Iranian Journal of Science & Technology, Transaction B, Vol. 28, No.

B6
Printed in The Islamic Republic of Iran, 2004
Shiraz University

MATHEMATICAL MODELING AND COMPUTER

*
SIMULATION OF A DRUM DRYER
N. KASIRI, M. A. HASANZADEH** AND M.MOGHADAM
Computer Aided Process Eng. Lab, Chem. Eng. Dept., Iran University of Sci. & Tech., Tehran, I. R. of Iran
Email: Kasiri@iust.ac.ir
Abstract In this study, a mathematical model based on principles of heat and mass transfer taking
place during the drying process has been developed. Element material and energy balance equations
are solved simultaneously using the modified Euler method with time step variation. In order to
consider evaporation rate reduction after the critical moisture content, a factor is defined which
could be evaluated from drying curve. The developed model is then used as a base to build a
simulation program. The program is eventually used to predict the performance of a dryer for baby
food compared with real plant measurements. Relatively good compatibility is observed to exist
between the predicted and measured data. Errors observed between the calculated results and real
plant data are about 10.32% for drying time and 15.40 % for final moisture content. The simulator
also used to study the behavior of a dryer for qualitative analysis and the influence of different
parameters on drying time and product quality.
Keywords Simulation, drum dryer, drying film, drying rate

1. INTRODUCTION
Drum drying is one of the most energy efficient drying methods and is particularly effective for drying high
viscous liquids or pureed foods. In a drying operation, liquid, slurry or puree material is applied as a thin
layer onto the outer surface of revolving drums that are internally heated by steam. After about threequarters of a revolution from the point of feeding, the product is dried and removed with a static scraper.
Nowadays, drum dryers are used in the food industry for drying a variety of products such as milk product,
baby foods, breakfast cereal, fruit and vegetable pulp, mashed potatoes, cooked starch and spent yeast. It is
also employed in the production of various chemicals such as poly acryl amide, sodium benzoate, various
acetates, etc. According to various sources, different parameters such as temperature, drying time, etc. may
affect product quality [1-3]. In this study, heat and mass transfer equations were solved simultaneously to
predict the temperature and humidity profiles of the solid layer as it dries on the external surface of the
rotary drum [4].
2. PROCESS DESCRIPTION
As the material layer is formed on the drum, a saturated film develops on the outermost surface of the layer
and evaporation begins from there [5]. The drying process has been investigated in three segments.
Temperature and moisture content distribution for the drum dryer in question is depicted in Fig. 1. During
the first segment, feed undergoes an increase in temperature up to maximum temperature of slurry where its
water starts boiling [6]. During the second segment, evaporation takes place from the outer surface at the
boiling point. Having lost the surface moisture in this segment, the drying material then experiences an
increase in temperature from water boiling point to the final product temperature during the third segment
[7].

Received by the editors June 3, 2002 and in final revised form October 12, 2004
Corresponding author

680

160

Tp
Xf=4

120
T em perature (C )

m ois ture c ontent (k g m ois ture/k g dry s olid)

N. Kasiri / et al.

Tboi

80

40
1

Tf=25

Xcr=0.751

Xp

0
0

100

200

300

100

200

300

Dry ing angle (deg)

Dry ing angle (deg)

Fig. 1. Temperature and moisture content distribution of a drum dryer

Due to an abundance of moisture in the layer during the first drying segment, the moisture loss of the surface
is quickly replaced from the main body to maintain the surface saturation condition. As the heat source
temperature (hot water or steam) is high, the feed temperature gradually increases in the first segment which
causes an evaporation rate increase [6]. During the second segment the evaporation rate is constant because
of constant temperature. At the beginning of the third segment where there isnt enough moisture in the main
body to maintain the saturation conditions on the surface (critical moisture content), a dried solid film is
formed. Since the moisture diffusion through this film is slower than surface evaporation, diffusion becomes
the rate-limiting step [4, 8].
3. MODEL DEVELOPMENT
To develop model equations, a volume element of width Rd , thickness d, and length L is used as shown in
Fig. 2, [6]. The model starts with a material and heat balance on the element which provides the temperature
and moisture content of the element.
4. MATERIAL BALANCE
The net mass entered the element by moisture concentration gradient is as follows:

