Conceptual design of a column dryer for paddy rice: Fabrication and testing of prototype
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1 Conceptual design of a column dryer for paddy rice: Fabrication and testing of prototype A. M. Olaniyan 1, A. A. Alabi 2 Department of Agricultural and Biosystems Engineering, Faculty of Engineering and Technology, University of Ilorin, P. M. B. 1515, Ilorin , Kwara State, Nigeria; 1 amolan397@hotmail.com, 2 contactabiola@yahoo.com Abstract Rice (Oryza sativa) is an important food crop which belongs to the Gramineae (grass) family. It is an excellent source of carbohydrates, vitamins (such as vitamin D), minerals (such as thiamine, iron, riboflavin and calcium), fibre and other nutrients that are valuable for human growth and health. As a staple food for more than 60 percent of the world population, rice is low in fat and salt and contains no cholesterol, preservatives or additives that are injurious to human health. Drying is one of the most important processes involved in the postharvest handling and processing of rice - other processes include threshing, parboiling, post-drying milling, cleaning, polishing and packaging. In this study, a column dryer was designed, built and tested for small scale drying of paddy rice in order to make the produce available all the year round in reasonable quantity, good quality and affordable costs. While designing and in material selection, consideration was given to portability, durability, ease of operation and maintenance, and techno-economic status of the and small scale tomato farmers and rice processors who are the intended users of the dryer. The functional parts of the dryer included air vent, locking device, an 0.5 hp centrifugal fan inside a fan casing, thermostatically-controlled electric heaters inside a heating chamber and a drying chamber consisting the plenum chamber surrounded by two perforated grain columns. In operation, paddy is fed through the hopper and flow into the vertical grain columns surrounding the plenum unit in the drying chamber. Air is heated by the heaters in the heating chamber and the heated air is conveyed to the plenum chamber and passes through the grain-filled columns. Hence, drying takes place by heat and mass transfer processes in the two perforated vertical grain columns on either side of the plenum chamber while the residual air escapes through the vents on either side of the dryer. A preliminary test carried out on the dryer showed that it was able to reduce the moisture content of paddy rice samples from % to % indicating that the dryer performed satisfactorily. Powered by a 1.0 hp singlephase electric motor, the dryer has a production cost of USD 375 including labour and the cost of electric motor. Keywords: Column dryer, Conceptual design, Paddy. Diseño conceptual de un secador de la columna para arroz con cáscara: Fabricación y pruebas del prototipo Extracto El arroz (Oryza sativa) es una cosecha de la comida importante que pertenece a Gramineae (hierba) la familia. Es una fuente excelente de hidratos de carbono, vitaminas (como la vitamina D), minerales (como tiamina, hierro, riboflavina y calcio), fibra y otros nutrientes que son valiosos para crecimiento humano y salud. Como un alimento básico para más del 60 por ciento de la población mundial, el arroz es bajo en grasa y sal y no contiene ningún colesterol, preservativos o aditivos que son perjudiciales para la salud humana. Secar es uno de los procesos más importantes implicados en el manejo de la postcosecha y procesamiento de arroz - otros procesos incluyen trillar, cocer a medias, postsecar la molienda, limpieza, pulimento y embalaje. En este estudio, un secador de la columna se diseñó, se construyó y se probó de secar de pequeña escala del arroz con cáscara a fin de hacer los productos disponibles todo el durante todo el año en cantidad razonable, buena calidad y gastos económicos. Diseñando y en la selección material,dieron la consideración a portabilidad, durabilidad, facilidad de operación y mantenimiento y estado techno-económico del y agricultores del tomate de pequeña escala y procesadores de arroz quienes son los
