H.P. required
Height of air column (m) x air flow rate

=
4500
200.84 × 173.0116983
=
4500
= 7.72 hp ≈ 7.5 hp
Heating System :-
fuel consumption
q 'a
Diesel F=
η ηb ηex C n
348317
F=
1 × 1 × 41263 / 4.1865
= 35.33 ≈ 36 Kg
= 12 Kg/hr.
Same above
Petrol = 11 Kg/hr Bagase dry = 25 kg/hr.
Kerosene = 11 Kg/hr Cotton batting = 27 Kg/hr
Wood = 21 Kg/hr Wheat strain = 30 Kg/hr
Design of a Centrifugal blower
1) Specific speed (Ns)
N Q
Ns = rpm
Ps 0.75
C.O.E.&T.,Akola 84
1440 5404
=
8.935 0.75
= 20483.268 ≈ 20484 rpm
2) Fig 6.1 indicates that two types of air units are quite efficient at Ns = 28451.19 a
forward curved centrifugal blower. While the forward curved centrifugal blower seems to
have a substantially higher static efficiency Table 6.1 shows that both the pressure and flow
coefficient of forward curved centrifugal blower are high. Therefore, a forward curved unit is
selected.
3) from table 6.1 ψ = 1.5
2.35 × 10 B Ps
ψ=
N 2d 2
4) Since 2.35 × 10 B × 8.935
d =
2
(1440) 21.5
d = 25.98 ≈ 2611 = 660 mm
5) from table (6.1) φ = 0.62
Q
W = 175
φNd 2
175 × 5404
W=
0.62 × 1440 × (25.98) 2
W = 1.57" = 40 mm
Blower housing
M = 1.25 W + 0.1 d
M = 1.25 x 40 + 0.1 x 660
M = 116 mm
Diffuse angle
C.O.E.&T.,Akola 85
 116 
αW = 12  −1
 660 
αW = 9.8 ≈ 100
TABLE : Air, Fan, Heat, Fuel, blower and H.P. Requirement for drying Paddy with
heated air from different percentage of M.C. and different grains depths.
Paddy Capacity - 0.67 tonnes/hr
ture cont-ent grain depth, pressure ended required consumption, requirement Required
% w.b ft drop water minimum air Kcal/hr Kg/hr
inch/mm flow rate, cfm
of water or m3/min
Ini Final
30 15 1.5 8.935/227 5404/153 116106 Diesel -12 Ns-20484 rpm 7.5
Wood - 21 d-660 mm
Cotton W-40 mm
Batting - 27
25 15 1 4.15/106 3616/103 77716 Diesel -9 Ns -29781 2-3
Wood - 16 rpm
Bagas - 18 d-450 mm
W-58 mm
20 15 0.667 1.71/44 2042/59 44149 Diesel -6 Ns -43516 0.5-1
Wood-9 rpm
Cotton d-289 mm
Batting -12 W-73 mm
Note :
1) From above table we can say that farmers may use wood, cotton batting, wheat straw
as a fuel for drying grains in drying system as it is easily available at free of cost for
them.
C.O.E.&T.,Akola 86
2) Also industrial user of dryers can use diesel, kerosene, LPG as a fuel for drying system
which is economical and efficient for them.
Suggested Drawing
C.O.E.&T.,Akola 87
DRYER IN COMPLETE ASSEMBLED CONDITION

Technical Specification
Model Paddy (3)
Heat output Kcal/hr 44,149
Drying capacity kg/hr 667
Moisture removing capacity
(from initial moisture %/hr 5
content of 20)
Fuel consumption
1) Kerosene Kg/hr 5
2) Wood Kg/hr 9
3) Cotton batting Kg./hr 12
Power Supply 240 V 50 Hz single phase
Electric loading
Blower motor HP 0.5 - 1
Cost Estimation
Particulars Cost Rs.

