Industrial Drying Systems: Guidelines for Agriculture, Food, and Wood Products

Preface
Contents
Chapter 1: Primary Drying Factors
1.1 Required Energy
1.2 Drying Rates
Chapter 2: Step-by-Step How to Design an Energy-Efficient Drying System
2.1 Initial Project Studies
2.2 Conceptual Drying System Design Studies
2.2.1 Phase One
2.2.2 Phase Two Modeling
2.3 Construction
2.3.1 Purchasing Contracts
2.3.2 Construction and Contract Compliance
2.3.3 Startup, Acceptance Testing, and Recordkeeping
Chapter 3: Costs of Energy and Drying Equipment
3.1 Current Factors
3.2 Future Issues
Chapter 4: Safety, Health, and Fire Protection
4.1 Mission Statement by the CEO
4.2 Availability of Published Safety Codes
4.3 Health and Safety Program Resources in the United States
4.4 Fire and Explosion Protection
4.4.1 NFPA Resources
4.4.2 Fire-Rated Protection Barriers for Industrial Dryers
Chapter 5: Environmental Impact of Industrial Drying Systems
5.1 Introduction
5.2 Environmental Protection
5.2.1 Air Emissions – Sources of Significant Discharges
5.2.2 Liquids – Sources for Significant Discharges
5.2.3 Solids – Sources for Significant Discharges
Chapter 6: Economic Issues in Industrial Drying Systems
6.1 Introduction
6.2 Drying System Scope for Wood Products
6.3 Economic Scope
Chapter 7: Legal Issues in Industrial Drying Systems
7.1 Disclaimer
7.2 Retain an Attorney
7.3 Contracts, Assignments, and Warranties
7.4 Qualification/Assignment/Ethical Issues for Consultants and Engineers
7.5 Qualifications of the Designer
7.6 Qualifications of the Equipment Manufacturer
7.7 Qualifications of the Installer
7.8 Qualifications of Machine Operators
7.9 Commissioning Equipment
7.10 Third-Party Issues
7.11 Keeping Secure Complete Records on Equipment Involves the Following
7.12 Preventive Maintenance and Inspection Programs
7.13 Concepts in Moral and Legal Negligence
Chapter 8: Industrial Drying System Design, Operation, and Maintenance
8.1 Introduction
8.2 Legal Duty of the Engineer and the Owner
Chapter 9: Drying System Definition Review
9.1 Introduction
Chapter 10: Green-End Systems
10.1 Introduction
10.2 An Example of Green-End Systems (Wood)
Chapter 11: Solid-Wood Industrial Drying Systems
11.1 Global Drying Industry Standards: Why We All Need Them
11.1.1 Health and Safety Issues
11.1.2 Protection of the Environment and Our Natural Resources
11.1.3 Advancing the Wood-Drying Process Through Industry Standards
11.1.4 Junk Science: What Is It?
11.1.5 The Need for Global Dryer Standards
11.2 Modeling the Drying Process
11.2.1 Basic Research Models
11.2.2 System Application Models
11.2.3 Equipment Design Models
11.2.4 Examples of Drying and Equipment Models
11.2.4.1 Finite-Element Model of 1″ Northern White Oak
11.2.4.2 Finite-Element Package Model for Air/Heat Delivery in Lumber Kilns
11.2.4.3 1975 Regression Model of a Steam Heating System in a Lumber Kiln
11.3 Drying Challenges, Dryer Types, Classes, and Terms in Drying
11.3.1 Objectives in Wood Drying
11.3.2 Common Methods Used in Wood Drying
11.3.3 Major Obstacles in Wood Drying
11.3.4 Most Common Mistakes Made in Wood Drying
11.3.5 Future Challenges in Wood Drying
11.3.6 Current Dryer Technologies
11.3.7 Industry Code Assignments for Wood Dryers
11.3.8 Predominant Types of Convection Wood Dryer Systems
11.3.9 Classes, Types, Configurations, and Applications of Wood Drying Systems
11.4 Industrial Dryer Product Loaders
11.5 Moisture, Energy, and Drying Uniformity Terms in Wood Drying
11.6 Air Delivery Efficiency (ADE)
11.7 Moisture Movement in Wood Drying
11.7.1 Moisture Movement in Lumber Pre-dryers, Kilns, and E&C Chambers
11.8 Measuring Air Velocity in Convection Lumber Dryers
11.9 Wave Theory in Lumber Drying
11.10 Drying Curves in Wide-Package Lumber Dryers
11.11 Minimum CFM for Wide-Package Lumber Drying
11.12 Model 74 Fan Speed Control Curves
11.13 Moisture Content Control with Stress Control
11.14 Moisture Movement in Lumber Storage Facilities
11.15 Pre-drying Conditions and Equipment Needed for Successful Lumber Drying
11.16 Loading the Dryer
11.16.1 Loading a Pre-dryer
11.16.2 Loading a Lumber Kiln
11.17 Restraint Drying
11.18 Lumber Dryer Buildings
11.18.1 Introduction
