Utilization of rice husk
biomass in the conventional corn dryer based on the heat
exchanger pipes diameter
by I Gede Bawa Susana
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Case Studies in Thermal Engineering 22 (2020) 100764 Contents lists available at ScienceDirect Case Studies in Thermal Engineering journal homepage: http://www.elsevier.com/locate/csite Utilization ofrice husk biomass in the conventional corn dryer based on the heat exchanger pipes diameterIda 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: Heat exchanger Conventional dryer Biomass Rice husk Utilizing rice husk biomass for drying corn is an alternative solution for drying corn in direct sunlight. This is done through the conversion of thermal energy with heat-exchanging furnaces. This model provides opportunity that the drying process is independently of the weather con- dition and gain more hygienic products. In addition, it creates energy independence through the use of waste that has an energy value is quite high. Utilization of rice husks by optimizing the performance of heat exchangers through the application of stainless-steel pipes. The diameter of the pipes varies, namely 1 inch, ¾ inch, and ½ inch. The conventional dryer design has di- mensions of drying chamber (600 × 536 x 536) mm3 and furnace (800 × 500 x 500) mm3. Nine of heat exchanger pipes are arranged in parallel to one air flow path. The results show the utilization of rice husk biomass provides satisfactory performance on drying 4 kg of corn. The average temperature of the drying chamber, which is based on the outlet temperature of the heat exchanger pipes diameter of 1 inch, ¾ inch, and ½ inch are 91.20 ± 0.70 ◦C, 73.95 ± 0.65 ◦C, and 58.27 ± 0.48 ◦C, respectively. 1. Introduction Corn is an important food ingredient besides wheat and rice. In Indonesia, the corn is also used as animal feed ingredients, seeds and processed industrial materials. In order to maintain the quality of the corn, post- harvest handling is prioritized in the drying process. Drying of corn is needed to reduce the moisture content to reach the equilibrium moisture content. Some advantages of the drying process are reducing packaging costs and cooling requirements; reducing product spoilage and damage; cheaper in terms of trans- portation and storage costs; and guarantee the availability of seasonal products [1].
As animal feed, the corn quality must guarantee the health and peace of the community, with a maximum moisture content of 14% for the first quality and 16% for second quality [2]. To reduce the corn moisture content from 29% to 14% and to avoid damage, drying using direct sunlight is carried out from 08.00 to 11.30. When the weather is sunny, it takes about three days, and it will be seven days during the rainy season, it is done by fumigation as well [3]. The process of drying corn is carried out on a household scale by drying in the direct sunlight. It has an impact on dry products that it requires large areas, susceptible to animal interference, unhygienic, experiencing obstacles cloudy or rainy weather, time and the temperature less than optimal. The application of drying chamber is a solution by utilizing renewable energy sources. The energy source used is easily obtained in the vicinity of the community’s residence.
One of them is rice husk biomass. Rice husk produced from * Corresponding author. E-mail address: [email protected] (I.G.B.
Susana). https://doi.org/10.1016/j.csite.2020.100764 Received 10 June 2020; Received in revised form 28 September 2020; Accepted 10 October 2020 Available online 17 October 2020 2214-157X/© 2020 The Author(s). Published by Elsevier Ltd. This is an open access article under the CC BY license (http://creativecommons.org/licenses/by/4.0/). the rice milling process by 20–30%, if it is not utilized, it can cause problems to the environment. The conventional dryer is used to dry corn through conversion of rice husk biomass to thermal energy. This is an effort to anticipate cloudy or rainy weather. Biomass is organic materials derived from living bodies in the form of plant, animal and agricultural waste. Biomass can be used as an alternative energy to replace fossil energy. Indonesia has huge potential of biomass as a renewable energy. One of them is rice husk. Rice husk is a waste from rice production. Rice is the main foodstuff for most of Indonesia’s population. Hope for the fulfillment of electricity, especially in rural areas can be done through the process of energy conversion. Energy conversion with gasification technology of 30% can produce 49.5 MW h of electrical energy [4].
Rice husk is an important energy source and it has a good potential energy to be converted into electricity by gasification methods [5].
