CFD ANALYSIS OF THE EFFECT OF HEATING COIL INSTALLATION ON HEAT AND AIR FLOW DISTRIBUTION WITHIN COMPARTMENT WOOD

DRYING KILN

Asst. Prof. Dr. Nirundorn Matan1 Marhaindra Gary Isworo2

1

Department of Material and Science, School of Engineering and Resources, Walailak University, Thailand 222 Thaiburi, Thasala District, Nakhon Si Thammarat, Thailand mnirundo@wu.ac.th 2 Department of Mechanical Engineering, Engineering Faculty, Sriwijaya University, Indonesia Jalan Palembang-Prabumulih Km.32 Indralaya, South Sumatra, Indonesia

ABSTRACT Problem that exists in the timber industry in particularly process of water content reducing in the wood using compartment kiln is about heating coil installation within the kiln. In this research, the coil installation will be determined the best of coil installations by taking samples from the factories by looking at the heat and airflow distribution uniformity within the kiln. Method of This study is CFD (Computational Fluid Dynamic) analysis by software Flovent 9.1. There are 3 variable coil positions, the coil placed horizontally (parallel to the fluid flow of the fan), vertically (perpendicular to the fluid flow), and with slope of 57. This research concluded that the position of the coils have uniform distribution of heat and air flow is in the horizontal position or parallel to the direction of air flow. Keywords: Compartment Kiln, Flovent CFD, Heating Coil Introduction The timber of living trees and freshly felled logs contains a large amount of water, which often constitutes over 50% of the woods' weight. Water has a significant influence on wood. Wood continually exchanges moisture or water with surroundings, although the rate of exchange is strongly affected by the degree wood is sealed. Drying timber is one method of adding value to sawn products from the primary wood processing industries. The lumber cannot be used to produce a high quality finished product. Properly dried lumber sells for a higher price and is much easier to work than lumber that has not been dried. When lumber is dried right, it machines better, glues better, and finishes better. Drying also improves the strength of the lumber, kills infestations, hardens pitch, preserves color, reduces weight and controls shrinkage. Lumber that is not dried under controlled conditions is prone to warping, staining, and other degrade that diminishes its selling price and workability. Most of this water must be removed in order To obtain satisfactory performance from wood that is to be processed into consumer and other types of useful products (Bousquet, 2000).

Figure 1. Compartment Kiln (source: http://wnyhardwoods.wordpress.com)

Take the example of a truck load of oak. Fresh cut oak weighs about 5,4 kg/m2. So a truckload of 8 m2 so weighs about 43,2 kg. Once you remove enough water to get the oak down to a moisture content of 6% - 8%, it weighs about 3.5 kg/m2. So that truckload

now weighs 28 kg. That means that to completely dry a truckload of 8 m2 of oak, you have to remove 15,2 kg of water. Thats why choosing the right drying system and using the proper method are so important. Conventional way of drying is most frequently used way of drying wood because the kilns are technically very simple, even for large capacity kilns (over 100 m3 of timber). They do not require extra maintenance and electrical power consumption is reduced by using wood wastes as fuel for boiler. There are two types of convention kiln, Compartment Kiln (figure 1) and Progressive Kiln, which are different from the way to dry the wood (Sucipto, 2009). In this research defined to analyze Compartment Drying Kiln and the energy source is constant temperature from steam. The airflow in the kiln chamber is very important. The velocity of the air over the wood affects the drying rate and provides even drying. We should know air velocity with the kiln manufacturer to be sure that the air velocity in the kiln will be adequate for the species and thickness of the lumber we are drying and the type of kiln you are using. The air velocity is depending on how we put the coil installation. Now, in Thailand there are many company using coil verticality and another country using with different direction. Generally, industries have not take attention about coil installation. Then, this research would be analyzed which one is the best coil installation within the kiln. Method The modeling and simulation process starts with the consideration of a series of assumptions related to how the physical and chemical phenomena occur within the pieces of equipment, and then, they are inserted in a series of fundamental equations (mass balance, quantity of movement and energy, conservation equations, etc.) The model is, then, mathematically solved - simulation generating answers that are compared to the data of the experiment, to its validation (Islabo, 2010).

