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Vol.

9, No. 4, pp. 195-203,

1998
0 199X Elsevier
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PAPER

Dynamic simulation and

control of direct rotary dryers
J. R. Pkez-Correa, *: F. Cubillos,+ E. Zavala,+
C. Shene* and P. I. Alvarez+
Adaptive and conventional
control of a direct rotary dryer has been assessed
through simulations.
A dynamic model of the process was developed specifically
for this purpose. The model is based on mass and energy balances and includes
a drying kinetic derived from mass transfer principles. In the modelling process,
ten discrete perjectly mixed elements were considered for the dyer with each
containing four difSerentia1 equations. A well tuned discrete PID and an adaptive
algotithm
were used to control the outlet solid humidity.
Both controllers can
regulate the controlled
variable for diRerent disturbances, although the adaptive
controller is more eflective. 0 1998 Elsevier Science Ltd. All rights reserved
Keywords: dynamic modelling; water content control; temperature control; adaptive control

NOMENCLATURE
Lower case letters
Parameters of a linear dynamic model
a,, 6,
b
Parameter of drying model
Specific heat of dry air at constant pres5
sure, kJ kg Cm
c,
Specific heat of dry solid, kJ kg C
Specific heat of wet air at constant volume,
c,,
kJ kg C
Specific heat of liquid water, kJ kg C
cc,
Specific heat of wet solid, kJ kg C
c/z
C c
Specific heat of dry air at constant volume,
kJ kg Cm
C Pb
Specific heat of vapour at constant pressure, kJ kg C
Specific heat of vapour at constant volume,
cv,
kJ kg C
Average particle diameter, m
4
e
Control error, kg kg-
*Departamento
dc Ingcnieria Quimica y Bioprocesos, Pontificia Universidad Catcilica de Chile, Casilla 306, Santiago 22,
Chile, +Departamento dc Ingenieria Quimica, Univcrsidad de
Santiago de Chile, Casilla 10233, Correo central, Santiago,
Chile and *Departamcnto
de Ingcnicria Quimica,
Universidad dc La Frontcra, Casilla 54-D, Tcmuco,
Chile. 6To
whom all correspondence should be addrcsscd.

h
ho
h,
4
t
4
s
U

U,
V,
v,:
Y

Humid enthalpy of moist solids, kJ kg-

Lifter volume per drum length, rn, m-
Heat transfer coefficient, kJ s- C m -3
Delay operator
Time, s
Average falling time of the particles in the
drum, s
Slope of the drum, mm
Manipulated variable
Positive roots
Axial solid velocity, m sm
Axial gas velocity, m s 1
Measured variable

Upper cuse letters

A
Drum cross section, m2
Parameter in drying model
A,
Heat transfer area, rn
A.5
Biot number
B,
D
Drum diameter, m
Effective diffusivity, m2 s
D,,
Parameter in drying model, K
-6,
Fourier number (D,#/R2)
F,,
G
Mass flowrate of dry air, kg s
H
Humid enthalpy of gas phase, kJ kg-
Enthalpy
of saturated vapour, kJ kg-
H,.,
Proportional
gain
K
Food Control

1998 Volume

9 Number

195

Direct rotary dryers: J. R. Pbrez-Correa

NR
Nu,
R
Rep
T
7
7-d
T,
TO
T,,
U,
u
X
xc,
X*
Y
Z

et al.

Parameter of drying model, s

Mass flowrate of dry solid, kg s
Lifter length, m
Drying velocity, kg kg s
Number of lifters in the upper half of the
drum
Rotation speed, s
Nusselt number
Particle radius, m
Reynolds number
Temperature, K
Reference
temperature
for
internal
energy, K
Derivative time, s
Integral time, s
Reference temperature for variable diffusivity model, K
Sample time, s
transfer
volumetric
coefficient,
Heat
kJs- C-1 m-7
Vapour internal energy, kJ kg
Dry base solid moisture content, kg kg
Dry base initial solid moisture content,
kg kg~m
Dry base equilibrium
solid moisture
content, kg kg -
Dry base gas moisture content, kg kg
Axial distance, m

