Design of a Small Scale Biomass-based Paddy Drying System

By

Joel A. Ramos
Vinh Q. Le
Maribel Peneyra
Carolyn Grace G. Somera
Jean C. Balicha
Sherwin Valdez

A course activity submitted to Dr. Teresito A. Aguinaldo as a requirement for

the subject “Processing of Grains and By-products” (CPE-729)

March 2010
 Small Scale Biomass-based Paddy Drying System

Introduction

Primarily, handling of damp grain during the rainy season is a major problem in the
grain industry. If not properly addressed, the grains deteriorate and lose its quality.
Mechanical drying on one hand offers the best alternative during the wet season, however its
adoption becomes unpopular primarily because of high drying cost incurred by the user
partially due to high cost of fuel. On the other hand, cutting down that cost by way of
introducing alternative source of fuel like rice hull can saved about 50% of drying expenses.
Most farmers individually can’t afford mechanical dryers. Non profitability and lack
of technical knowledge in operating dryers underlie the expressed constraints in their usage.
(Cardiño 1986) The need for immediate drying of high moisture grain at the farmer’s level
during the wet season can certainly addressed by a small scale mechanical dryer, which
complements and compares favorably with sun drying. It must include features found in sun
drying such as simplicity or ease of operation, minimum operating expenses and low capital
costs which are the usual requirements made by farmers and grain processors who intend to
invest in dryers. (De Padua et al. 1984)

Objective

The project aims to design, construct and test a small-scale paddy dryer with rice hull
fueled furnace.

Methodology

1. Conceptualize design of a drying system based on the following criteria:

 capacity should range 0.5-0.6 ton/batch
 utilizes rice hull biomass as heat source
 batch-in-bin type construction
2. Do theoretical calculations of the drying parameters required for the 0.5 ton volume of
paddy as basis for the design, such as the amount of heat required, air flow rate, size of
holding bin, size of furnace, and many others.
3. Prepare a detail AutoCad drawing of the drying system (holding bin, blower, furnace) as
guide for fabrication.
4. Facilitate fabrication and construction of the system.
5. Conduct preliminary test and evaluation of the system.

Results

A. Theoretical Calculation of Design Parameters

Assumptions:
Capacity: 500 kgs
Initial grain moisture (wet grain): ~ 28%
Final grain moisture (dried grain): 13 - 14%
Relative humidity: 80%
 Bulk density of paddy: 550 - 570 kg/m3

1) Holding bin:
Capacity is 500 kgs per batch. We need a chamber volume of around 1.0 m3 (provide
impurities for impurities in grain).
Researches show that for flatbed dryer, depth of grain should be around 0.3 to 0.4 m
Using 0.3m, then we will obtain a floor area:
1.0
S Floor 3.33 m2.
0.3
 Length would be 1.83 (m); Width would be 1.83 (m)
 Height of drying chamber (H) is; includes height of plenum (below grain mass) +
depth of grain mass + 0.065 (from surface of grain mass to top)
H = 0.25 + 0.30 + 0.065 = 0.615 (m)

2) Fan:
Total pressure drop is around 30 mmH2O (include: pressure drop per unit depth of
grain, pressure drop for screen, pressure drop for pipe, partial pressure drop).
From several references, for flatbed dryer, the superficial air velocity is best from 0.15
to 0.25 m/s (or 9 to 15 m/minute).
Therefore, fan’s airflow is;
VFan = 0.15 [m/s] * 3.33 [m2] = 0.5 [m3/s]

Theoretical air power;

Q(m3 / s ) * P(mmH 2O) 0.5*30
Pt 0.15 kW
102 102
Sometimes, the static pressure can be higher than 30 mmH2O (e.i. if grain is
compressed), so airflow will be reduced, and the practical consuming power will be
increased. On the other hand, because of losses due to transmission (bearings, V-
belts), the practical consuming power will be greater than the theoretical air power.
Therefore, we should choose a motor with at least 0.5 kW rated capacity.

3) Drying process:
Using Psychrometric chart, determine the state points for drying process.
- Point 1: Ambient air state (at Patm = 101,325 Pa; suppose Tdb = 27 oC, RH1 =
80%) => Twb = 24.3 oC, d1 = 0.018 (kg H2O/kg dry air), Enthalpy I1 = 73.11 kJ/kg
dry air, v1 = 0.875 m3/kg (or air density = 1.143 kg/m3).

- Point 2: Air state after heating. During the sensible heating process, d2 = d1 =
0.018 kg H2O/kg; P2 = Patm + 250.00 Pa = 101,575 Pa). We need to be achieved
Tdb.drying = 45 oC => hence, RH2 = 29.74%, Twb = 28.61 oC, I2 = 91.84 (kJ/kg dry
air), v2 = 0.93 m3/kg (or air density = 1.075 kg/m3)
 - Point 3: Exit air state, after drying process. This is adiabatic process: I3 = I2 =
constant = 91.84 kJ/kg; P3 = Patm = 101,325 Pa, and suppose Tdb.exit = 31 oC =>
RH3 = 84.0%, Twb = 28.65 oC, d3 = 0.024 (kg H2O/kg dry air), v3 = 0.89 m3/kg (or
air density = 1.124 kg/m3)

I = I2 – I1 = 91.84 - 73.11 = 18.73 (kJ/kg dry air) => this heat difference is to be
supplied by furnace

