Thermal characteristics of the dryer with rice husk double furnace-heat exchanger for
smallholder scale drying
by I Gede Bawa Susana
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Case Studies in Thermal Engineering 28 (2021) 101565 Contents lists available at ScienceDirect Case Studies in Thermal Engineering journal homepage: www.elsevier.com/locate/csite Thermal characteristics of the dryer with rice husk double furnace - heat exchanger for smallholder scale drying Ida Bagus Alit, I Gede Bawa Susana *, I Made Mara Department of Mechanical Engineering, Faculty of Engineering, University of Mataram, Jl. Majapahit No. 62 Mataram-Nusa Tenggara Barat, 83125, Indonesia ARTICLE INFO ABSTRACT Keywords: Smallholder farmer scale drying is very dependent on sunlight because of limited costs and Drying technology. The downside is when the weather is erratic due to weather changes. In addition, the Heat exchanger Rice husk temperature is less than optimal which affects the time and quality of the dried product. The study aims to determine the thermal characteristics of the dryer design in the application of appropriate technology through the use of rice husks. The dryer is designed to use two furnaces in which heat exchanger pipes are added. The distribution of heat through the heat exchanger pipes and conduction from the furnace attached to the wall of the drying chamber. The test results show that the average ambient air temperature of 32.14oC can be increased to 92.10oC, 93.27oC, and 94.96oC in the drying chamber for variations in the diameter of the furnace wall holes of 8 mm, 10 mm, and 12 mm, respectively. Sequentially, the temperature in the drying chamber reaches a maximum of 119.13oC, 127.98oC, and 140.89oC. This dryer model is expected to be a solution for small farmers in a sustainable and energy-efficient post-harvest drying process. 1. Introduction Drying is a process of heat transfer and mass transfer of water vapour simultaneously. This process requires energy to evaporate the water content removed from the surface of the material being dried. In general, the drying process can be carried out through direct sun drying and drying using a dryer with biomass energy. Sun-drying produces a temperature that is not optimal because it takes advantage of environmental temperatures and is constrained by cloudy or rainy weather. An alternative is by using a dryer from biomass energy. Biomass that can be used includes wood, twigs, dry leaves, coconut husks, corn cobs, and rice husks. Its utilization is through the process of converting biomass energy into thermal with the application of a heat exchanger. A heat exchanger is a device that can be used to process heat transfer between two fluids having different temperatures without the occurrence of the mixing of the fluids with each other [1]. The heat exchanger is applied in waste heat recovery to reduce the need for additional heating [2]. The heat exchanger can function as heating or cooling. The heat exchanger is used for the process of transferring heat from a high-temperature fluid to a low-temperature fluid. In this case, the heat exchanger is used as a heater for the drying process. A heat exchanger is an implementation of the heat transfer process between two fluids that are separated by walls and have different temperatures [3]. The use of heat exchangers in the heat transfer process can increase the temperature significantly, one of which is post-harvest drying. Drying is a unit operation with the most important and high energy consumption for post-harvest [4]. Heat exchangers installed in the biomass gasification system in parallel flow and counter flow can increase the overall heat transfer * Corresponding author. E-mail address:
[email protected] (I.G.B. Susana). https://doi.org/10.1016/j.csite.2021.101565 Received 20 July 2021; Received in revised form 7 October 2021; Accepted 15 October 2021 Available online 16 October 2021 2214-157X/© 2021 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY license (http://creativecommons.org/licenses/by/4.0/). coefficient [5]. The use of a heat exchanger with tube banks arrangement in drying fish with firewood biomass can maintain a temperature of 40–50oC, while the use of coconut husk biomass produces an average temperature of 41.30oC [6,7]. In this study, the heat exchanger was placed separately from the biomass furnace and drying chamber. The heat exchanger pipes are arranged in an alignment with one path of the ambient air fluid with an average temperature of 34.75oC in sunny weather. The use of a heat exchanger in a heat generator with an appropriate model is very important for post-harvest drying on a small farmer scale. Post-harvest handling is an important step to maintain product quality during storage [8]. The emergence of post-harvest losses in the agricultural sector in some developing countries due to improper storage and drying facilities [9]. Drying is the easiest way to preserve foodstuffs.