Based on data from 2001 to 2012 in Indonesia, the potential energy of rice husk to become electrical energy is around 39.07 GW h and electrical power around 4.46 MW [6]. The potential of electrical energy that can be generated from bioenergy, especially rice husks, is estimated to reach 9.8 GW, and it is estimated that only 22% of this potential energy can be realized in 2030 [7]. Experiments using rice husks as fuel were carried out on rectangular fluidized bed combustors. The results showed a stable flame, low emissions, and high combustion efficiency of 99.2% [8]. Rice husk had a fairly high heating value which was equivalent to a half of the coal heat value of 11–15.3 MJ/kg [9] and 12.3 MJ/kg [10]. Biomass was used as fuel in the drying process through an energy conversion process. Rice husk was a secondary crop that refers to a byproduct. This product was used for energy production with a net calorific value of 12–16 MJ/kg [11]. Especially in rural areas, rice husk was considered as waste and pollutants for the environment. Households used rice husk for both drying and cooking. Rice husk can be used as a renewable energy source if the properties and logistics factors are improved [12]. However, the process of drying food to be efficient and effective should use a furnace with a heat exchanger. A heat exchanger
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highest temperature in the drying chamber were 72.79 C and 109.20 C, respectively. This temperature is obtained in a dryer with a furnace equipped with a heat exchanger. The heat ◦ ◦ exchanger is made of black steel pipes [18]. This research was carried out with no-load drying room. The pipes are arranged in parallel with one-pass fluid flow. The dryer with heat exchangers furnaces is very suitable for the utilization of rice husk biomass. Heat ex- changers by arranging pipes triangularly are used as standard agricultural techniques in the Philippines. This model is used in furnaces with rice husk fuel indirectly [19]. This aims to prevent the exhaust gases from burning rice husk entering the drying chamber along with the air. Research [20] was carried out to optimize the transfer of heat from the heat exchanger into the drying chamber. The research was carried out by varying the number of holes in the rice husk burning stove. The results show that the time needed to dry 4 kg of corn from 19% to 12% moisture content in the drying chamber is 58 min. The study of dryer using variations in the diameter of the heat exchanger pipes for the utilization of rice husk biomass still needs to be optimized. 2. Materials and methods This study aims to examine the effect of the diameter of the heat exchanger pipes on the conversion energy process of rice husk Fig. 1. Conventional dryer design with heat exchanger. biomass. The heat exchanger is placed at the bottom of the furnace. The furnace and drying chamber are in separate position. This dryer model adopts the results of the previous study of Susana et al. [18,20]. The furnace has dimensions of 800 mm × 500 mm × 500 mm, the stand is 400 mm high and it is made of steel sheet plates. The furnace wall consists of 468 holes. The diameter and the distance between the holes are 1 cm and 5 cm, respectively. Furthermore, the diameter of the furnace ash hole is 12 mm and the heat exchanger pipes are stainless steel pipe. The weight of burned rice husk biomass in the furnace is the same for all variations in the diameter of the heat exchanger pipes.
The process of burning rice husks produces heat. This heat will be transferred to the air flowing in the pipes. Furthermore, this hot air flows into the drying chamber. The design of the dryer for this study is presented in Fig. 1. Drying chamber is made of aluminum with 4 shelves. Drying chamber insulation is made of rubber with a thickness of 3 mm. The dimensions of the drying chamber are 600 mm × 536 mm x 536 mm, with 400 mm footrest. Drying chamber load is constant with 4 kg of corn with distribution on each shelf is 1 kg.
The initial moisture content of corn is set at 19%. The hot air is circulating with forced convection system by mean of an exhaust-fan.
