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Development of A Solar-Biomass Integrated Drying System for Spice Crops

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Chapter 6

Summary and Conclusion

Drying offers a multitude of advantages which includes reduction in volume, easy

handling and transportation, less chance of pest and microbial attack during storage for

almost all agricultural products. The basic essence of drying is to reduce the moisture

content of the product to a level that prevents deterioration within a certain period of time.

For products like turmeric, drying is an absolute necessity for size reduction and to have a

powdered end product.

In many rural locations of most developing countries, grid-connected electricity and

supplies of other non-renewable sources of energy are either unavailable, unreliable or, for

many farmers, too expensive. Thus, in such areas, crop drying systems that employ

motorized fans and electrical heating are inappropriate. The large initial and running costs

of fossil fuel powered dryers present such barriers that they are rarely adopted by small

scale farmers. The traditional open sun drying utilized widely by rural farmers has inherent

limitations. The crop also requires an undesirably long period to reach this equilibrium

moisture content. Meteorological data, even for the ‗most favoured‘ areas, show that this is

not always feasible. In hot and humid climates, crop deterioration is obviously worse, as

both warmth and high moisture contents promote the growth of fungi, bacteria, mites and

insects in crops. Thus, these climatic conditions dictate the need for more effective drying

methods. In such conditions, solar-energy crop dryers appear increasingly to be attractive

commercial propositions.

From the review of the literature, it was observed that quality of the product dried

finally reflects the acceptability of a drying system. Quality attributes of heat sensitive

materials are of much importance under hot air drying. Apart from thermal degradation

viz. loss in quality, colour, shape, texture, nutrient content, etc. during the drying of food

products, their sensitivity to mechanical stress and long drying time should be given due

considerations. In a study to understand the effect of heat processing of spices on the

concentrations of their bioactive principle, significant loss of spice active principles was

observed. Drying resulted not only in the disappearance of some volatile components but

also in the appearance of others which were absent in fresh ginger pulp. It was reported

that, when fresh ginger was dehydrated, relative contents of benzene decreased as


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compared to those in fresh ginger. In a study of comparison of the retention of 6-gingerol

in drying of ginger under modified atmosphere heat pump drying and other drying

methods, inert gases such as N2 and CO2 was used as the drying media which resulted in

increase of effective diffusivity. In a study on performance evaluation of a hybrid drier for

turmeric drying, it was reported that retention of volatile oil was near double when

compared to open sun drying. Drying carried out using heated air also results in

undesirable alterations of certain characteristics of the material, such as shrinkage and

colour changes. In addition, there is a partial destruction of tissue structure, which affects

in water permeability, consequently rehydration ability and changes in the texture. The

determination of rehydration conditions in order to minimize colour changes during

dehydration, rehydration process is an important quality attribute.

Any drying system should be energy efficient due to obvious reasons. Energy

consumption during drying varies owing to different shapes of food product. It was found

that the cylindrical samples in comparison to slices result in faster moisture removal and

hence lower specific energy consumption. The drying efficiency determination based on

energy ratio in terms of drying time is the traditional method commonly used in

performance evaluation of any dryer system.

Ginger is grown over a wide area of the tropic although the major areas of

production are Southern and Eastern Asia. India produces about 50% of the world ginger

and the N-E region as a whole occupies a formidable position in this 50% production. As

per Spices Board of India report (2006) production of ginger (138370 MT) and turmeric

(20360 MT) is quite significant in the North East region of India and have high intrinsic

values. The preserved and dried products are the major forms in which ginger is

internationally traded in the whole or split forms and is ground in the consuming centres.

In light of the above facts, present research was undertaken to develop a suitable

dryer of small scale for drying ginger / turmeric rhizomes and other high valued crops in

the production catchment was thought be the most appropriate technological intervention

for value addition, post harvest loss reduction and for economic benefits of stake holders.

