IMSEGEC’17

1st International Materials Science and Engineering for Green Energy Conference

Solar phosphate flash drying : Modelling and bench scale design

Z. EL HALLAOUI1,2 ,T.MOUDAKKAR12, S.VAUDREUIL2 , T.BOUNAHMIDI1,2

1 Laboratoire d’Analyse et Synthèse des Procédés Industriels (LASPI), Ecole Mohammadia
d’Ingénieurs (EMI), Université Mohamed V, Avenue Ibn Sina, BP. 765 Agdal-Rabat, Morocco
2
Euromed Research Institute, Euro-Mediterranean University of Fes (UEMF), Eco-Campus, Route
Meknes,Route de Moulay Yacoub, Morocco
email address: z.elhallaoui@ueuromed.org , t.moudakkar@ueuromed.org

Abstract:
The present work aims a design of a bench scale phosphate flash dryer powered by solar parabolic
trough collector. The design is achieved through a one-dimensional transport phenomena model of the
flash dryer, and a heat balance model of the solar receiver. The model was solved using a 4th order
Runge-Kutta method implemented in MATLAB, and a second-order predictor-corrector algorithm
implemented in EES Software for the dryer and the solar receiver, respectively. Simulations results
along with a sensitivity analysis of the models were used to size a bench scale solar phosphate flash
dryer.
Introduction

Drying technologies, one of the oldest unit operations [1], are encountered in numerous applications
from food, chemical, pharmaceutical, mineral to paper and wood processing. Among the various
dryers, flash drying is a wide spread technology for which the temperature of the drying medium can
reach 700°C, except for food and pharmaceutical products in order to keep the nutritional value and
avoid undesired reactions, respectively. These technologies are considered as energy-intensive
processes. In this context, phosphate drying requires 80 000 L/day of fuel per 8000 dried tonnes/day,
representing an annual expenditure of more than 100 MMAD per year [2]. This energy requirement is
an important source of greenhouse gas emissions -26.02 kg CO2 eq /dried tonne- contributing to
climatic warming. Hence, besides reducing its operating costs, shifting toward renewable energy
sources is one of the best options for the environment preservation. In this context, Sharma et al. [3]
presented the worldwide potential of the solar thermal collectors in meeting the industrial process
heating demand. Actually, several solar collector technologies are commercially available, providing
the energy requirement supply at temperature up to 250°C for domestic hot water heating, air
conditioning, desalination and solar chemistry. According to a comprehensive review on PTC and their
applications presented by Frenandez Garcia et al. [4], PTC as a much mature solar heating technology
could be chosen for industrial application, enabling heat production at temperatures up to 400°C
meeting the needs for phosphate flash drying. However, several barriers have obstructed the use of a
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1st International Materials Science and Engineering for Green Energy Conference

high temperature of PTC collector for industrial applications, among which an important upfront cost
and unavailability of the appropriate thermal storage [3].
The special feature of this project is the fit of the flash drying requirement in terms of high temperature
to the solar plant limitations, within a financially cost-effective approach.
The present paper relates a design and performance analysis of a flash drying technology powered by
PTCs. This will be achieved through experimental tests on the bench scale dryer, designed via a
mathematical modelling of the flash unit and the solar field and through a parametric sensitivity
analysis to evaluate the effect of the model’s variables on the design parameters.

1. Flash dryer modelling

Flash dryer, also known as pneumatic drying technology, is a process where simultaneous heat and
mass transfer occur with the solid pneumatic conveying. The technology consists of a drying tube
where the solid and gas phase are in a co-current contact. The mixture is then separated in a cyclone,
where the dried product is recovered from the lower part and the exiting air from the upper part before
crossing the filter (figure 1).

Many models exist in the literature, from one-dimensional to three-dimensional. However, for time and
simplicity constraints, the 1-D model was chosen for the design of the bench scale dryer. In this
context, the 1-D model for the flash dyer is based on Bhattarai et al. model developed for sawdust
drying [5] and being adapted in this work to simulate the phosphate particles flash drying.

