A model to Simulate Chopped Alfalfa Drying in Fixed Deep-Bed

A.N. Dimitriadis , C.B. Akritidis

Dept of Hydraulics, Soil Science and Agricultural Engineering, Aristotle University of Thessaloniki, 54006 Thessaloniki, Greece
e-mail of corresponding author: akritid@agro.auth.gr

A model to simulate the drying process of alfalfa is presented aiming to produce design data for alfalfa dryers. The
drying profile of a fixed bed dryer has been simulated through a system of five partial and ordinary differential
equations, which describe the changes of the physical properties of the product, as well as the thermodynamic data
of the drying air. The equations were solved using the thin-layer drying theory. In order to check the accuracy of
the model, the drying rate curves were calculated at various depths of four deep bed batches and the results were
compared with experimental measurements, under the same conditions.
1. Introduction
The drying profile of alfalfa in a fixed deep bed dryer has been attempted in a previous work [Akritidis and
Dimitriadis, 1998] based on the thin layer drying theory [Brooker at al, 1964]. The results of this model were not
satisfactory, and thus, an improved model should be developed, which is presented in this paper. The main problem
that should be faced was the fact that the values of a number of physical parameters during drying of alfalfa are not
constant. Equations relating these parameters to drying variables, e.g. the moisture content, the temperature of the
drying air and the temperature of the dry matter, were developed to estimate their values with respect the time. The
non-constant physical parameters are; the drying constant, the equilibrium moisture content and the airflow rate,
which increases due to the shrinkage as a result of the moisture content decrease.
The objective of this work was to introduce experimentally determined values of the aforementioned parameters
into the equations, which describe the drying process of alfalfa hay. The values of the parameters were expressed as
functions of the moisture content, as well as of the drying air temperature.
A set of differential equations was used to describe the drying process of a fixed bed dryer of alfalfa hay under
the following assumptions.
1. The change of the volume of the bed during drying is negligible.
2. The change of temperature and absolute humidity with respect to time ( T / t , H / t ) are negligible
compared with their changes with respect to distance ( T / x and H / x ).
3. The bin walls are adiabatic, with negligible heat capacity.
4. The heat capacities of moist air and hay are constant during short time periods.
5. The process can be considered as one-dimensional problem.
Energy and mass balances of a differential volume (S dx) located at an arbitrary position in a fixed bed of hay
was written taking into consideration five unknowns in this model, namely; the average hay moisture content (M);
the air humidity ratio (H); the air temperature (T); the hay temperature (); and the drying air velocity (v).

2. Model of the drying process

The following equations were used to model the drying of alfalfa:
Conservation of the enthalpy of the drying air,

Kf
T
=
(T )
v ( c + Hcv )
x

(1)

Conservation of the enthalpy of the drying matter,

Kf
v h fg + c v ( T )

=
(T ) -
t
m ( cm + Mcw )
m
c m + Mc v

H
x

(2)

Humidity ratio of air,

m dM
H
=x
v dt

(3)

dM
= k( M M e )
dt

(4)

Drying rate,

Solving equation (4) with respect to M, equation (5) is derived:

M = Me + (Mo-Me) e-kt

(5)

The velocity of the drying air

vai =

dxi
dt

(6)

3. Determination of the variable parameters

3.1 Airflow rate
The airflow rate, and consequently the air velocity, is not constant during drying due to the shrinkage effect. As
the void increases the static pressure drop decreases and simultaneously the airflow rate increases. The amount
Q=q/S represents the specific airflow rate, where q is the airflow and S is the cross section of the dry matter. The
mean velocity of the drying air, passing through the voids of the drying volume, is:

v ai =

Q
p

(7)

where; p is the porosity of the dry matter

+ M m
p = 1 m w
w m

(8)

The specific airflow rate Q, depends on the characteristics of the blower and the static pressure drop between
two points of the hay bed [Shedd, 1953]:

Q = P b

(9)