W W + d =

Dwe Ld 2 X
R2
2

(1)

where Dwe is the moisture diffusivity in the element, is the element density, R2 is the drum outside radius
and is the percentage of the volume of solid phase. Moisture evaporated from the element is evaluated by
the following equation:
WE =

M
K G R2 L( P sat Pw )
1000

(2)
h,Tair

T
Element
TB

Element

Fig. 2. A sketch of the volume element

Iranian Journal of Science & Technology, Volume 28, Number B6

December 2004

681

Mathematical modeling and computer

where KG is the mass transfer coefficient from the saturated surface to the surrounding air, M is the moisture
molecular weight, Psat is the saturation pressure at element temperature and Pw is moisture partial pressure in
the surrounding air. Using Eqs. (1) and (2) transient mass balance is given by
D we Ld 2 X
M
X
K G R 2 L ( P sat Pw ) = LdR 2

2
1000
R2
t

(3)

In order to solve Eq. (3) an initial time condition and two partial boundary conditions are required. The
following relationship between time and rotation angle is used instead of a time dependent initial condition

X X
=
2Vrc
t

(4)

where Vrc is the drum rotation velocity.

Equation (3) demonstrates the drying rate before the critical moisture point [5]. During the third drying
period a factor is defined to consider evaporation rate reduction.

Evaporation rate during the third period

Evaporation rate during the second period

X < Xcr = 1 ,

X > Xcr

(5)

<1

is evaluated from drying curve (rate of drying as a function of material relative moisture content x or
absolute moisture content X). It should be noted that the drying curve which has been used to simulate a real
plant (a baby food dryer) is different from that which has been used for our qualitative analysis. Real plant
drying curve is represented in Fig. 3. In order to apply this curve in programming, a four order polynomial
as a function of X is fitted for this curve after Xcr as follows:

E = 3.9098 X 4 6.1117 X 3 + 2.6640 X 2 + 0.6828 X

(6)

0.0012
(2)

Xcr

Evaporation rate (kg/s)

0.001
0.0008

(1)

(3)

0.0006
0.0004
0.0002
0
1.8

1.6

1.4

1.2

0.8

0.6

0.4

0.2

Moisture content (kg/kg dry solid)

Fig. 3. Baby food dryer drying curve

For qualitative analysis it has been assumed that evaporation rate of feed solution (sodium sulfate
slurry) varies inversely with X after Xcr, so that Ev=Ecr(X/Xcr). By substitution of and Eq. (4) into Eq. (3),
overall mass transfer equation is given by
D we Ld 2 X
M
dX
K G R 2 L ( P sat Pw ) = 2V rc LdR 2 s

2
R2
d
1000

(7)

5. ENERGY BALANCE

Energy balance of the element gives the following relation:

December 2004

Iranian Journal of Science & Technology, Volume 28, Number B6

682

N. Kasiri / et al.

T T
kLd d 2T
M
dT
K G R2 L ( P sat Pw )C pwT = 2Vrc C p dR2 L
+ k d R1 L B
hR2 L(T Tair )
2
R2 d
d
x
1000

(8)

where k and kd are the element and drum thermal conductivity, respectively, R1 is the drum inside diameter,
Cp is the element heat capacity, Cpw is the moisture heat capacity, TB is the internal surface temperature of
the cylinder and h is the surrounding air convective heat transfer coefficient. The first term in Eq. (8) is the
net energy entered into the element by conduction heat transfer during to +d . The second term is the
energy entered into the element by conduction heat transfer from R1+dx. The third term is the exhausted
energy from the element by convection heat transfer. The last term in the left-hand side of this equation is
the energy exiting the element by water evaporation.
In the two balance equations, parameters such as density, film thickness, specific heat, heat transfer
coefficient, mass transfer coefficient, vapor pressure and drum external diameter vary with drying film
(element) temperature and moisture content. Element thickness is given by

d = d0

f w

(9)

where w is the moisture density, f is the feed density and d0 is the initial feed layer thickness. Element
thickness is constant during the third drying period, dd = 0 or d = constant. Drum external diameter is as
dt
follows:
R2 = R1 + d +dx