2 usuarios intencionados del secador. Las partes funcionales del secador incluyeron el ventilador, cerrando con llave dispositivo, un 0.5 ventilador centrífugo hp dentro de una cubierta del admirador(ventilador), radiadores eléctricos termoestáticamente controlados dentro de una cámara calentador y una cámara secante que consiste la cámara del pleno rodeada por dos columnas del grano perforadas. En la operación, el arrozal se alimenta a través del saltador y flujo en las columnas del grano verticales que rodean la unidad del pleno en la cámara secante. El aire es calentado por los calentadores en la cámara calentador y el aire acalorado(con calefacción) se comunica a la cámara del pleno y pasa por las columnas llenas del grano. De ahí, secar ocurre por procesos de transferencia de masa y transferencia de calor en las dos columnas del grano verticales perforadas a ambos lados de la cámara del pleno mientras el aire residual se escapa a través de las aberturas(respiraderos) a ambos lados del secador. Una prueba preliminar realizada en el secador mostró que era capaz de reducir el contenido de humedad de muestras del arroz con cáscara del 22.36% al 13.37% que indica que el secador funcionó satisfactoriamente. Impulsado por un 1.0 motor eléctrico de la fase sola hp, el secador tiene unos costes de producción de 375 USD incluso el trabajo y el coste del motor eléctrico. Palabras clave: Secador de la columna, diseño Conceptual, Paddy. Introduction Rice (Oryza sativa) is an important food crop which belongs to the Gramineae (grass) family. It is an excellent source of carbohydrates, vitamins (such as vitamin D), minerals (such as thiamine, iron, riboflavin and calcium), fibre and other nutrients that are valuable for human growth and health. As a staple food for more than 60 percent of the world population, rice is low in fat and salt and contains no cholesterol, preservatives or additives that are injurious to human health. Drying minimizes postharvest losses in rice, enhances safe storage, improves milling quality, facilitates efficient transportation, distribution, further processing and utilization. According to Gummert et al (2004), delay in drying, incomplete drying or ineffective drying reduce grain quality of paddy and results in qualitative and quantitative losses. This suggests that drying cannot be overemphasized in handling and processing of rice in order to ensure food and nutritional quality and abundant food supply among majority of the world population. A multipurpose dryer was developed by Ilechie et al (2010) to help minimize losses of agricultural produce by drying them to the safe moisture content that will enable them to have long storage life. Bahnasawy et al (2010) experimentally evaluated the performance of a laboratory-scale dryer for drying some milk-juice blends and whole milk under different drying conditions. There is scarcity of knowledge on fundamental design computations and theoretical analysis of dryers for paddy rice. Therefore, the objectives of the work reported in this paper were as follows: (i) to design and analyze a small scale semi-continuous flow dryer for paddy rice; (ii) to fabricate the dryer based on the design specifications using locally available and low cost construction materials and; (iii) to test and evaluate the performance of the dryer using freshly-harvested and parboiled paddy rice. Materials and methods Description of the dryer The dryer consists of four major units: a feeding hopper, a drying chamber, the tapering section and the heating unit. The drying chamber consists of the plenum chamber surrounded by two perforated vertical columns. The plenum chamber is the unit in which the blower delivers the drying air before entering the grain bulk. It was designed to be between the vertical grain columns in order to distribute the air uniformly trough the grain. In the heating chamber, which has four electrical heating coils of 1.20 kw each, air is heated and a backward curved centrifugal fan sucks the heated air into the plenum chamber while residual exits through the vent. In operation, In operation, paddy rice is fed into the hopper and then flows into the vertical grain columns surrounding the plenum unit in the drying chamber. Heated air flows into the plenum and passes through the paddy-filled grain column. Drying takes place between the two perforated parallel screens on either sides of the plenum chamber while the residual air escapes
3 through the vents on either sides of the dryer. After drying, the locking device is opened, the dried paddy is released into the tempering section, allowed to cool and later discharged. The exploded view of the dryer is shown in Figure 1. Design considerations While designing the dryer, considerations included quantity of fresh paddy rice to be dried over a specified period of time = 24 kg of fresh paddy rice in 2 h; average ambient temperature and relative humidity for Ilorin area at the particular time under consideration = 27 0 C and 70 % respectively; initial moisture content of fresh paddy rice = 27 % (wet basis); and final moisture content considered safe for dried paddy = 14 % (wet basis). Other considerations included ease of loading fresh paddy rice into and removing dried paddy rice out of the drying chamber; mechanism of heat sensing and temperature control systems; and no leakage of heat during the drying process. Also considered was a strong main frame to ensure structural stability and strong support for the dryer; a backward-curved centrifugal fan having enough power to force the required quantity of heated air through the paddy-filled vertical column in the drying chamber during the drying process. Figure 1. Exploded view of the column dryer