Exhaust-fan is placed in the chimney of the drying chamber with a constant air velocity of 2 m/s. The heat exchangers are varied based on the pipe diameter such as 1 inch, inch, and inch. Drying performance is ¾ ½ measured based on drying temperature and moisture content of the dried corn. Drying time lasts for 240 min. This study uses measuring devices such as data loggers, K type
thermocouples, digital scales, anemometers, and moisture meters. Fig. 2 shows a) the furnace with heat exchanger pipe, and b) rice husk. Rice husk is a biomass made of lignocellulose. Rice husk is produced around 20% of the weight of paddy. Rice husk consists of silica (15%–20%), cellulose (50%), lignin (25%–30%), moisture (10%–15%), and bulk density of 90–150 kg/m3 [21,22]. The silica con- tained in rice husks has amorphous properties. Amorphous silica in rice husks can undergo transformation into crystalline silica at a thermal process >700 ◦C [23]. Burning rice husks in an open area will produce ash containing crystalline silica. The effect of crystalline silica is that it can be harmful to health and is carcinogenic. In addition, the inhaled amorphous silica for 12–18 months at a level of 6.9–9.9 mg/m can cause respiratory irritation [24]. Rice husk which has high cellulose produces an even and a stable combustion. So, the rice husk is good to use as an energy source. Ultimate and proximate analysis of rice husk contains Carbon (36.74%), Hydrogen (5.51%), Oxygen (42.55%), Nitrogen (0.28%), and Sulfur (0.55%) [25]. The CO2 emission of rice husk is relatively the same compared to fossil fuels [26]. The testing method in this study is shown in Fig. 3. The measurement of research data was carried out for 240 min drying time with corn moisture content measurements carried out every 60 min. The mass of rice husk biomass is constant, without adding any amount of biomass during the test. The observed data are ambient temperature, heat exchanger pipes temperature, drying chamber temperature, initial mass and dried mass of corn. The initial mass of corn, mt (kg) and dried mass of corn, mk (kg) are used to calculate moisture content, Ka (%) [27–29]. Ka = mt − mk x 100% mt (1) The dried mass of corn, mk is obtained by heating the corn at a temperature of 105–110 ◦C for 3 h or until there is no weight loss anymore. The mass of water lost due to the drying process is the mass of water that is evaporated, mw (kg). This is influenced by the initial mass of corn, mt and corn mass after drying, mp (kg). mw = mt – mp (2) The heat used for drying, Q (kJ) [30]. Q = Q1 + Q2 (3) Q1 is the amount of heat used to heat the material and raise the temperature of the water in the material or the sensible heat of corn (kJ). Q2 is the amount of heat that is used to evaporate moisture content of material or the latent heat of water evaporation (kJ) [29, 31]. Fig. 2. a) The furnace with heat exchanger pipe, b) rice husk. Fig. 3. Testing of corn samples in conventional dryers based on the diameter of the heat exchanger pipe. Q1 = mt.Cpb(Tb − Ta) Q2 = mw x hfg (4) (5) Cpb is specific heat of corn (kJ/oC). Tb is the temperature of corn (oC). Ta is the ambient temperature (oC). hfg is latent heat of water evaporation (kJ/kg). q is energy conversion of air to the dried corn (kJ) [13]. q = ρu.Vu.Cpu(Tin − Tout) (6) ρu is density of drying air (kg/m3), Cpu is specific heat of air (kJ/kgoC). Tin and Tout is the temperature of inlet air and the temperature of outlet air/flue gas. The ratio of Q with q is the drying efficiency as presented in equation (7) [32,33]. Fig. 4. Distribution of drying temperature on each shelf (Ts) for each variation of the diameter of the heat exchanger pipe on a) shelf 1 (Ts1); b) shelf 2 (Ts2); c) shelf 3 (Ts3); and d) shelf 4 (Ts4). η = x 100% Q q (7) Drying rate, ṁp (kg/s) is the ratio between the mass of evaporated water, mw (kg) and the drying time, t (seconds) [34,35]. ṁp = mw t (8) Error analysis is done to analyze the uncertainty of experiment. Error analysis is an uncertainty to indicate the measurement deviation of the true value.