Figure 1: schema of a flash dryer plant

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Figure 2: Schema of the bench scale solar flash dryer

The model is based on momentum, heat and mass balances for the solid and gas phases. The model
parameters were estimated through a literature review, to choose reliable correlations of physical
properties of phosphate [2] and air [5,9], as well as transport properties for flash dryer.

The main governing equations for the momentum, heat and mass balances for the solid and gas phase
are given by:
Momentum balance:
𝑑𝑉𝑔 1 𝑑𝑃 3 1−𝜀 𝜌𝑔 𝑉𝑔 1 6𝑤 1−𝜀
𝑉𝑔 = −𝜌 − 4𝑑 ( )𝐶𝑑 𝜌 (𝑉𝑔 − 𝑉𝑝 )2 − 𝑔 − 4𝑓( 2 )2 (𝐷) − 𝜌 ( )(𝑉𝑔 − 𝑉𝑝 ) (1)
𝑑𝑧 𝑔 𝑑𝑧 𝑝 𝜀 𝑝 𝑔 𝑑𝑝 𝜀
Representing the main force acting on the air velocity resistance due to pressure drop, drag force,
frictional force and mass transfer respectively.
𝑑𝑉𝑝 3 𝜌𝑔 𝜌𝑔 𝑉𝑝 1
𝑉𝑝 = 4 𝑑 𝐶𝑑 𝜌 (𝑉𝑔 − 𝑉𝑝 )2 − (1 − 𝜌 ) 𝑔 − 𝑓𝑝 ( 2 )2 (𝐷) (2)
𝑑𝑧 𝑝 𝑝 𝑝

The right terms of this equation illustrate the motion of the solid due to drag, gravitational and
frictional force respectively.

Energy balance:
𝑑𝑇𝑔 6ℎ 1−𝜀 6𝑤𝐶𝑣 1−𝜀 𝑄
𝑉𝑔 = −𝑑 ( ) (𝑇𝑔 − 𝑇𝑝 ) − 𝑑 ( ) (𝑇𝑔 − 𝑇𝑝 ) − 𝐺 𝑤𝑎𝑙𝑙_𝑙𝑜𝑠𝑠 (3)
𝑑𝑧 𝑝 𝐶𝑔 𝜌𝑔 𝜀 𝑝 𝐶𝑔 𝜌𝑔 𝜀 𝐶 (1+𝐻)
𝑔 𝑔

The right terms of this equation representing the air energy loss due to convection, mass transfer and
the pipe loss respectively.
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1st International Materials Science and Engineering for Green Energy Conference

𝑑𝑇𝑝 6
𝑉𝑝 =𝑑 (ℎ(𝑇𝑔 − 𝑇𝑝 ) − 𝑤 𝐿𝑣 (𝑀, 𝑇𝑝 )) (4)
𝑑𝑧 𝑝 𝐶𝑝 𝜌𝑝

The right terms of this equation illustrate the heat transfer and the latent heat of vaporization,
respectively, in the solid
Mass balance:
𝑑𝐻 𝐺𝑝 𝑑𝑋
= −(𝐺 )( 𝑑𝑧 ) (5)
𝑑𝑧 𝑔
𝑑𝑋 6𝑤(1+𝑋)
=− (6)
𝑑𝑧 𝑑𝑝 𝑉𝑝 𝜌𝑝

2. Solar system modelling

The solar system model is based on heat transfer analysis described by Forristall [10] to evaluate the
collector’s performances. The model is improved in the present work by adding a mass balance to the
model throughout a kinetic term. It is adapted in this case for the heat production to power the flash
dryer.
In addition, heat exchanger model was presented to complete the solar plant.