Tests were run by Day [1964] in order to determine the effect of moisture content on the resistance to airflow.
Curves of the pressure drop vs specific airflow rate are shown in figure 1, for various values of moisture content.
Since the initial value of the airflow rate and the moisture content are known the pressure drop at the start of the
drying process can be determined. As the moisture content decreases the pressure drop decreases and consequently
the airflow rate increases. Considering a linear correlation between the increase of the airflow rate and the decrease
of the moisture content the procedure can be described by a straight line, which starts from the initial point
coordinators and crosses perpendicularly the straight line of the next smaller value of the moisture content.
Considering the cross point as a new initial point and repeating the procedure the function of airflow rate, and thus
the air velocity, with respect the moisture content is obtained.
Static pressure [mm H2O /m]

100

66,50%
65%
60%

10

52%
33%
10%

1
1

10

100
3

Air flow rate [m /min - m ]

Fig 1. Pressure drop vs. airflow rate for chopped alfalfa hay at various moisture contents.

3.2 Equilibrium moisture content

The drying curve of the alfalfa hay can be divided into three drying periods, e.g. constant-rate, first falling-rate
and second falling-rate drying period. The critical moisture content of the first falling-rate has been determined by
Henderson & Henderson, [1968] as Mc1 = 0.36 (d.b.), while the second falling-rate drying period has been
determined by Dexter et al. [1947] as Mc2 = 0,2 (d.b.).
The equilibrium moisture content was derived from the empirical equation [Callaghan et al., 1971]:
Me = c1

H
+ c2
T2

(10)

The values of the constants c1 and c2 were calculated using experimental data figured by various researchers [Hall,
1980, Akritidis, 1977]. A number of values of the equilibrium moisture content of the hay (Me), which were
obtained by the results of the various experiments, were introduced into the equation (10), then the matrix was
solved with respect to c1 and c2 using the mean square method. The values of the constant c1 and c2 found to be:
c1= 82.7 , c2 = 0.34 for

M>Mc1

and

c1= 350 , c2 = 0.017 for

M<Mc1.

3.3 Drying constant

The drying constant k can be calculated from equations (11) and (12) [Callaghan et al. 1971]:
k = 4.97 10-5 e(0.07214To)
-6

k = 9.26 10 e

(0.07675 To)

for M>Mc

(11)

for M<Mc

(12)

The kinetics of the water into the material depends on the temperature of the material, the moisture content and
the relative humidity of the drying air, M=f(aw, ), [Azzouz et al., 1998, Pakowski, 1999]. As the moisture content
of the hay falls below the critical point, the pressure depression decreases, and consequently, the water activity
(aw=P/Ps) decreases. So, we introduced a factor , which is defined as:
T Ts
P Ps
=
=
To Ts
Po Ps

(13)

This factor expresses the driving potential of the drying process, as the air moves through the drying bed of the hay,
and it is related to the drying constant.
During the second falling-rate period the moisture content gradient within the drying product increases
significantly and the product temperature rises above the wet-bulb temperature. Since aw=f(T,M) and M=f(T,H), a
second order temperature depended coefficient must be introduced in the drying constant. Considering a reverse
relation between the temperature and the moisture content the factor that enters the drying constant k is:

= (1 a w ) 2

(14)

Introducing the values of equations (13) and (14) into the equations (11) and (12) we obtain:
k = 4,97 10-4 e 0,07214 To

> 0.36

(15)

-6

0,07674 To

for 0.2 < < 0.36

(16)

-6

0,07674 To

for 0.2 <

(17)

k = 9,26 10 e
k = 9,26 10 e

for

Considering the assumptions 2 and 5 and the equation (5), equation (1) becomes:
Kf
dT
=
(T )
dt
( c + Hcv )

(18)

The value of the convective mass transfer coefficient into the hay is (Spencer H.B., 1969):

v ( T + 273 )
hc=0.1997

Pt

0 ,6011

From equations (2), (3) and (6) we obtain:

h fg k ( M M e )
d hc p cv k ( M M e )
=
(T ) dt
p ( c p + Mcw )
c p + Mcv
The equations (18) and (19) consist a deferential system with two equations and two variables (T,).
dT
d
= f 2(t ,T , )