The drying process slows down microbial and enzymatic activity and reduces water activity and moisture content to a minimum level so that the quality of the final product can be maintained and is safe for consumption and storage [10,11]. A heat exchanger in drying is needed to overcome the mixing of ash, dust, and other impurities into the dried foodstuffs. Small scale farmers need this drying model because it is cheap and easy to operate. In addition, the resulting product is hygienic and of better quality. A heat exchanger is used in the process of converting rice husk biomass energy into thermal energy for post-harvest drying. The exit temperature of the heat exchanger pipes reached 91.20 ± 0.70oC [12]. The heat exchanger is placed in the rice husk furnace using a separate model from the drying chamber. In addition to the drying process, the application of a heat exchanger can improve the thermal performance of the air heater. Utilization of a heat exchanger can increase the maximum hot air exit temperature reaching 149.4–152.9oC [13]. It is useful for agricultural applications, the textile industry, and food processing. Moreover, the application of a heat exchanger in the drying process can improve the thermal performance of the air heater. A heat exchanger is one of the effective devices that is widely implemented for heat recovery in various engineering applications because it can increase heat transfer from a small exchange area [14]. A heat exchanger is a key component of most power conversion systems and is widely used for a variety of energy conversion, power generation, and energy recovery/waste heat applications [15]. The application of a heat exchanger in a biomass furnace can
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sustainable alternative energy source. Utilization through the process of energy conversion and improvement of its property factor. Rice husk is potential biomass waste because rice is a staple food source [21]. In addition, the utilization of rice husks as energy resources, logistical improvements are needed to reduce the cost of trans- porting rice husks. The availability of waste biomass from crops such as paddy for bioenergy applications depends on factors such as harvesting procedures and agricultural practices [22]. Based on several studies that rice husk gives satisfactory results when used as alternative energy. The study of 1 kg of rice husk was carried out through the combustion process using a stove, after complete combustion occurs in 30 min, it can produce a maximum temperature of 556.5oC [23]. Investigation [24] found that heating water using heat from burning rice husks is sustainable and feasible. Rice husk is no longer a waste but a sustainable resource. Rice husk has a Fig. 1.
Paddy rice production worldwide in 2019 by country [19]. Fig. 2. Potential of rice husk worldwide in 2019 by country. fairly high calorific value and is equivalent to half of the calorific value of coal, which is 11–15.3 MJ/kg [25]; net calorific value 12–16 MJ/kg [26]; and 13–19 MJ/kg with an average close to the higher calorific value of 18 MJ/kg [27]. The utilization of rice husks as an energy source can be used to replace the drying process carried out by drying in the sun. Drying of agricultural products by drying directly in the sun causes temperature conditions to be difficult to control because it is very dependent on the weather. In addition, it is susceptible to exposure to dirt, dust, and animal disturbances. The impact of drying by drying directly in the sun is that the resulting product is dusty and hard which has implications for the absence of added value and low quality [28]. The low quality of the product is a result of the damage to the product structure due to drying by drying in the sun. This is based on evaluations carried out through physical parameters such as pore size distribution, volume, porosity, and texture [29]. Drying by direct drying in the sun can damage the sensory and nutritional properties such as vegetables and fruits due to the heat sensitivity of these products [30]. The utilization of rice husks as an energy source is to add value to the waste. So far, in rural areas in Lombok, rice husks are only used as livestock warmers and are simply burned to clean the environment. In [31] it is explained that rice husk is an ecological problem because of its abundant rice production and sustainable growth. Rice husk is biomass whose utilization can improve the economy of small farmers based on the added value of the biomass. The use of biomass reduces the individual vulnerability of rural communities in developing countries to the energy sector and improves their economic status [32]. In addition, rice husk is unique as renewable energy because it is a resource in terms of sustainability. To optimize the process of converting rice husk energy into thermal energy, it can be done through the use of a furnace with added pipes that function as heat exchangers. The study was carried out on the thermal conditions through the temperature distribution in the heat exchanger pipes and the drying chamber. The dryer is designed for small farmers. The dryer uses a drying chamber and a double furnace by adding single-pass parallel- flow heat exchanger pipes. 