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Design and Analysis of Bagasse Dryer To Recover Energy of Water Tube Boiler in A Sugar Factory
Design and Analysis of Bagasse Dryer To Recover Energy of Water Tube Boiler in A Sugar Factory
Design and Analysis of Bagasse Dryer To Recover Energy of Water Tube Boiler in A Sugar Factory
Ambient temperature of air = 31 0C Characteristic Thermal Conductivity of Flue Gas @ 135 oC,
length for inner flue gas flow is 0.37 m K = 0.0338 W/mk
Velocity of ambient air = 3.5 m/s Coefficient of Convective Heat Transfer For
V. DESIGN ANALYSIS Internal Flow
COEFFICIENT OF CONVECTIVE HEAT hi = (Nu × K) / L
TRANSFER FOR INTERNAL FLOW
= (273.427 x 0.0338) / 0.37
hi = (Nu × K ) / L
hi= 24.977 W/m2k
Where Nu = Nusselt number
Coefficient of Convective Heat Transfer For
K = Thermal Conductivity of Flue Gas External Flow
L = Characteristic length ho = Nu x K / L
0.8
Nusselt Number, Nu = 0.02 Re Where Nu = Nusselt number
Where K = Thermal Conductivity of Flue Gas
Re=Reynolds Number for internal flow. L = Characteristic length
Reynolds Number for internal flow, Nusselt Number, Nu = 0.24 Re 0.6
Re = (V×L) / Ʋ Where Re = Reynolds Number for external flow.
Where, Reynolds Number for internal flow,
V = Velocity of flue gas (m/s) Re = (V×L) / Ʋ
L = characteristic length (m) Where,
2
Ʋ = Kinematic Viscosity (m /s) V = Velocity of flue gas (m/s)
Characteristic length (m) = cross sectional area of L = characteristic length (m)
pipe / perimeter of the tube= (π × (1.48/2)2)/(2×
π×(1.48/2)) Ʋ = Kinematic Viscosity (m2/s)
MF= Final moisture content in the bagasse is also is increases with reduction in
bagasse at temperature Tbo moisture.The final temperature of bagasse and flue
h1 =Enthalpy of moisture at gases from the bagasse dryer is given as follows
temperature Tbo h2= Enthalpy of moisture in
Total heat transfer in heat exchanger
bagasse at Tbi h = Enthalpy of gas at Tgi
Q = 359.1Kw
From steam tables
h1 = 469.8 KJ/kg Final Temperature of bagasse after drying
Tbo=112.0640C
h2 = 251.1 KJ/kg
hgo = 2726.6 KJ/kg Final Temperature of flue gases after drying
Tgo=72.0640C
THE ENERGY BALANCE EQUATION FOR
THE BAGASSE DRYER Final moisture content in bagasse afterdrying
MF
mg x Cpg x [T gi-Tgo] = mb x Cpb x [Tbo-Tbi] + MFh2+
=0.38115
[M-MF] x h0-Mh1
% of moisture after drying is 38.115%
mg x Cpg x [T gi-T go] - mb x Cpb x [Tbo-Tbi] + MFh2 +
Mh1 =Mho-MFho Efficiency of Boiler before Drying bagasse, ɳ
= 63.288%
mg x Cpg x [T gi-T go] - mb x Cpb x [Tbo-Tbi] + M(h1-
ho) = - MF (ho+h2) Efficiency of Boiler after Drying bagasse, ɳ
= 72.877%
20.32 × 0.2808× (135-72.064) – 6.5×1.055 ×
(112.366-60) + 0.503 (469.8-2726.6) By adopting the improved milling such as adoption
= -MF (2726.6+251.1) of proper mill settings , differential, grovings, hot
water imblition, application of lotus roll, donally
-1135.1704= -MF (2978.2) MF = -
chutes and optimum hydraulic load with the
1135.1704 / -2978.2 MF =
proposed bagasse drying process it has been
0.38115
expected to achieve around 6% to 12% of moisture
FINAL MOISTURE OF BAGASSE (MF) reduction and 10% increment in the boiler
efficiency.
MF = 0.38115×100
MF= 38.115% VII. CONCLUSION
FLUE GAS EXIT ARRANGEMENT AFTER The aim of project work proposed was to design a
DRYING PROCESS bagasse drying technique and to numerically
analyze which it is achieved by 6.15% by just
Once the flue gas is diverted after the ID fan, the flue gas
utilizing the flue gas heat, the wet bagasse dried up
with temperature around1350 will flow through the 1.48
from 50.30 to 38.115%. Reduction in the moisture
m diameter pipe and enters the rectangular duct of (1.5
content of bagasse has increased its CV from
m × 2 m) size. There in the conveyer section where heat
2261Kcal/Kg to 2715KCal/Kg which enhanced
exchanger takes place from flues gas to bagasse. After
boiler efficiency by 63.2822% to 72.877% The
heat exchanger process the flue gas temperature slower
main objective of the project is to design bagasse
down to around 72.064℃ will exits the conveyer section
drying system to reduce the moisture percent in the
rectangular duct. The flue gas will be sent back to
bagasse, hence to improve boiler efficiency and to
chimney with help of 1 m diameter pipe.
improve the manufacturing cost of per sugar bag
VI. RESULT AND DISCUSSION device. The analytical results obtainable show
evidently that the amount of moisture percentage
Fuel economy depends upon proper milling, can be reduced by using the hot flue gas and which
efficient generation of steam and its use in the will directly increases the efficiency of the boiler in
sugar factory. Fuel economy is directly related to the sugar.
moisture per cent bagasse. The design of heat
exchanger as bagasse dryer seems effective to VIII. FUTURE SCOPE
reduce the moisture per cent of the bagasse. The The design analysis of bagasse drier report
increase in boiler efficiency due to reduced has been submitted to the Shri. Halasidhanath
moisture per cent of bagasse is analyzed. At the Sahakari Sakkare Karkhana Ltd. Nippani.
50.30% of moisture the boiler efficiency was
It has been suggested to sugar factory that the use
63.288% and after drying the bagasse with the
of conveyor plate material of copper or aluminum
proposed drier system the moisture per cent
then the M S steel will further improve the
reduced to 38.115% and the improved boiler
efficiency of the boiler.
efficiency is 72.877%. Thetemperature of bagasse
after drying is increases and the moisture content in boiler by drying the bagasse. The next step
the bagasse is decreases. The calorific value of would be to carry out the numerical analysis