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Project Example: Flash Dryer Operating Data Analysis Historical operating data from a flash dryer was analyzed using AI-assisted statistical modeling to better understand how exhaust humidity relates to key process variables and dryer performance. Figure 1: Sensor Installation The objective was to determine whether the exhaust humidity measurement could improve process visibility, strengthen predictive models, and support a more efficient dryer control strategy. Variables... Read More

Combined cycle power plants (CCPPs) are expanding rapidly to meet the growing global demand for electricity. Because they are more efficient than traditional single-stage turbines and solid-fuel combustion plants, their growth is expected to continue, especially with rising demand from AI and data centers. ACID DEWPOINT MAKEUP Adjusting the exhaust stack temperature based on the acid dewpoint can boost plant efficiency. The acid dewpoint depends on the sulfur content of the natural gas... Read More

Real time product moisture percentage is a very valuable parameter to monitor for industrial dryer applications. If a plant is under drying a product, then the product will be out of specification and cannot be sold. On the other hand, if a product is over dried, the plant is wasting energy and losing valuable capacity on the dryer. Over drying by 1% on a 1000 kg/hr dryer results in a yearly average deficit of about 60,000 kg/yr. Depending on the price of the product and size of the dryer,... Read More

In today's carbon conscious environment, it is important to optimize dryer efficiency. The first step in improving dryer efficiency is to monitor in real time. In many cases, the efficiency can be improved by simply adjusting air flow to an ideal value. Other applications will need to look at modifications like feed improvements and better end-product moisture control. Real-time dryer efficiency measurement is also very useful in identifying upset conditions, indicating when maintenance is... Read More

There are two connectors in each crate. 1 power (4 pin female) 1 signal (7 pin male) For the power connector, pin 1 is closed, 2 is common, 3 is hot and there is a ground. For the signal connector, 1 is positive and 2 is negative. It sends out a 4..20 mA isolated signal. The probes should NOT be in the process without power on them. Power units up for 2 days to stabilize. Then you need to calibrate to ambient conditions. Take Cover off electronics - Leave open for 30... Read More

Detailed Drying Equation According to the “Industrial Dryer Handbook” the wet bulb temperature is a key parameter in dryer control improvement. The following equation represents the correlation to product moisture and drying parameters: X=K*LN((T1-Tw)/(T2-Tw)) where,X= Product MoistureK = is a dryer constant dependent upon product being dried and dryer designT1 = Inlet TemperatureT2 = Outlet TemperatureTw = Wet Bulb Temperature In general, industrial dryers have not come equipped... Read More

There are various industrial dryers utilized in production facilities. The dryers include spray dryers, flash dryers, rotary (both steam and direct fired), conveyor dryers and many others. Most of these dryers are typically controlled using the exhaust gas temperature as a set point and then control the inlet temperature or feed rate to keep the set point constant. Industry uses exhaust temperature sensors as surrogates to product moisture sensors or exhaust humidity sensors. The... Read More

Industrial dryers and ovens are major sources of energy consumption in various business segments. Pulp and paper, petrochemical, chemical, insulation, wallboard, pet food, corn wet milling, food, cement and lime are just some of these business segments. One of the most important variables in drying is to control exhaust humidity to a certain humidity content. If the humidity content is too high, evaporation rates can be affected and condensation on backend equipment can occur. If the... Read More

What Is a Dry Scrubber? In dry scrubbing, lime is injected directly into flue gas to remove SO2 and HCl.  There are two major dry processes: “dry injection” systems inject dry hydrated lime into the flue gas duct and “spray dryers” inject an atomized lime slurry into a separate vessel.  A spray dryer is typically shaped like a silo, with a cylindrical top and a cone bottom.  Hot flue gas flows into the top.  Lime slurry is sprayed through an atomizer (e.g.,... Read More

In today’s power production environment, thermal cycling is more common which stresses process equipment causing higher tube leak rates. The forced outage rate in 2019 for power plants was 6.97%.  Forced outages for combined cycle plants typically cost a plant $110,000 in fines, repairs and lost income.  Other causes of tube leaks include acidic / dew point corrosion from process gas and flow accelerated corrosion (FAC). We will review the diagnostic techniques to determine tube... Read More