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C. M. Kinoshita
F or decades, hot flue gas was viewed as a readily sugar industry and discusses the experiences of factories
available source of thermal energy to dry bagasse, that practice bagasse drying.
the fibrous byproduct of milled sugarcane, to make it
more suitable for various possible commercial uses.
However, it was not until 1975 that the worldwide sugar
BAGASSE DRYING VERSUS OTHER
community, spurred by the need to conserve energy, METHODS OF HEAT RECOVERY
installed its first commercial dryer system using flue gas Bagasse boiler efficiency varies widely throughout the
from bagasse boilers to dry bagasse prior to combustion Hawaiian sugar industry, from 55% to nearly 70%
(Furines, 1976). Since then, the number of reported
commercial bagasse dryer systems installed throughout the
TABLE 1. Type of dryer, dryer operating pressure, percentage of
world has grown to at least ten (Arrascaeta and Friedman, gas and bagasse bypassing the dryer, and change in excess air across
1987) (several installations not reported in the literature the dryer/cyclone system at four Hawaiian sugar factories
have also been seen by this author); of these, four were
Dryer Type/ Gas Bagasse Change in
installed in Hawaii. Operating Bypass Bypass Excess Air
In the mid 1970s, when the Hawaiian sugar industry Factory Pressure (%) (%) (%age Points)
first seriously contemplated using flue gas to dry bagasse, Hamakua rotary/
there were no commercial systems operating in the world, Sugar Co. vacuum 25 40 50
although two bagasse drying systems were in the planning
HCPC rotary/
vacuum 40 0 30
Article was submitted for publication in April 1991; reviewed and HC&S Co.- flash/
approved for publication by the Food and Process Engineering Inst, of Paua Factory atmospheric 40 65 0
ASAE in August 1991.
The author is Charles M. Kinoshita, Hawaii Natural Energy Inst., Waialua rotary/
University of Hawaii at Manoa, Honolulu. Sugar Co. vacuum 10 15 30
VOL. 7(6): NOVEMBER 1991 © 1991 American Society of Agricultural Engineers 0883-8542 / 91 / 0706-0729 729
(Kinoshita, 1990), as does the type of heat recovery systems without dryers but with other heat recovery
equipment used - air preheaters, economizers, and flue gas devices.*
bagasse dryers. Considering heat recovery as part of the EPA Method-5 tests (USEPA, 1977) conducted on the
steam generation system, for a given set of conditions - four bagasse drying systems in the industry indicate an
fuel moisture content, flue gas temperature, and excess air average gas temperature at the exit of the dryer cyclone of
entering the heat recovery device - the effectiveness of 90° C (200° F), with three of the four systems averaging
heat recovery can be gauged completely by 1) the flue gas 75° C (170° F); however, all systems allow a portion of the
temperature exiting the heat recovery device, 2) the excess hot flue gas to pass around the dryer. This brings the
air in the flue gas exiting the device, 3) the combustion effective flue gas temperature - the weighted mean of the
losses (unburned fuel as char and incomplete products of cold gas exiting the dryer cyclone and the hot gas
combustion, such as carbon monoxide) which result from bypassing the dryer - to 100-150° C (210-300° F),
the use of the device, and 4) the heat loss from the device. averaging 115° C (240° F) for the four Hawaiian systems
These factors are discussed individually below. (the average effective flue gas temperature for the three
rotary dryer systems is 105° C (220° F). By comparison,
FLUE GAS TEMPERATURE the three boiler systems equipped with both economizers
Flue gas temperatures (after the last heat recovery and air heaters, but without dryers, have an average stack
device) vary widely throughout the Hawaiian sugar temperature of about 155° C (310° F).
industry - from below 100° C to over 300° C (200° F to The moisture content of the dried bagasse depends
600° F) (fig. 1). Based on simple energy balances, it can primarily on the moisture content of the undried bagasse,
be shown (Kinoshita, 1988) that boiler efficiency increases the excess air in the flue gas, and the flue gas temperature
linearly as stack temperature decreases, by roughly one drop across the dryer. The calculated moisture content of
percentage point for each 15° C (27° F) drop in dried bagasse, as a function of flue gas temperature drop
temperature under typical industry conditions (bagasse across the dryer for various undried bagasse moisture
moisture content -45-50% and excess air ~50-100%). content and excess air, assuming that all of the bagasse
When bagasse is dried with flue gas, both heat and mass burned is dried by all of the flue gas in an adiabatic dryer
transfer takes place, as opposed to heat transfer alone with system with no entrained tramp air, is shown in figure 2.
