Enhancing gas-solid fluidized bed dryer performance with horizontal axis rotary agitators: a simulation approach

Abstract High energy consumption in fluidized bed dryers (FBDs) remains a critical challenge for tea processing, largely due to poor fluidization quality of sticky, irregular, and non-uniform tea particles. To address this issue, this study investigated the potential of horizontal-axis rotary agitators to improve the hydrodynamics of a gas-solid FBD and reduce energy losses. Computational fluid dynamics (CFD) simulations were performed using the two-fluid model combined with the kinetic theory of granular flow (TFM-KTGF), focusing on key parameters including pressure drop, standard deviation of pressure drop, solid volume fraction distribution, and granular temperature. Some configurations were analyzed: a bed without an agitator, and beds equipped with rotary agitators of varying blade numbers (three and five) and diameters (200 mm and 300 mm) at different rotational speeds. The results demonstrated that introducing a horizontal-axis rotary agitator significantly improves fluidization. The largest rotary domain (five blades, 300 mm diameter) achieved the lowest pressure drop of 315,135 Pa at 6.28 rad/s, while also promoting more uniform solid distribution and increasing granular temperature up to 2.5 × 10⁻ 3 J/kg. The agitator enhanced particle circulation, expanded lean regions within the bed, and reduced dense packing, leading to improved gas-solid contact and reduced resistance to airflow. Furthermore, increasing the agitator speed decreased pressure drop and its standard deviation, while increasing the granular temperature, confirming the beneficial effect of enhanced stirring energy. This study highlights the effectiveness of horizontal-axis rotary agitators in enhancing the hydrodynamic performance of FBDs, offering a promising approach to improve energy efficiency and drying uniformity in tea production. The insights presented here can guide future design and optimization of industrial-scale dryers handling cohesive, irregular particles.