To reduce the cost of drying by harnessing solar radiation when it is available followed by

a bio-waste fired heat generation system completely devoid of grid electricity dependency

was thought of to be highly beneficial for the stake holders. The idea of an energy efficient


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drying system to partly run on solar energy and partly on bio-waste energy with natural

draft mechanism for induced air flow was conceived.

The research was undertaken in three phases. Firstly to design and develop an

integrated drying system followed by study the drying characteristics of ginger and

turmeric in the developed system and finally to optimize the drying process based on

quality attributes.

A solar biomass fired integrated drying system (IDS) was developed. Functional

design of a solar flat plate collector was carried out to harness maximum solar intensity.

The absorber plate consisted of 1.5 mm thick black painted aluminum sheet with ply board

insulation at the bottom and the two sides. For trapping solar radiation, 8 mm thick

transparent glass Pyrex was used over the collector surface area. The collector was

provided with an inclination of 150 facing south (26.75

o N and 94.22

o E) for maximum

exposure to insolation. To increase the air velocity, neck of the collector was designed

tapered in width to 950 mm. For efficient drying of product through indirect drying

method, a compound parabolic concentrator (CPC) was installed. Six numbers of semi-

cylindrical parabolic concentrators were interpolated on a receiver plate for direct

conversion of solar energy to thermal energy by trapping the maximum incident rays into

metallic tubes which were placed on focus lines of the parabolas. Experiments were carried

out to study the comparative performance of a solar flat plate collector and compound

parabolic concentrator of same size. Average temperature rise of 9.50 C was observed

during the period. A manual solar tracking was facilitated along the two axes up to 4.680

vertical and 11.540

horizontal. Average temperature increase of 11.20

C could be achieved

over the ambient. Solar radiation trapping time at a constant temperature level was

increased by 1.5 hours in comparison to fixed CPC.

A cylindrical combustion chamber was fabricated for combustion of husk and other

agro waste. The exhaust end of the combustion chamber was connected to a chimney for

necessary draft creation and exit of flue gas. A baffle plate was fixed in the out let for air

flow control. A layer of rock was placed at the bottom for better heat retention. Over the

cylinder, iron scraps were laid to increase heat transfer area and air residence time. Sliding

type closing and opening plates were provided in the two ambient air ports for inlet air

flow control. The ambient air entering into the chamber gets heated while in contact with

the hot combustion chamber surface and gets sucked into the bottom of the drying chamber


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due to natural convection and draft created by the wind turbine fitted on top of the drying

chamber. For feeding of paddy husk into the combustion chamber, an inclined grate type

feeding mechanism with hopper was fabricated. The arrangement was made in such a way

so that by stroking the flat iron through the liver provided, the inclination of the grates

altogether could be increased or decreased between 450 – 90

0. This was done to ensure

sufficient inflow of air for proper burning and smooth flow of husk from the hopper to the

combustion chamber. A fluted type feeding system was fabricated and used in the hopper

for controlled flow of husk for continuous combustion.

The drying chamber consisted of plenum chamber, drying chamber, free board and

exhaust. A total of 6 trays were fabricated using SS sieves and GI side bunds as per design

specifications. From the top most trays, a free board of 80 mm depth was provided beyond

which the chamber was made tapered and a wind turbine was fitted over the chamber for

creation of draught. The hot air generating parts were attached to the drying chamber from

two sides fixed through flanges. The fuel feeding side of the bio-waste fired unit and

loading- unloading side of the drying unit were placed as front of the drying system. To the

right of the dryer the solar part was attached through a flexible neck made up of water

resistant canvas cloth. This was done to enable tracking of the sun during second half of

the day.

To understand the drying kinetics, drying experiments on ginger and turmeric

rhizomes were carried out by interchanging the trays in a predetermined sequence and time

interval for uniform drying. Drying of ginger was accomplished in 16 hour of effective

drying time reducing moisture content from 88.8 % to 6 % (wb), when air temperature was

maintained at 55±30

C using paddy husk as the source of fuel. Drying curves were drawn

and moisture ratio (ln MR) against time was computed. While drying turmeric, it was

observed that drying was accomplished in 14 hours of effective drying. The moisture

content was brought down to 6.26% (wb) from initial level of 89.26% (wb).

