Numerical simulation of a greenhouse coffee drying

system using a continuous flow of hot air

Jose A. Casas Julio Chavez
Jose Oliden Leonardo Vinces
Mechatronics Engineering Mechatronics Engineering
Mechatronics Engineering Mechatronics Engineering
Universidad Peruana de Universidad Peruana de
Universidad Peruana de Universidad Peruana de
Ciencias Aplicadas Ciencias Aplicadas
Ciencias Aplicadas Ciencias Aplicadas
Lima, Peru Lima, Peru
Lima, Peru Lima, Peru
[email protected] [email protected]
[email protected] [email protected]

Abstract— This paper presents the development and Manual coffee drying methods such as sun drying are
validation of a Coffee Bean Drying System that usually inefficient, meaning that even if they help to
corresponds to the capacities and needs of small coffee accomplish a dry product, it is not usually done in the most
2022 IEEE ANDESCON | 978-1-6654-8854-9/22/$31.00 ©2022 IEEE | DOI: 10.1109/ANDESCON56260.2022.9989935

farmers in Peru, which are specifically harvested in optimal way. This means that while they are easy and cheap
regions greater than 800 meters above sea level. This methods to execute, they offer no control of the variables
dryer utilizes hot air, which will be introduced into the that affect the drying rate. Another disadvantage of this
drying area by a fan, it will be heated using electrical methods is that they depend heavily on favorable climate
resistances thanks to the principle of Convection, and a conditions, often producing overlabor and delays. For
new air distribution system will homogenize the flow and example, if it happens to rain over a drying patio, all grains
speed of the hot air to which the trays filled with coffee must be removed and stored until the rain ends. For these
beans will be exposed. The coffee beans will enter with reasons, drying is usually not uniform. In addition, it should
an approximate humidity of 50% and will leave the be noted that coffee beans cannot be subjected to more than
drying chamber with a degree of humidity between the 35°C, since they would lose organoleptic characteristics [5].
range of 11% to 13%. The thermodynamic analysis of All these problems affect the quality of the final product [6].
the system was carried out using Computational Fluids For this reason, a new coffee drying system has been
Dynamic (CFD) through the ANSYS program, obtaining devised, the effectiveness of which will be validated by
as a result the validation of the geometry and means of CFD in this document.
effectiveness of the hot air distribution system in the
dryer, and concluding that the implementation of said Computational Fluid Dynamics or CFD is one of the
element in the system will correspond to an increase in branches of fluid dynamics where the analysis is done by the
the total efficiency of the Coffee Dryer once simulation of fluid flows using numerical methods. Thanks
implemented. to CFD the analysis of complex systems of different
combinations (fluid-fluid, fluid-solid or fluid-gas) can easily
Keywords— Coffee Beans, Mechanical Drying, Fluid be achieved [14]. The CFD method consists of discretizing a
Dynamics, Computer simulation, CFD. region of space creating what is known as a "spatial mesh".
Meaning that a region of space is divided into small control
I. INTRODUCTION volumes. Then the discretized conservation equations are
solved in each of them [2]. In this project, the CFD will help
Coffee is the most popular beverage worldwide. It is
estimated that around 400 billion cups are consumed every to validate the geometric design of the dryer by analyzing
year [8]. The largest producer and exporter of coffee in the variables like pressure, temperature and flow variations in
the system. The necessary studies carried out on different
world is Brazil, while Peru is ranked 11th [7]. In Peru, the
types of coffee bean dryers were used as a reference for the
production is centered on the entire eastern slope of the
appropriate air flow and temperature used in the
Andes, the harvest is done mainly by hand, and it is usually
simulations.
sun-dried. Drying is important in the coffee production
process, since it serves to reduce the moisture in the grains
to an optimal range between 10 and 13% [5]. The main Prada, A et al. [13] proposes a design for a greenhouse-
type solar dryer with continuous air flow. In addition, it is
methods used today for drying are of the manual type, as
energetically powered by photovoltaic energy. This type of
mentioned above, and they include patio drying, wooden
dryer solves various problems of manual drying. The main
carts, solar dryers and African beds [15]. However, the
improvement is that it reduces the drying time from up to 14
quality of the coffee varies greatly depending on the process
chosen and the meteorological factors of the area. Kath et al. days to 5 days. However, this process time is still long and
can be improved by heating up the air.
[10] concludes that a greater probability of rain is associated
with an increase in grain defects, such as the presence of
Buitrago, O et al. [4] proposes a prototype design for
mold and a variety of fungi. Lilia et al. [11] experimented
converting a drying cart to a mechanical dryer. However,
with coffee beans by exposing them to conditions with
excessive rainfall and high humidity, founding at least 10 this design, like most mechanical dryers, works with a low
different types of fungi in each sample. However, this and volume of product. In addition, it uses high temperatures,
and, like most mechanical dryers, it lacks an adequate
other defects can be controlled by increasing the drying
temperature.