(10)

Weight average element density is given by

s (1 + X )
1 + ( X s / w )

(11)

where s is the powder density. Element material heat capacity, Cp, which varies considerably during
rotation due to moisture content variation, is evaluated as follows:

Cp =

C ps + C pw X

(12)

1+ X

where Cps is the powder heat capacity. Element thermal conductivity, k, is given by a similar formula
k=

ks + kw X
1+ X

(13)

where ks and kw are the powder and moisture thermal conductivities, respectively. Since the drum is rotating
quite fast (0.07 s-1) and sometimes fans are used for better heat transfer, the transfer mechanism is
considered to be forced convection type. Hence the following formula is used to evaluate external transfer
coefficient [2].

Nu = Pr 0.33 Re n

(14)

and n are constants which could be determined for a specific range of Re. For example, for 0.4<Re<4, =
0.989 and n = 0.33. Nu is the Nusselt number defined by Nu = hair D k air , D is drum diameter, Pr is the
Prandtl number defined by Pr = C p ,air air k air and Re is the Reynolds number defined by
Re = air u air D air . Moisture transfer coefficient from the saturated film surface to the surroundings is
given by
K G Pt 0.56
Sc
= 0.281 Re 0.4
(15)
Gm
Iranian Journal of Science & Technology, Volume 28, Number B6

December 2004

Mathematical modeling and computer

683

where Pt is the ambient pressure, Gm is the surrounding air molar flux and Sc is the Schmidt number defined
by Sc = air air D w,air . It should be noted that all dimensionless numbers in Eqs. (14) and (15) (Nu, Pr, Re
and Sc) are evaluated at the mean temperature of the drum surface, and surrounding air is referred to as the
film temperature. As the partial pressure gradient causes mass transfer, the transfer rate is given by

Mass transfer rate = K G P sat Pw

(16)

Saturation partial pressure is evaluated using Antoine formulae

LnPi = A +

B
C +T

(17)

Element solid content is obviously related to the element moisture content and is given by

1/ s
1/ s + X / w

(18)

Element equation and the main temperature and moisture content equations are solved simultaneously
using the modified Euler method with time step variations using the initial conditions of the system.
Parameters and initial system conditions are: temperature, moisture content, density, viscosity, heat capacity
and thermal conductivity of the initial feed, initial drying film thickness, temperature of the drying medium
(hot water or steam), comprehensive dryer specification (thickness, thermal conductivity, length and
diameter) and the surrounding air condition (viscosity, temperature, moisture content and the velocity with
which it passes over the drum).
6. RESULTS AND DISCUSSION

Figure 4 shows that time steps smaller than 0.001 (s) are generally adequate to provide acceptable results. To
verify the validity of the developed mathematical model, a baby feed dryer in a local industry, a double
drum type which operates under atmospheric conditions and results in final product moisture content of 3
(kg / kg dry solid) after a 270 degrees rotation was simulated. This plant data is compared with drying
simulation results in Table 1. According to this table there is a good agreement between simulation and plant
data. However, errors observed in this table (10.32% for drying time and 15.40 % for final moisture content)
are due to:
1. Plant data was not accurate because the dryer was not operating properly at the time. Some of the
required data had to be estimated.
2. Some of the material property such as critical moisture content and the drying curve had to be
evaluated using laboratory experiments which cause an inherent error
3. Some of the required property such as material heat capacity and conduction heat transfer coefficient
had to be estimated.
0.00001

integration step (s)

0.0001

0.001

0.01

0.1
9.5

10

10.5

11

11.5

drying time (s)

Fig. 4. Drying time variations with step size change

December 2004

Iranian Journal of Science & Technology, Volume 28, Number B6

684

N. Kasiri / et al.

Table 1. Dryer simulation results compared with real plant data

Drying Time (s)
Final moisture content
(kg moisture/kg dry solid)