Greek letters
h
Vaporisation enthalpy at T =
Ts+To, K
P
D,,lR=, s
Y
62
Length of a discrete element,
Internal energy change due
&
tion, kJ kJJ
Retention time, s
+
Apparent density of the solid,
PR
Particle density, kg m 3
P,J
Subscripts
k-l
Inlet in dryer mode1
k
Outlet in dryer model;
discrete control algorithm
Gas
phase
g
s
Solid phase

T, kJ kg

m
to vaporiza-

kg mm.

time

interval

in

Superscripts
d
Delay time
n
Order of a linear dynamic model

INTRODUCTION
Rotary dryers are usually employed to dry large
volumes of economically significant products, such as
fish meal and mineral concentrate. The complexity of
the interaction
among mass, heat and momentum
transfer phenomena, make it very difficult in practice
to operate a direct rotary dryer well. Automatic
196

Food Control

1998 Volume

9 Number

control plays a key role in improving process operation and product quality. However, long response
delays and dead times, the variable composition
of
raw materials and lack of adequate on-line instrumentation are all factors that hinder the development
and implementation
of efficient control systems for
direct rotary dryers.
Now that it is simple and inexpensive to implement
sophisticated algorithms in computers, it is possible
to overcome many of the difficulties, to a degree, by
using advanced control algorithms. In order to test
the effectiveness and limitations of such algorithms, it
has become convenient to develop a simulator that
can reproduce the main dynamic characteristics of
the process.
The modelling of a rotary dryer includes mass and
energy balances applied to a process that exhibits the
combined effects of mass and heat transfer. There
are several published papers that deal with steady
state modelling
of a rotary dryer. These models are
used to predict humidity and temperature profiles of
both phases inside the dryer. They differ in the way
the drying kinetic, the retention
time and the heat
transfer are described (Shofield and Glikin, 1962;
Kamke and Wilson,
1986; Shene et al., 1996).
However, there are few papers dealing with dynamic
modelling
of rotary dryers. Among the latter we
should mention the paper of Balchen and MumeC
(1988), where four partial hyperbolic
differential
equations are obtained.
While this mode1 used a constant drying velocity it
did not include varying the solids flowrate. The equations were solved with a finite difference method.
Tihua (1986) developed a dynamic model to study
the performance of an adaptive Dahlin controller.
The model also includes four partial differential
equations, but with constant coefficients for heat and
mass transfer; the method of lines was used to solve
the equations. Najim (1989a) and Wood et al. (1986)
analyzed the performance
of advanced adaptive
controllers
also using phenomenological
models.
However, these models include simplified mass and
heat transfer relations that are of limited applicability
in practice. This is especially true when the solid has
heterogeneous characteristics, like fish meal or other
products of biological origin.
This work, like the articles mentioned above, also
deals with the dynamic modelling
and control of
rotary dryers. However, it includes several new
features, like varying solids flowrate, drying kinetic
obtained from first principles and the evaluation of
an extended horizon adaptive controller
(PerezCorrea et al., 1995) with the latter particularly suitable for processes with large and varying dead times.

MODELLING
The model is obtained from dynamic mass and
energy balances applied upon a discrete element of

et al.

Direct rotary dryers: J. R. Phez-Correa

Folids average residence time

Alvarez and Shene (1994) developed a model for

residence time using data obtained in a 3 m long pilot
rotary dryer of 0.3 m diameter. This model considers
both the feedstock physical properties and the drum
characteristics:
41 l.d~ll.Oh5.,,~Kl2

0.0~659.d~;~2.p~

+=
SOLID

Figure

F.NR(18.95s+

Control volume for mass and energy balances

the dryer (see Figure I). In addition,

design simplifications are included:
adiabatic
negligible
constant
the drum
negligible
effects
constant
constant
negligible

dryer
radial gradients
average residence
radiation,

time

diffusion

6 5.G

the following

of solids along
and

conduction

1)

