Solutions for a Wet Corn Milling Plant

Solutions for a Wet Corn Milling Plant

Customer’s Problem Dryer had Material Build-up and Tube Failures

 

When a prominent wet corn milling plant contacted Louisville Dryer Company for solutions to their drying problems, our process engineers promptly met with their production staff. Loss of their drying capability resulted in a loss of revenue for their company, a problem we were eager and fully equipped to help solve.

This processor had multiple dryers which were demonstrating broad swings in processing rates. The primary dryer in question was a rotating tube bundle dryer. The dryer had a stationary housing with a tube bundle that rotated inside the casing.

When they fired up their steam bundle, material would build up in the unit causing variations in retention timewhich resulted in some under-drying and some overdrying of their product. The issue was exacerbated by two catastrophic failures of the tube bundle. Such unplanned outages can cost hundreds of thousands of dollars in repairs and millions of dollars in lost revenue.

Louisville Dryer Solutions for Wet Corn Milling Plant

Louisville Dryer Co. provides effective and profitable drying solutions for Wet Corn Milling processors

Using custom mixing protocols to match their needs, we developed a successful recipe for their recycle stream. Along with our performance guaranty, the company engaged us to build a replacement steam tube dryer for their plant.

Steam tubes on dryers engineered by Louisville Dryer Co. process material with precise accommodation of temperature, pressure and speed requirements

Steam tube dryers generally rotate at a slower speed and operate at a lower temperature than other rotary dryers. Within steam tube dryers, the material tumbles gently around the tubes which rotate with the shell. Once we custom fabricated their dryer, with Louisville Dryer field engineers on-site for installation and startup, the dryer ran exactly as we had designed and predicted.

This is but one of hundreds of examples of our commitment to high quality, long-lasting customer solutions using our proven Application Engineering, Custom Design, Project Management, Manufacturing, Installation and Commissioning services.

Why are Consistent Drying Temperatures Important for Wet Corn Milling?

 

Drying conditions influence corn wet-milling performance as well as the physiochemical and functional properties of corn wet-milled fraction. The effect of the drying process on the quality of starch, gluten, germ, and fiber recovered during the wet-milling process help to develop more accurate engineering and economic models. Drying temperature combined with the initial moisture content of the grain has a significant impact on the wet-milling performance and the quality of recovered materials.

We are Ready to Help you Solve your Mission-Critical Challenges

 

At Louisville Dryer Company, we stand ready for jobs that are out-of-the-ordinary. Each project creates new challenges and opportunities for us to provide custom-engineered solutions to complex problems.

We have vast experience in processing materials including organic and inorganic chemicals, petrochemicals, grains, metals, aggregates and waste byproducts.

Louisville Dryer Co. is an ASMA Division I design and manufacturing center

Louisville Dryer Company is qualified as an ASME Division I design and manufacturing center. We have completed thousands of installations, processing hundreds of materials around the world, and pioneered many of the industrial drying technologies. We focus on:

Let us know how we can assist you and your company.

 

Contact Us Today

Why you Should Button up your Plant with Dryer Seals

Why you Should Button up your Plant with Dryer Seals

Dryer Seals are Key to Efficient Production 

During the cold of winter when you are running your furnace to heat your home, would it be HVAC-efficient, environmentally helpful or financially wise to leave some of your windows open? Of course not.

Yet for closed controlled systems on a much grander scale, hundreds of industrial direct heat dryers are operated every day without being effectively sealed. Drum Seals which are either absent, poorly designed or damaged often contribute to excessive gas flow through the drum due to air leaking in. Such exhaust gas leaks in the rotary drying process increase fuel consumption (to heat the excess air), increase material carry-out (due to higher gas velocity), place a heavier burden on air pollution equipment and increase operating expenses.

Furthermore, these leaks reduce product quality, fuel efficiency and even production capacity. (Common causes for seal failures are abrasion/contamination, shell expansion/contraction, excessive shell run-out, poor maintenance and product overflow.)

The Problem with Air Leaks

Rotary drums, dryers and kilns serve a crucial role in the processing of hundreds of various consumer products including bulk solids and chemicals.  Since dryers utilizing heat transfer in these controlled systems operate with internal temperatures much higher than ambient air, any outside air allowed to leak into* the vessel will reduce the operating temperature and cool the gas stream, thus reducing the overall effectiveness and cost-efficiency of the system.

Furthermore, unintended changes in the processing temperature alter the intended chemical reactions – which negatively affects the state and quality of the end-product.

* Note: When rotary dryers are operated as designed to be under slight negative pressure, out-gassing will be reduced, i.e. leakage of heat and combustion gases from the vessel will be minimized.

Specific Examples of How Air Leakage Affects Dryer Efficiency

 

The 1” gap around the end circumference of this drum shell can cause an air leakage of approx. 5,400 ACFM, which places an unnecessary/avoidable significant burden on the baghouse and fan, resulting in loss of 10-15% of production capacity.

A 1" gap can result in a leakage of 5,000 to 6,000 ACFM

 

The air leakage allowed by the 1 ½” gap (from missing seals) on this 8 ft. diameter drum is equivalent to a 1’ 9” square hole (= 3.1 sq. ft.) in an exhaust duct!

Air leakage in an Industrial Dryer

Poorly maintained (or absent) seals contribute to poor performance and loss of efficiency

Cracked Dryer Seals
Cracked dryer seals

The Louisville Dryer Solution

Correctly sealed dryer
Properly sealed dryer

We button up your plant with high-quality durable seals

To close the gap between our rotating vessels and their stationary discharge housing, we custom-design and install seal systems. Our application engineers emphasize that properly designed and maintained seals are a significant contributor to the system’s overall efficiency and can thus provide a relatively prompt ROI for plant owners/managers who invest in them.

If your direct heat dryer does not have a seal system – or is missing leaves/sections of its existing seal, contact us soon to request a diagnostic inspection and solution recommendation from our engineers.

Properly sealed dryer

Benefits which your plant could realize from installing/maintaining a proper seal system for your rotary drum/dryer:

  • Decreased production expenses
  • Lower maintenance costs (from reduced gas volume/velocity and fan wear)
  • Saved MBTUs
  • Raised flame temperature
  • Increased production capacity

Types of Dryer Seals

When it comes to seals, clearly one size does not fit all. Louisville Dryer Company can offer many different types of drum sealing devices specifically designed to meet the needs of the application process – considering factors including operating temperatures, material in process, dryer size and rotational speed.