Dryer systems: Optimizing efficiency and quality

Dryer systems

Key Takeaways

Dryer systems require a coordinated combination of process engineering, control technology and energy balancing to ensure product quality, energy efficiency and process stability at the same time.
The CONENGA Group optimizes dryer systems by combining process and control strategies to reduce energy consumption, emissions and unstable operating conditions.
Using model-based control, data analysis and soft sensors, fluctuations in material moisture, temperature and throughput can be detected at an early stage and automatically compensated for.
Modern drying processes use recirculation, load forecasts and dynamic control algorithms to minimize specific drying energy and stabilize exhaust air conditions.
The CONENGA Group integrates simulations, plant balancing and APC solutions into existing industrial plants to enable stable production conditions and low-emission operating modes.

We are looking forward to answering your questions
Dominik Gappmaier & Bernhard Kronberger are your experts when it comes to dryer systems!

We are familiar with a wide range of process engineering challenges for different types of dryers and in specific industries. You benefit from this wealth of experience in combined process and control engineering optimization. The customized control concept gets the maximum out of your dryer systems, usually leading to smoother and therefore more robust operation with consistently high energy efficiency, quality and performance of the drying process.

Your advantages at a glance

High energy efficiency, corresponding economic efficiency
Quiet, robust operation
Constant product quality
Emissions within the limit values
High degree of automation
Transparent KPIs

Our extensive experience from many implemented projects is integrated into our EPOC Dryer product.

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The CONENGA Group combines process engineering, simulation, advanced process control and data analysis for the energy-efficient and low-emission optimization of industrial dryer systems.

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Dryer-specific design levers

Indirectly heated drum dryers

- Shortening the start-up times of a dryer after standstill (rapid achievement of a stable operating state, e.g. for chip feeding)
- Stable discharge of condensate from the tube bundles
- Good material transport in the drying drum
- Optimum drying air recirculation with centre extraction
- Automatic optimization (minimization) of specific energy consumption for chip drying
- Avoidance of oscillations of the exhaust air temperature
- Avoidance of chip supply shutdowns due to “dryer clogging

Directly heated drum dryers

Epoc Dryer, moisture sample from laboratory

- Optimum process control with and without exhaust air recirculation for energy-efficient operation through optimum saturation of the drying gas
- Optimum loading and temperature of the extract air, taking into account the humidity balance (sorption isotherms)
- Good material transport in the drum

Trough-air drying (screen drum and belt dryers)

- Minimization of the specific drying energy requirement
- Optimum throughput
- Minimization of start-up times
- Minimization of rejects during start-up and in the event of malfunctions

Airstream dryer

- Optimum energy distribution with 2-stage drying
- Maximum recirculation of drying air by regulating the negative pressure
- Regulation of exhaust air temperatures, thus optimum saturation of the drying air

Dryers of paper and coating machines

- Fast automatic ramp-up after tear-off and standstill from performance speed to maximum target speed – especially for “light” products (low grammage)
- Maximizing the target speed while maintaining the highest product quality, especially for “heavy” products (high grammage)
- Minimization of grammage change waste by accelerating grammage changes
- Automatic provision of optimized tear-off/feed cylinder parameters
- Maximum quality with high energy efficiency
- Automatic detection and visualization of the maximum speed, taking into account the condition of the line
- Visualization of limiting factors

Depending on the technology, we use the basic levers mentioned above in our combined process and control optimization.

Further links & information:

APC - Advanced Process Control

Plant conversion (turnkey)

BCS® Suite

EPOC® Dryer

EPOC, Industry-specific solutions, Boiler, Distant Heating, Steam Manager, Dryer, Load Hierachy Management

EPOC® Suite

Potential studies

Controller technologies

Fire power control

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Further links & information:

APC - Advanced Process Control

flue gas cleaning

Facility conversion

Soft sensors

BCS® Suite

EPOC® Dryer

EPOC® Suite

Potential studies

Controller technologies

Fire power control

dynamic simulations

Asset accounting

FAQ about dryer systems

What are drying systems?

Drying systems are process engineering systems for the targeted reduction of the moisture content of materials, products or raw materials in industrial processes. They are used in the wood, paper, food and process industries, among others, to ensure defined material properties and stable production conditions. Temperature control, air flow, energy efficiency and control technology play a key role in product quality and cost-effectiveness. The CONENGA Group supports industrial companies in the optimization of drying systems through engineering, simulations, advanced process control, data analysis and the integration of energy-efficient control concepts.

How do industrial drying systems work?

Dryer systems remove moisture from materials through controlled heat and air flow processes. The temperature, air volume, pressure ratios and dwell times are continuously regulated to ensure a constant residual moisture content. Depending on the application, drum dryers, belt dryers, airflow dryers or drying systems are used in paper machines.

How can the energy efficiency of drying systems be improved?

Energy efficiency is improved by optimized air recirculation, precise temperature control, load adjustment and stable humidity control. In addition, model-based control strategies reduce unnecessary overheating and unstable operating states. The CONENGA Group develops combined process and control technology optimization concepts including system balancing and dynamic simulation.

What role does control technology play in dryer system emissions?

Unstable drying processes often lead to increased energy consumption and fluctuating emissions. Precise control of heat sources, air flows and process conditions can stabilize combustion conditions and ensure compliance with emission limits. The CONENGA Group integrates APC systems and adaptive control algorithms into existing plant structures for this purpose.

Why are data analysis and soft sensors relevant in dryer systems?

Many relevant process variables can only be measured directly to a limited extent or fluctuate greatly during operation. Soft sensors and data-based models make it possible to calculate critical conditions such as material moisture, heat quantities or process stability in real time. This allows control strategies to react more quickly, reduce rejects and stabilize product quality.

Can existing dryer systems be subsequently optimized?

Existing systems can often be technically improved without having to be completely rebuilt. Typical measures include the integration of modern control technology, the optimization of air flow, the analysis of energy losses and the stabilization of critical process variables. The CONENGA Group provides support from data analysis and potential studies through to commissioning and performance optimization.