Burner ( Diesel fired) 10,000
Blower (centrifugal) 3,000
C.O.E.&T.,Akola 88
Blower motor 1,000

Dryer structure fabrication considering 25% labour cost 5,000
Unforeseen cost 2000
Prod. cost 21,000
Profit 20% 4,000
Selling price 25,000
CHAPTER IX
COMPARISON OF VARIOUS DAL MILL DRYER
We visited to various dryer users, from their information we compare our
suggested models with their running models as follows.
Industry R.R. Niranjan Bhala Dal Geeta Gajanan Our suggested

Udyog Dal mill mill Udyog Udyog model
Factors
Manufacturer Thermax local made local made local made Super
thermal
ltd -
engg. works
Nagpur.
Capacity
2.5 4 3 3 2.5 2.5
(tonnes/hr)
Sample initial
9.1 9.5 13.9 9.4 10.3 12
m.c.(%)
Sample final
8.5 8.6 8.6 8.8 8.1 10
m.c.(%)
Reduction in
0.6 0.9 5.3 0.6 2.2 2
moisture (%)
Power
consumption 7460 7460 7460 7460 7460 2238
(Watt)
Heat
requirement 1,20,000 1,20,000 1,20,000 1,20,000 1,20,000 50,000
(Kcal)
C.O.E.&T.,Akola 89
Diesel,kerosene,
Fuel used Diesel Kerosene Kerosene Diesel Coal/wood
LPG, wood.
Fuel
consumption 10-12 12-15 12-15 13-15 125 5-6
(kg/hr)
Cost in Lacks 3.5 2.5 2 2 2 1.25
* Note : By comparing various dryers with our suggested models for reducing 2% m.c.
As we seen a comparison of various dryers in Dal mills in the above table 9.1.
It is very clear that the available dryers are not efficient. We have tested different samples of
pulses before drying and after drying at Dr. P.D.K.V. Akola.
We found that moisture removed after drying on an average 1.8% and fuel
consumption is of cost 264-336 (Rs./hr) which is very costly as compared our suggested
model to Dal Millers. It is very efficient as we can remove 1.8% moisture with fuel
consumption is of cost 192 Rs/hr which is always economical.
This is not enough data as we are also saving large power consumption. As
available dryer consumes 9698 watts power and we are using 2238 watts of power. Which
means that we are saving 80% of powers and it is helpful in reducing operating cost of dryer
user.
Different Visited Dryers
THERMAX INDIA LTD. AVAILABLE AT R.R. UDYOG, MIDC AKOLA
C.O.E.&T.,Akola 90
THERMAX INDIA LTD. AVAILABLE AT R.R. UDYOG, MIDC AKOLA
KOREAN DRYER AVAILABLE AT PDKV, AKOLA
C.O.E.&T.,Akola 91
WOOD FIRED DRYER, AVAILABLE AT GAJANAN UDYOG, MIDC AKOLA .

CHAPTER X
DIFFERENT DRYER MODELS
SUNCUE GRAIN DRYER
C.O.E.&T.,Akola 92
Specification Chart
Item Model NPC 130