Figure 3: heat transfer model in a cross section at (HCE) and the control volume used for the heat transfer analysis. (a)
heat transfer (b) control volume. [10]

2.1 PTC modelling

A PTC consists of parabolic trough shaped mirrors, heat receiver, support structure and tracking
system. It focuses direct solar radiation into the absorber -located on its focal line - and converts the
radiation into useful thermal energy in the HTF circulating through the HCE.
The heat transfer model in the PTC is based on an energy balance between the heat transfer fluid and its
surroundings. Figure 3.a shows the various heat transfer modes in a cross section of the solar collector,
and the control volume used for heat transfer analysis.
For each control volume 𝑉 𝑖 of the receiver (Figure. 3.b) ,the unknown variables are
𝑖
𝑇𝑓𝑖 , 𝑇𝑎𝑖 𝑖
, 𝑇𝑎𝑜 , 𝑇𝑒𝑖i , 𝑇𝑒𝑜
i
and the governing equations (7-11) for the working fluid, absorber tube and glass
envelope can be represented as follows :
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2
𝜕 𝑖 𝑣𝑓𝑖
−𝑚̇𝑓 𝜕𝑧 [𝐶𝑝,𝑓 𝑇𝑓𝑖 + 2
𝑖
] + 𝑄𝑎𝑖−𝑓,𝑐𝑜𝑛𝑣 =0 (7)
𝑖 𝑖 𝑖 𝑖 𝑖
𝑄𝑎−𝑎𝑏𝑠 − 𝑄𝑎𝑖−𝑓,𝑐𝑜𝑛𝑣 − 𝑄𝑎𝑜− 𝑒𝑖,𝑐𝑜𝑛𝑣 − 𝑄𝑎𝑜−𝑒𝑖,𝑟𝑎𝑑 − 𝑄𝑐𝑜𝑛𝑑,𝑏𝑟𝑎𝑐𝑘𝑒𝑡 =0 (8)
𝑖 𝑖 𝑖 𝑖 𝑖
𝑄𝑒−𝑎𝑏𝑠 + 𝑄𝑎𝑜−𝑒𝑖,𝑐𝑜𝑛𝑣 + 𝑄𝑎𝑜−𝑒𝑖,𝑟𝑎𝑑 − 𝑄𝑒𝑜−𝑠𝑎,𝑐𝑜𝑛𝑣 − 𝑄𝑒𝑜−𝑠,𝑟𝑎𝑑 =0 (9)
𝑖 𝑖
𝑄𝑎𝑖−𝑎𝑜,𝑐𝑜𝑛𝑑 = 𝑄𝑎𝑖−𝑓,𝑐𝑜𝑛𝑣 (10)
𝑖 𝑖 𝑖
𝑄𝑎𝑜−𝑒𝑖,𝑐𝑜𝑛𝑣 + 𝑄𝑎𝑜−𝑒𝑖,𝑟𝑎𝑑 = 𝑄𝑒𝑖−𝑒𝑜,𝑐𝑜𝑛𝑑 (11)

The various heat transfer interactions are presented by Forristall [10]. The heat gain and collector
efficiency are calculated as follow:
𝑄𝑔𝑎𝑖𝑛,𝑓 = 𝑄𝑎−𝑎𝑏𝑠 + 𝑄𝑒−𝑎𝑏𝑠 − 𝑄𝑙𝑜𝑠𝑠 = 𝑚̇𝑓 (ℎ𝑓,𝑜𝑢𝑡 − ℎ𝑓,𝑖𝑛 ) (12)

𝑄𝑔𝑎𝑖𝑛,𝐻𝑇𝐹
𝜂𝑐𝑜𝑙 = ⁄𝐼 𝐴 cos(𝜃) (13)
𝑏 𝑐𝑜𝑙

In order to determine the solar system area, it was necessary to choose the PTC module based on a
benchmark study, selecting then the GAIA SOLAR modules PT20 for this purpose [11].
Once the collector chosen, the collector efficiency will depend on the operating conditions. Thereby:
𝜂𝑐𝑜𝑙,𝑃𝑇20 = 𝑓(𝑇𝑓,𝑖𝑛 , 𝑇𝑎𝑖𝑟 , 𝐼𝑏 , 𝜃, 𝑣𝑎𝑖𝑟 ) (14)

Hence, the aperture area requirement for the flash dryer and the inlet HTF temperature are determined
by solving the system of equations (15-16) defined as follow:
𝑄𝑑𝑟𝑦𝑒𝑟
𝐴𝑟𝑒𝑞 = 𝜂𝑐𝑜𝑙,𝑃𝑇20 𝜂ℎ𝑒𝑥 𝐼𝑏
(15)

𝑄𝑔𝑎𝑖𝑛,𝑓 = 𝑚̇𝑓 (ℎ𝑓,𝑜𝑢𝑡 − ℎ𝑓,𝑖𝑛 ) = 𝐴𝑟𝑒𝑞 ∗ 𝐼𝑏 ∗ 𝜂𝑐𝑜𝑙 (16)

While 𝑇𝑓,𝑜𝑢𝑡 depends on the design drying air temperature.