978-1-6654-8854-9/22/$31.00 ©2022 IEEE

1

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 temperature control system. This would lead to problems Figure 1. CFD simulation stages - Ansys Workbench Student.
such as loss of organoleptic properties and uneven drying. 1) ANSYS - Geometry.

Loja, G et al. [12] proposes the prototype design of an This Ansys Workbench tool allows you to import a 3D
automated coffee bean dryer. It achieves a specific humidity solid from a CAD file and, using preparation tools for
level of 11% and a drying temperature of no more than computer analysis, allows you to extract the interior volume
35°C. The control is carried out by a PLC and reduces the of the solid. Thus producing a geometry that represents the
volume occupied by the fluid within the solid. See figure 2.
drying time to 8 hours. However, the volume of work is
very low, which makes the system not beneficial for the
owner due to the high cost of implementation.

Considering the observations made from the studies

shown, this article proposes to simulate the design of a
hybrid coffee bean dryer (solar/mechanical). This solution
combines the best of mechanical drying by bringing the
grain to a controlled 35°C and of greenhouse-type solar
dryers by eliminating the disadvantages of patio drying
without losing its production capacity in kg. To validate the
geometric design and the possible impact of the hot air Figure 2. Geometry (A) and its interior volume (B).
distribution system within the dryer, numerical simulations
are made through computational fluid dynamics (CFD) 2) ANSYS - Mesh.
using the Ansys simulation software and its respective In the second sub-stage, the so-called “meshing” is
design, meshing and simulation tools. Lastly, a controller carried out. This technique is a fundamental step for the
can be added in charge of achieving the autonomy of the simulation since through it the work area is discretized. In
system. In this way, the resolution of the main problem to the present application a tetrahedral geometry is used due to
achieve a correct drying of coffee beans would be achieved. its great versatility to represent complex geometries.
Likewise, inflation will be used when the size of the
II. METHOD geometry allows it (the use of inflation increases the number
For the development of the project, two main stages of cells in the mesh, sometimes exceeding the limit allowed
have been established. by the Ansys version used). Inflation in a mesh allows
correctly capturing the velocity and temperature gradients
A. Mechanical desing of the hybrid drying system found in the system for the respective analysis. See figure 3.
In the first stage, CAD software is used to model the
drying system. SolidWorks software was used in this project,
but Inventor or SpaceClaim (ANSYS) could also be used.
The dryer its divided into two main components: the drying
chamber, and the distribution ducts used to introduce the hot
air into the chamber.
Each of the parts must satisfy certain conditions that will
be validated in the simulation analysis. Among them we have
the number of air distribution holes, their diameter, the size
of the trays where the coffee beans are, etc. It is necessary to
satisfy all these conditions in order to achieve a correct and
uniform distribution of the drying fluid (air) in the drying
area. Figure 3. Tetrahedral mesh and inflation. - Ansys Mesh.

3) ANSYS - Fluent.
B. CFD analysis
In the last sub-stage, the evaluation of the behavior of the
In the second stage, the validation of the system will be air inside the system is carried out. That is, its temperature,
carried out using the ANSYS software. This software will speed and pressure values along all the surfaces (pipes and
allow simulation and CFD analysis to be verified if the drying chamber).
system is ideal to be implemented. Parameters such as
temperature, pressure, and air speed will be used to correct
the system in order to promote the fastest and most III. DESIGN AND SIMULATION CONSIDERATIONS
homogeneous drying possible, respecting the quality A. Drying area
parameters initially set.
For the dimensioning of the drying area and later of the
To perform a CFD analysis, the Ansys software divides distribution pipes, the guidelines described by Besora, J. [3]
the process into 3 sub-stages, Figure 1. in his technical report for the construction of a solar coffee
dryer will be followed.
The structure must be able to support 40 trays of
91x91cm and weighing 20kg (of coffee). These trays will be