4 Design calculations Mass of water to be removed to be removed from the paddy The mass of water to be removed from the paddy rice is calculated from the relationship given by Ichsani and Dyah (2002) as: m w = m i (M o - M f ) (100 - M f ) (1) where; m w and m i are the mass of moisture to be removed and initial mass of paddy rice respectively in kg; M o and M f are the initial and final moisture contents of paddy rice respectively in % (wet basis). With m i = 24 kg, M o = 27 % (wet basis) and M f = 14 % (wet basis), hence, m w = 3.63 kg. Therefore, 3.63 kg of water would be removed from the paddy rice to obtain the shelf-stable moisture content of 10 % (wet basis). Quantity of air required for drying the paddy rice The quantity of air required for drying the paddy rice can be calculated from the basic energy balance equation for drying process (Ichsani and Dyah, 2002) as: m a C pa T B - T C = m w L (2) where; m a is the mass of drying air in kg; C pa is the specific heat capacity of air at constant pressure in J/kg 0 C; T B and T C are the initial temperature and final temperature of drying air respectively in 0 C; and L is the latent heat of evaporation of free water from the paddy rice in J/kg. The quantity of air can be calculated by idealizing the drying process on the psychometric chart. If ambient air at temperature T A (27 0 C) and relative humidity ϕ A (70 %) is heated to temperature T B (45 0 C), then ϕ A will reduce to ϕ B. This heated air is used to remove water, m w (3.63 kg) from paddy rice of mass M o (24 kg) until an equilibrium ϕ C is reached. The temperature of drying air will reduce from T B to T C and the humidity ratio, w, will increase from W B to W C with increment of W CB = (W C - W B ). It follows therefore that the mass of air required to remove moisture in the drying process is represented by Ichsani and Dyah (2002) as: m a = m w ( W CB n) (3) where; m a is the mass of air required to remove moisture from the paddy rice; m w is the quantity of water to be removed; W CB is change in humidity ratio which is the moisture that can be removed by the heated air; and n is the pickup factor. According to Axtell (2002), a perfect transfer of moisture is not possible in practical drying of food and biological materials and, therefore, in designing dryers for these products, a pick up factor is introduced. This pick up factor takes into account the nature of the food and biological materials to be dried and the ease with which it releases moisture to the air. Hence, the actual amount of water that would be removed from the products per kg of drying air can easily be determined. Given that from the psychometric chart (at ambient temperature and relative humidity of 27 0 C and 70 % respectively), W B = kg/kg dry air and W C = kg/kg dry air, hence, W CB = kg/ kg dry air. Therefore, using a pick up factor of 0.25 and substituting m w = 3.63 kg and W CB = kg/ kg dry air into Equation 3 above resulted in m a = kg. Since drying is to be carried out at 2 h per batch, hence, m a =
5 kg/h or kg/s. Therefore the mass flow rate or quantity of moisture to be removed from the fish per unit time is kg/s. Size and type of fan to convey the heated air to the drying chamber for drying The fan size can be deduced by calculating the volumetric flow rate of the heated air which was given by Axtell (2002) as: m v = m a v s (4) where; m v is the volumetric flow rate of the drying air in m 3 /s and is the specific volume of the drying air in m 3 /kg. Substituting v s = m 3 /kg (from psychometric chart) and m a = kg (from Equation 3), hence, m v = 832 m 3 /h or m 3 /s. Therefore, a 0.5 hp centrifugal fan of speed m 3 /s is selected for the dryer. Energy required to heat the quantity of air meant for drying the paddy rice In order to select the heating element for the dryer, the quantity of heat energy required for raising the drying temperature to 45 0 C from ambient temperature of 27 0 C is calculated from Equation 5 (Axtell, 2002) as: Q = m a (h 2 - h 1 ) (5) where; Q is amount of heat energy in kj/s; m a is air mass flow rate in kg/s; h is specific enthalpy of air at inlet in kj/kg air; and h 2 is specific enthalpy of air at the drying temperature in kj/ kg air. With h 1 = 68.0 kj/kg air; h 2 = 86 kj/kg air; and m a = kg/s (from Equation 3), hence, Q= 4.7 kj /s or 4.7 kw. Therefore, 4 units of electric heater each of 1.20 kw each or 3 units of 1.6 kw each can be used. Fabrication of the dryer The specification of construction materials is shown in Table 1. Using power hacksaw, Standard lengths of square pipe of dimension 25 mm x 55 mm were cut to four pieces of 550 mm length, six