= f 1(t ,T , )
dt
dt

(19)

(20)

(21)

A numerical solution can be accomplish with the method Runge Kutta of forth order (Conte and De Boor,
1972).
4. Results and discussion

Experimental data were used to test the accuracy of the model. The values of the moisture content measured by
Clark and Lamond [1964] in a batch dryer were compared to the values calculated by the model under the same
conditions. The experiments took place under deferent conditions of drying (initial temperature, initial depth of the
batch, initial moisture content of the hay, specific airflow rate).
As it has been pointed out, the specific airflow is not constant during the drying. The value of the specific
airflow rate as a function of the initial moisture content of the hay for a period of time dt, can de calculated from
Figure 1. The specific airflow rate for the first batch is presented in figure 2, as an example. Although the moisture
content at three deferent depths of each batch (the inlet, the middle and the upper layer) were displayed by Clark
and Lamond [1964] only the experimental values of the layers at the inlet and the middle were used, because the
values of the upper layer show a great dispersion and discontinuity and they could not be used for this
investigation.
Air flow rate (m/min)

18
y = -0,0284x + 16,936

17
16
15
14
13
12
0

20

40

60

80

100

Moister content % (d.b.)

Fig. 2 Airflow rate as a function of the moisture content of alfalfa

The adaptability of the model to the experimental measurements of the rate of moisture content of the layer at
Moister content (d.b.)

the inlet, for four batches, is presented in Figures 3, 4, 5 and 6.

0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0

Experimental

10

12

14

16

18

20

22

24

Model

26

28

30

Drying time (hours)

Fig 3. Rate of moisture content, of the layer at the inlet (first batch).

Moister content
(d.b.)

0,9
0,8

Experimental

0,7

Model

0,6
0,5
0,4
0,3
0,2
0,1
0
0

10

12

14

16

18

20

22

24

Drying time (hours)

Fig 4. Moisture content rate, of the layer at the inlet (second batch).

26

28

32

Moister content
(d.b.)

0,8

Experimental

0,7

Model

0,6
0,5
0,4
0,3
0,2
0,1
0
0

10

12

14

16

18

20

Drying time (hours)

Fig 5. Moisture content rate, of the layer at the inlet (third batch).

Moister content
(d.b.)

0,8
0,7

Experimental

0,6

Model

0,5
0,4
0,3
0,2
0,1
0
0

10

12

14

16

18

Drying time (hours)

Fig 6. Moister content rate, of the layer at the inlet (fourth batch).

The adaptability of the model to the experimental measurements of the rate of moisture content of the layer at
half depth, for four batches, is presented in Fingers 7, 8, 9 and 10.

0.9

Moister content
(d.b.)

0.8

Experiment

0.7

Model

0.6
0.5
0.4
0.3
0.2
0.1
0
0

10

15

20

25

30

Drying time (hours)

Drying time (d.b.)

Fig. 7. Moisture content rate of the layer at half depth. (first batch)

0.9
0.8

Eperimental

0.7

Model

0.6
0.5
0.4
0.3
0.2
0.1
0
0

10

12

14

16

18

20

22

Drying time (hours)

Fig. 8. Moisture content rate of the layer at half depth. (second batch)

24

26

28

Moistercontent
(d.b.)

0.8
0.7

Experiment

0.6

Model

0.5
0.4
0.3
0.2
0.1
0
0

10

12

14

16

18

20

Drying time (hours)

Fig. 9. Moisture content rate of the layer at half depth. (third batch)

Moister content
(d.b.)