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 supported by horizontal beams and there will be up to 2 humidity of 11% was presented and the maximum drying
floors of trays at most. temperature used was 35°C. Also, according to Cadena [5],
35°C is the maximum temperature to which a coffee bean
B. Air distribution pipes can be subjected before starting to lose their organoleptic
Distribution piping is included as part of the drying properties. Therefore, a maximum temperature of 35°C will
system to ensure a uniform flow of hot air through the entire be used in this dryer.
system. This addition is intended to achieve an even drying 3) Environmental variables
time for all trays in the drying area.
The main two environmental variables are outside
During their design, the principle of conservation of mass temperature and air humidity. The temperature outside the
should be considered. Although we are working with a system won’t have a drastic impact in the inner temperature
compressible fluid with a changing density, the inversely since the air is in constant circulation (it is not a closed
proportional relationship between the velocity of the fluid system), this variable will only alter the amount of energy
and the area of the pipe is maintained. By this same needed to heat up the air induced into the system up to the
relationship and following the law of conservation of energy, control value (of 35 °C approx.). On the other hand,
we know that if the speed decreases, an increase in pressure humidity will affect the efficiency of the dryer, and a less-
will occur.
humid environment will produce a faster drying of coffee at
The dimensioning is carried out based on the drying area the same temperature [9]. That being said, mechanical dryers
and this is how a preliminary design of the pipe is obtained, already reduce drying times immensely, and the variation on
this being 0.3m in diameter and approximately 11 meters in air humidity won’t have a severe impact on the overall
length. The design includes an air inlet (0.3m) and 76 outlets drying times.
(0.08m) spread over 2 pipes symmetrically with the inlet, 36 4) Coffee variables
on each side. See figure 4.
Coffee humidity over time and grain temperature are key
variables that will allow an appropriate drying temperature
control and therefore the highest quality product possible.
Given the complex nature of the mathematical models that
describe grains humidity coffee can’t easily be represented in
a simulation. These variables will have to be measured once
the dryer is built and up to testing. This will help with any
tuning the controller might need.
D. Flow of hot air (heater fan)
Given that the desired velocity for the outlets of the
Figure 4. Preliminary design of the distribution pipe distribution pipes is 0.4m/s, an air velocity for the inlet must
C. Variables be estimated. Since we know the diameters of the inlet and
the 76 outlets, the total areas can be calculated:
1) Air speed
To determine the ideal speed of the air that will circulate
in the system, reference is made to the studies of E. Alves,
Guilherme et. al. [1] regarding the influence of temperature
and air flow on coffee drying time. The results of such
experimentation show that while inducing a stream of hot air Ati: Total inlet area and Ats: Total output area.
at different flows has a significant impact on drying time, Knowing the inlet and outlet areas, and the speed we
varying the air speed from 0.4m/s to 2.2m/s only reduces need at the outlet, we can estimate the approximate speed of
drying time. by 9% (from 13.3 hours to 12.13 hours). the inlet:
Therefore, the selection of a fan capable of generating at
least a current of 0.4m/s will be favored in the
implementation and this will be the speed used for all
simulations from here on out.
2) Air temperature
To determine the ideal temperature of the air that will Vi: inlet air speed y Vs: outlet air speed
circulate through the coffee beans, research by other authors Finally, using the total inlet area and the air inlet speed,
was used. A first work corresponds to Alves et al. [1], whose we can calculate the volumetric flow that will allow the
research: "Influence of different temperatures and airflows selection of the heater fan used for a possible future
on drying of natural and pulped coffee" aimed to evaluate the implementation of the system as follows:
drying kinetics of coffee beans using different drying
temperatures and air currents. Concluding that a temperature
of 45°C is the optimal value for efficient drying. A second
work corresponds to Loja [12], who developed an:
"Automatic drying system for coffee beans powered by solar
energy". In this thesis, a proposal for the design of an Fv: volumetric flow
automated coffee machine capable of achieving a specific

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 In conclusion, it is determined that the minimum Additionally, the data presented has been linearized as shown
volumetric flow that the fan must have for a possible future in Figure 9.
implementation is 550 m3/h.

IV. VALIDATION

A. Of the distribution pipes geometry

Following the dimensions of the drying area indicated in
the design considerations, a first piping design is proposed,
shown in figure 5.