air heaters and economizers. The temperature of the cold (Here, the relative rates of bagasse and flue gas, which
stream (i.e., the moist bagasse) remains nearly constant and affect drying, are implicitly in the excess air.) Although
relatively low throughout the heat recovery device (at or data for only a single dryer inlet temperature, 260° C
below the wet bulb temperature, unlike economizers and (500° F), are presented in figure 2, the data are valid (to
air heaters, for which the temperature of the cold stream within about three percentage points) for dryer inlet
continuously increases). Hence, thermal energy in the flue temperatures between 150° and 400° C (300° and 750° F),
gas can be recovered more readily with waste heat bagasse since the temperature drop across the dryer system
dryers than with other conventional heat recovery devices. influences the amount of drying that occurs more than the
This is illustrated quite dramatically in figure 1, which
shows that flue gas temperatures in boiler systems with
bagasse dryers are much lower, on average, than in boiler * For boiler systems with bagasse dryers, the flue gas temperature
data presented in figure 1 are weighted averages of the gas temperature at
the dryer exit and the temperature of the gas bypassing the dryer.
6 0 - 460)
•yer
50- >^L
IExcess A r (%)
40- ^ 0 ) ^
""""^ 0
Bagasse Mo sture
30-
\ „ 50
20-
Wai Hai HCP Pio Lih Pai Oah Kek Puu Kau McB Olo
Factory 10- Xs °
\100
100 50 100 0 50
Notes . 0- r I
Characters above bars signify installation of following heat recovery devices
D: Bagasse dryer 0 100 200 300
E: Economizer
A: Air heater Temperature Drop Across Dryer (°C)
N: No heat recovery device installed
Similar shading denotes comparable heat recovery devices
Figure 2-Bagasse moisture content at dryer exit vs. temperature drop
Figure 1-Flue gas heat recovery devices installed and gas across dryer for various dryer inlet moisture content (numbers in
temperature after heat recovery in Hawaiian bagasse boiler systems. parentheses), and excess air; gas temperature at dryer inlet is
(Note: For systems with bagasse dryers, flue gas temperature is assumed to be 260° C (500° F). Arrows denote dew point temperature
weighted average of temperature of gas at dryer cyclone exit and gas (beyond which the curves are extrapolated in the vapor phase) for the
bypassing dryer.) particular conditions assumed.
Hamakua Sugar -30 -18 Main dryer stack versus dryer-bypass stack
Co.(1981)
points would be required just to recover such a parasitic from the entrapment of gas particulates in the dryer drum
load. In terms of recovery of flue gas energy, this is and in the cyclone with the dryer in operation.
equivalent to a reduction in gas temperature of ~30° C Bagasse boiler emissions tests have been performed on
(~50° F). Given that factories with bagasse dryers have nearly every Hawaiian bagasse boiler, but usually for
effective stack temperatures of about 100° C (-200° F) or regulatory purposes only. Therefore, except for the
higher, it does not seem practical from a net energy aforementioned Waialua Sugar Company test, the effect of
standpoint to adopt bagasse drying unless the temperature flue gas bagasse drying on boiler emissions was not studied
of the flue gas to be used for drying is, say, 200° C explicitly. Nevertheless, in most emission tests involving
(400° F) or higher. boiler systems with bagasse dryers, particulate emissions
Some studies on bagasse drying (e.g., Keenliside, 1983) and gas composition and flow rate were measured from the
have suggested that drying of bagasse with flue gas dryer stack and from the dryer-bypass stack. (In these
provides very little net exportable energy, i.e., the systems, separate stacks were installed to emit the gas
incremental electrical power that results with bagasse which passed through the dryer and which bypassed the
drying barely covers just the parasitic power requirement dryer.) Those data permit calculation of the particulate
of the dryer system. By contrast, information compiled in emissions rate per unit of carbon in the gas stream from the
this study suggests that bagasse dryer systems in Hawaii dryer stack and from the dryer-bypass stack. In tests on
are, in general, sound from a net energy standpoint. For boiler systems with bagasse dryers performed by the HSPA
example, the three rotary dryer systems have a power during 1981-1985, the rate of particulate emissions per unit
generation:power consumption ratio of 2.7 to 3.7, of carbon in the gas stream from the dryer stack varied
averaging 3.1; only the flash dryer system has a ratio below widely from 75% below to 22% above the rate from the
1.5. dryer-bypass stack (Table 2). Nevertheless, the particulate
emissions rate was generally much lower for the gas stream
which passed through the bagasse dryer than the stream
CONTROL OF STACK EMISSIONS which bypassed the dryer, reinforcing the conclusion of the
Numerous EPA Method-5 type tests performed by the Waialua Sugar Company test that drying bagasse with flue
Experiment Station of the Hawaiian Sugar Planters' gas can reduce boiler stack emissions.
