The adoption of indirect drying equipment with energy-saving and environmentally friendly features is becoming a key trend in the evolution of drying technology. This article explores the technical advancements in energy-efficient tube bundle dryers, focusing on their working principles, structural design, and performance improvements.
The new tube dryer developed by Northeastern University Shenyang Yitong Venture Technology Co., Ltd. represents a significant leap forward in thermal efficiency. It achieves 30% higher drying capacity compared to conventional models, with energy consumption reaching an advanced level within China’s market. The system requires only 1.2–1.5 tons of water and 1.3 kg of steam per kilogram of evaporated water, making it highly efficient and sustainable.
At the core of this dryer is a high-quality boiler steel pipe (GB3087), which ensures durability and reliability. Advanced expansion joint technology eliminates the risk of fractures that commonly occur at weld seams in traditional designs. The semi-axial turning mechanism, along with precise coaxial alignment, significantly extends the service life of the main bearings and ensures smooth operation of the tube bundle.
To optimize the drying process, the lifting uniform distribution tube blade is designed based on material-specific drying curves. This allows for consistent and effective drying across different materials. The blade ensures a completely mixed state inside the dryer, reducing thermal resistance and enhancing overall performance.
In contrast, traditional tube dryers often suffer from incomplete mixing due to the use of push-pull plates, tipping blades, and unloading shovel plates. These components can lead to gas stratification, especially when rotor speed decreases or diameter increases. While these blades are easier to clean, they result in lower filling rates (0.1–0.2), limiting efficiency.
The new tube dryer addresses these issues by incorporating lifting uniform blades that allow material to fall at various angles, ensuring full contact with the heating surface. This improves the utilization of the tube surface and enhances the particle coverage factor (fR). Blade design is adjusted along the length of the dryer to accommodate changes in material properties during the drying process, ensuring even distribution and breaking up gas layers.
The arrangement of shovel plates includes pushing, tipping, equalizing, and unloading types, with the tipping and uniform blades playing a crucial role in mixing. These blades ensure even material distribution across the entire cross-section of the rotor, leading to better heat transfer and drying performance.
According to field measurements, the new dryer increases tube surface utilization by over 20% and raises fR by more than 30% compared to traditional models. The number of shovel plates is related to the rotor diameter, with research suggesting a formula: n = (10–14)D, where D is the rotor diameter. Blade height also varies depending on the size of the unit.
Another innovation is the siphon-type condensate discharge system, replacing the traditional scoop bucket. This system uses pressure differences to continuously remove condensate without losing steam, improving steam utilization and preventing residual water in the lower parts of the tube bundle. The nozzle gap is maintained at 5–10 mm, with pipe diameters ranging from DN15 to DN25 depending on the unit size.
Finally, jet technology has been introduced to enhance heat transfer at the inlet. Instead of a traditional filling mode, steam is injected as a jet, increasing velocity and promoting turbulent flow. This boosts the local heat transfer coefficient, improving both the end tube sheet and the inlet section’s heat exchange efficiency.
By applying Newton’s cooling law, the heat transfer rate is calculated using the equation Q = αSΔTm, where α is the convection heat transfer coefficient, S is the area, and ΔTm is the average temperature difference. With enhanced jet flow, the local heat transfer coefficient increases, resulting in greater heat transfer efficiency and improved drying performance.
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