Career Episode 1: Forced Convectional Solar Dryer

1.1
I was part of the academic project executed to attain the criteria of a bachelor’s degree in mechanical
engineering from Rathinam college campus, Coimbatore of Anna University. The project ran from
19/11/2013 to 5/4/2014. I had a supervisor to look upto in the project; Assistant professor Mr G
Badmanaban.
1.2
1.2.1
During the harvesting of food products, it is essential to dry them for storing it for a long duration.
Normally, solar heat is used for drying the food products, this process is slow and consumes at lot of time.
Thus drying of food is not achieved properly. So, in order to find an alternative effective method different
methods of researches have been conducted for developing a highly efficient solar dryer for agricultural
purpose. The man-made solar dryers are efficient than the normal conventional method. These solar dryer
device have higher heat absorption capacity with a higher rate of drying efficiency.
In our project I designed a small working prototype of the conventional solar dryer. At the very first stage
of this project, appropriate parts required for fabricating of solar dryer were purchased. Then I designed a
three Dimensional (3D)model of the solar dryer was designed using SOLIDWORKS software with the
required dimensions (mm). Then, a required solar dryer was developed in the machine shop in our college
by assembling the purchased components. Once the prototype was completed, I took initiative to test the
solar dryer by placing 20kg of chilli and then its efficiency and relative humidity were calculated after
testing.
1.2.2
In this project our target was at designing and fabricating the conventional solar dryer for heating the raw
vegetables dry them and store it for longer period. Apart from the main design and fabrication activity,
the project was critically satisfying some goals like:

 To promote the renewable energy application for drying purpose of raw vegetables and food
grains
 To improve the speed of drying efficiently even when there was limited sunlight to work on
1.2.3
I had many contributions to present in the project duration. I designed 3D model of the solar dryer under
the guidance of my assistant professor Mr G Badmanaban and analyzed the principal factors associated
with solar energy therefore I finally came to conclusion for developing the prototype of solar dryer for
project execution. I did the model of the system depicting the vital components. I properly developed a
strategic plan on which the experiments were carried out since they are crucial in executing our solar
energy project. I collected and observed the results as soon as the experiments were conducted.
1.2.4
 Anna university

Rathinam college
campus,
Coimabtore

Department of
Mechanical
Engineering

Department
Head

Project mentor

Athul Krishna
Oruvil Sasindran Project members
(Me)

Figure: Organization Chart

1.2.5

 To contemplate the solar drying operation and the ways to enhance the efficiency associated with
forced convection
 To determine the operating principle and the vital elements of the machine according to the
required functions
 To design the system for forced convection and model it in SolidWorks
 TO fabricated the various elements of the drying machine with the exact dimensions used in the
model
 To arrange the setup as required for the experiment and test the efficiency of the system
  To review the consequences presented by the tests run on the system
1.3
1.3.1
At the beginning of this project, I studied numerous books, research papers, articles, and journals
associated with the solar dryer. I learned about types of solar dryer, way of operating it, different
approaches to food processing, and energy consumed for drying food products. In-depth, I read the
optimizing procedure of the dryer running on solar energy, its essential components, and design
procedure. I also studied the conventional sun dyer, indirect forced convection solar drier, solar wind
ventilated cabinet dryer, natural, conventional solar dryer. Furthermore, I accumulated skills for utilizing
the modelling software SOLIDWORKS. In overall, I combined the vital theoretical knowledge necessary
for performing this project.
1.3.2
After reviewing the literature, I ensued to select the necessary apparatuses of the solar dryer. I picked a
piece of sheet metal made from mild steel. I also chose two pieces of the V-groove which were made
from aluminium. I selected an electric blower for force movement of air and chose a glass sheet for
decreasing the heat loss and increasing the greenhouse effect. I also selected an electronic voltage dimmer
and a bottle of black paint. Furthermore, I collected glass wool for insulating the drying chamber, and
sand for collecting heat during the pick solar hour. After listing the essential components, I amassed these
components from the market before assembling them.
1.3.3
After collecting the essential components for fabrication, I proceeded to model a 3D model of the forced
conventional dryer. I selected SOLIDWORKS as modelling software. I took reference from the books for
determining the dimensions of the machinery involved with the solar dryer. I initially prepared a 3D
model of the V-groove absorber in the SOLIDWORKS. In the same way, I made a 3D model of a casing
of the solar dryer with an appropriate measurement. I also designed a hollow shaft for free movement of
the natural air and also prepared a glass sheet in the modelling software. I made a 3D model of the
essential components separately and then assembled them for obtaining the final view of the forced
convection solar dryer.
1.3.4
After achieving the final model, I progressed to constructing the solar dryer. I placed a 2 mm thickness
aluminium absorber plate with black paint directly behind the glazing material, i.e. glass, and maintained
an appropriate gap of 25 cm between them for air circulation. I used a glass cover of 5 mm thickness, and
a v-grooved solar air heater of an area 1.5m*0.5m was attached with drying chamber. I attached an
electric blower at the one end of the collector with the assistance of the reducer, and another end was
coupled with the drier cabin. I maintained a 100 mm break between the insulation and absorber and I
packed the insulation chamber with sand and aluminium crumbs. I made a drying chamber of a dimension
of 0.5m*0.5m*0.5m which was fabricated from mild steel of 2 mm size. I insulated a drying chamber
with 10mm wide glass wool, and a solar heater was slanted at 25-degree angle to horizontal. I found the
total cost of materials to construct the dryer amassed to Rs 2950.

