A multiscale
dynamic mass and energy process model was developed
for an industrial rotary dryer with both unflighted and flighted sections.
This paper focuses on the development and integration of energy balances
into a validated solid transport model published by the authors in
an earlier paper. In order to facilitate the drying process, a gas
phase model is introduced. The gas phase in both the unflighted and
flighted sections was modeled as a plug flow system. Simulations and
parameter estimation were undertaken using gPROMS (process modeling
software). Parameter estimation and model validation were carried
out using the experimental moisture content profile, residence time
distribution data, and gas and solid internal temperature profiles.
The developed model was utilized to gain better understanding of the
interactions between solids transport, operational parameters, and
internal solids distribution on heat and mass transfer that occur
in flighted rotary dryers. The model provides a means to quantify
and solve dryer operational challenges in a real industry example.