Development and Testing of Small-Scale Flash Dryer for Maize Bran

Abstract

Sun drying is the most common technique used to dry various food products due to its economic convenience. However, it is not effective owing to its unreliable nature leading to microbial deterioration and aflatoxin contamination of food. In Tanzania, about 1.3 million tonnes of maize bran are at risk of deterioration annually due to improper drying. The aim of this study was to design, fabricate and test an efficient small-scale flash dryer for maize bran. Using principles of material and energy balance, a small-scale flash dryer with a throughput of 500 kg of dry product per hour was designed resulting in a nominal diameter of 387 mm and a drying length of 20 m. Design calculations and drawings were done using MS Excel 2021 and SolidWorks 2018 respectively. Empirical procedures were used to fabricate and test the dryer. The material of construction used in the flash duct was food grade (stainless steel, SS 201). A fuel blend of Waste Engine Oil (WEO) and diesel (85%-15%) was used with a novel heavy oil burner. It was observed that at an inlet air temperature of 150 °C and air velocity of 12 m/s, moist maize bran was dried from 37% to 10% w.b. The fabricated flash dryer's energy efficiency, specific energy consumption, and specific energy utilization are 74%, 3.4 MJ/kg water evaporated, and 1.71 MJ/kg dry maize bran respectively. It was concluded that the fabricated small-scale flash dryer displayed improved energy performance compared to others presented in literature. Better instrumentation was recommended for feedback control on burner operation and process monitoring which further enhances the performance of the fabricated small-scale flash dryer.