11.18.2 Safety and Code Requirements
11.18.3 Dimensional Requirements of Dryer Buildings
11.18.3.1 Holding Capacity
11.18.3.2 Pre-dryers
11.18.3.3 Track Kilns
11.18.3.4 Side-Loader (Package) Kilns
11.18.4 Equalization, Conditioning, and Steaming Chambers
11.18.4.1 Introduction to E&C Chambers
11.18.4.2 Application of E&C Chambers
11.19 Dry Storage Facilities
11.20 Calculations for Holding Capacities of All Types of Lumber Dryers
11.21 Classes of Large Wood Dryer Building and Enclosure Designs
11.22 Life Expectancy of Dryer Buildings
11.23 Temperature Rating of Dryer Buildings
11.24 Insulation Requirements of Dryer Buildings
11.25 Condensation Inside Walls, Roofs, and on Floors
11.26 Dryer Roof Design
11.27 Dryer Door Design
11.28 Catastrophic Dryer Implosion Prevention
11.29 Replacement of Steam Coils, Fan Motors, and Fans
11.30 Dryer Foundation Design, Construction, and Site Management
11.31 Underground High-Temperature Concrete Ducts – 450 degrees F Max
11.32 Foundations for Fuel Silos (Hog Fuel, Shavings, etc.)
11.33 Flat Slabs for Lift-Truck Traffic
11.34 Quality Control in Foundation Construction
11.35 After Construction Is Completed
11.36 Air Circulation Fan System Dynamics in Convection Lumber Dryers
11.37 Air Heat Dynamics in Convection Lumber Drying
11.38 Dryer Uniformity Factor (DUF)
11.39 Sticker Thickness Versus Air Velocity Testing Methods for Convection Dryers
11.40 Optimum Sticker Thickness for Maximum Drying Production Rate
11.41 Optimum Economic Sticker Thickness
11.42 Location of Fan Systems for Convection Lumber Dryers
11.43 Fan Safety Rules
11.44 Designing the Fan System for the Dryer
11.45 Designing Dryer Fan Systems for Maximum Electrical Energy Efficiency
11.46 Choosing the Best Drive for the Dryer Fans
11.47 Bearing Selection
11.48 Fan Housings
11.49 Fan Orifice Designs
11.50 Fan Tip Clearance
11.51 Drive Attachment Pedestals and Struts
11.52 Fan Walls
11.53 Fan Decks: Air Baffling and Structural Requirements
11.54 Propeller Fan Balancing, Installation, and Inspection
11.55 Baffles in Convection Wood Dryers
11.56 Heating Systems for Wood Dryers
11.57 Temperature Control Zones
11.58 Energy Studies for Commercial Drying Operations
11.59 Heating System Design and Operation
11.60 Dehumidification (Heat-Pump) Systems for Drying Wood
11.61 High Frequency Heating Systems
11.62 Direct-Heated (Direct-Fired) Kiln Designs
11.63 Humidity Control Systems for Wood Dryers
Chapter 12: Veneer and Paper Dryers
12.1 Veneer Operations
12.2 Paper Dryers
Chapter 13: Particle Dryers
13.1 Particle Drying Operations
13.2 Press Dryers
13.3 Rotary Dryers
13.4 Flashtube Dryers
13.5 Belt Bed Dryers
13.6 Pellet Dryers
13.7 Fluidized Bed Dryers
13.8 Suspension Burner/Dryers
13.9 HF/Radio/Microwave Dryers
13.9.1 The HF/Radio Dryer Technology
13.9.2 The Microwave Dryer Technology
13.9.3 The Infrared Dryer (IR) Technology
13.10 Superheated-Steam Drying
Chapter 14: Dry-End Systems
14.1 Introduction
14.2 Example for Wood Dry-End Systems
14.3 Final Grading Systems
Chapter 15: Agricultural/Food Dryers
15.1 Introduction
15.2 Classes of Dryers
15.3 Types of Dryer Energy Systems
15.4 Types of Product Material-Handling Systems
15.5 Dryer Configurations
15.6 Target Moisture Contents
15.7 The Terms: Dryers, Dry Kiln, Kilns, Ovens, and Stoves
15.8 Dryer System Design Codes
15.9 List of Organizations and Journals Applicable to the Agricultural/Food Industry
Chapter 16: Process Controls and Automation
16.1 Disclaimer
16.2 The ISA Organization
16.3 Agricultural, Food, and Wood Dryers, Furnaces, and Boilers
16.3.1 Example of Process Control Notes for Lumber Dryers
16.3.2 Process Control Notes for Furnaces and Burners
Chapter 17: Management of Industrial Drying Systems
17.1 Rules for the Workplace
17.2 Management Models
17.3 Reactive Impulses
17.4 Reward Conditioning
17.5 Loss Prevention
17.6 Myths and Causes of Accidents
17.7 Drying Disasters – What to Do About Them
17.8 Quality Control
Chapter 18: Managing and Investigating an Injury or Property Loss
18.1 First Thing to Do
18.2 Second Thing to Do
18.3 Third Thing to Do
18.4 Fourth Thing to Do
18.5 Fifth Thing to Do
18.6 Fire and Explosion Investigations and Scene Management