Association (HSPA) on sugar factory stack emissions have From the standpoint of emissions control, the most
indicated that drying bagasse with flue gas can have a important component in the dryer system is the dryer
significant positive or negative effect on boiler particulate cyclone. Changes in the dryer cyclone have led to dramatic
emissions and stack opacity. Probably the most differences in the amount and composition of emissions
comprehensive test performed in Hawaii was the 1981 from the dryer/cyclone system (figs. 3 and 4, and Table 2).
HSPA test on the boiler/dryer system at Waialua Sugar For example, at one factory, prior to modifying the cyclone
Company (Kinoshita, 1989). Although only one-half of the system, the combustible fraction of the particulates exiting
gas was used to dry just one-half of the bagasse in that test, the dryer stack more closely approximated that of the
the effect of drying bagasse with flue gas on both unburned bagasse than the particulates which passed
particulate emissions and opacity was dramatic and through the furnace (in the dryer-bypass stream). After
favorable. Specific emissions rate (mass of particulate modifying the cyclones, the combustible fraction more
emissions per unit mass of fiber burned) decreased by 42% closely approximated that which passed through the
and boiler opacity decreased by 26% when the dryer furnace than the unbumed bagasse. In most instances, the
system was in use. It is believed that the substantial particulates exiting the dryer system have a significantly
reduction in emissions resulted from better combustion, higher fraction of combustibles than the particulates in the
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' ** M »•• E 60 -•
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W 40 -•
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-•if
Before Modification After Modification
Figure 4-CombustibIe fraction in flue gas particulate matter sampled
from the dryer stack and from the dryer-bypass stack prior to and
following modification to the cyclone system at a Hawaiian sugar
factory (corresponds to samples shown in fig. 3).
REFERENCES
Arrascaeta, A. and P. Friedman. 1987. Bagasse drying.
International Sugar Journal 89:68-71.
Furines, J.H. 1976. Pre-drying bagasse using flue gases. The
Sugar Journal 39:39-40.
Keenliside, B. 1983. A comparison of air pre-heaters and
bagasse drying systems for energy efficiency.
Proceedings of the International Society of Sugar Cane
Technologists, 1508-1516.
Kinoshita, CM. 1988. A theoretical analysis of predrying of
solid fuels with flue gas. Journal of Energy Resources
Technology 110:119-123.
Kinoshita, CM. 1989. Flue-gas drying of bagasse. Report
HNEI89-1003 by the Hawaii Natural Energy Institute
for the Office of Energy of the United States Agency for
International Development/Tennessee Valley Authority
through a subcontract from the Hawaiian Sugar Planters'
Association. Contract No. TV-73595A. Honolulu:
HNEI.
Kinoshita, CM. 1990. Cogeneration in the Hawaiian sugar
Figure 5-Bagasse boiler/dryer stacks with bagasse dryer operating
(white plume, top) vs. not operating (gray plume, bottom).
industry. Report HNEI 90-1002 by the Hawaii Natural
Energy Institute for the Office of Energy of the United
States Agency for International Development/Tennessee
tramp air in and around the dryers. This may be reducing Valley Authority through a subcontract from the
the potential for heat recovery and increasing the fan power Hawaiian Sugar Planters' Association. Contract No. TV-
required to convey the flue gas, the boiler wear rate, and 73595A. Honolulu: HNEI.
the amount of bagasse fines that pass through the cyclone Miller, C F . 1981. Economic study of bagasse dehydration.
system. At all factories studied, substantial and increasing Proceedings of the American Society of Sugar Cane
amounts of the total flue gas produced by the boilers are Technologists, 1978 Meeting, 148-153.
bypassing the dryer systems, due in part to loss in dryer USEPA. 1977. Standards of performance for new stationary
system fan capacity over time, aggravated by greater sources: Revision to reference method 1-8. Federal
infiltration of tramp air into the dryer systems. In addition Register, August 18, Part 11:41754-41789.