1.3.5
After completing the fabrication of the forced convection solar dryer, I proceeded to test the fabricated
machine. I initially placed 20 kg of chilli in the first batch. I then measured the temperature value of the
drier. I measured 50.4oC as a mean temperature for drying air at the inlet section of the dryer, 68, and 43
degrees Celsius as the maximum and minimum temperature of drying air, 950 W/m 2 as the maximum
solar intensity during the peak sunshine hours. I also recorded 31 and 26 degrees Celsius as average dry
and wet bulb temperature, and I measured 78% as relative humidity in the outlet chamber at the initial
stage of testing which was reduced to 36%. I also found that 72.8% of average moisture content was
reduced to 9.1% and 9.8% in the bottom and top of the tray respectively after a day.
1.3.6
After completing an experiment, I did drying analysis by following standard formulas of the
thermodynamic. I found that the moisture reduction rate at the initial stage of drying was relatively high,
and it decreased slowly. I also discovered that the rate of drying became very slow at the later stage of
drying. I calculated the specific moisture extraction rate of the fabricate machine to be 0.87 kg/kWh, and
the mean thermal effectiveness was designed as 21%. On analyzing these outcomes, I found that the
designed dryer was successful for achieving its objectives and was more effective than the natural drying.
To sum up, I found the designed solar dryer worked properly and was effective for drying food products.
1.3.7
The first difficulty, I confronted was associated with the moisture content of the chilli. I found that there
was a huge difference in the moisture content of the chilli contained in the top and bottom layers. On
testing, I found that the chilli contained in the upper layer was almost dried, but the chilli contained in the
bottom layer contained a huge amount of moisture. It was creating hurdles on drying the chilli and
decreased the drying efficiency of the fabricated solar drier. For solving it, I discussed with the professors
of the thermodynamic faculty and also visited several web portals. I also reviewed the different types of
solar dryers. I found that it was due to the use of the flat plate absorber. In the initial case, I had used a flat
plate absorber this did not allow to flow the air properly in the bottom layer so, the action of drying was
not achieved properly. I then replaced the flat plate absorber by a V-groove absorber plate and placed 20
kg of chilli on it and left for a day. Then, I measured the moisture content of both layers and found that
9.1% and 9.8% moisture in the bottom and top layer. It solved the encountered problem, and the action of
drying was also achieved successfully.
1.3.8
I collected the suitable material for fabricating the solar dryer. I reviewed the design book and took
reference for the dimension of the solar dryer and prepared a 3D model of the dryer powered by solar
energy in the SOLIDWORKS. I also invented the force convection sun dryer and tested the drying
efficiency by placing 20 kg of chilli. I also did drying analysis and found that the designed dryer was
successful in achieving the objectives.
1.3.9
I endorsed the way of team coordination as I went forward in the project. I labelled the critical activities
among the ones to be performed for which the delays were not excusable. I was involved in the team
formation to divide the project into an equal division of activities. I collaborated to communicate with the
supervisor that opened the doors for expert advice. I habituated the practice of tracking the listed activities
in the schedule. I consulted with the personnel recruited in the fabrication lab to support us with the
materials needed in the experiment. I was present in all discussion sessions where the possible gains in
the project duration were put up for discussion.
1.3.10
I overviewed the guidelines related to the solar energy engineering ICS 27.160 when I was assessing the
essential elements of the system to be designed. I also applied the glass relating to the ICS 81.040
guidelines by which the experiment got conducted. I also focused very high to adapt to the safety
directions in the lab as I strived for more accurate outcomes.
1.4
1.4.1
I summarized the whole group of activities as I worked on the project to create the solar dryer working on
the theory of forced convection. The experiment was the basis of verification for the effectiveness of the
system as the fabrication followed the modelling and component selection step. The outcomes assessed
after the tests were enough to prove the effectiveness of the system overall. The modelling activity was
done by using salient workspace of the SolidWorks application.
1.4.2
I went towards polishing my engineering skills when I carried out the project. I excelled in whatever
material cutting and joining procedures were needed as the project went forward. I got the background
knowledge on the outcomes of such experiments could be improved in relation to its accuracy. I also
learnt the importance of coordination when several factors have to be regulated for a single experiment.