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46th ISTE Annual National Convention & National Conference 2017International Journal of Advance Research and Innovation (ISSN 2347 – 3258)

Designing and Fabrication of Grain Moisture Drier & Experimental Study of their Results

Manjot Singh1,Mohit Kumar2,Vishal Sharma3,Jagwinder Singh4

Ravinder Goyal5. Kulvir Singh6.1,2,3,4Student: Department of Automobile Engineering

5,6Assistant Professor: Department of Automobile Engineering Gulzar College of Engineering

Ludhiana, Punjab, [email protected]

AbstractAs we know in country like India farmers are facing so many problems in agriculture. One of their problems is presence of excess moisture content in the crops. Due to moisture it became very hard to sale their crops in grain markets. In current scenario Indian farmers are totally dependent on whether conditions or sunlight for drying their crops. In grain markets they spread the grains on ground in presence of sunlight to remove moisture from it. They have to wait very long time for drying their crops. This problem of farmers increases many times in bad weather conditions. They did not get proper amount of money if moisture is not properly removed from the crops. They wait in grain markets till moisture reduces from the crops. To resolve this problem we develop a machine known as GRAIN DRIER. It will directly attach with COMBINE machine while harvesting. Due to this combine machine is able to perform jobs of grains drying with reaping and thrashing of crops. It is fitted with combine machine after doing small changes in it. These changes are done for heat treatment in grain storage tank and in exhaust line of vehicle. In Grain drier the heat is taken from engine exhaust. Grain drier is fully efficient because it does not need any external source of energy for its working. It only takes engine heat which previously wasted in atmosphere.Keywords—Drier; Moisture; Harvesting; Exhaust etc.

1. INTRODUCTION

In developing nations like India agriculture is a one of the major source of income for country. With advancement in technology agriculture is modernized due to use of latest machineries & techniques. For harvesting purpose COMBINE harvesting machine is used on large scale. With combine various jobs like reaping, threshing and winnowing can be perform in single process. Among the crops harvested with a combine are wheat, oats, rye, barley, corn (maize) , sorghum, soybeans, flax (linseed), sunflowers, and canola. The waste straw left behind on the field is the remaining dried stems and leaves of the crop with limited nutrients which is either chopped and spread on the field or baled for feed and bedding for livestock. Combine harvesters are one of the most economically important labor saving inventions, significantly reducing the fraction of the population that must be engaged in agriculture. The speed of harvesting of average combine is 0.8hectare/hour -1.4hectare/hour varies according to crops and external conditions. After harvesting the grains are collected in grain tanks which further move to other vehicle like tractor.

In case of some crops there is excess amount of moisture present in grains. Due to the moisture these grains are neither able to store nor to the sale in grain market. Grains are needed

to be stored properly until consumed. Grain storage is affected by two main factors: moisture and temperature. Grain stored at high temperature spoiled fast. It increases the amount of carbon dioxide and free fatty acids in grains.

For reducing shattering losses and to grow two or more crops in a year grains are harvested at high moisture. Sometimes bad weather conditions also forces farmer to harvest their crops in high moisture level. For safe storage of grains artificial moisture removing is essential. In grains depots mostly grains are stored for one year approximately. A list of moisture percentage for safe storage is shown in table 1.

Table 1. Upper limit for safe storage of grain are

Crops Moisture content

(%w.b.)

Wheat 14.5

Oats 14.0

Barely 14.8

Rye 14.0

Flaxseed 10.0

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Gulzar Group of Institutes, Ludhiana, Punjab-141401 (INDIA)


Canola and rapeseed 10.0

Mustard seed 9.5

Peas 16.0

Lentils 14.0

Fava beans 16.0

Buck wheat 16.0

triticale 14.0

Corn 15.5

Soybean 14.0

Sunflower seed 9.5

Safflower seed 9.5

Dried grains have slow microbial growth as compare to moisturized grains. After drying grains loses its weight and becomes easy for transportation and handling. In natural process of moisture removing ambient air is used without heating directly. In artificial heating grains are dried by external source of energy. For this external heating there is temperature limit below which grains remains safe and consumable.

