UNIVERSITY OF NAIROBI SCHOOL OF ENGINEERING

DEPARTMENT OF ENVIRONMENTAL AND BIOSYSTEMS ENGINEERINGFEB 540: ENGINEERING PROJECT

DESIGN OF AN OPTIMIZED SINGLE DRUM DRYERDESIGN OF AN OPTIMIZED SINGLE DRUM DRYER

STUDENT: WAITHAKA, VERONICA WAMBUIREGISTRATION: F21/2488/2009

SUPERVISOR: JANUARIUS O. AGULLOEMAIL: roniwaithaka@gmail.com TEL: 0729007494

A solution to the paradox of famine A solution to the paradox of famine amidst rotting surplus food is the amidst rotting surplus food is the instantaneous starches.instantaneous starches.

+ =

INTRODUCTIONINTRODUCTION

There is a lack of appropriate and There is a lack of appropriate and affordable potato drying affordable potato drying technologies in Kenya.technologies in Kenya.

vs.

PROBLEM STATEMENTPROBLEM STATEMENT

OBJECTIVESOBJECTIVES

Overall objectivesTo design a sustainable optimized industrial

single drum dryer for producing potato flakes.

Specific ObjectivesI. To establish the pertinent parameters that

affect the design of a single drum dryerII.To use the parameters obtained in (1)

above to size a single drum dryer for the manufacture of potato flakes

III.To analyze the costs and benefits of the resulting design

Ol Kalou, Nyandarua was a Ol Kalou, Nyandarua was a suitable location for a potato suitable location for a potato flaking factory.flaking factory.

SITE ANALYSIS & INVENTORY

• Potatoes• Water• Labour• Electricity• Transport• Software

Kenya Counties Electrification (Knoema, 2014)

SITE ANALYSIS & INVENTORY-Cont’d

Amongst industrial Amongst industrial dryers the SDD is the dryers the SDD is the best for potato flaking.best for potato flaking.

LITERATURE REVIEW

There are 4 parameters that There are 4 parameters that affect quality of potato affect quality of potato flakes.flakes.

TemperatureResidence timeSlurry solids Thickness

(Quality potato flakes) (Quality instant mashed potatoes)

METHODOLOGYMETHODOLOGY

RESULTSRESULTS

Parameter Result Formula

Residence time

5 sec

Drum sizing 1.5m by 3.5m

Heater sizing 5 kW Q=(mcΔT + mL)/t

Drum Thickness

0.0035m, hoop stress=72.6 MPa

Motor sizing 15 HP, 1500 rpm

Belt sizing 355.6, 71.12 and 55.88 mm sheaves

Stand sizing Steel sections

Belt configurationBelt configuration

Drive BeltsDrive Belts

Part Center to center

distance(m)

Theoretical belt length

(m)

Actual belt length

Motor to pulley/sheave 1 1 2.65 2.663

Sheave 1 to sheave 2 1 2.65 2.663

Sheave 2 to sheave 3 1 2.65 2.663

Roller 1 to Chute stirrer 0.75

1.676 1.684

Drum to Roller1 0.84

1.856 1.864

Roller 1 to Roller 2 0.5

1.176 1.184

Roller 2 to Roller 3 0.5

1.176 1.184

Roller 4 0.5

1.176 1.184

Stand DesignStand DesignPart supported Load(N) Area

required(mm2)

Steel section Area

provided(mm2)

Moment of inertia

cm4

Roller 1 66.6 0.264 12x12x1 0.44 0.08

Roller 2 66.6 0.264 12x12x1 0.44 0.08

Roller 3 66.6 0.264 12x12x1 0.44 0.08

Roller 4 66.6 0.264 12x12x1 0.44 0.08

Knife 242.9 0.97 12x12x1 0.44 0.08

Electric element 49.05 0.20 12x12x1 0.44 0.08

Slurry Chute 11106.21 44.42 200x200x6 46.56 2923.35

Drum 5563.55 22.35 100x100x6 22.56 333.59

Stand Design cont’dStand Design cont’d

Part supported

Load(N) Bending Moment Maximum

Bending moment

Shear Stress Maximum

deflection(m)

Roller 1 66.6101.98 116.55 116.55 2.41E-02

Roller 2 66.6101.98 116.55 116.55 2.41E-02

Roller 3 66.6101.98 116.55 116.55 2.41E-02

Roller 4 66.6101.98 116.55 116.55 2.41E-02

Knife 242.9371.94 425.08 425.08 8.78E-02

Electric element 49.0575.11 85.84 85.84 1.77E-02

Slurry Chute 11106.2117006.38 19435.87 19435.87 1.10E-04

Drum 5563.558519.19 9736.21 9736.21 4.82E-04

Main beam 18102 6539.35 15386.70 15386.702.05E-05

SimulationsSimulations

Graph of moisture content variation with time Transient heat transfer(Tg, Tw and Ts are air, wall and slurry temperatures respectively)