0.8
0.7
0.6

Experimet

0.5

Model

0.4
0.3
0.2
0.1
0
0

10

12

14

16

18

20

Drying time (hours)

Fig. 10 Moisture content rate of the layer at half depth. (fourth batch)

Figures 3 to 6 show a real good coincidence between the values of the model and the values of the experiments
for the layer at inlet in all of the batches. Concerning the half depth layer of the batches, figures 7 to 10 show a
good correlation between the values of the model and the values of the experiments for moisture content greater
than 20 % w.b. (0.167 d.b.), which is save for alfalfa storage. For lower values of moisture content, a small
discrepancy of the two values exists. This discrepancy may be attributed to the fact that the experimental conditions
in the batch were not exactly described.
5. Conclusions

1. A mathematical model to describe the alfalfa drying process in a fixed deep-bed batch has been developed,
which adequately predict the drying rate. Applying this model to subsequent layers of the drying bed, the profile
of hay drying can be obtained.
2. The model shows a real good accuracy of moisture content prediction.
3. Introducing the local ambient conditions into the equations the design parameters of a batch dryer can be drawn.
References

Akritidis C.B., 1977. Mathematical analysis and solve of the deep-bed hay drying. PhD Thesis, ThessalonikiGreece

Akritidis C.B., Dimitriadis A.N. 1998. Mathematical simulation of alfalfa drying in deep-bed. Drying 98
Proceedings of the 11th International Drying Symposium (IDS98). Halkidiki, Greece. Vol. A, pp. 87-89
Azzouz S., Jomaa W., Belghith A. 1998. Drying kinetic equation of single layer of grapes. Proceedings of the 11th
International Drying Symposium (IDS98). Halkidiki, Greece. Vol. B, pp. 988-997.
Brooker D.B., Bakker-Arkema F.W., Hall C.W. 1992. Drying and storage of grains and oilseeds. AVI Publishing
Co. pp 205-240.
Clark R.G., Lamond W.J. 1968. Forced air drying of herbage: effect of drying air conditions, J. Agric. Engng. Res.
13 (1) 19-26.
Conte S.B., De Boor C. 1972. Elementary numerical analysis: An Algorithmic approach, McGram Hill Book
Company (second edition)
Day C.L. 1964. Resistance of Hay to Air Flow. Research Bulletin 864. University of Missouri Columbia, U.S.A.
Dexter S.T., Sheldom W.H., Waldran D.I. 1947, Equilibrium moisture content of alfalfa hay. Agric. Engng. (28)
295-296.
Hall C.W. 1980. Drying and Storage of Agricultural Crops. AVI Publ. Co.
Henderson J.M., Henderson S.M. 1968. A computation procedure for deep-bed drying analysis. J. Agric. Engng.
Res. 13:87-95.
OCallaghan J.R.., Menzies D.J. and Bailey P.H., 1971. Digital simulation of agricultural dryer performance, J.
gric. Engng Res. 16: 223-244
Pakowski Z. 1999. Impressions of IDS98. Drying Technology, 17(6), 1247-1253.
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Notation

aw

water activity into the material,

specific heat of the air,

J/ kg K

cm

specific heat of the hay,

J/kg K

cv

specific heat of the water vapor

J/kg K

cw

specific heat of the water,

J/kg K

porosity,

m3/m3

absolute humidity of air,

kg/kg

Kf

convective heat transfer coefficient

W/m2 K

hfg

heat of evaporation,

J/kg

hfm

total energy of water vapor,

J/kg

drying constant,

moisture content of the hay, dry bases,

Mc1

first critical moister content

Mc2

second critical moister content

Me

equilibrium moisture content,

kg/kg

kg/kg

initial moisture content of the hay, dry bases,

kg/kg

vapor pressure,

kg/m s2

Pat

atmospheric pressure,

kg/m s2

Po

the ambient air pressure,

kg/m s2

Ps

saturated vapor pressure

kg/m s2

PW

pressure of water vapor at saturation at wet-bulb temperature,

kg/m s2

specific flow rate,

m3/min m2

control surface,

m2

time,

air temperature,

T0

initial air temperature,

Tw

dew point temperature,

Ts

temperature of the saturated air,

air velocity,

m3/min m2

vai

mean air velocity,

m3/min m2

air density,

kg/m3

product density,

kg/m3

water density,

kg/m3

volume,

m3

driving potential of the drying process,

factor of the drying activity

product temperature,

C
C
C
C