Table 2. Maximum safe temperature (°c) of grain drying for different uses.

crops Seed Sold for commercial use

Animal feed

Corn 43 54 82

Shelled corn 43 54 82

Wheat 43 60 82

Oats 43 60 82

Barley 43 41 82

sorghum 43 60 82

soybean 43 49 -

Rice 43 43 -

peanuts 32 32 -

On drying grains artificially air heated up to 50-200°c. There is also temperature limit for grains below which they can heat

safely. Maximum safe grain temperature limit are shown in table 2.

A. Understanding the need

There are various methods and equipment are available in market for drying of crops. One of the oldest methods of moisture removing from crops are drying through fans. This is cheapest and easy way of grain drying but it is not much efficient. In some countries there are some equipment and devices that are used for crops drying. In these equipment heat is given to grains through external source of energy. These equipment have high initial and operating cost. They are beyond from the reach of average farmers. To find alternate solution for this problem we develop a grain drier. Grain drier is purely efficient machine. It does not require any external source of energy for it working. Grain drier is directly attached with the combine harvesting machine. In combine machine some changes are done in grain tanks and exhaust line. To remove moisture from the crops, engine heat of combine machine is used which previously wasted in environment. Exhaust line is fitted with external silencer or heat exchanger through which heat is taken and supply to grain tank of combine machine through injectors.

B. CONSTRUCTION OF GRAIN DRIER

As mentioned above grain drier is fitted in combine machine. All the components of grain drier are explained below. Combine machine and its parts are also shown in figure 1 & 2 respectively.

Figure 1. Combine harvesting machine

Heat exchanger: Combine harvesting machine are consist of heavy engines. The power output of branded combine harvesting machine is in range of 100hp-150hp @ 2500 rpm. But in local made combines engine of lp1613 trucks or tractor engines are used. The power outputs of these combines are in

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range of 100hp-130hp. The approx. temperature distributions of these combines engine are

At engine head-550°C

At exhaust silencer start point-338°C

At silencer end point-144°C

Figure2. Components of combine harvesting machine

The heat exchanger is attached at exhaust line before the exhaust silencer of engine. The copper coils are wrapped inside the heat exchanger for exchange heat. The exhaust gases coming from cylinders first passes from heat exchanger by increasing temperature of coil and then pass to exhaust silencer. The construction of heat exchanger is done by considering NVH characteristics of vehicle. To reduce vibration heat exchanger is provided with sound absorbing

Figure3. Heat exchanger

material and proper sealed at joints. Second heat exchanger is attached with the radiator. The constructions of both heat exchangers are same. It is placed before the radiator hot water inlet. The hot water coming from water jackets of engine first passes through the heat exchanger then to the radiator. Hot water increases the temperature of the

coil thus air inside the coil get heated. In this heat exchanger proper sealing is done to avoid leakage. Thus air gets heated from both heat exchanger and this hot air is supplied to the grain tank through injectors.

Copper coils: Long lasting copper tube is a favorite choice for plumbing, heating, cooling and other systems. In the United States, it is manufactured to meet the requirements of specifications established by ASTM International. All tube supplied to these ASTM standards is a minimum of 99.9 percent pure copper. The copper customarily used for tube supplied to these specifications is deoxidized with phosphorus and referred to as UNS C12200 or DHP1 Copper. Other coppers may also be used. "Temper" describes the strength and hardness of the tube. In the piping trades, drawn temper tube is often referred to as "hard" tube and annealed as "soft" tube. Tube in the hard temper condition is usually joined by soldering or brazing, using capillary fittings or by welding.

Properties of copper tubes are following;

Inner diameter - 0.311in

outer diameter - 0.375

Cross sectional area- 0.76 in2

Weight - 0.134pound/ft.

