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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: [email protected] 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)
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
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
RecommendationsRecommendationsFabrication and testing of a
prototypeAdjustable drum-applicator roll
clearance Variable speed driveSustainable sources of power.
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DESIGN OF OPTIMIZED SINGLE DRUM DRYERSTUDENT: WAITHAKA, VERONICA WAMBUIREGISTRATION: F21/2488/2009EMAIL:[email protected] TEL:0729007494
THANK YOU!THANK YOU!