pieces of 600 mm length and two pieces of 300 mm length to form the frame motor seat of the dryer. Using a treadle operated guillotine, eight pieces of sheet of dimension 350 mm x 600 mm and four pieces of dimension 600 mm x 700 mm were cut from a mild steel sheet of gauge 1 mm to form the outer and inner walls, top cover and base of the drying chamber. In the same manner, the shutter and locking device were constructed using a gauge 1 mm mild steel sheet. The vertical columns which hold the paddy rice during drying were fabricated from four pieces of gauge 1 mm perforated galvanized steel sheet of dimension 660 mm x 350 mm with holes 2 mm diameter. All the various components were joined together by welding and then assembled. Table 1. Some materials used for construction of the dryer and their specifications Materials Specifications Quantity Thickness 1 mm I200 mm x 600 mm, thickness 1 mm Thickness 1 mm 75 mm size 0.5 hp Centrifugal fan with prime mover 1.20 kw electric heater 10 0 C C (graduated in 5 0 C) Wool fibre 16 mm x 16 mm mild steel 40 mm x 40 mm mild steel 25 mm x 25 mm mild steel Galvanized steel sheet Perforated galvanized sheet Mild steel sheet Pair of hinges Blower Heater Thermostat Lagging material Square pipe Angle iron Square pipe 1 standard size 6 pieces 2 standard size Lump 1 standard length 1/2 standard length 1 standard length
6 Heater cable Copper wire Painting 3 mm 2 mm 6 yards 6 yards Lump Testing of the dryer Testing procedure was carried out in the Processing Laboratory of the Department of Agricultural and Biosystems Engineering, University of Ilorin, Ilorin, Nigeria. Enough paddy rice was purchased from a farm in Tsaragi in Edu Local Government Area of Kwara State and parboiled using a steam parboiler designed and built prior to this study. After parboiling, draining and equilibration at room temperature, the initial moisture content was determined by an oven method using a laboratory convective air oven. The dryer was pre-heated to a temperature of 45 0 C by means of temperature regulator while the paddy rice samples were being prepared to ensure stability of the condition of the drying chamber. 6 kg of the parboiled paddy rice were weighed and transferred through the hopper into the vertical grain surrounding the plenum unit in the drying chamber. After the 2 h drying time, the dried paddy rice was from the dryer and the final moisture content determined and the test was carried out in triplicates. Results and discussion Results showed that the dryer was able to dry paddy rice from initial moisture content % to a moisture content of %. The result obtained compares favourably with previous study in product drying including Omodara and Olaniyan (2012), Bahnasawy et al (2010) and Hassanain (2010). The result of the testing indicated `the satisfactory performance of the dryer but there is still room for improvement. The dryer can be scaled up for commercial drying of paddy rice; hence, it is recommended for use in rice processing industry. Conclusion A column dryer was designed, fabricated and tested for paddy rice drying. The dryer was able to dry the paddy rice from an initial moisture content % to a moisture content of %. Powered by a 1.0 hp single-phase electric motor, the dryer has a production cost of USD 375 including labour and the cost of electric motor. The dryer can be used for small scale paddy rice processing and should therefore be scaled up for industrial application. Bibliography Axtell, B. (2002). Drying Food for Profit: A Guide for Small Business. 1st ed. London, UK: Intermediate Technology Development Group Publishing Ltd. Bahnasawy, A. H., Okasha, A. E., and Gonbeej, E. E. (2010). Performance evaluation of a laboratory scale spray dryer. Misr Journal of Agricultural Engineering 27 (1): Gummert, M.; Rickman, J. F. and Bell, M. (2004). Drying systems. Rice fact sheets. International Rice Research Institute Bulletin, Manila, Philippines. Hassanain, E. E. (2010). Some construction parameters of unglazed perforated solar dryers for medicinal plants. International Journal of Agricultural and Biological Engineering 3 (4): Ichsani, D. and Dyah, W. A. (2002). Design and experimental testing of a solar dryer combined with kerosene stoves to dry fish. American Society of Agricultural and Biological Engineers 1-3. Ilechie, C. O.; Ige, M. T.; Aibangbee, G. F.; Ogblechi, S. R.; Amiolemhen, P. E., and Abikoye, B. O. (2010). Development and performance evaluation of a multipurpose dryer. Proceedings of the 3rd International Conference on Engineering Research and Development Omodara, M. A. and Olaniyan, A. M. (2012). Effect of pre-treatments and drying temperatures on drying rate and qualities of African catfish (Clarias gariepinus). Journal of Biology, Agriculture and Healthcare 2 (4): 1-11.
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