Simulation data
40.350

Plant data
45.00

Error %
10.32

0.025

0.03

15.40

A qualitative analysis of the dryer operation was then carried out using the simulation program. In this
study, the effect of drying film thickness, drum thickness, dryer conduction heat transfer coefficient, system
pressure passing over air velocity, drying medium temperature, rotation velocity on drying time and final
product moisture content have been investigated. The dryer used is a single cylinder. The initial input
conditions are:
Input feed: sodium sulfate solution (20 weight percent):
Xf = 4 kg moisture / kg dry solid, Tf = 25 C and d = 0.001 m
Drum specification:
L = 3 m, dx = 0.008 m, D = 2 m and kd = 35 W /m C
Air initial conditions:
Tair = 30 C and uair = 0.25 m/s
Other parameters:
Tboi = 100 C, Vrc = 0.07 s-1, Pt = 1 atm and Xcr = 0.751 kg moisture / kg dry solid
Figure 5 shows that increasing drying film thickness increases drying time. This result is quite expected
since the thicker the material film, the longer the second period of drying, and therefore it takes longer for
drying material to reach critical moisture content condition. Furthermore, having reached critical moisture
content condition, diffusion time required for the moisture to reach the surface before being evaporated is
longer, causing longer drying time.

50

drying time (s)

40
30
20
10
0
0

0.5

1.5

2.5

feed layer thickness (mm)

Fig. 5. Drying time variations as a function of film thickness

Drying time variations as a function of drum thickness is depicted in Fig. 6. Obviously drum thickness
increase will increase drying time due to the fact that thicker drums, usually used when higher operating
pressure is required, cause a delay in the time taken for the heat to be transferred from the inside to the
material being dried. According to Fig. 7, increase in thermal conductivity of the drum material increases
heat transfer rate which causes a drop in drying time. Effectiveness of this parameter decreases at high k
values because the importance of heat transfer across the metal material diminishes. The temperature of the
drying medium is another parameter which affects final product moisture content in Fig. 8. Under similar
conditions of drying time, film thickness, etc, the higher the drying medium temperature, the larger the
temperature driving force, and therefore heat transfer rate becomes faster causing a faster rate of
evaporation.
Iranian Journal of Science & Technology, Volume 28, Number B6

December 2004

685

11.5

13.2

11

12.4
drying time (s)

drying time (s)

Mathematical modeling and computer

10.5

10

11.6

10.8

9.5
0

0.002

0.004

0.006

0.008

10

0.01

10

drum thickness (m)

20

30

40

50

60

70

80

kd (w /m.c)

Fig. 7. Drying time variations as a function of thermal

conductivity of the drum

Fig. 6. Drying time variations as a function

of drum thickness

Figure 9 demonstrates the way in which surrounding air velocity increase reduces drying time as
expected. Here again velocity reaches a saturation point above which an increase does not affect drying time
considerably. The initial rapid decrease is due to an increase mass transfer coefficient resulting from a higher
Reynolds number. Another parameter affecting drying time and therefore final product moisture content is
drum rotation speed. As shown in Fig. 10, rotation speed increase causes considerable increase in final
product moisture content due to shorter drying time. Surrounding pressure increase has an inverse effect on
mass transfer coefficient [8]. As the pressure increases, mass transfer coefficient and consequently diffusion
rate and mass transfer decreases. This eventually means an increased drying time and final product moisture
content as represented in Fig. 11.