However, the aperture area installed is larger than the area requirement, and is calculated by:
𝐴𝑟𝑒𝑞
𝑁𝑚𝑜𝑑 = ⌊ ⁄𝐴 ⌋+1
{ 𝑚𝑜𝑑 (17)
𝐴𝑖𝑛𝑠𝑡 = 𝑁𝑚𝑜𝑑 ∗ 𝐴𝑚𝑜𝑑

2.2. Heat exchangers modelling

Three heat exchangers are needed in the plant: heater, cooler and heat recover (figure 2). The first is used for
heating the drying air at the design temperature, while the cooler enables to carry the residual energy away from
the surrounding air. The last one is used mainly to improve the efficiency of the heater by raising the inlet drying
air temperature. The cross flow arrangement is assumed for the heater and cooler, and the effectiveness-NTU
method [12] is used for all the heat exchangers.
𝐶𝑚𝑖𝑛 𝑚̇ 𝐶
𝑍= ⁄𝐶 = 𝑎𝑖𝑟 𝑎𝑖𝑟⁄𝑚̇ 𝐶 (18)
𝑚𝑎𝑥 ℎ𝑡𝑓 ℎ𝑡𝑓
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𝑄𝑟𝑒𝑒𝑙 (𝑇ℎ𝑡𝑓,𝑖𝑛 −𝑇ℎ𝑡𝑓,𝑜𝑢𝑡 )

𝜖= ⁄𝑄 = 𝑚̇ℎ𝑡𝑓 𝐶ℎ𝑡𝑓 𝐶 (19)
𝑚𝑎𝑥 𝑚𝑖𝑛 (𝑇ℎ𝑡𝑓,𝑖𝑛 −𝑇𝑎𝑖𝑟,𝑖𝑛 )

𝜖 = 1 − 𝑒𝑥𝑝{(1⁄𝑍)[1 − exp(𝑁𝑇𝑈 ∗ 𝑍)]} (20)

𝑈𝐴 = 𝑁𝑇𝑈 ∗ 𝐶𝑚𝑖𝑛 (21)

The heat recover efficiency is defined as [12]:

{1−exp[−𝑁𝑇𝑈∗(1−𝑍)]}
𝜖 = {1−𝑍∗exp[−𝑁𝑇𝑈∗(1−𝑍)]} (22)

3. Simulation results and discussion

The set of differential equations of the flash dryer model is solved using the 4th order Runge- Kutta
method implemented in MATLAB. The differential equations of the solar system model are solved
using a second-order predictor-corrector algorithm implemented in EES Software (Engineering
Equation Solver) [13]. It should be noted that EES is interfaced to MATLAB. The inlet air temperature
used for simulations of the flash dryer is determined

200
0,2
solid moisture
0,18 180
0,16
Air temperature °C

air humidity 160

0,14
Humidity

0,12 140
0,1
120
0,08
0,06 100
0,04
0,02 80
0
60
0 0,5 1 1,5
0 0,5 1 1,5
Dryer length, m
Dryer length,m
by the solar system constraints.