Minimum Capacity
Capacity (Maize) 13100 KGS
Dimensions
Overall Ht.(mm) 7792
Overall Length (mm) 3609
Overall width (mm) 1941
Power Consumption 3 phase, 220V/380V/440,50Hz/60Hz
6.5 Kw
Fuel Burner
Type Gun Type, High pressure spray burning
Ignition High pressure automatic ignition
Combustion Max. Combustion 17.5 liter/hour
Fuel Kerosene or Premium diesel
Gas Burner
Type G
Ignition High Pressure automatic ignition
Combustion 150000 Kcal/Hr
Gas Natural Gas
Function
Loading 55 min (Approx)
Unloading 50 min (Approx)
Drying Rate 1.0 ~ 1.5 %/ hour
Safety Devices Thermo Over relay, air pressure switch full
load buzzer, timer, control fuse, burner
alarm, abnormal combustion sensor.
C.O.E.&T.,Akola 93
( Model A ) ( Model B )
TECHNICAL SPECIFICATION
Model Cap. Drying Tray Heat Burner Fuel Blower Electric Fuel
Tons/Batch (LxBxH) cm Exchanger Output consumption Cap. motor
(LxDia) Keal/hr LPH with CMH HP 440
max Max. single stage V 3 Ph.
single burner A.C.
stage
burner
12,000 Light
Model 305x183x12 at 50 oil,
2 2440x760 1,00,000 10-12 7.5
A 2 mm diesel
WGSP oil
5,000
Model 51x51x18 244x76x12 cfm at
5 96,300 8-12 5 HSD
B each tray 2 5cms
WGSP
CHAPTER - XI
OPTIMUM ACHIEVEMENTS
 Ultimate Achievements of this project work
 Highlighted specific problems of farmers and grain processors.
C.O.E.&T.,Akola 94
 At a glance information of effects of temperature on various parameters of grain such
as chemical composition proteins, fats, carbohydrates and quality of grain.
 Provided information about various types of drying methods which can be used in
various circumstances.
 Guidelines for selection of grain dryers, depending on various characteristics and
parameter of grain.
 Provided a simple approach towards designing of grain dryers.
 Simple approach towards checking of dryer performance.
 Suggested high performance, low cost model for Dal Mill farmers as a option to
costlier imported companies dryers. Our proposed model cost is around is Rs.1.25
lacks while other dryers available in market is 3 to 5 lacks and above.
 Thirteen solved problems to find out heat and air requirements for particular type of
grain.
 Tables are provided gives information of calorific values of various fuels so that any
body can easily fix up the amount of fuel required for particular application.
 At glance information of air requirement static pressure drop, fuel consumption,
blower, HP required in the table is provided to design the drier for various crops in
various grain depths.
 Project work gives information about various models available in market.
C.O.E.&T.,Akola 95
CHAPTER - XII
CONCLUSION
There is heavy loss of grain on field which can be avoided by providing simple
and low cost (Rs.25000 dryer design to the farmers. This cost Rs.25,000/- in within reach of
small farmers.
The loss of 10,800 million rupees per year during harvesting of grains can be
saved. It is observed that number of dal millers are using local made dryers of low
performance which are not suitable for their purpose. But they are helpless at the cost of
reputed company driers. Hence the model and design which we have suggested is high
performance, best suited, comparatively low cost and within reach of average dal miler.
The design will definitely improve. Cost of fuel and electricity saved by dal
miller per season ( if 500 tonnes output ) is approximately Rs 10 lacks considering 200 dal
mill in Akola total saving of approximately Rs 20 crores.
If high performance dryers with proper design is suggest one can save crores of
rupees lost due to excessive power and fuel consumption and definitely our project work
gives scientific approach towards designing of high performance dryers matching to the
requirements of particular user.
C.O.E.&T.,Akola 96
BIBLIOGRAPHY
 Elements of Agricultural Engineering.
- Dr. Jagdishwar Sahay
 Design and Storage of Agricultural Crops
- C.W. Hall
 Post Harvest Tech. of Cereal Pulses and Oilseeds
- A. Chakraverty
 Unit Operations of Agricultural Processing
- K.M. Sahay
- K.K. Singh
 Unit Operations
- McAbey and Smith
 Seed Processing and Handling.
- Handerson and Perry
 Agricultural Engineers Handbook
- C.B. Richey
- Paul Jacobson
- Carl W. Hall
 www.osawagro.com
C.O.E.&T.,Akola 97
APPENDIX 1
C.O.E.&T.,Akola
APPENDIX 2
C.O.E.&T.,Akola
ACKNOWLEDGEMENT
It is challenging task to complete the project work. it is difficult to complete the
project work without any guide line of respective field persons But we have completed the
project,"DESIGN & STUDY OF GRAIN DRYER" under the guidance of our
respective guide Prof. S. K. Patil. He is not only master person in hydraulic &
pneumatic but also key person in technical field, as he designs & fabricates number of
agricultural equipments successfully.
We are thankful to our H.O.D. Prof. C. V. Deshmukh for his valuable
guidance and encouragement. We are also thankful to all staff members of production
department and our friends who help us directly or indirectly in our work.
We are kindly thankful to Prof. R.T. Kausal (M.Tech.) Asst. Prof. Seed
Tech. Dept. Dr. P.D.K.V., Akola. Also B.Sc. B.Tech. Agriculture Engg. Students giving their
valuable knowledge about drying technology.
We are also thankful to the firm owners in MIDC Akola; Mr. R.R. Rathi of
R.R.Udyog and Mr. Bhala of Gajanan Udyog.
Last but not the least Mr. Sachin Shirbhate for co-operating with us for the
completion of Project.
PROJECTEES
C.O.E.&T.,Akola
INDEX
Sr. No. Particulars Page No.
1 Introduction 01
2 Theory of Grain Drying 09
3 Methods of Grain Drying 20
4 Grain Dryers 23
5 Selection of Grain Dryers 28
6 Design Procedure of Grain Dryers 31
7 Dryer Performance and Testing 50
8 Suggested Models 55
9 Comparison of Various Dal Mill dryers 90
10 Different Dryer Models 93
11 Optimum Achievements 96
12 Conclusion 97
Bibliography 98
Appendix
C.O.E.&T.,Akola