27.22.~ + 1

(5)

-29.19.s+1

where s is the slope of the drum (m m-l), d,. (m) is

the average particle diameter;
pe (kg m - ) is the
apparent density; F is the dry solids flowrate (kg s-l),
G is the gas flowrate (kg s- ) and NR is the rotation
speed (rotations s-l).
Physical properties

gas hold-up
physical properties
pressure drops

Humid

heat of moist solids:

c,, = c, +xc,,
Humid

Mass and energy balances

(6)

enthalpy of moist solids (dry basis):

h = c,,T,

(7)

Applying mass and energy balances to both phases in

a discrete element of volume, as shown in Figure I,
the following equations can be obtained for each k
element (Cubillos, 1992):

Saturated
0C:

Solid moisture

Specific heat of wet gas at constant volume:

content, X:

vapour enthalpy

based on liquid

water at

H,., = c,,T,+ h.Y

(8)

c, = c,<+c,:Y

(1)
Gas humidity,

H = (c,+Yc,,,) T,+h.Y

Y:

Internal

(2)
Solid temperature,

(9)

Enthalpy of wet gas:

(10)

energy of vapour:

U, = c,,(T-~)+E*Y

(11)

Heat transfer coefficient

T,:

hd
(3)

The modelling of heat transfer in cascading rotary

dryers, can be approached using an average heat
transfer coefficient for all the suspended particles at a
given instant within the drum. Shofield and Glikin
(1962) defined a heat transfer coefficient, h,, using
the following equation:
Q, = h, A, AL,.

Gas temperature,

(12)
Langrish et al. (1988) estimated the heat transfer
area, A,, using a mass balance on the material
entering the upper half of the drum, resulting in:

T,:

A, = N,.h,,*p,,N,.t,.L;p

phase a dynamic enthalpy

(Denn, 1986). A dynamic
has to be used instead
1995).

(13)

p,a&

(4)
Note that for the gas
balance is inappropriate
internal energy balance
(Perez-Correa and Farias,

In rotary dryers the amount of gas that bypasses

the solid particles may be significant, especially for
small ones. Under this condition, it is reasonable to
use the heat transfer relationship
proposed by Kunii
and Levenspiel (1991) for fluidized beds:
Food Control

1998 Volume

9 Number

197

Direct rotary dryers: J. R. Pkrez-Correa

et al.

0.25

Table

I
0.20

. Data

-0.03.R:;,,
0.034.Re

.
.

1.

0.05

variables and parameters of the pilot rotary

Mean particle diameter

Particle density
Dry solid flowrate
Inlet solid moisture content
Inlet solid temperature
Inlet flowrate of dry air
Inlet air moisture content
Inlet air temperature
Drum diameter
Rotation velocity
Drum length
Solids residence time

z
0.10

Operating

015

dryer

0.00 I

m
12OOkgm
0.017kgs
0.27 (kg of water)/(kg of dry solid)
50 C
0.0304 kg K
0.005 (kg of water)/(kg of dry air)
150C
0.3 m
9 rpm
3m
0.0012

480 s

10

20

30

40

50

60

Re
Figure

Validation

of heat transfer coefficient correlation

F,, = Fourier number = D$

(19)

Nu I = 0 .03 ReI

(14)
In the present model, the experimental
value of
Nu,, was obtained from an energy balance in each
section of the drum (Zavala and Moya, 1994). Figure
2 compares the values of Nu,, obtained from energy
balances with those given by the fluidized beds correlation. It can be seen that the data show too much
caused by measurement
difficulties.
dispersion,
However, the least square fit of the experimental
values gives a slope slightly different (0.034) from
that of the Kunii and Levenspiel correlation (0.03).
Moreover, if those experimental values that deviate
more are not consider in the least square fit, the
slope gets quite close to 0.03. Given this, it seems
reasonable to apply equation (14) to estimate the
heat transfer coefficient in the rotary dryer model.
Drying kinetics

