Performance Optimization of a Brick Dryer Using Porous Simulation Approach

In the present study, an innovative method for an accurate simulation and design of a chamber dryer used in the brick/ceramic industry has been proposed. A thorough investigation of currently used dryers is conducted and optimization criteria are detected and discussed. Three-dimensional modeling of the chamber dryer has been performed. In the second step, from the result of 3D modeling, the critical values for heat transfer coefficient are obtained. The governing equations for a two-dimensional brick as a porous solid are derived by combining conservation laws and Fourier's law for heat conduction and Darcy's and Fick's laws for mass diffusion in porous material. The set of partial differential equations governing heat and mass transport in a single brick together with the respective temperature and humidity boundary conditions have been solved numerically based on finite difference method. Finally, an efficient scheme for the air circulation devices, inlet air temperature and humidity, burner characteristics, flow rates, and drying process control have been proposed for a typical industrial-scale brick dryer.