Continuous Tunnel Dryers

Continuous tunnels are in many cases batch truck or tray compartments, operated in series. The solids to be processed are placed in trays or on trucks which move progressively through the tunnel in contact with hot gases. Operation is semicontinuous; when the tunnel is filled, one truck is removed from the discharge end as each new truck is fed into the inlet end. In some cases, the trucks move on tracks or monorails, and they are usually conveyed mechanically, employing chain drives connecting to the bottom of each truck. Schematic diagrams of three typical tunnel arrangements are shown in Fig. 12-54. Belt-conveyor and screen-conveyor tunnels are truly continuous in operation, carrying a layer of solids on an endless conveyor.

Air flow can be totally cocurrent, countercurrent, or a combination of both as shown in Fig. 12-54. In addition, cross-flow designs are employed frequently, with the heating air flowing back and forth across the trucks in series. Reheat coils may be installed after each cross-flow pass to maintain constant-temperature operation; large propeller-type circulating fans are installed at each stage, and air may be introduced or exhausted at any desirable points. Tunnel equipment possesses maximum flexibility for any combination of air flow and temperature staging. When handling granular, particulate solids which do not offer high resistance to air flow, perforated or screen-type belt conveyors are employed with through circulation of gas to improve heat- and mass-transfer rates.

In tunnel equipment, the solids are usually heated by direct contact with hot gases. In high-temperature operations, radiation from walls and refractory lining may be significant also. The air in a direct-heat unit may be heated directly or indirectly by combustion or, at temperature below 475 K, by finned steam coils.

Applications of tunnel equipment are essentially the same as for batch tray and compartment units previously described, namely, practically all forms of particulate solids and large solid objects. In operation, they are more suitable for large-quantity production, usually representing investment and installation savings over (multiple) batch compartments. In the case of truck and tray tunnels, labor savings for loading and unloading are not significant compared with batch equipment. Belt and screen conveyors which are truly continuous represent major labor savings over batch operations but require additional investment for automatic feeding and unloading devices.

Auxiliary equipment and the special design considerations discussed for batch trays and compartments apply also to tunnel equipment. For size-estimating purposes, tray and truck tunnels and furnaces can be treated in the same manner as discussed for batch equipment.

Continuous Through-Circulation Dryers Continuous through-circulation dryers operate on the principle of blowing hot air through a permeable bed of wet material passing continuously through the dryer. Dryer rates are high because of the large area of contact and short distance of travel for the internal moisture.

The most widely used type is the horizontal conveying-screen dryer in which wet material is conveyed as a layer, 2 to 15 cm deep, on a horizontal mesh screen or perforated apron, while heated air is blown either upward or downward through the bed of material. Its drying characteristics were studied by Marshall and Hougen [Trans. Am. Inst. Chem. Eng., 38, 91 (1942)]. This dryer consists usually of a number of individual sections, complete with fan and heating coils, arranged in series to form a housing or tunnel through which the conveying screen travels. As shown in the sectional view in Fig. 12-55, the air circulates through the wet material and is reheated before reenter-ing the bed. It is not uncommon to circulate the hot gas upward in the wet end and downward in the dry end. A portion of the air is exhausted continuously by one or two exhaust fans, not shown in the sketch, which handle air from several sections. Since each section can be operated independently, extremely flexible operation is possible, with high temperatures usually at the wet end, followed by lower temperatures; in some cases a unit with cooled or specially humidified air is employed for final conditioning. The maximum pressure drop that can be taken through the bed of solids without developing leaks or air bypassing is roughly 50 mm of water.

Through-circulation drying requires that the wet material be in a state of granular or pelleted subdivision so that hot air may be readily blown through it. Many materials meet this requirement without special preparation. Others require special and often elaborate pretreat-ment to render them suitable for through-circulation drying. The process of converting a wet solid into a form suitable for through circulation of air is called preforming, and often the success or failure of this contacting method depends on the preforming step. Fibrous, flaky, and coarse granular materials are usually amenable to drying without preforming. They can be loaded directly onto the conveying screen by suitable spreading feeders of the oscillating-belt or vibrating type or by spiked drums or belts feeding from bins. When materials must be preformed, several methods are available, depending on the physical state of the wet solid.

1. Relatively dry materials such as centrifuge cakes can sometimes be granulated to give a suitably porous bed on the conveying screen.

Rockwell Rotary Hearth Furnace Drawing
FIG. 12-52 Rotary-hearth furnace. (W S. Rockwell Co.)

2. Pasty materials can often be preformed by extrusion to form sphaghetti-like pieces, about 6 mm in diameter and several centimeters long.

3. Wet pastes that cannot be granulated or extruded may be predried and preformed on a steam-heated finned drum. Preforming on a finned drum may be desirable also in that some predrying is accomplished.

4. Thixotropic filter cakes from rotary vacuum filters that cannot be preformed by any of the above methods can often be scored by knives on the filter, the scored cake discharging in pieces suitable for through-circulation drying.

5. Material that shrinks markedly during drying is often reloaded during the drying cycle to 2 to 6 times the original loading depth. This is usually done after a degree of shrinkage which, by opening the bed, has destroyed the effectiveness of contact between the air and solids.

6. In a few cases, powders have been pelleted or formed in briquettes to eliminate dustiness and permit drying by through circula-

FIG. 12-53 Small muffle furnace. (W S. Rockwell Co.)

tion. Table 12-14 gives a list of materials classified by preforming methods suitable for through-circulation drying.

Steam-heated air is the usual heat-transfer medium employed in these dryers, although combustion gases may be used also. Temperatures above 600 K are not usually feasible because of the problems of lubricating the conveyor, chain, and roller drives. Recirculation of air is in the range of 60 to 90 percent. Conveyors may be made of wire-mesh screen or perforated-steel plate. The minimum practical screen opening size is about 30 mesh.

Design Methods for Continuous Tunnel Dryers In actual practice, design of a continuous through-circulation dryer is best based upon data taken in pilot-plant tests. Loading and distribution of solids on the screen are rarely as nearly uniform in commercial installations as in test dryers; 50 to 100 percent may be added to the test drying time for commercial design.

A mathematical method of a through-circulation dryer has been developed by Thygeson [Am. Inst. Chem. Eng. J., 16(5), 749 (1970)]. Results obtained by Gamson, Thodos, and Hougen [Trans. Am. Inst. Chem. Eng., 39, I (1943)] and Wilke and Hougen [ibid., 41, 444 (1945)] for the rates of adiabatic evaporation of water from packed beds of porous solids are applicable when drying gases flow upward to downward. Use of average additive properties of the drying gas leads to

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