1) Software: Its not always possible to make experiments with systems or prototypes. In these cases, the CFD analysis shows parts of the systems or phenomena, which enable assumptions to be materialized, tested situations. In this research using Software Flovent 9.1 Copyright 1989-2010 Mentor Graphics Corporation. 2) Subject Space: Dimensional kiln is 4.20m x 7.50m x 5.20m with wall thickness of 0.1 meter. There are 4 fan motors diameter 0.2 meter, 1.2 meter outer diameter, and thickness of 0.1 meters as a fan maker of fluid flow at a distance of 6.7 cm coil. This kiln is illustrated by incorporating wood stick by dimensions 0.1m x 1.3m x 0.038m. Inside, there is a layer of wood stick that juxtaposed as many as 29 stems. Each turn of the pinned layer of wood stick 3 buffer rod transverse to the wood stick by dimensions 3 x 2.54 cm x 2.74 cm, the distance of each buffer as far as 0.65 m. Forming a space for air to flow between the layers of wood stick as high as 2.74 cm. Nested layers of wood stick to 48 layers, so that the total dimension lumber is 3m x 1.3m x 3.5m. 3) Coil Installation: Coil dimension is 7.5 meters long and radius 3.3 cm. This research will be analyzed the airflow and the temperature changes by coil K0067 (horizontally), K5767 (slope 57o), and K9067 (vertically) see figure 2. Distance of each coil is the same, namely by 6.7 cm. The amount of coil at K0067 is 5 pieces, K5767 is 11 pieces and K9067 is 9 pieces.

Figure 2. Coil Installation Variable

4) Boundary Condition:
Table 1. Boundary Condition of Kiln Design

No. 1 2 3 4 5 5 6 7

Subject Wall Fan Fan Deck Wood Stack Template Lumber Coil Vent Buffle

Material Brick Wood Axial Fan Brick wood Wood Blocks Wood Blocks Iron Hole Aluminum

Construction 0,84 W/moK 8 m3/s Non-conducting 30oC 30oC 90oC 100% open 201 W/moK

are almost the same only some point differences and darker than K0067. From these figures can be seen if the air speed of K9067 is the fastest airflow, but we dont know yet about the uniformity.

5) Experiments: All of design (K0067, K5767, and K9067) will be run using Flovent, then the result that will be taken are temperature, x-velocity, and speed on each wood stack space from bottom to top in every lumber. After all of parameters has been taken then researcher will analyze the result and make some group of analyzing, those are Top to Bottom (TB), Front to Rear (FR), and Left to Right (LR). From these group of analyses should be determined the airflow distribution and thermal in every wood stack space and combining and analyzing all results and put the value into the graphic then make the conclusion. We can see which one the design that has uniform distribution of airflow and thermal. Results and Analyses Based happened in the industry today, there are some companies using closed kiln system or otherwise kiln without ventilation. However, in this research also made kiln design with open ventilation system to keep the pressure within the kiln. Based on the results obtained that the vents open or closed the temperature and velocity of fluid in the system does not change significantly. It means that company should open vents in certain time to maintain the stability of the pressure within the kiln. So in this research selected kiln system with open ventilation conditions. Figure 3 showing the airflow distribution of K0067 with color approximately the same, only at one point. Figure 4 or K5767 is colorful, it means the airflow distribution is not uniform. And figure 5 showing the colors

Figure 3. X-Velocity K0067

Figure 4. X-Velocity K5767

Figure 5. X-Velocity K9067

Figure 6 presents the pattern of air flow distribution only at x-axis within the kiln, where the blue color given to K0067 has a shape that is almost like a horizontal straight line. It is claimed that the kiln with horizontally mounted coil installations have a

good uniformity of air flow from the top to the bottom of the lumber.
X-Velocity (Bottom to Top)
3.5 3

Air Speed (m/s)

2.5 2 1.5 1 0.5 0 0 0.3 0.6 0.9 1.2 1.5 1.8 2.1 2.4 2.7 3 3.3 3.6

the temperature is very low (low efficiency). K9067 is a highest efficiency but the airflow is not uniform. Based on the hypothesis of the researcher, main cause why K0067 is low temperature due to the amount of coils is only 5 coils, while the K9067 is 9 coils. To have a kiln with high temperature and a uniform distribution of air flow, K0067 need 4 coils to be added without changing the flow rate of the air.