The variation in quality attributes in dried samples obtained from selected drying

methods viz. electrical oven, fluidized bed dryer (FBD), normal open sun drying and the

developed solar biomass fired integrated drying system (IDS) were studied. Results

obtained of ginger and turmeric samples dried in the selected methods were statistically

analyzed using 1-way analysis of variance (ANOVA) test to estimate the difference

between different drying methods. Quality attributes viz. texture, colour, rehydration ratio;


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oleoresin and volatile oil content of dried ginger rhizomes were studied. Ginger dried in

IDS was found to be hygienic and showed high quality over the other methods of drying

suggesting its suitability for spice drying. FBD was found unsuitable for sliced ginger

drying as rapid drying resulted in negative quality attributes. Overall quality of ginger

including colour, rehydration ratio; oleoresin and volatile oil content of dried ginger

rhizomes were found to be better while drying in IDS. As of drying of turmeric was

concerned, it was observed that turmeric dried in IDS required maximum peak force which

was an indication of achieving maximum uniform drying whilst positive area under curves

was minimum amongst all indicating dried turmeric would require minimum energy during

size reduction operations. Maximum deviation of colour from raw turmeric was observed

in case of oven dried samples. Lowest deviation was observed in samples obtained from

IDS indicated most acceptable characteristics colour of turmeric. Curcumin content of

turmeric samples obtained from all the four drying methods along with that of raw

turmeric were studied following standard procedure. Taking curcumin content of raw

turmeric as base, percent retained in samples after drying was compared for the selected

drying methods. It was observed that variation in curcumin content between oven and sun

drying was insignificant but significant difference was observed in samples from FBD and

IDS.

Variation in drying material and their biological differences, coupled with heat

supply method in different types of dryers makes mathematical modeling of drying

complicated. Attempt was made to simulate a drying process and to identify best suitable

model out of six selected drying models, for drying of ginger and turmeric slices separately

for the developed drying system. Moisture content data were converted into the moisture

ratio (MR) expressions and curve fitting with drying time for the selected drying models

were analyzed. Sigma Plot software was used for nonlinear regression to the data obtained

during drying and for modeling of drying curves. The suitability of the equations was

evaluated in terms of statistical parameters such as coefficient of determination (R2), mean

percentage error (P) and standard error estimate (SEE). While drying of ginger, the

minimum average value of R2 was found to be 0.968 among all the models irrespective of

tray positions. However, Page model showed highest value of R2 (0.997), lowest value of

SEE (0.020) and P < 0.0001suggesting it to be the best suitable model for the developed

drying system. The predicted moisture ratios were in good agreement with the


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experimental values and the effective moisture diffusivity for ginger was found to be

2.97×10-7

m2s

-1. For drying of turmeric, representations of experimental MR values of

turmeric were also fitted with all the six selected models that were obtained from

Sigmaplot software. As in the case of ginger drying, analysis of overall statistical

parameters of drying kinetics obtained from drying turmeric rhizomes also validated Page

model as the most suitable one among the six chosen models. Experimental and simulated

moisture ratio curves were drawn after conducting drying experiments for turmeric for the

best fit model. It was seen that Page model was the best fit model. The curves were near

similar, again confirming sound drying conditions.

Effective moisture diffusivity reflects the capability of moisture evaporation rate of

any material to be dried while keeping other drying conditions under control. The effective

moisture diffusivity during drying for different trays was determined using method of

slopes for ginger and turmeric, respectively. The effective moisture diffusivity (Deff) for

ginger was found to be, 2.97×10-7

m2s

-1, while experimenting with turmeric rhizomes

effective moisture diffusivity was found to be 3.747×10-7

m2s

-1. It was observed that,

diffusivity in IDS was 35.7% more in comparison to diffusivity reported in literature under

sun drying. Effective moisture diffusivity in case of turmeric drying was nearly 21%

more in comparison to ginger drying. Moisture diffusion was easier in turmeric rhizomes

due its less fibrous nature compared to ginger. Thus, drying ginger will always be more

energy intensive than drying turmeric.