18.7 Product-Defect Loss Investigations
18.8 Qualifications of Investigators
18.9 Preservation of Loss Scene Evidence
18.10 Cooperation During Investigations and Claims Adjustments
Chapter 19: Furnaces and Steam Generators for Industrial Dryers
19.1 Dryer Heat Demand Rates
19.2 One Dryer Versus Multiple Dryers in a Drying System
19.2.1 If Only One Dryer Is Being Used
19.2.2 If Numerous Dryers Are Being Used
19.3 Furnaces
19.4 Steam Generators (Saturated Steam)
19.4.1 Safety-Code Compliance
19.4.2 Annual Inspections
19.4.3 The Two Classes of Steam Generators
19.4.4 Typical Saturated Steam Generator Operating Pressures and Temperatures Are
19.4.5 Steaming Capacity
19.4.6 Avoiding Superheat
19.4.7 Boiler Makeup Water Treatment
Chapter 20: Wood Drying with On-Site Cogeneration Systems
Chapter 21: Material Handling Systems and Terms
21.1 Introduction
21.2 Material-Handling Types, Classes, and Terms
21.2.1 Classes of Material-Handling Systems
21.2.2 Classes of Materials Handled
21.2.3 Common Types of Wood, Agriculture, and Food Material Handling Systems
21.2.4 Safety Systems in Material Handling
21.2.5 Third-Party Inspections and Documentations
Chapter 22: Needed R&D Projects in Industrial Drying Systems
Chapter 23: Preventing Frauds in Industrial Drying Systems
Chapter 24: Industrial Drying Industry Terms, Processes, and Topics
Appendixes
Appendix A – Industry Codes, and Standards
Codes, Standards, Guidelines, Practices, and Ethics
Professional Responsibility Models for Professional Engineers
Professional Responsibility Tests for Professional Engineers
Associations, Societies, and Institutes
Legal Requirements for Equipment Codes and Standards
Global Organizations – Partial List Includes Organizations with Multinational Memberships
National and Regional Organizations – Partial List
Organizations Connected to the Ag/Food Industry
Recommended NFPA Safety Standards and Codes for Drying Systems, Partial List
Appendix B – OEM Directory
A. Drying System Equipment, Parts, and Service
B. Moisture Sensors, Instruments, & Control Systems
C. Steam Boilers, Hot Liquid Systems and Furnaces
D. Process Controls and Instrumentation
Appendix C – Recommended Reading and Information Resources
Systems of Measurements – Different Countries Use Different Measurements of Unit
Internet Resources for Industrial Drying Technologies
Universities, Schools, Institutes, Science, Engineering, and Industrial Organizations
Industrial Search Engines
Videos of Wood, Agricultural, and Food Industrial Dryers in Operation
ASME Publications – Go to www.asme.org/catalog
ASABE Publications – Go to www.asabe.org
Health Effects of Wood Drying and Burning
Pollution Control Technology
Fire Protection
Licensed Engineers www.ncees.org/licensure/licensing_boards
Lumber Drying, Lumber Dryers, and Wood Technology
Drying Books Involving Advanced and/or Modern Drying Research
Drying Books Available from Springer Series in Wood Science
Drying Books Available from Taylor and Francis Publishing
American Wood Products Associations and Organizations, Partial List
Food Science and Technology
Food Manufacturing Trends at the Global Scale with Significant Health, Safety, and Social Risks
Combustion Technology, Environmental, and Safety Codes and Standards
Process Controls and Automation
Insurance Resources
Business Ethics, Moral Attitudes, Psychopathy, and Social Responsibility
Scientific Frauds, Misinformation, and Disinformation
Appendix D – Needed R&D Projects in Industrial Drying
Background and Discussion
Introduction
2019–2020 US Survey
Kiln Types and Survey Findings
Hardwood Mills
Intrinsic Low Energy Efficiencies in Hardwood Lumber Drying
Softwood Mills
Batch-Type Lumber Kilns
Progressive Lumber Kilns, Jogging-Batch Lumber Kilns, and (True) Continuous Lumber Kilns
Sidewinder Lumber Kilns
Types of Industrial Lumber Drying Systems
Global Energy Consumption and Challenges in all Methods of Drying Lumber
Required Heat Energy for Drying Lumber
Benefits of Having a Simple Term for Lumber Drying System Efficiency Studies
Significant Issues in Existing Industrial Lumber Drying Systems
Biography of the Author
Executive Biography
Index