Industrial Dryer Simulation & Energy Optimisation
About Client
- Name: A&R Purn House Farm
Project Overview
This project focused on improving the efficiency, automation, and quality control of a blackcurrant drying plant through the development of a digital simulation model. A MATLAB-based dryer simulation was created to replicate the performance of a three-pass industrial dryer and identify optimal control parameters. The model was validated against experimental data and used to analyse system performance, energy consumption and potential inefficiencies, such as air leakage and heat loss.
Software
- MATLAB
Methods
- Mathematical Modelling & Simulation
- Finite Difference Methods
- Model Validation Against Empirical Data
- System Optimisation
Analysis
- Energy Efficiency Analysis
- Fuel Consumption Modelling
- Dryer Control Parameter Optimisation
Project Details
Developed a MATLAB-based simulation of a three-pass industrial dryer to model heat and mass transfer processes for blackcurrant pomace drying.
Validated the simulation against empirical data, achieving gas temperature of 97°C and 10% moisture content within ±1% tolerance.
Used the model to identify optimal operating conditions, including drum rotational speed and airflow characteristics.
Identified potential air leakage within the system and evaluated its impact on energy efficiency and fuel consumption.
Key Results
- Achieved accurate simulation results with gas temperature of 97°C and outlet moisture content of 10% within ±1% tolerance.
- Reduced fuel consumption by 9.7 L/h by optimising drum rotational speed to 7 rpm.
- Quantified heat loss effects, requiring an additional 1.68 L/h of fuel to maintain drying performance.
- Demonstrated significant potential for improving industrial drying efficiency and sustainability through simulation-driven optimisation.
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