Altitude (m) K0067 K5767 K9067

Figure 6. X-Velocity Comparison

Uniformity of air velocity has not been able to be a benchmark of good or not a kiln system. Speed is uniform but the temperature is not uniform can produce the products are not uniform as well, and vice versa. So, it should be noted also how the temperature distribution in each wood stack space at the same point as in the analysis of fluid velocity. Figure 7 can be seen that each coil has the same pattern, which is the highest temperature is at the center of the lumber. However, the average temperature is highest become to K9067 and the lowest is K0067. Although the K5767 has the highest number of coil is 11 coils but the temperature is under of K9067.
Temperature (Bottom to Top)
32.8 32.6

Figure 8. K0067 with 5 coils

Figure 9. K0067' with 9 coils

Themperature (oC)

32.4 32.2 32 31.8 31.6 31.4 31.2 31 30.8 0 0.3 0.6 0.9 1.2 1.5 1.8 2.1 2.4 2.7 3 3.3 3.6

Altitude (m) K0067 K5767 K9067

In figure 8, kiln has 5 coils horizontally and Figure 7 can be seen that kiln is added 4 coils to raise the temperature of the coil and names become to be K0067'. At K0067 design made 2 lines parallel with the coil distance is 1 cm to prevent air flow velocity changes. To fulfill the total coil then there is a vacancy on the inside of, the reason why researcher select this point is based on researched before. That was almost the same result as before when the vacancy is at the outside of. Figure 10 presents changes that happened due addition the number of coil on K0067. Purple line is the temperature for K0067' while the green line is the K9067.

Figure 7. Temperature Comparison

Based on the results obtained could not be determined conclusion yet, because the K0067 has a uniform speed of the airflow but

Temperature value of K0067' is a little bit higher than the K9067. In another hand K0067' velocity of air flow that occurs has a pattern similar to the K0067.
Temperature (Bottom to Top)
33 32.8

from fan deck to the roof and 0,8 meter from wall to the wood stack is 11 coils, this design is the greatest number of coil but for temperature and air flow distribution are worst than the others. Compartment kiln with coil direction 90o by the same dimension has 9 coils, temperature efficiency of this system is 36% otherwise the temperature is better than 57o of coil direction, but air flow distribution is not good.

Themperature (oC)

32.6 32.4 32.2 32 31.8 31.6 31.4 31.2 31 30.8 0 0.3 0.6 0.9 1.2 1.5 1.8 2.1 2.4 2.7 3 3.3 3.6

Altitude (m) K0067' K0067 K9067 K5767

Figure 10 Temperature Comparison

Compartment kiln with coil direction 0o by the same dimension has 5 coils and modified to be 9 coils with 2 row coil (5 coils above, 4 coils below), at this design the air flow is uniform from top to bottom of wood stack and the temperature efficiency is 36% as same as coil direction 90o. References Bousquet, Dan. 2000. Lumber Drying: An Overwiew of Current Processes. University of Vermont Extension, Burlington. Gebhart, B. 1973. Natural Convection Flows and Stability: Advances in Heat Transfer. Volume 9. Academic Press. Islabo, G. I.; Pinto, J.C.; Junior, A.D. 2010. Technological Trends in CFD Applications. Journal of Technology Management & Innovation. Volume 5. Universidad Alberto Hurtado: 77. Mike Papkes Portable Sawmilling & Specialty Hardwoods. 2010. Second Dried Load. http://wnyhardwoods.wordpress.com. [Accessed: October 20, 2013]. Mills, A.F. 1999. Heat Transfer. PrenticeHall, New Jersey.

From the figure above we can make the conclusion of the best coil installation is K0067. It has good uniformity of air flow distribution and the thermal efficiency also good. Let see figure 11 shows the color of temperature within the kiln, the color is dark yellow and approximately the temperature at the points are the same 32,4oC.

Figure 11 Visualization of Thermal DIstribution K0067'

Sucipto, T.S. 2009. Pengeringan Kayu Secara Umum. Ph.D. Thesis, Universitas Sumatera Selatan, Medan, Indonesia.

Conclusions The coil amount of compartment kiln with coil direction 57o by dimension 1,3 meter