BILL OF QUANTITIESBILL OF QUANTITIESPart Details Supplier Unit cost No. of

Units

Total cost

AC induction motor 15Hp, 1500rpm Electrical

Supermark

et

70,000 1 70,000

Electric heater

element

5kW high temperature heater Electrical

Supermark

et

10,000 1 10,000

3vx drive-belts -2.663m

-1.864m

-1.184m -

1.684m

Seal Belt -3000

-2500

-2000

-2500

1

1

3

1

3000

2500

6000

2500

Sheaves

(where D is pitch

diameter)

D= 355.6mm

D=71.12mm

D=155.88mm

Seal Belt -3000

-1500

-1000

3

3

1

9000

4500

1000

Automation

components

Atmega 328p, sensors, CB,

LCD, LED, resistors, wires

Nerokas 5000 1 5000

Stainless steel 1200x2400mclass 316 gauge 25,000 12 300,000

Mild steel 12x12 hollow section Insteel 500 13.58m 6,900

Mild steel 175x175 hollow section Insteel 2,500 6m 15,000

Mild steel 200x200 hollow section Insteel 3,000 2.4m 7,200

Roller Bearings(SKF) GE50 ESX2LS Seal belt 5,000 4 20,000

Roller Bearings(SKF) GE20 ESX2LS Seal Belt 2000 10 20000

TOTAL(Ksh) 482,600

COST BENEFIT ANALYSISCOST BENEFIT ANALYSIS

Cost of materials=Ksh 482,600Cost of operation=Ksh 60,000Business/factory expenses=Ksh 4.58

millionTotal sales=Ksh 29 millionNet profit=Ksh 24.3 million

Residence timeDrum sizeDrum thicknessHeater sizeMotor sizingBelt sizingStand sizing

DISCUSSIONSDISCUSSIONS

CONCLUSIONSCONCLUSIONS

The objectives for the engineering project were met.

The parameters were identified as temperature, residence time, thickness and slurry solids concentration.

The benefits outweighed the cost

DESIGN DRAWINGSDESIGN DRAWINGS

Assembled machineAssembled machine

Section diagramSection diagram

RecommendationsRecommendationsFabrication and testing of a

prototypeAdjustable drum-applicator roll

clearance Variable speed driveSustainable sources of power.

REFERENCESREFERENCES Gas Technology Institute. (2011). High Efficiency Gas Fired Drum Dryer for Food Processing

Applications. California: California Energy Commision. Abong', G. O., Kabira, J. N., Okoth, M. W., & Ogolla, J. (2011). Potential of Processing Potato Flakes

from Popular Potato Varieties. Nairobi: University of Nairobi. Becchi, F. (2011). Lectures on Mechanics. Retrieved 01 2014, 01, from www.telerobot.it. Budynas, R. G., & Nisbett, J. K. (2006). Mechanical Engineering Design. McGraw-Hill Companies, Inc. Cording Jr., J., & Willard Jr., M. J. (1957). Patent No. US2787553 A. United States of America. Gibson, S. (1994, September/October). Industrial Dryers: Sizing, Selection, Costs. Process Heating . Goyal, S., Kumar, M., & Kaur, A. (2014). Thin Layer Drying Kinetics of Potato Mash. BEST:

International Journal of Management, Information Technology and Engineering(BEST:IJMITE) , 43-56.

Hughes, E. (2008). Electrical and Electronic Technology. London: Pearson Education Limited. Jurendic, T., & Tripalo, B. (2012). Mathematical Modeling of Conductive, Convective and Irradiative

Drying of Cereal Based Baby Foods. Journal of Agriculture and Food Technology , 126-133. Kakade, R. H., Das, H., & Ali, S. (2011). Performance Evaluation of a Double Drum Dryer for Potato

Flake Production. Journal of Food Science and Technology , 432-439. Rodriguez, G., Vasseur, J., & Courtois, F. (1996). Design and Control of Drum Dryers for the Food

Industry. Part2. Automatic Control. Journal of Food Engineering , 171-183. Singh R, P., & Heldman, D. R. (2009). Introduction to Food Engineering. London: Elsevier Publishing. Lienhard IV, J. H., & Lienhard V, J. H. (2006). A Heat Transfer Textbook (3rd Edition ed.). Cambridge:

Phlogiston Press. Luther, W. R., Suter, D. A., & Brusewitz, G. H. (2004). Drying and Dehydration. Food and Process

Engineering Technology , 259-284. Luther, W. R., Suter, D. A., & Brusewitz, G. H. (2004). Heat Transfer. Food and Process Engineering

Technology , 111-141.

REFERENCESREFERENCES Kakade, R. H., Das, H., & Ali, S. (2011). Performance Evaluation of a Double Drum Dryer for

Potato Flake Production. Journal of Food Science and Technology , 432-439. Kalogianni, E. P., Xynogalos, A. V., Karapantsios, T. D., & Kostoglou, M. (2002). Effect of Feed

Concentration on the Production of Pregelatinized Starch in a Double Drum Dryer. Lebbensm-Wiss.u.-Technol. , 703-714.