Summary of parameters related to the drying process

Absolute Specific
Point o o RH, Enthalpy
Tdb, C Twb, C humidity d, volume v,
No. % I, kJ/kg
kg/kg m3/kg
1 27.0 24.30 80.0 0.018 73.11 0.875
2 45.0 28.61 29.74 0.018 91.84 0.93
3 31.0 28.65 84.0 0.024 91.84 0.89

4) Biomass Furnace:
- Airflow of fan, GFan
GFan = VFan / v2 = 0.5 [m3/s] / 0.93 [m3/kg] = 0.59 kg/s.
- Furnace Power, PFurnace
PFurnace = GFan * I = 0.59 [kg/s] * 18.73 [kJ/kg] = 11.05 kJ/s = 11.05 kW
= 11.05 * 3.6 = 39.78 MJ/hr
- Fuel Consumption (rice-husk)
Calorific value of ricehusk (10%MC); q 11.3 MJ/kg (lower heating value)
Suppose the furnace can obtained a common heat efficiency = 70%, then the
fuel consumption is;

PFurnace 39.78
GFuel = 5.03 (kgs/hr)
q* 11.3*0.70

5) Drying time:

a) Weight of water vapor to be removed by fan:

- Weight of water vapor that the drying air removes from the grain (for 1 kg dry air);
d = d3 – d2 = 0.024 - 0.018 = 0.006 (kg H2O/kg dry air)
- For the fan with a 0.59 kg/s airflow, weight of water vapor that the drying air
removes from the grain;
DH2O = GFan * d = 0.59 [kg/s] * 0.006 [kg H2O/kg dry air] = 0.00354 (kg H2O/s)

b) Computing the drying time:

Weight of water to be removed from grain;

M1 M 2 M1 M 2
GH 2O Gi * or GH 2 O Gf *
100 M 2 100 M 1
where:
Gi: initial grain weight (wet grain)
Gf: final grain weight (dried grain, after drying)
M1 : initial grain moisture (wet grain), %
M2 : final grain moisture (dried grain), %

Here:
Gi = 500 kgs; M1 = 28%; M2 = 14%

Weight of water that needs to be removed from grain

M1 M 2 28 14
GH 2O Gi * 500* 81.40 kgs
100 M 2 100 14

Thus, the theoretical drying time will be:

Tt = GH2O / DH2O = 81.40 / 0.00354 = 22,994.35 (seconds)

Tt = 22,994.35 / 3,600 = 6.39 (hrs)

Note:
 Weight of water evaporated is different between inside and surface of grain.
 At the end stage of drying process, the air exit on the surface (point No. 3) is
rather dry, so weight of water evaporated is less (proof: RH is rather low).

Therefore, the practical drying time will be longer than the theoretical drying time.
I2 = I3
3 d3
I1
1 2 d1 = d2

Tdb1 Tdb3 Tdb2

Figure 1. Plot of drying process on the Psychrometric Chart

B. Autocad Drawing of the Drying System

As shown in Figure 2 is the autocad drawing of the proposed drying system.

a) side view

b) top view

c) front view
Figure 2. Autocad drawing of the paddy drying
system showing its different view.
It is a rice hull fueled batch-type flatbed dryer with 0.5 ton capacity per batch of
operation. It is composed of 3 main components, namely: 1) holding bin; 2) fan assembly;
and 3) heating unit (furnace). The holding bin is made from G.I. sheets stiffened by flat bar.
Perforated sheet with 2.4mm hole was used to hold the grains while drying, heated air is
blown from beneath the plenum chamber. The blower is a tube axial fan also made from G.I.
sheets secured by pillow blocks which are bolted on the frame on both ends. The furnace is
made from locally source bricks piled layer by layer about a fabricated guide frame which is
made from angle bars. Aside from primary air sucked beneath the grate, secondary air is
introduced to the combustion area which was tapped from the air blown by fan thus
improving combustion efficiency.

C. Fabrication and Installation

As shown in Figure 3 is the installation of the drying unit. Holding bin was made
from angle bar as its frame where the G.I. sheet is riveted. Then G.I. sheet panels (sidings)
were bolted to form the holding bin, thus this may allow dismantling of bin whenever
necessary.
Construction of furnace was done using locally home-made bricks. It was piled layer
by layer through a guide frame and using mixture of heavy clay soil, sand and cement as
binding material.

Figure 3. Installation of components of the drying unit (holding bin, furnace, and
blower, CLSU, Munoz, Nueva Ecija, March 2010.
D. Evaluation of the Drying System
(To follow once samples become available)

Summary

A small scale paddy drying system with rice hull fueled furnace was designed,
fabricated and installed. It has a capacity of 0.5 ton per batch of operation with 3 main
components; holding bin which is made of G.I. sheets, a tube axial type fan, and furnace
which is made from home-made bricks.

References

CARDIÑO , A.G. 1986. Case studies of mechanical dryers in the Philippines: Lessons
learned. In: Small Farm Equipment for Developing Countries. IRRI, Los Baños,
Laguna, Philippines. pp. 431-437.

DE PADUA, D.B., A.A. MANILAY and A.S. FRIO. 1984. Drying and handling of wet
paddy. In: Proceedings of the FAO/UNDP Regional Workshop of Rice Post-harvest
Technology, 17-22 July 1984, NFA, Quezon City, Philippines.

RICE POSTPRODUCITON TECHNOLGY. A technical Reference Guide, First Edition,

2003. A collaborative project between KOKKEN and PRPC.

HENDERSON S.M., R.L. PERRY, 1976. Agricultural Process Engineering. 3rd Edition:
Henderson & Perry. 442 p.