Test results are stated along with uncertainties x = x + Δx units in the form of absolute error. x is the average value of physical of a number of repeated measurements or the best single measurement results. Δx is the measurement uncertainty describing the deviation of measurement results from true value. The physical quantity obtained through the calculation of equations using the error
propagation methods. 3. Results and discussions The test was carried out by drying the corn from an initial moisture content of 19% in each of the heat exchanger pipes diameter. The drying temperature data has a similar trend both in 1 inch, inch, and inch pipe diameter as presented in Fig. 4. ¾ ½ Fig. 4 shows the temperature distribution on a) shelf 1 (Ts1), b) shelf 2 (Ts2), c) shelf 3 (Ts3), d) shelf 4 (Ts4). This temperature distribution is for each variation of 1 inch, ¾ inch, and ½ inch heat exchanger pipes diameter. On shelf 1, the 1-inch diameter pipe produces the highest temperature (Ts1-1′′) compared to ¾ inch diameter (Ts1-3/4′′) and ½ inch (Ts1-1/2′′). This result is in line with [36] which illustrates that increasing the diameter of the pipe increases the heat transfer area of the heat exchanger. Increasing the heat transfer area will increase the rate of heat transfer. The drying temperature on the diameter of 1-inch heat exchanger pipes reaches 85.18 0.29 C on shelf 1 (Ts1), 71.07 0.12 C on shelf 2 (Ts2), 64.69 0.11 C on shelf 3 (Ts3), and 60.31 0.42 C on shelf 4 ± ◦ ± ◦ ± ◦ ± ◦ (Ts4). Shelf 1 is closest to the output temperature of the heat exchanger pipes or the drying chamber input temperature. This gives the highest temperature distribution effect compared to shelf 2, shelf 3, and shelf 4. The smallest temperature distribution in the drying chamber occurs in shelf 4. This is due to the heat is absorbed beforehand by the corn on the shelf below. In addition, the position of shelf 4 is far from the heat source. The same condition also occurs in the diameter of the heat exchanger pipes ¾ inch and ½ inch. This is in line with the research [37], which states that the heating source which is close to the shelf will directly contact the dried product. This gives the effect of the highest drying temperature. The increasing of drying
temperature as a result of increasing inlet temperature (Tin) as presented in Fig. 5. The inlet temperature is the hot air that comes out of the heat exchanger pipes. This hot air flows into the drying chamber. The hot air is produced by the heat transfer process of burning rice husk biomass in the furnace to the air which flows in the heat exchanger pipes. The test results show that the ambient temperature (Ta) has no significant changes. The average ambient temperature at 1 inch, ¾ inch, and ½ inch diameter pipes is 29.21 0.05 C, 29.81 0.05 C, and 29.79 0.02 C, respectively. The highest inlet tem- ± ◦ ± ◦ ± ◦ perature occurs in the diameter of 1-inch (Tin-1′′) heat exchanger pipe. The highest drying temperature of corn occurs in this condition. The drying chamber inlet temperature is based on the outlet temperature of the heat exchanger pipe. The average inlet temperature at diameters of 1 inch, ¾ inch, and ½ inch is 91.20 ± 0.70 ◦C, 73.95 ± 0.65 ◦C, and 58.27 ± 0.48 ◦C, respectively. While, the average drying temperature (Tad) in the drying chamber are 58.71 ± 0.50 ◦C, 51.11 ± 0.51 ◦C, and 42.65 ± 0.36 ◦C, respectively. The pattern of temperature distribution is shown in Fig. 5 follows the phenomenon of burning of rice husk biomass in the furnace. At the beginning of the combustion process, there is evaporation of rice husk moisture content so that, the temperature has not significantly increase. Fig. 5. The phenomenon of temperature distribution on variations in the diameter of the heat exchanger pipes. The temperature increases significantly as the rice husks begin to turn into charcoal. The highest temperature occurs when the rice husk is in the form of charcoal. Because there is no additional biomass in the furnace, so, the temperature will decrease. This happens because the rice husk burns to ashes. Biomass undergoes a drying process to reduce moisture content before further burning [38] and the moisture content of rice husk is 10% [39]. The process of drying 4 kg of corn for 240 min in the diameter of heat exchanger pipes of 1 inch (Tout-1′′), ¾ inch (Tout-3/4′′), ½ inch (Tout-1/2′′) and produces an average temperature of 50.76 ± 0.48 ◦C, 46.03 ± 0.43 ◦C, and 40.26 ± 0.35 ◦C, respectively. Estimate uncertainty component calculated from repeated measurement. Error analysis on the results of temperature measurements using the method in Bevington and Robinson [40]. The changes in corn mass due to the drying process respect to the influence of the diameter of the heat exchanger pipes as presented in Table 1. Measurement data in Table 1 are measured every 60 min. This is to reduce the process of opening and closing the drying chamber. The process of opening and closing affects the drying temperature. This effect can be seen in Figs. 4 and 5.