Figure 4: Variation of solid moisture content and air humidity Figure 5: air temperature along the dryer
along the dryer
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Vp

8 Va

7
6
Velocity m/s

5
4
3
2
1
0
0 0,5 1 1,5
Dryer length,m

Figure 6: Variation of solid velocity (Vp) and air velocity (Va)

along the dryer

Simulation results were carried out for an inlet air temperature of 180°C, an air inlet velocity of 7.4 m/s
for a solid flow rate of 50 kg/h having an inlet moisture content of 18%, for a dryer of 200mm and
1.7m of internal diameter and length, respectively. Figures 4, 5 and 6 show variation of the moisture
content of the air and phosphate, the air temperature, and the solid and air velocity profile along the
dryer, respectively. As expected, a decrease in the solid moisture content involves a decrease of the air
temperature due to the heat transfer and an increase in the air humidity due to the mass transfer of the
humidity from the solid into the gas stream.
3.1. Effect of the inlet air temperature and dryer diameter

A sensitivity analysis was performed to identify the effect of the model variables on the design
parameters. Hence, the inlet air temperature was varied in the range [180 -320°C] at constant dryer
diameter (D=200mm) in order to determine the required dryer length. Figure 7 illustrates the effect of
the inlet air temperature on the dryer length. The results show that increasing the inlet air temperature
involves a smaller dryer length to achieve the same final solid moisture content of 2%.
Furthermore, the effect of the dryer diameter on the solid final moisture content was studied at
Ta=200°C and L=1.5m as shown in figure 8. It can be seen that increasing the diameter implies
additional moisture removal.
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330
12,00%
Solid final moisture content

310

Inlet air temperature °C

10,00% 290

270
8,00%
250
6,00%
230
4,00% 210

2,00% 190

170
0,00% 0,6 1 1,4
140 160 180 200 220 240
Dryer length, m
dryer diameter (mm)

Figure 8: Effect of the dryer diameter on the final moisture Figure 7: Effect of inlet air temperature on the dryer
content at Ta=200°C and L=1.5m length at D=200mm

3.2. Effect of the drying air temperature on the PTC area requirement
A sensitivity analysis of the PTC model was carried out to evaluate the variation of the collector
efficiency as a function of the HTF temperature and its impact on collector area requirement.
Figures 9 and 10 show different inlet air temperature, drying air flow rate and HTF temperature
configurations for the flash dryer requirement and the variation of energy and collector area
requirement for flash dryer, respectively.

380
Inlet Air and HTF Tempetaure °C

370
360
T_Drying air
350
340 T_HTF bulk
330
320
310
300
290
0,0095 0,01 0,0105 0,011 0,0115 0,012
Drying Air flowrate (kg/s)

Figure 9: Inlet drying air temperature and related HTF temperature for different drying air flow rate configurations
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3500 1,8

Energy requirement for flash dryer (W)

3000 1,75

Collector Area (m2) needed for 1kW

2500
1,7
2000
1,65
1500
1,6
1000
Q_dryer

500 Area(m²)/kW 1,55

0 1,5
0,003 0,005 0,007 0,009 0,011 0,013
drying Air mass flow (kg/s)

Figure 10: Variation of energy requirement for flash dryer with air mass flow

In order to minimize the drying energy requirement (fig 10), it is recommended to work at higher
temperatures. Nevertheless, this leads to a higher 𝐴𝑟𝑒𝑞 /𝑘𝑊𝑟𝑒𝑞 . In order to reduce this ratio, it is
important to choose a PTC with better thermal and optical performance as well as a favorable site in
terms of solar irradiation.

5. Design of the solar flash dryer

Once the simulations and the parametric sensitivity analysis have been carried out, the parameters of
the design, namely the dimensions of the dryer and the inlet air temperature, can be determined.
This leads to the determination of the HTF working temperature and the energy requirement 𝐴𝑟𝑒𝑞 ,
allowing the sizing of the solar system.
Table 1 regroups the design parameters of the solar phosphate flash dryer.
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Flash dryer Heat Air-oil Air-oil Heat recover