Two drying models based on mass transfer principles

were used here; the variable diffusivity model and the
combined resistance model (Shene et al., 1996). Both
models were successfully applied in describing the
drying kinetics of a wide spectrum of particulate solid
materials.
Combined
N=

--$

resistances model:
=6(&,-X*)

i A,ufe-ufF,,
,=I

(15)

Zavala and Moya (1994) calibrated the variable

diffusivity drying kinetic model, with experimental
data obtained in a pilot rotary dryer (Table I) with
soy meal as the substrate. It was found that the
effective diffusivity (D,,) follows an Arrehnius type
function, as suggested in Crank (1975):
) = K,, exp( -;

(20)

In order to calibrate this model properly, several

experiments were carried out where operating conditions, such as inlet air temperature, inlet air flowrate,
inlet solid water content and inlet solid flowrate, were
varied over a wide range (Zavala and Moya, 1994).
Measurements were taken at steady state every 30 cm
along the length of the drum. As an example, Figure
3 shows the steady state profiles for T, = 25OC,
T, = 24C, L = 0.0202 kg s , G = 0.076 kg s- and
X=0.477kgkg~.
In the drying kinetics model (equation (18)), the
coefficient h was set to - 10, which yielded a reasonable approximation
over a wide range of operating
conditions. The Arrehnius type model for y (equation
20) was fitted with experimental
data for different
250

200
where,
A = (SW,) -w COS(~,))~
d,(u, - sin(u,) cos(u,))

(16)

and U, the positive roots of the equation,

U, = (1 -B,) tan(u,)

(17)

Variable diffusivity model:

+x

(18)
i
Figure3

with,
198

Dryer
Food Control

1998 Volume

9 Number

Experimental

+Ts+Tg

steady state profiles in the Pilot Rotary

Direct rotary dryers: J. R. PBrez-Correa

-6.0

-6.6 .__.______;. . . . . . ..i

i . . . . . . . . . . . . . . . . . i ._._._..; __......

-8.4 _......___; . . . .._.. i ._._._..i _----.-. h...is

. . . . . . ---.-.-..

-9.0 T
26

29

30

31

32

33

34

B
o data

model

35

et al.

mainly through water evaporation

from saturated
surfaces, the gas flowrate will strongly influence the
moisture content of the product due to changes in
both the heat and mass transfer surface coefficients.
However, if the water has to diffuse from within the
particle, the gas flowrate will not appreciably affect
the moisture content of the product. The majority of
industrial fish meal dryers, for example, use the inlet
gas temperature
indirectly as an input variable, by
manipulating
the fuel flowrate (JerCz and Peters,
1990).
It is assumed, in this paper, that the inlet gas
temperature
is manipulated
directly and the solid
moisture content is measured on-line.

Figure 4 Calibration of drying kinetic model

Control

solid temperatures as shown in Figure 4. Here, the

experimental
value of y was obtained from the integration of equation (18), using a value of b = - 10
and measured values of X. The calibration parameters were K,] = 1.066 [s- 1 and E, = 2440 [K].
The dynamic model of the rotary dryer, which
includes all of the above equations, describes the
evolution over time of the following variables: X, Y,
T, and T,. Table I displays the specifications of the
pilot rotary dryer. Through trial and error, it was
determined
that a model deploying
10 discrete
elements could represent the behaviour of the rotary
dryer sufficiently accurately (Zavala and Moya, 1994),
without consuming too much computing time.