2. Materials and methods The materials and equipment used in this study include rice husks, stainless steel pipes, iron plates, aluminium plates, solar panels, Fig. 3. Design of double furnace type dryer with parallel flow heat exchanger. batteries, exhaust fans, type K thermocouples, and data loggers. Rice husk is used as the main energy source in the drying test process. A stainless steel pipe with a diameter of 1 inch is used as a heat exchanger. Steel plates are used for the design of the rice husk burning furnace which has dimensions of 40 cm × 50 cm x 60 cm. The dimensions of the drying chamber are 50 cm × 50 cm x 140 cm which is made of aluminium sheet. A solar panel is used as an energy source to drive the exhaust fan with batteries as energy storage. Furnaces and drying chambers are designed according to the needs of small farmers in rural areas in Lombok. The test design consists of a drying chamber and two rice husk burning furnaces which are equipped with heat exchanger pipes. Treatment of rice husks through direct combustion in the furnace. The heat exchanger pipes are placed at the bottom of the furnace. This is based on the characteristics of the burning of rice husks starting from the bottom of the furnace and moving upwards until all the rice husks are burned. The combustion furnace is positioned and attached to both sides of the drying chamber. The walls of the furnace are equipped with circulation holes with a distance of 5 cm between the holes. The diameters of the furnace wall holes were varied, such as 8 mm, 10 mm, and 12 mm. The heat exchanger consists of pipes arranged in parallel with one fluid flow path. These pipes connect the furnace to the drying chamber. The drying chamber is equipped with an exhaust fan and is installed in the exhaust duct/ chimney. An exhaust fan serves to drain hot air out of the drying chamber. The walls of the drying chamber are insulated using a rubber insulating material with a thickness of 3 mm. The design of the double furnace type dryer is shown in Fig. 3. The test is carried out for the drying chamber without load. This is done to determine the temperature characteristics that can be produced from the test equipment model. Based on these temperature characteristics, it will be easy to determine which post-harvest crops will be dried. The temperature standard of crops is adjusted to the characteristics of the dryer temperature.
Temperature measurement in the dryer is carried out for each variation of the diameter of the furnace wall hole. The hole in the wall of the furnace serves to supply air for the process of burning rice husks. The furnace is closed during the rice husk burning process. Tests were carried out for 500 min. The test method is carried out as shown in Fig. 4. 3. Results and discussions The thermal characteristics of the dryer were measured based on the tests carried out on the ambient air temperature, the tem- perature of the heat exchanger pipe, the temperature of the drying chamber without a load, and the temperature of the air leaving the drying chamber. Tests were carried out on each variation of the diameter of the hole in the wall of the rice husk burning furnace, namely 8 mm, 10 mm, and 12 mm. The ambient temperature did not significantly affect the test on the three diameter variations. Figs. 5–7 show the temperature characteristics for the environment (Ta), heat exchanger pipe (Tp), drying chamber (Tdc) and drying chamber exit (Tout). The temperature is measured starting when the ignition time has been running for 5 min.
The increase in ambient temperature (Ta) occurred significantly as a result of heat transfer from the burning of rice husks in the furnace to the heat exchanger pipes. Fig. 5 shows the temperature characteristics for a furnace wall diameter of 8 mm. The ambient temperature (Ta) is in the range of 30.50–33.31oC with an average temperature of 32.14oC. The average temperature of the heat exchanger pipes or the air temperature in the pipe reaches 249.74oC with a range of 161.06–365.32oC. The average temperature in the drying chamber (Tdc) reaches 92.10oC with a range of 45.88–119.13oC. The average temperature outside the drying chamber (Tout) is 82.09oC with a range of 31.90–110.74oC. In this condition, there is an increase in ambient air temperature (Ta) by an average of 186.56% in the form of hot air in the drying chamber (Tdc). Fig. 6 shows the temperature characteristics for the diameter of the furnace wall are 10 mm. The average temperature of the heat exchanger pipes or the air temperature in the pipe reaches 220.38oC with a range of 99.95–422.46oC. The average temperature in the drying chamber (Tdc) reaches 93.27oC with a range of 57.94–127.98oC. The average temperature outside the drying chamber (Tout) is 81.67oC with a range of 43.48–113.81oC.
In this condition, there is an increase in ambient air temperature (Ta) by an average of 190.20% in the form of hot air in the drying chamber (Tdc).
Fig. 7 shows the temperature characteristics for a furnace wall diameter of 12 mm. The average temperature of the heat exchanger pipes or the air temperature in the pipe reaches 255.73oC with a range of 105.83–433.13oC. The average temperature in the drying chamber (Tdc) reached 94.96oC with a range of 57.65–140.89oC. The average temperature outside the drying chamber (Tout) is 82.54oC with a range of 49.78–120.98oC.