Every 60 min, shows that the temperature distribution is decreased. This follows the pattern of the corn mass measurements performed
every 60 min. The corn experiences a different mass reduction on each shelf in the drying chamber. The reduction in mass of corn follows the drying tem- perature distribution pattern. The highest mass reduction of corn occurs on shelf-1. This is because the position of shelf-1 is very close to the outlet temperature of the heat exchanger pipes. The further the shelves position from the heat source, the lower the mass reduction of corn. Fig. 6 clearly illustrates the changes in mass of corn on each shelf for the variation of the diameter of the heat exchanger pipes, as presented in Table 1. The highest reduction in corn mass occurs at a diameter of 1 inch (ms-1
′) compared to ¾ inch (ms-3/4 ′′), and ½ inch (ms-1/2′′). The greater the diameter of the heat exchanger pipes has implications for the higher outlet temperature of the heat exchanger pipes. This condition reflects the difference between the two temperatures, which causes the greater heat absorbed by corn. Based on the initial mass as shown in Table 1 and Fig. 6, the ratio of corn moisture content obtained respect to the variation of the diameter of the heat exchanger pipes 1 inch, inch, and inch, as shown in Fig. 7. The initial moisture content of corn is 19%. Based ¾ ½ on the test results in the diameter of 1 inch, ¾ inch, and ½ inch obtained that the final moisture content of corn is 2.85 ± 0.030%, 5.8 ± 0.029%, and 12.39 ± 0.027%, respectively. The calculation used the standard uncertainty of sample moisture content [41]. The heat exchanger with a 1-inch diameter pipe produces the highest reduction in corn moisture content. The percentage reduction in moisture content in the 1-inch pipe diameter by 85% is much higher than the diameter of the ¾ inch pipe by 70% and ½ inch by 35%. Reducing the drying temperature causes a slower reduction in moisture content. To reach the corn moisture content of 12% [20] from the initial 19% moisture content requires the shortest time, 58 min on the conventional corn dryer with 1-inch diameter of heat exchanger pipes. However, if the diameter of the heat exchanger pipes is ¾ inch and ½ inch, it requires 100 min and 258 min, respectively. This is influenced by the drying temperature. The lower drying temperature causes a longer drying time. Drying at a lower temperature requires a longer operating time [42]. The drying efficiency on the use of 1 inch, ¾ inch, and ½ inch heat exchanger pipes, are 28.8 ± 0.7%, 24.7 ± 0.6%, and 13.9 ± 0.4%, respectively. Error analysis is evaluated in percentage uncertainty using method in Sansaniwal and Kumar [43]. Drying rate is presented in Fig. 8. Fig. 8 shows that the drying rate at 1-inch heat exchanger pipes diameter is faster than ¾ inch and ½ inch. The drying rate decreases as decreasing of drying temperature. This is due to the smaller diameter of the heat exchanger pipe. The drying temperature and drying rate increase, while drying time decreases. The increasing drying rate implies a decrease in corn moisture content. Based on the results of this study, the rice husk biomass can be used as a source of drying energy. This is in line with [44] that biomass is a reliable source of energy because it can be recycled. In addition, it is also beneficial to reduce agricultural waste related to rice production which is the main food ingredient in many countries, especially in Asia. In contrast to the research [45] which utilizes gasification of rice husk to drying process. To avoid gas exposure in the process of drying food in research [45], a heat exchanger must be added. Whereas in this