Two digital control algorithms were tested, a PID and

an extended horizon selftuning regulator
(PCrezCorrea et al., 1995). The PID is the most widely used
control algorithm
in the process industry, and is
particularly useful in controlling linear systems with
non varying dynamics (constant process gain and time
response). The control action is computed in an ideal
PID according to;

CONTROL
Manipulated

and control variables

There are several strategies for automatic control of

direct rotary dryers. Inlet gas temperature, gas flowrate, solids feedrate and rotation velocity of the drum
can be considered as manipulated
variables. The
usual control objective is the product moisture
content. However, it is seldom measured on line.
Other plausible output objectives are the outlet gas
temperature
and humidity,
and outlet
solid
temperature.
Under normal operation, the solids feedrate and
rotation velocity is fixed by the operator in order to
avoid overheating
resulting from poor solid/gas
contact. In addition, these inputs affect the controlled
variables too slowly. Consequently, these are rarely
used as manipulated
variables. Although the gas flowrate is easily manipulated
and has a strong and fast
effect in the output variables, it is also not normally
used as a manipulated
variable. This is because its
operating range depends on the characteristics of the
solids, and therefore a fluidynamic analysis has to be
performed
to estimate the quantity of particles
discharged by the gas. Furthermore, the effect of the
gas flowrate on the output variables is highly
dependent on the drying mechanism. If drying occurs

algorithms

de (4
dt

e(t)dt+ T,,-

(21)

where u is the manipulated

variable (inlet gas
temperature) and e the output error (X,-X,,,).
Here,
the design is restricted to finding appropriate values
of the control parameters K,, T, and T,, and is known
as control tuning. However, as this algorithm cannot
be directly implemented
in a digital computer, equation (21) is discretized giving the following algorithm;

(22)
where T,, is the sample time and the subscript k
refers to the time interval.
Normal industrial processes are non linear and
exhibit varying dynamics. As a result, the PID algorithm does not always work properly and requires
periodic tuning. In these situations adaptive controllers would perform better, as they follow the process
dynamics through using on line estimation of model
parameters. An adaptive controller
consists of a
process model, a control algorithm and a recursive
parameter estimation. A typical process model is of
the form;
Nq >yl = B(q--)u,
(23)
where y is the observed variable, u is the input variable, k refers to the time interval and q- is a delay
operator (q yI =yk~ ,). A and B are polynomials in
9 ;
A(q )= l+a,q-+ag2+...+a,,q
-I
(24)
Food Control

1998 Volume

9 Number

199

Direct rotary dryers: J. R. PBrez-Correa

B(q-)

et a/.

=q-(b,+bq-+...+h,,q-~I)

(25)

The data used in this model can be the full value

of the variables or the difference between the present
and past values. In the first case, the model is called
positional while in the second it is called incremental.
There are several control laws that can be used in
adaptive control,
however an extended horizon
controller is easy to use and robust to disturbances
and variable time delays, as shown in Kershenbaum
and Perez-Correa (1989). The basic idea is to obtain
an output predictor
and then select a control
sequence that drives the output to the reference at a
pre-specified future time. If the parameters of the
output predictor model are directly estimated on-line,
the control algorithm is called implicit. On the other
hand, if the parameters of the output predictor model
are calculated from on-line estimates of the process
model parameters, the algorithm is known explicit.
In this work, a recursive least squares with variable
forgetting factor (Fortescue et al., 1981) is used for
parameter
estimation,
and an explicit/incremental
extended horizon algorithm for control computation.
A brief version of this controller
is given in the
Appendix; a complete derivation can be found in
Jadrijevic (1991). The algorithm
has three tuning
parameters: the model order, the control horizon and
the memory length of the estimator.
The tuning of the PID parameters was based on
the classic ultimate response rule to obtain a first
approximation,
and then adjusted by trial and error
with the simulator. Although the tuned parameters
do not produce tight control, they ensure stable
operation for all kinds of disturbances. The adaptive
controller was tuned by increasing the model order
and the time horizon from 1 on, until proper control
was achieved. Next, the memory length was varied
from 10 7 to lo-, and an optimum value was finally
selected. An average step response time in the actual
pilot dryer is T, = 800 s, and consequently
an
adequate sample time was found to be 100 s (Najim,
1989b). Table 2 summarizes the control parameters
used in the simulations.

RESULTS
It was found that the model reproduced the main
features of the observed process dynamics well, those
such as the inverse rlsponse in the water content of
the outlet solid stream. On the other hand, a model
Table

Tuning

paramctcrs

PI11
500
100
loo

Y
T,
T,
Adaptive
N
771
z,.