In this condition, there is an increase in ambient air temperature (Ta) an average of 195.46% Fig. 4. Test method of double furnace type dryer. Fig.
5. Temperature characteristics for a furnace wall diameter of 8 mm. Fig. 6. Temperature characteristics for the hole diameter of the combustion furnace wall are 10 mm. Fig. 7. Temperature characteristics for the diameter of the combustion furnace wall hole 12 mm. Fig. 8. The comparison of the temperature of the heat exchanger pipe diameters of the furnace walls of 8 mm (Tp1), 10 mm (Tp2), and 12 mm (Tp3). in the form of hot air in the drying chamber (Tdc). Based on Figs. 5–7, the temperature characteristics are obtained from the energy conversion process of rice husks using a heat exchanger. Heat transfer occurs from the direct combustion of rice husks in the furnace to the heat exchanger pipes. Furthermore, heat transfer occurs from the surface temperature of the pipes to the ambient air flowing in the pipes. This is in line with [33] that direct burning of rice husks to obtain energy is still the most widely used technology because of its economic feasibility and domain of use. The temperature comparison of heat exchanger pipes between hole diameters of 8 mm (Tp1), 10 mm (Tp2), and 12 mm (Tp3) for a test time of 500 min is shown in Fig. 8. The temperature characteristics of the heat exchanger pipes as shown in Fig. 8 are affected by the direct burning of rice husks in the furnace. This combustion is influenced by ambient air circulation. Air circulation is influenced by the diameter of the furnace wall hole diameter.
Each diameter produces unique temperature characteristics. The maximum heat exchanger pipe temperature occurs at the hole diameter of 12 mm (Tp3), which is 433.13oC compared to the 10 mm (Tp2) of 422.46oC, and 8 mm (Tp1) of 365.32oC. Based on these characteristics, it is found that the diameter of the largest hole in the wall provided the highest air circulation, thus affecting the direct burning of rice husks. The higher the air circulation, the impact on the initial temperature will be higher, but after the peak temperature is reached, it is followed by a lower temperature compared to the smaller hole diameter. The maximum temperature occurs at a burning time of 140 min. While the maximum temperature for the hole wall diameter of 10 mm and 8 mm occurred at 185 min and 195 min respectively. From Fig. 8, it can be seen that the diameter of the hole in the wall of the furnace affects the burning of rice husks which has an impact on the temperature of the air flowing in the heat exchanger pipe. The initial temperature has not shown an increase because it follows the phenomenon of burning rice husks in the furnace. The initial stage is the process of evaporation of the moisture content of the rice husk. This can be seen from the formation of a lot of smoke. Rice husk has a moisture content of 6–10% [34, 35]. Biomass undergoes a process of evaporation of water content before further heating occurs which is referred to as the drying zone [36]. The temperature distribution is relatively similar, that is, the initial combustion pattern increases until it reaches the maximum temperature and then decreases as the mass of rice husks decreases in the furnace. The study used a one-cycle system of feeding rice husks into the furnace from start to finish. The temperature distribution pattern of the heat exchanger pipe (Tp) affects the pattern of the drying chamber temperature (Tdc) as shown in Fig. 9. The distribution pattern of the drying chamber temperature (Tdc) is directly proportional to the heat exchanger pipe (Tp). The temperature distribution pattern is that the initial combustion pattern increases until it reaches the maximum temperature and then decreases as the temperature of the heat exchanger pipe decreases. From the beginning to the highest maximum temperature occurred at the diameter of the hole wall 12 mm, after that the temperature decrease occurred the fastest in this condition. From the test, it is known that the diameter of the hole in the furnace wall of 12 mm, the highest air circulation occurs. This affects the direct burning of rice husks in the furnace. Rice husks have a higher flame and burn faster. This has an impact on the heat transfer to the air in the heat exchanger pipe occurs higher and the heat loss occurs faster. The maximum temperature of the drying chamber is highest at a diameter of 12 mm (Tdc3) of 140.89oC. While the maximum temperature of the drying chamber at a diameter of 10 mm (Tdc2) and 8 mm (Tdc1) are 127.98oC and 119.13oC, respectively. The drying chamber temperature pattern as shown in Fig. 9 shows that the slowest decrease in temperature occurs at 8 mm in diameter compared to 10 mm and 12 mm. This follows the pattern of the heat exchanger pipe temperature as shown in Fig. 8. The temperature of the drying chamber at the end of the test (500 min) at diameters of 8 mm, 10 mm, and 12 mm is 76.21oC, 70.99oC, and 57.65oC, respectively.