To understand performance of the considered mechanical drying systems, specific

energy consumption (SEC) data were studied. It was seen that, highest SEC was in case of

Oven drying followed by IDS and FBD for ginger drying. However, in case of turmeric

drying minimum SEC was observed in IDS followed by FBD and Oven drying. This was

because; in IDS drying occurs from both surfaces and less fibrous nature of turmeric slices

enables easier drying.

The drying process was optimized for same temperature, using a nine point

Hedonic scale. The nine point scale range was fixed based on maximum and minimum

values of drying time, specific energy consumption, texture, colour change, rehydration

characteristics, oleoresin and volatile oil content in case of ginger. In case of turmeric,

instead of oleoresin; volatile oil and rehydration ratio, curcumin level was considered apart

from other parameters. In case of ginger, the panel of researches gave highest average


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score to IDS and gave FBD lowest score. The FBD system is totally unsuitable for ginger

drying as evident from its lowest score. Average score in case turmeric for IDS and sun

drying was almost at par. Oven drying scored very low score suggesting its absolute

unsuitability for turmeric drying.

After computing overall heat loss coefficient of collector surface area, the rate of

useful energy extracted by the collector was calculated. Energy utilization efficiency by the

solar collector assembly was found to be 49.27%. Energy utilization efficiency of the bio-

waste fired assembly was found to be 62.32%. Finally, energy balance for developed IDS

was carried out. Considering total heat available in the plenum chamber and latent heat of

evaporation, the IDS showed 39.33% of overall energy utilization efficiency.

The following are the summaries of the research work:

1. The present study includes the design and development of solar and biomass

integrated drying system for ginger and turmeric rhizome.

2. As per the design dimensions of various components, a prototype integrated drying

system (IDS) was fabricated at a cost of Rs.80,000/-.

3. Experiments to study the drying air conditions, drying kinetics of ginger and turmeric,

comparative performance, effects of drying on texture, colour, rehydration

characteristics, volatile oil, oleoresin content and curcumin content (turmeric) were

carried out.

4. Capacity of the dryer was designed as 100 kg/batch with 6 SS trays. Length and

diameter of combustion chamber in bio-waste fired section: 1620 mm (L) x 150 mm

(dia.). Design calculations for chimney height was carried out and found to be: 3350

mm (H) x 200 mm (dia.).

5. Functional design dimension of solar collector was 2220 mm (L) x 1230 mm (B) x

160 mm (H). The designed dimension of compound parabolic collector: 1860 mm in

(L) x 1220 mm (B) with 15 mm space between each of the 6 CPC‘s.

6. Overall dimension of the IDS: 3700 mm (H) x 4300 mm (L) x 2000 mm (B)

7. Incorporation of compound parabolic collector and sun tracking facility resulted in

average rise in temperature by about 37.72% and 47.2%, respectively over Design

stage-I i.e simple flat plate collector.


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8. Drying air temperature could be raised to 50 – 550 C using paddy husk as fuel and to

650 C while using wood stalks.

9. Ginger dried in IDS required minimum force among all indicating controlled and

uniform drying in comparison to the other methods during texture analysis.

10. Rehydration Ratio values of ginger samples dried in IDS was highest in comparison to

samples from other drying methods.

11. Colour deviation from raw product was minimum in samples dried in IDS for both

ginger and turmeric.

12. As regards to volatile oil and oleoresin content, no significant difference was observed

in dried ginger obtained between IDS and normal sun drying.

13. Drying at the present set of conditions, effect on curcumin content of turmeric was

negligible.

14. The simulation work done indicated that, the experimental results obtained from

drying of both ginger and turmeric in IDS suitably fits with Page model. This supports

the soundness of the design of the developed dryer while drying the selected spices.

15. Effective moisture diffusivity in case of turmeric drying was nearly 21% more in

comparison to ginger drying. However the values in both the cases were in accordance

with observations reported in literature.