Material Thermal conductivity(Cal/sec)/(cm2 C/cm)

Thermal conductivity(W/m K)*

Diamond ... 1000

Silver 1.01 406.0

Copper 0.99 385.0

Gold ... 314

Brass ... 109.0

Aluminum 0.50 205.0

Iron 0.163 79.5

Steel ... 50.2

Lead 0.083 34.7

Copper coils or copper tubes are wrapped inside the heat exchanger which is fitted in exhaust. Copper tubes have very high thermal conductivity due to which its temperature rises very rapidly. The copper coils are wrapped in helical form along the heat exchanger. At the center of helix hollow pipe is placed which have large number of holes on its surface. It

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carries the hot air of exhaust from one end to another due to which heat exchanger has same temperature distribution throughout the heat exchanger. When hot air is passes through the heat exchanger then temperature of copper tube increases. Thus air inside the copper tubes gets heated.

Grain tank: Combine machines with grain driers also have some changes in grain storage tank. The storage capacity of the tank is about 1200kg-1500kg varies with the different model of combines. The approximate speed of harvesting or

grains collection is 5-8 min per 100kg for healthy crops. Thus to remove moisture from crops efficient heating system is required to meet the speed. To make the system efficient some changes are also made in grain tank. Grain tank is fitted with a roller and blades. This roller is fitted in center of tank horizontally supported by UCS bearings at both ends. The roller has curved shaped blades which is mounted over surface at angle of 90degree. At one end of roller pulley-belt system is attached. The drive is given to the roller through flywheel. The purpose of roller is to mix up the grains. It also helps to increase time of contact of hot air and grains. Air injectors are also fitted above the roller. Thus grains coming from harvesting are continually mixing up through roller blades.

Nozzle/air injectors: A nozzle is a device designed to control the direction or characteristics of a fluid flow (especially to increase velocity) as it exits (or enters) an enclosed chamber or pipe. A nozzle is often a pipe or tube of varying cross sectional area, and it can be used to direct or modify the flow of a fluid (liquid or gas). Nozzles are frequently used to control the rate of flow, speed, direction, mass, shape, and/or the pressure of the stream that emerges from them. In a nozzle, the velocity of fluid increases at the expense of its pressure

energy.

Figure 6. Nozzle/ air injector

The hot air is injected in the grain tank through the air injectors. It increase the kinetic energy of the air by reducing its pressure energy. The direction of injectors is such that the air is directly falls on the blade of the roller. The injectors positioned in such a way that it covers whole tank.

Pressure tank: In grain tank hot air is injected through nozzles. For this injection high amount of pressurized air is required. This pressurized air is given by combines’ air reservoir. These reservoir have pressurize air of 85psi-90psi.within 2-3mins the air is pressurize up to 90psi at 800rpm.

The pressure is released by cut-out governor when pressure limit exceeds from125psi in tank. And cut-in governor works below 25psi-35psi pressure below cut-out governor. This reservoir supply air to pneumatic brake, pressure horns etc. To heat exchanger air is also supplied from air reservoir of vehicle.

Pipes: Two types of pipes are used in grain drier. First one has to carry air coming from pressure tank to the heat exchangers. This air is at room temperature. The second type of pipe carries air from heat exchangers to the grain tanks. This air is get heated after coming from the heat exchanger. And the temperature of this air is up to 150degree Celsius.

PVC Pipes: First type of pipes is simple PVC pipe. It can withstand with certain pressure range. Polyvinyl chloride starts to decompose when the temperature reaches 140 °C, with melting temperature starting around 160 °C. PVC has high hardness and mechanical properties. The mechanical properties enhance with the molecular weight increasing but decrease with the temperature increasing. The mechanical properties of rigid PVC are very good; the elastic modulus can reach 1500-3,000 MPa. The soft PVC (flexible PVC) elastic is 1.5–15 MPa.

Metal Pipes: Metal pipe or hoses are second type of pipe that used at high temperature. It can withstand up to 200degree Celsius. A metal hose is a flexible metal line element. There

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are two basic types of metal hose that differ in their design and application: strip wound hoses and corrugated hoses. Strip wound hoses have a high mechanical strength (e.g. tensile strength and tear strength). Corrugated hoses can withstand high pressure and provide maximum leak tightness on account of their material. Corrugated hoses also exhibit corrosion resistance and pressure tightness under the most extreme conditions, such as in aggressive seawater or at extreme temperatures such as found in space or when transporting cooled liquid gas. They are particularly well suited for conveying hot and cold substances.