200

2
3
10

Food Control

1998 Volume

9 Number

kg/(kg
5
s

C)

sensitivity analysis (Zavala and Moya, 1994), showed

the highly non-linear characteristics of the process,
with three fold variations in some parameter values
(see Table 3).

To compare the performance of the control algorithms mentioned

above, the simulated controlled
process was subjected to three consecutive step
disturbances in those variables, that from industrial
experience, most affect the operation of the dryer.
Hence, inlet solids flowrate, moisture content, the
velocity inside the drum (which represents changes in
particle size distribution)
and set point changes were
considered, as shown in Table 4. Other perturbations
like inlet solid temperature, physical properties (Cp,
density, etc.) or gas flowrate, were not considered
here as they do not cause control problems or are
almost constant under normal operation.
Control performance
was measured using the
following indices;
Summation

Time Absolute Error

6sman
= STAE = ,;, k.ABS(e,)

Summation
= SSE=

Square Error
k I.,\
1 e,
k=,

Square Control U
I lilX
= ssu = ,;, (L&-24- ,)L

(26)

(27)

Summation

G-9

Table 5 gives the values of the normalized control

indices for all the simulation runs.
Figure 5 shows the evolution
of controlled
and
manipulated
variables for both the system controlled
with PID and that with an adaptive controller, under
disturbances in the solids feedrate. The adaptive
controller (AC) keeps the output closer to the reference, but requires stronger control action. The first
disturbance causes a deviation in the output with the
PID control mode that is not observed with the adaptive mode. For the other two disturbances, the PID
mode generates larger output deviations than the
adaptive mode. The control action appears much
stronger with the adaptive controller. The indices
(Table 5) confirm what is seen in the figure; the error
indices (STAE, SSE) are, respectively, four and eight
times higher for the PID and the control index (SSU)
is six times higher for the adaptive algorithm.
The most difficult disturbance to attenuate is the
inlet solid moisture content, where input and output
responses are given in Figure 6. Here the adaptive
controller clearly outperforms the PID, with considerably smaller overshoots and shorter settling times.
Again, the cost that must be paid is that of stronger
control action. The error indices are three times
lower for the adaptive controller and the control
action index is eight times higher.
Figure 7 shows the system response for disturbances in solids velocity. Here the adaptive controller

Direct rotary dryers: J. R. PBrez-Correa

Table

Transfer

function

parameters

for inlet air tcmpcrature

et al.

disturbance

output

(I (s)

T (s)

K [kg/(kg

X
Y
T
TV

27.5<0<44.1
1.4<0<2.4
4.1<11<9.9
1.0<0<2.4

8Y.4<r<l63.1
23.h<r<83.6
3).4<r<Y7.1
3Y.Y<s<8X.2

-5.05~10
l<K<
-2.99.10
0.18~10 <K<2.09~10
0.16<K<O.54
0.24 < K < 0.65

keeps the output closer to the reference than the

PID, specially after the first disturbance. However,
the PID controller responds smoothly and the adaptive controller very actively. According to Table 5, the
error indices are 2-3 times lower and the control
index is over 10 times higher with the adaptive algorithm compared with the PID.
As shown in Figure 8, both controllers respond well
for set point tracking. Although, the control action
with the adaptive algorithm looks more oscillatory.
There is no clear difference between the algorithms
in terms of output regulation, In Table 5 the PID
exhibits a 15% higher STAE index, a 10% lower SSE
index and a 20% lower SSU index than the adaptive
controller.
Table

