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The function of the gas-fired burner is to be the source of heat energy into the AST Dryer. The burner heats the process air to an elevated temperature (400°-1200° F) and is responsible for controlling the energy balance of the system. The energy control is achieved by monitoring the process control thermocouple located at the discharge of the dryer. The drying system utilizes a PID loop (via the PLC) to maintain a set point by controlling the firing rate of the burner.

The burner is typically a direct-fired gas burner complete with flame supervision system, fuel train, etc. Other fuel options include propane vapor, fuel oil or an indirectly heated system.

The Inlet Zone achieves size reduction (when applicable) and the majority of moisture evaporation. This is accomplished by a highly turbulent agitator area and efficient mixing area utilizing adjustable paddles.

The agitator plates (with a high concentration of fixed blades) work to reduce the product into small pieces and provide a highly turbulent zone for efficient heat transfer. The smaller particle allows for more efficient heat penetration into the material and also allows the moisture to more readily escape to the surface as a vapor. High velocity achieved in this zone, 11,000-12,000 ft/min, further aids in the efficient transfer of heat to the material.

This combination of velocity and agitation, working in concert with a high temperature differential, results in efficient and rapid evaporation. This zone of the dryer is sometimes considered the “flash zone” of the unit.

Further downstream in the first zone are a set of adjustable paddles that allow for back mixing. Product that is still moist and potentially sticky will continue to be agitated and back-mixed via the adjustable paddles until it can be carried into the next zone by the airflow. The back-mix process is continuous with some product being carried over as new product is introduced.

At the division between Zone 1 and Zone 2 is a set of air dams. The purpose of these dams is to classify the product. Material that is dry enough to be free flowing and easily conveyed by the air stream can pass on to the next zone.