Design and Study of Grain Dryer

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What are the main reasons for post-harvest losses in India?

What are the main reasons for post-harvest losses in India?

What are some common drying methods mentioned in the document?

What are some common drying methods mentioned in the document?

Design & Study of Grain Dryer

II) CHEMICAL COMPOSITION OF GRAIN:-

IV) PHYSICAL PROPERTIES: -

Resistance of grain bed to air flow:

VI) CHANGES IN STORED PRODUCTS -

Table 1.1 : Estimated loss of production during harvest and storage.

Product Harvesting % Storage %

THEORY OF GRAIN DRYING

content on dry basis.

The moisture content, m per, wet basis -

The moisture content, M, dry basis percent

Where Wm = weight of moisture.

TABLE 2.1 Approximate moisture content for safe storage % (w.b.)

FOR SAFE STORAGE

III) DETERMINATION OF DRYING CONSTANT: -

Drying Time, Min

IV) DRYING EQUATION:-

If the temperature term t is replaced by the moisture term M, then

where M = Moisture content (d.b), %

Integrating the above equation within proper limits, we get

V) THIN LAYER DRYING: -

Where - M1 = Initial moisture content of grain ( d.b) %

G = Mass flow rate of dry air, Kg/hr m2

ii) Decreasing rate period: -

where, θ2 = Time of drying during decreasing rate period, hr.

VII) EFFECTS OF DIFFERENT FACTORS ON THE DRYING PROCESS: -

METHODS OF GRAIN DRYING

II) HEATED AIR DRYERS :-

 An air flow rate of 2.94 - 3.92 m3/minute per tonne is

In the flat bed batch type dryer

 There is less likehood of over drying.

Fig. LSU dryer

vi) Fluidized bed dryer :-

II) COMPARISON OF DRYERS :-

III) FINAL SELECTION OF DRYERS.

AMB. AIR HEATER HEATER AIR EXHAUST AIR

Where G' = rate of air supply, kg/min.

or G' = (0.24+0.45 H1) (t2 - t3 ) θ

where f = fuel rate, kg/hr.

Where, N = speed of motor, rpm

Q = air flow rate, cfm

ps = static pressure, inches water gauge.

where Ψ = pressure coefficient

Dimension Specifi Typical Typical

4,000 1.4 0.002

15,000 1.0 0.08

Fig.6.1 Specific speed vs. static

A review of manufacturer's literature is done to see that whether blower wheel

Fig. 6.3 Scroll development of a centrifugal blower

The diffuser angle can be determined graphically and expressed in terms of

As shown by above equations, the diffuser angle decreases if either dimensions

The housing width may be determined by the following equation

(6) Grain parameters :-

Table 6.2 : Bulk densities of grain at different moisture contents

Grain Moisture content % (w.b.) Density Kg/m3

Table 6.3 : Latent Heat of vaporization of grain moisture