Apphcd

disturbances

Input

Dlsturbancc

Disturhancc

IXsturbance

L
X

0.020
0.30

0.0150
0.23

0.017
0.27

0.00830
0.150

0. IYO
O.OOf~25

0.1 x2
0.00500

Normalized

Input

control

performance

0.20

0.18

B
3 0.16
25
X

0.14
150
0.12

50

0 10
0

25

50

75

100

125

150

Time [min]
Figure
6 Outlet
dlsturhances

solid

m&ture

control

under

inlet

solld

moisture

3
0.22

450
PID
-AC

0.20

350
+

indlces

0
250 e
l-

Adaptwe

150

STAE

SSE

ssu

STAE

SSE

ssu

L
X
Ii
Set point

0.33 1
l.(HK~
0.157
0.467

0.222
1 .ooo
0.020
0.X67

O.OI 5
0.124
O.007

0.077
0.301
0.059
0.406

0.027
0.313
0.020
0.Y52

O.OYh
1 .ooo
0.101
0.482

0.305

0.12

0.10 '
0

1 50
25

50

75

100

125

150

Time [min]
Figure
7 Outlet
dlsturhanccs

0.22

ijl
e
P

250

G
s
mu 0.16
Y

PlD

450

0.22

0.18

Table

C)

solid

moisture

control

under

inlet

solid

velocity

450
450

0.20
350
0.18

350

a
s
c1) 0.16
25
X
0.14

250

E
I-

250

0
&
I-

150
0.12

150

0.10

50

25

50

75

100

125

150

50

Time [min]
Figure 5 Outlet
disturbances

solid

moisture

control

under

inlet

solid

25

50

Timlimb]

100

125

150

flowratc
Figure

8 Outlet

solid moisture

Food Control

cwtrol

under

1998 Volume

set point

disturbances

9 Number

201

Direct rotary dryers: J. R. Pbrez-Correa

et al.

CONCLUSIONS
The dynamic model developed here can reproduce
the observed qualitative dynamic behaviour of industrial and pilot rotary dryers. The main feature of this
behaviour is the presence of long dead times and
time responses in the solid phase, with much quicker
outputs associated with gas phase responses. The
process is extremely non-linear
since the transfer
function parameter values are highly dependent on
the point at which it is operated.
Simulation
results showed that both PID and
adaptive control algorithms are able to regulate the
main outputs when the dryer is subjected to the kind
of disturbances normally found in industrial plants.
However, the adaptive controller
yielded error
performance indices 3-8 times lower than the PID,
although it also presented 6-10 times higher control
action indices. Of course these results are tuning
dependent, but less tuning effort was spent on the
adaptive controller than the PID. The good regulation performance of the adaptive controller is due to
its capacity to detect the changes in the dynamic
behaviour of the dryer.

Najim, K. (1989a) Modelling and learning control of a rotary

phosphate dryer. International
Journal of Systems Science 20(9),
1627
Najim, K. (1989b) Process Modelling
and Control
in Chemical
Engineering.
M. Dekker Inc., New York
PCrez-Correa, J. R. and Farias, F. (1995) Modelling and control of
a spray dryer: a simulation study. Food Control 6(4), 219-227
Perez-Correa, J. R., Septilvcda, F. R. and Duarte, M. A. (1995)
Adaptive control in a heating vessel: a comparative study. International

Journal

of Adaptive

Control

and

Signal

Processing

9,

183-197
Shene, C., Alvarez, P.I., Cubillos, F. and Perez-Correa, J. R.
(1996) Modeling and simulation of a direct control rotary
dryer. Drying Technology 14( lo), 2419-2436
Shofield, F. and Glikin, P. (lYh2) Rotary dryers and coolers for
granular fertilizers. Transactions
of the Institute
of Chemical
Engineers 40, I83
Tihua, W. (1986) Modelling and design of an adaptive control
system for a rotary dryer. Proceedings of IASTED, Geneva,
Switzerland
Wood, H., Jawuanda, K. and Sokhansanj, S. (1986) Simulation and
control of the dehydration process. Proceedings of IASTED,
Vancouver, Canada
Zavala, E. and Moyd, A. (1994) Simulaci6n DinBmica y Control de
un Secador Rotatorio Piloto de Contact0 Directo. Memoria de
titulo (in Spanish), Depto. Ing. Quimica USACH, Santiago,
Chile

ACKNOWLEDGEMENTS

APPENDIX

The authors wish to thank the support received by

FONDECYT
through projects 344/92 and 640/93.