The drying chamber in the no-load condition produces an exit temperature (Tout) as shown in Fig. 10. The drying chamber exit temperature (Tout) as shown in Fig. 10 follows the pattern shown in Figs. 8 and 9. The maximum tem- perature out of the drying chamber at diameters of 8 mm, 10 mm, and 12 mm is 120.98oC, 113.81oC and 110.74oC, respectively. The drying chamber exit temperature is still high as a result of the no-load drying chamber. Hot air is only absorbed by the drying chamber material so that the residual temperature is still high. Based on the test results on a drying chamber with a double combustion furnace added a heat exchanger and the main energy source of rice husk, it produces a high temperature. Rice husk used as the main energy source can significantly increase the ambient temperature for hot air drying. This is in line with the study [37] that rice husk has good potential to produce useful energy based on basic analysis which shows the percentage of carbon 40.68%–
42.29% and total lignin 31.55%–33.21%. In addition, in the examination [37] it was also found that lignin presents a higher enthalpy of combustion and a lower specified ash content, which facilitates its application in the combustion process. Rice husk mostly contains cellulose, lignin, and silica so it is suitable for the use of thermal energy [38]. This study resulted in a better temperature when compared to research [16,39].
Research [16,39] used a furnace with added a heat exchanger and rice husk energy as an energy source. Thermal testing was carried out for the drying chamber without load. The average drying chamber temperature is 71.10oC [39] and 72.79oC [16], respectively. Research [16] is a follow-
up study from [39] but the increase in temperature is still small. Meanwhile, the average drying chamber temperature in this study was able to reach 92.10oC, 93.27oC, and 94.96oC for the diameter of the furnace wall holes, respectively 8 mm, 10 mm, and 12 mm. The study also found that direct burning of rice husks in the furnace was shown to improve its thermal conditions. It is as shown in Figs. 5–7. The indirect method by utilizing heat exchanger pipes to connect the furnace to the drying chamber affects the smoke from burning rice husks not entering the drying chamber. This is in line with [38] that for efficient use of energy husks can be burned directly and the use of pipes to ensure an even distribution of heat in the chamber. In [40] it is explained that direct combustion has advantages in terms of thermal efficiency, indirect combustion connects the heat exchanger to the husk furnace to maintain the quality of the dried product due to the influence of odour from combustion exhaust gases.
Based on the temperature characteristics, the results of this study can be continued for testing on foodstuffs that are following the allowable temperature standards. In addition, this dryer model is suitable to be applied to small farmers in rural areas at an affordable price and is easy to operate. The use of rice husks has an impact on the process of maintaining a sustainable environment starting from a small area. This is related to how to treat energy waste and reduce deforestation. Fig. 9. The comparison of the drying chamber temperature (Tdc) between the diameters of the furnace walls of 8 mm, 10 mm, and 12 mm. Fig. 10. The comparison of the drying chamber exit temperature between the diameters of the furnace walls of 8 mm (Tout1), 10 mm (Tout2), and 12 mm (Tout3). 4. Conclusions Double furnaces are used for the direct burning of rice husks and heat exchanger pipes for the indirect method. As a result, the performance of the dryer shown based on the temperature of the drying chamber using ambient air can be significantly improved. The heat from the rice husks is transferred to the ambient air flowing in the heat exchanger pipes. The hot air is flowed into the drying chamber through the heat exchanger pipes and is transferred by conduction through the walls of the furnace and the drying chamber. The heat generated can keep the temperature high. For ambient air temperature with an average of 32.14oC, the average temperature of the drying chamber for variations in the diameter of the furnace wall of 8 mm, 10 mm, and 12 mm reached 92.10oC, 93.27oC, and 94.96oC, respectively. While the maximum temperature of the drying chamber reaches 119.13oC, 127.98oC, and 140.89oC. These results can be used as an alternative for developing energy-efficient and sustainable smallholder-scale post-harvest dryers. CRediT authorship contribution statement Ida Bagus Alit: Data curation, Formal analysis, Investigation, Resources. I Gede Bawa Susana: Conceptualization, Methodology, Roles/Writing - original draft, Writing - review & editing. I Made Mara: Writing – review & editing. Author statement We declare that this paper is purely our work and we are ready to pay the publication fee if our paper is accepted. Declaration of Competing Interest The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper.
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