Figure 9. Metal pipes

Water separator: In grain tank hot air is injected which is coming from pressure tank of combine machine by passing through heat exchanger. In pressure tank air is pressurized by compressor. Due to presence of moisture in air, vapors are also collected in pressure tank. To remove moisture from grains air should be moisture free. Thus to separate moisture from compressed air water separate is used.

Working of water separator: Water contaminated air enters the inlet port and is directed through our primary chamber where directional changes causes the air to spin in a cyclonic motion. The air then passes through a small annulus causing the air to expand rapidly and cool, at this stage 98% of the liquid water is removed. Liquid water then falls to the base of the unit where it is collected and then dried. The air then passes through the DCC (dropout clarification chambers) where precision engineered venture deflects the air causing particle coalescence. The compressed air is then polished and remaining aerosol particles are removed. Leaving the compressed air is downstream of the dropout product.

Figure 10. Water separator

Grain moisture meter: To sale crops in grain market 16% moisture content is acceptable. This is measure by grain moisture meter. The working of grain moisture is following

Exhaust by pass line: Heat exchanger is attached in series with exhaust silencer after exhaust ports. When engine is running at high speed then temperature of exhaust increases very rapidly. With long running of combine machines the temperature of air coming through heat exchanger becomes very high. This extremely hot air is not good for grains. The grain starts roasting in the tank due to overheated air. To avoid such condition it is necessary to control temperature of the air. This controlling is done by passing exhaust air directly through exhaust silencer without passing it through heat exchanger. Before heat exchanger temperature sensing valve is placed. When temperature of heat exchanger outlet increases from certain range then this temperature sensing valve automatically closes heat exchanger line and open by pass line for exhaust air

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Figure 11. Grain moisture meter

Figure 12. Exhaust bypass line

Conclusion

This machine can be used to save the grains from moisture. By this machine we have removed 40% grain moisture. Hence we can say that loss of our farmers due to moisture can be minimized and hence it will be helpful in fulfilling the demand of grains.

WORKING

In the combine all the parts and accessories are fitted as mentioned above. The combine machine starts harvesting and crops are start collecting in grain tank. In grain tank s line is open by temperature sensing valve. roller is rotating. The

compressed air of vehicle air reservoir is passes through water separator which remove moisture content from compressed air. Then it passes through the heat exchangers which are placed in exhaust line. The temperature of compressed air is rises due to conduction through copper tubes in heat exchanger. This hot air is comes to injectors through metal pipes and then injectors inject the air in the grain tank. In grain tank roller blades mix up the grains and increase the contact of air with the grains. Thus grains losses their moisture easily. With long running of combine machine, when temperature of air coming from injectors increases too high then exhaust

REFERENCES

[1] PRESERVING QUALITY IN HEAT DRYING. 2010. HEAT DRYING. [ONLINE] Available at: HTTP://SPIRU.CGAHR.KSU.EDU/PROJ/IWCSPP/PDF2/9/KPS81.PDF. [Accessed 14 November 2016].

[2] COMBINE HARVESTING MACHINE- WIKIPEDIA. 2011. wikipedia. [ONLINE] Available at: HTTPS://EN.WIKIPEDIA.ORG/WIKI/COMBINE_HARVESTER. [Accessed 16 November 2016].

[3] COPPER TUBE HANDBOOK. 2009. google. [ONLINE] Available at: HTTPS://WWW.COPPER.ORG/PUBLICATIONS/PUB_LIST/PDF/COPPER_TUBE_HANDBOOK.PDF. [Accessed 15 November 2016].

[4] COMPRESSED AIR WATER SEPARATOR. 2009. google. [ONLINE] Available at: HTTPS://WWW.DROPOUTTECHNOLOGY.COM/HOW-. [Accessed 13 December 2016].

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