The explicit/incremental
regulator

extended horizon selftuning

Preliminary computations

REFERENCES

AYE=y,-yk

Alvarez, P. I. and Shene, C. (1994) Exerimental study of residence

time in a direct rotary dryer. Dlying
Technology
12(7).
1629-1651
Balchen, J. and Mume& K. (1988) Process Control Structures and
Applications,
Appendix L. VNR Co, New York
Crank, J. (1975) The Mathematics
of Diffusion.
2nd edn. Oxford
University Press, Oxford
Cuhillos, F.A. (1992) Simulaci6n dinamica y control de secadores
rotatorios directos. M.Sc. thesis (in Spanish), Depto. de Ingenieria Quimica, Univ. de Chile, Santiago. Chile
Denn, M.M. (1986) Process Modeling. Longman Inc., London
Fortescue. T. R., Kershenbaum. L. S. and Ydstie, B. E. (1981)
Implementation of self-tuning regulators with variable forgetting factors. Automatica
17(b), 831
Jadrijevic. M. (1991) Selecci6n de Controladores Adaptables
Robustos. Memoria de titulo (in Spanish), Dpto. de lngenieria
Quimica, Univ. de Chile, Santiago, Chile
JerCz, J. and Peters, E. (1990) Practical aspects of automatic
control. IAFMM Workshoo on Fish Meal and Fish Oil Oualitv
_ i
and Processing, Island

Kamke, F. and Wilson, J. (1986) Computer simulation of direct

rotary dryers. AICHE Journal 32(2), 263
Kershenbaum, L. S. and Pkrez-Correa, J. R. (1989) An extended
horizon feedbacwfeedforward
self-tuning controller. AICHE
Journal 35( 1 l), 183.5
Kunii, D. and Levenspiel, 0. (1991 FIuidization
Engineering,
2nd
edn. Butterworths series in Chemical Engineering, Oxford
Langrish, T. A. G.. Raey, D. and Bahu, R. E. (1988) An investigation into heat transfer in cascading rotary dryers. Journal of
Separation
Procedures
Technology 9, 15-2

202

Food Control

1998 Volume

9 Number

$A., =

1,

Au,

[&-,,AY~

u,

1 -uk

-2,

vk

a...,&-,,+,;Auk.

=yk.-jZ

,,...,k

(Al)

r,,-,,+,I

0k ~, = [-a,,--a2,...,--a,,;h,,h2,...,h,~,+,,~,l

where y is the measured variable, u is the manipulated variable, v is the estimation error, d, is the data
vector and 8 is the estimation vector. The a,s and b,s
are estimated parameters.
Parameter

estimation

Wk= 4h ,,,Pk 14J3k,,,;

?L, =

K =p
P

I@--I;,

h,+w,

n,+jnL,+4w,

V2k
- ;
ic i
W)

2
0, = 0, ,+Kkvk;

pk=

n,=l-w,-

643)
P

k-

-K, K:(h,+w,)
hk

P is the covariance

the forgetting

matrix, C the memory length, h

factor and K the Kalman gain.

et a/.

Direct rotary dryers: J. R. PBrez-Correa

Control

computations

IX= IiI k,f;,

Au, =Y:+?;,- Y,
;K =y,+ ,=I
i a,Ayy,,+,-,
IL;.
+

,r+T,,- I
C PT,,+,Au~--r
,=I

@,= - ,=,c a&,,+,

~,-I>
qi = Min{n,T,,

- 1 +i}

Vi = l...n+2T,,-2;

r= Min{i-l,T,,-1);
,-I
fi = l- ,&%-,L

p = Max{O,i-n-T,,+l}
Vi= l...T,I-l;pi=Max{i,n);

fh= 1
Vi= l...n;

y* is the set point, Y is the predicted output based on

present data, and ol,s and p,s are the control
parameters.

Food Control

1998 Volume

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203