20

0.1
15

0.08
drying time (s)

moisture (kg moisture / kg dry solid)

0.12

0.06
0.04

10

0.02
0
100

110

120

130

140

150

160

steam-temprature (C)

0.2

0.4

0.6

0.8

1.2

air speed (m/s)

Fig. 8. Final product moisture content as a function of

steam temperature

Fig. 9. Drying time variations as a function of surrounding

air velocity
17
15

0.1

drying time (sec)

moisture (kg moisture / kg dry solid)

0.15

0.05

13
11
9
7

0
0

0.02

0.04

0.06

0.08

0.1

0.12

rotation speed (1/s)

5
0.4

0.6

0.8

1.2

1.4

pressure (atm)

Fig. 10. Final product moisture content as a function of

drum rotation speed
December 2004

Fig. 11. Drying time variations as a function of surrounding

pressure
Iranian Journal of Science & Technology, Volume 28, Number B6

686

N. Kasiri / et al.

7. CONCLUSIONS

In this study a mathematical model has been developed for a rotary drum dryer using material and energy
balance. This model is then applied for simulation of the dryer. Comparing simulation and plant data, it has
been found that the approached model gives satisfactory results. The effect of drying film thickness, drum
thickness, drum thermal conductivity, system pressure, surrounding air velocity, drying medium temperature
and drum rotation speed on drying duration and final product moisture content are investigated
quantitatively. Simulation results have then been analysed qualitatively in detail. Altogether it has been
found that simulation results are not only compatible with experimental data, but can also logically describe
the drying process.
NOMENCLATURE
T
X
E

temperature (C)
moisture content (kg moisture / kg dry solid)
evaporation rate (kg/s)

W
Dwe
Dw,air
D
L

mass rate (kg/s)

moisture diffusivity in element (m2/s)
moisture diffusivity in air (m2/s)
element thickness (m)
drum length (m)

R2

drum diameter
solid volume percent (%)
element density (kg/m3)
drum outside radius (m)

R1
M
KG
k
t

drum inside radius (m)

moisture molecular weight (g/mol)
mass transfer coefficient (mol/atm m2s)
thermal conductivity (W/mC)
time (s)

Vrc
P
TB
h

drum rotation velocity (s-1)

constant (dimensionless)
pressure (atm)
internal surface temperature of drum (C)
convective heat transfer coefficient (W/m2C)

Cp
Gm
Pt
Nu
Pr

element heat capacity (W/molC)

air molar flux (mol/m2s)
ambient pressure (atm)
Nusselt number (dimensionless)
Prandtl number (dimensionless)

Re
Reynolds number (dimensionless)
Sc
Schmidt number (dimensionless)
, n, A, B, and C constant (dimensionless)
Subscripts
p
f
cr

product
feed
critical

boi
w

boiling
water or moisture

Iranian Journal of Science & Technology, Volume 28, Number B6

December 2004

Mathematical modeling and computer

s
d
E

solid or powder
drum
evaporation

e
t

element
total

687

Superscript
sat

saturation

REFERENCES
1.

Mujamdar, A.S. (1987). Handbook of industrial drying. Marcel Dekker Inc, New York, 227 -241.

2.

Rodrigues, G., Vasseur, J. & Courtois, F. (1996). Design and control of drum dryers for the food industry, Part1:
Set-up of a moisture sensor and an inductive heater. Journal of Food Engineering, 28, 271-282.
Rodrigues, G., Vasseur, J. & Courtois, F. (1996). Design and control of drum dryers for the food industry, Part 2:
Automatic control. Journal of Food Engineering, 30, 171-183.

3.
4.
5.
6.
7.
8.

Keey, R. B. (1973). Introduction to industrial drying operation, William Clowes & Sons Ltd, London, 978, 223228.
Fritze, H. (1973). Heat and mass transfer problem in the production of foodstuffs on drum dryers. ESCHER. WYSS
NEWS, 46(2), 2-9.
Vasseur, J., Abchir, F. & Trystram, G. (1997). Modeling of drum dryer. ENSIAA-1 Ave des olympiades 91305
MASSY-FRANCE Drying, 121-129.
Novitskii, V. S. & Gryznov, V. V. (1976). Method of analytical calculation of the operation cost of a drum
atmospheric dryer. Chem. & Pet.Eng., 12(7-8), 624-627.
Treybal, R. (1980). Mass transfer operations. McGraw-Hill Ltd.

December 2004

Iranian Journal of Science & Technology, Volume 28, Number B6