exchangers heater cooler
Physical dimensions of the Solar field Finned circular Air to air
dryer Tubes heat counterflow heat
exchanger exhanger
Dryer length 1.7m Nmodule 2 𝑚̇ℎ𝑡𝑓 (kg/s) 0.3 0.34 𝑚̇𝑑𝑎 kg/s 0.13
4
Dryer diameter 200 mm Amod (m²) 15.3 𝑇𝐻𝑇𝐹,𝑖𝑛 °C 210 210 𝑇𝑑𝑎,𝑖𝑛 °C 21
Process Air stream ASCA (m²) 30.6 𝑇𝐻𝑇𝐹,𝑜𝑢𝑡 °C 182 206 𝑇𝑑𝑎,𝑜𝑢𝑡 °C 58
Air velocity 7 m/s LSCA (m) 13.5 𝑚̇𝑎𝑖𝑟 (kg/s) 0.134 0.07 𝑚̇ℎ𝑎 0.13
8
Air flowrate 0.134 Working fluid 𝑇𝑎𝑖𝑟,𝑖𝑛 °C 57.9 21 𝑇ℎ𝑎,𝑖𝑛 65
kg/s conditions
IN : Air 180°C HTF Thermi 𝑇𝑎𝑖𝑟,𝑜𝑢𝑡 °C 180 62 𝑇ℎ𝑎,𝑜𝑢𝑡 30
temperature nolVP1
Phosphate stream 𝑚̇ℎ𝑡𝑓 3𝑚3 /ℎ UA (W/°C) 253.2 17.9 UA (W/°C) 623
Flowrate 0.014kg/s 𝑇𝑓,𝑜𝑢𝑡 (°C) 210 U (W/m²°C) 39.86 21.2 U (W/m²°C 44.8
Initial Moisture 0.18 kg 𝑇𝑓,𝑖𝑛 (°C) 194 ε 80% 23% ε 84%
content water/kg
phosphate
outlet Moisture 0.02 kg
content water/ kg
phosphate
Tableau 1: design results

Conclusion
A one-dimensional mathematical model was used to design a bench scale solar phosphate
flash dryer. The model was solved for the flash dryer and the solar system. Simulations
results along with a sensitivity analysis were used to size the bench scale solar dryer. A
(200mm*1700mm) flash dyer powered by two PT20 modules were selected for the bench
scale, where experimental tests will be used to refine the solar flash dryer model and to
optimize the process.
Nomenclature
Acol Aperture area (m2)
C heat capacity (J/kg)
Cd drag coefficient (-)
f frictional coefficient (-)
dp solid diameter (m)
D Dryer diameter (m)
H air humidity (kg/kg)
h convective heat transfert
coefficient (W/m2.K)
Ib Solar irradiance (W/ m2)
G mass flow rate (kg/s)
Lv latent heat of
vaporization (J/kg)
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𝑚̇𝑓 HTF Mass flow rate

(kg/s)
𝑁𝑚𝑜𝑑 number of PTC module
Q Rate of heat transfer per
unit length (W/m)
T temperature °C
V velocity (m/s)
W drying rate (kg/s)
X solid moisture content
(kg/kg dry solid)
ηcol Collector efficiency

Subscripts
a air / absorber, absorber
coating
a-abs absorber–absorbed
ai Inside surface of the absorber
ao Outside surface of the
absorber
ai-f,conv absorber–fluid, heat transfer
by convection
ao-ei,conv absorber–envelope, heat
transfer by convection
ao-ei,rad absorber–envelope, heat
transfer by radiation
cond,bracket conduction bracket
e-abs envelope-absorbed
ei Inside surface of the glass
envelope
eo Outside surface of the glass
envelope
eo-s,rad envelope–sky, heat transfer by
radiation
eo-sa,conv envelope-surrounding air, heat
transfer by conv
f,ave average temperature of the
HTF
f,out outlet temperature of the HTF
g drying air
P particle
sa surrounding air
V vapor
Abbreviation
HTF Heat transfer fluid
PTC Parabolic trough collector
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Acknowledgement:
The authors would like to thank IRESEN, the Research Institute for Solar Energy and New
Energies for the continuous funding.

References

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[3] A.K. Sharma, C. Sharma, S.C. Mullick, T.C. Kandpal, Solar industrial process heating: A
review, Renewable and sustainable energy reviews 78 (2017),124-137.
[4] A. Fernandez-Garcia, E. Zarza, L. Valenzuela, M. Perez, Parabolic-trough solar collectors
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