Knoema. (2014). World Data Atlas. Retrieved 02 02, 2014, from Nyandarua - Households with Electricity: http://knoema.com/atlas/Kenya/Nyandarua/Households-with-Electricity

Ktheisen, K. (2008, 12 16). International Potato Center: World Potato Atlas. Retrieved 02 02, 2014, from Consultative Group on INternational Agricultural Research: https://research.cip.cgiar.org/confluence/display/wpa/Kenya

Mang'oli, M. K. (2013). Principles of Electrification. FEB 442 . Kenya: University of Nairobi. Motion System Design. (2001). Gears and Gear Drives. Retrieved 2013 Murage, G. (2014, 03 20). 1,000 km rural roads repaired in Nyandarua. The Star . Songa, W. (2009, 11 30). Trends in Food Crop Agriculture and Government Responses to Food

Insecurity in Kenya. Kenya: Ministry of Agriculture, Kenya. USDA. (2012, 01 January). Nutrient Data Laboratory. Retrieved March 1, 2014, from United States

Department of Agriculture: http://ndb.nal.usda.gov/ndb/search/list Wolf, L., Kazimi, M. S., & Todreas, N. E. (2003, 12 23). Introduction to Structural Mechanics. Note

L.4 . Massachusettes, USA: Massachusettes Institute of Technology Department of Nuclear Engineerng.

Strolle, E., O., Cording J. , Eskew, R., K., Edwards, P. W.(1954) Potato Flakes. A New Form of Dehydrated Mashed Potatoes. Retrieved October 2, 2013, from United States Department Of Agriculture: http://wyndmoor.arserrc.gov/Page/1964/2256.pdf Strolle, E., O., Cording J. (1954) Moisture Equilibria of Dehydrated Mashed Potato Flakes. Retrieved October 10, 2013, from United States Department Of Agriculture: http://wyndmoor.arserrc.gov/Page/1964/2256.pdf

Kasiri, N. , Hasanzadeh, M., A. and Moghadam, M. (2004) Mathematical Modelling and Computer Simulation of a Drum Dryer. Iranian Journal of Science & Technology, Transaction B, Vol. 28, No. B6. Shiraz University. The Islamic Republic of Iran.

Abong’ G.,O, Kabira JN. Diversity and Characteristics of Potato Flakes in Nairobi and Nakuru, Kenya. Global Journal of Science Frontier Research (D). 2012; 12(10):35-39.

Luther, W. R., Suter, D. A., & Brusewitz, G. H. (2004). Transient Heat Transfer. Food and Process Engineering Technology , 143-162.

MacDonald, M. (2013) Project Report on Potato Flakes Processing. Retrieved November 11, 2013, from Gujarat Agro Industries Corp. Ltd: http://www.gujagro.org/Portal/Tender/177/4_1_Project_Report-Potato_Flakes_Mfg.pdf

Lamberti, M., Geiselmann, A., Conde-Petit, A., Escher, F. (2004) Starch transformation and structure development in production and reconstitution of potato flakes. LWT - Food Science and Technology. Volume 37, Issue 4, June 2004, Pages 417–427.

Willard M., (1993) Potato processing: Past, present and future. American Potato Journal. May 1993, Volume 70, Issue 5, pp 405-418.

Willard, M., J., Cording, J, Eskow, R.K, Edwards, P.W and Sultran, J., F. (1954) Potato Flakes. A new Form of Dehydrated Mashed Potatoes. Review of Pilot Plant process. American Potato Journal January 1956, Volume 33, Issue 1, pp 28-31

Karel, M., Lund, D.B. (2005) Physical Principles of Food Preservation: Revised and Expanded. Marcel Dekker Inc. USA.

Earle, R. L. (1983) Unit Operations in Food Processing. Retrieved October 24, 2013, from New Zealand Institute of Food Science and Technology Inc.: http://www.nzifst.org.nz/unitoperations/drying1.htm#httransfer

Long, C., Sayma, N. (2009) Heat Transfer. Chris Long, Naema Sayma and Ventus Publishing Co.

Tang, J., Feng, H., Shen, G. (2003) Drum Drying. Encyclopedia of Agricultural, Food, and Biological Engineering. Marcel Dekker Ltd. DOI: 10.1081/E-EAFE 120007091.

Sanitary Design (2013) Modern expectations for the food industry. Retrieved October 31, 2013, from Sanitary Design: http://www.sanitarydesign.org/principles.cfm

Cyr, A. (2009) Sanitary Design for food Safety. AIB 8 September/October 2009

DESIGN OF OPTIMIZED SINGLE DRUM DRYERSTUDENT: WAITHAKA, VERONICA WAMBUIREGISTRATION: F21/2488/2009EMAIL:roniwaithaka@gmail.com TEL:0729007494

THANK YOU!THANK YOU!