study, the dryer is compact in which the drying process utilizes ambient air heated in a heat exchanger. Heat transfer occurs from the Table 1 The corn mass and temperature in the variation of the heat exchanger pipes. Pipe diameter of Time Ta Drying chamber temperature (OC) Corn mass (kg) Total heat exchanger (minutes) (OC) (inch) Tin Ts1 Ts2 Ts3 Ts4 Tout Shelf Shelf Shelf Shelf mass (OC) (OC) (OC) (OC) (OC) (OC) 1 2 3 4 (kg) 1 0 60 120 180 240 3/4 0 60 120 180 240 1/2 0 60 120 180 240 – – 28.42 92.06 29.56 103.16 29.94 87.57 30.52 77.05 – – 28.80 64.88 29.37 83.81 30.43 78.18 30.91 71.59 – – 29.66 55.31 30.62 64.61 29.85 64.15 29.46 55.04 – – 72.59 62.50 79.93 66.97 76.76 67.26 66.02 58.20 – – 49.35 43.33 68.76 57.08 69.48 63.32 56.65 53.90 – – 43.02 40.26 50.99 48.93 47.89 47.94 40.96 41.82 – – 52.65 49.36 59.92 53.55 62.30 56.86 58.25 50.57 – – 41.70 40.89 52.85 51.42 56.27 51.07 49.97 44.86 – – 37.12 36.93 46.24 46.02 47.51 46.35 41.05 39.78 – 1 48.08 0.904 53.54 0.849 58.13 0.821 51.79 0.816 – 1 40.56 0.942 51.20 0.881 50.84 0.862 44.58 0.846 – 1 36.24 0.975 45.02 0.943 45.28 0.92 38.03 0.906 1 1 0.922 0.936 0.868 0.875 0.835 0.849 0.826 0.845 1 1 0.959 0.966 0.907 0.924 0.877 0.89 0.855 0.866 1 1 0.982 0.985 0.952 0.966 0.931 0.949 0.916 0.932 1 4 0.944 3.706 0.882 3.474 0.858 3.363 0.848 3.335 1 4 0.968 3.835 0.929 3.641 0.894 3.523 0.871 3.438 1 4 0.988 3.93 0.974 3.835 0.959 3.759 0.944 3.698 Fig. 6. The corn mass distribution for each heat exchanger pipes diameter on a) shelf 1 (ms1), b) shelf 2 (ms2), c) shelf 3 (ms3), and d) shelf 4 (ms4). Fig. 7. The ratio of corn moisture content on the heat exchanger pipes diameter 1 inch (Ø 1′′), ¾ inch (Ø 3/4′′), and ½ inch (Ø 1/2′′). Fig. 8. The comparison of the drying rate in the diameter of the heat exchanger pipes 1 inch (Ø 1′′), ¾ inch (Ø 3/4′′), and ½ in (Ø 1/2′′). burning of rice husks to the ambient air flowing in the heat exchanger pipes. Food that is dried has good quality and hygiene because it is not exposed to smoke or gas from burning rice husks. So that the results of this study are strongly needed by people in villages who are majority farmers and need applied technology that is cheap, easy to apply, and hygienic products. 4. Conclusions Utilization of rice husk biomass creates energy independence for small businesses and households. The utilization is carried out through the conversion of biomass energy into thermal energy. The use of 1 inch, ¾ inch, and ½ inch heat exchanger pipes diameter in the furnace gives optimal temperature results, based on the results of testing 4 kg of corn samples. The average outlet temperature of the heat exchanger pipes is 91.20 ± 0.70 ◦C, 73.95 ± 0.65 ◦C, and 58.27 ± 0.48 ◦C, respectively. The application of this heat exchanger pipes in the drying process can be adjusted to the standard temperature of the food to be dried. This dryer model is technically easy to make, repair, and operate by the community. Moreover, the rice husk is easily found because it is a by-product of rice production. CRediT authorship contribution statement Ida Bagus Alit: Data curation, Formal analysis, Investigation. I.
Gede Bawa Susana: Methodology, Writing - original draft. I. Made Mara: Writing - review & editing. 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. Acknowledgements The authors wish to acknowledge DRPM for funding through the 2020 PTUPT research scheme with contract number 1746/UN18. L1/PP/2020 for the second year of research. The author also wishes to thank the Department of Mechanical Engineering, University of Mataram for facilitating the implementation of this research. References [1]
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