16. Energy utilization efficiency by the solar collector assembly was found to be 49.27%.

Energy utilization efficiency of the bio-waste fired assembly was found to be 62.32%.

Considering total heat available in the plenum chamber and latent heat of evaporation,

the IDS showed 39.33% of overall energy utilization efficiency.

17. Highest SEC was in case of Oven drying followed by IDS and FBD for ginger drying.

However, in case of turmeric drying minimum SEC was observed in IDS followed by

FBD and Oven drying. Nevertheless, cost of drying was found to be minimum in IDS

while drying both ginger and turmeric. In comparison to IDS, cost of drying ginger in

FBD and Oven were 5 and 19 times more, respectively. The same in case of turmeric

were 14 and 30 times more in FBD and Oven drying, respectively compared to drying

in IDS.


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Based on the aforementioned results of the drier evaluation for drying of ginger and

turmeric rhizome and its effect on quality and process of the product, it is concluded that:

(i) Design modification from solar flat plate collector to compound parabolic solar

collector for the same area could significantly increase temperature of the air.

(ii) The developed integrated solar-biomass drying system is capable of producing the air

temperature between 44°C and 55°C, that was optimum for drying of turmeric, ginger

rhizomes as well as other spices, herbs, fruits and vegetables.

(iii) The energy utilization efficiency of the unit as a whole was 39.33% which is quite

compatible with other such systems reviewed. Moreover, compared to open sun drying

of ginger and turmeric, drying time was also reduced by 20.66% and 12.5%,

respectively.

(iv) Unlike products obtained from open sun, oven and fluidized bed drying, the quality

attributes of products remained maintained in this drier.

(v) Soundness of design of the developed system was well supported by simulation study

carried out with established Page model of thin layer drying.

(vi) Study concluded that the integrated drying system is predestined for application in

small farms of developing countries due to its low investment, non-dependency on

grid power or fossil fuels and operative by unskilled personal.


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Suggestions for future work

1. Automatic tray interchange mechanism should be worked upon.

2. Different insulation material should be tried to reduce heat loss and thereby

increase the overall energy utilization efficiency.

3. The developed system should be tried for other spices and high value crops.

4. Microbiological studies and possible loss of phytochemicals in the dried product

should be studied to have wider acceptability of the developed drying system.


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List of Publications related to Ph.D Work

Borah, A., Khayer , S.M., Sethi, L.N. and Sarkar, S. (2014). Effect of Drying Methods on Quality

Attributes of Dried Ginger Slices. Proceedings of National conference on Emerging

Technology Trends in Agricultural Engineering, Dept. of agricultural Engineering NERIST,

Nirjuli (Itanagar), Arunachal Pradesh. 7-9 Nov‘2014.

Borah, A and Hazarika, K. (2014). Simulation and Validation of a Suitable Model for Thin Layer

Drying of Ginger Rhizomes in an Induced Draft Dryer. Proceedings of 18th World Congress

of Agricultural and Biosystems Engineers, China National Convention Centre, Beijing,

China. 16-19 Sept‘2014.

Borah, A., Khayar, S. and Sethi, L.N. (2013). Development of a compound parabolic solar

concentrator to increase solar intensity and duration of effective temperature. International J.

Agriculture and Food Science Technology. ISSN 2249-3050, 4(3), 161-168.

Seminar / Conferences attended

1. National conference on Emerging Technology Trends in Agricultural Engineering,

Dept. of agricultural Engineering NERIST, Nirjuli (Itanagar), Arunachal Pradesh. 7-9

November, 2014.

2. 18th

World Congress of Agricultural and Biosystems Engineers (CIGR 2014), China

National Convention Centre, Beijing, China. 16-19 September, 2014.

3. 2nd

International Conference on "Agriculture, Food Technologies and Environment-

New Approaches" (AFTENA- 2013). Jawaharlal Nehru University, New Delhi.

19 – 20 October, 2013.

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