Numerical Simulation, Method of Design and Optimization of a Brick Dryer

In the present study, an innovative method for an accurate simulation and design of a chamber dryer used in brick/ceramic industry has been proposed. A thorough investigation of currently used dryers is conducted and the source of losses and optimization criteria are detected and discussed. Three-dimensional modeling of the chamber dryer is done via a commercial CFD Package. In the second step, critical locations in the cell together with the critical values for heat transfer coefficient are obtained from the result of 3D modeling. Then a set of partial differential equations governing heat and mass transport in a single brick (critical) are discretized by Finite difference method. The resulting PDEs together with temperature and humidity boundaries have been solved numerically. These equations are derived by combining conservation laws with Fourier’s law for heat conduction and Darcy’s and Fick’s laws for mass diffusion in porous material. All necessary diffusion coefficients for liquid and vapor have been obtained experimentally via implanting relevant temperature and humidity sensors into the green product situated in a real-scale dryer and by logging the variations in both parameters. Finally an efficient scheme for mounting the air circulation devices, inlet air temperature and humidity, burner characteristics, flow rates and drying process control have been proposed for a sample dryer with a specific dimensions.