Figure 8. Mass flow through each hole in the pipe

Figure 5. First design of the distribution pipes - Ansys Fluent
(A: mechanical design, B: numerical simulation of the pressure along
the walls of the pipe)

The biggest drawback of the proposed design was the

inadequate distribution of pressure along the pipe. Therefore,
a following design was proposed in which the diameter of
the first section of the same shown in figure 6 was increased.

Figure 6. Second design of the distribution pipes - Ansys Fluent Figure 9. Linearization of the results
(A: mechanical design, B: numerical simulation of the pressure along
the walls of the pipe)
As can be seen from the linearized data in figure 9, with
each modification a linear trend of lesser slope is achieved,
This redesign considerably homogenizes the pressure this means that the air outlet between the holes in the pipe
throughout the pipe. However, it created another problem. has effectively been homogenized to some extent. It should
The abrupt increase in the diameter of the pipe generates a be noted that there is still a significant difference between the
vacuum at the height of the first hole, causing an entry of air outflows of the first and last holes (the furthest have the
where it should come out. Therefore, a third design was greatest difference). See table 1.
proposed in which the pipe was lengthened by 1 meter
(random measurement) before increasing the diameter. See
figure 7.

Table 1. Report of outlet flows by hole number for the 3 distribution

pipe designs.

*For reasons of comparison, outlet 4 has been taken as

the first since both in the first and in the second design the
Figure 7. Third design of the distribution pipes - Ansys Fluent first outlets had inflows towards the pipe, thus invalidating a
(A: mechanical design, B: numerical simulation of the pressure along
comparative analysis with design 3.
the walls of the pipe) As can be seen in the report, the flow at outlet 38 of the
As can be seen in figure 7, the pressure of the third first design is approximately 3.6 times greater than the flow
design is constant throughout the pipe sections that include at outlet 4 of the same. This ratio has been reduced to 2.3 for
holes. It is expected that in this way the output flow of these the third design.
will be more homogeneous.
B. Of the use of distribution pipes in the system
For a better understanding of the effect of the
modifications in the geometry of the pipe, a comparative In order to validate the usefulness of the air distribution
graph has been made between the hole number and its pipes, its behavior in the drying area must be compared with
respective outlet mass flow (for the 3 designs) in figure 8. and without said pipes. Due to the dimensions of the drying

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 area, the computational load required for its simulation Figure 12. Final design of the distribution pipes
exceeds the cell limits allowed by the Ansys version used.
Therefore, for this simulation, a scaled-down version of the B. Assembly in the drying area
drying area is being used. Within this test area, a matrix of
solid blocks has been included to generate turbulence and
simulate the presence of a tray full of coffee.
Using this modified new area, 2 simulations were carried
out, one inducing an air flow from the left side of the system
(figure 10) and the other inducing the same total volume
flow but through two entrances located in the lower part
(figure 11).

Figure 13. Final assembly of the distribution pipes in the drying area.
(A: isometric view, B: side view, C: top view)

VI. CONCLUSIONS
The inclusion of the distribution pipes, as shown in the
third design, will have a positive impact on the homogeneous
Figure 10. Velocity of an air pulse (lateral) - Ansys Fluent
distribution of air in the coffee drying area. The magnitude of
(A: Initial air pulse, B: Air speed after a given time.) the impact must be verified experimentally since the drying
conditions of such small grains are extremely difficult to
simulate with the tools that are currently available.
The final design of the distribution pipes homogenizes
the flow of the outlets to a certain extent compared to the
first design. A reduction of 40% is achieved between the
difference in the outflow of the last and the first hole (38 and
4 respectively) and an improvement of 53% if the slopes of
the linearization of their flows are compared. However, the
Figure 11. Velocity of an air pulse (bottom) - Ansys Fluent flow is still not completely homogeneous. It is possible that
(A: Initial air pulse, B: Air speed after a given time.)
with further modifications the design could come closer to
said homogeneity and this may be the subject of future
As can be seen in figure 9, when the air is introduced research. However, it is believed that the complexity of the
from the side of the drying area, it travels uninterruptedly to design could harm the cost-benefit balance in a real
the end of the space where it collides with the final wall, implementation for a coffee dryer.
generating a vortex-type turbulent flow, but exclusively close
to the final wall. On the other hand, in figure 10, where the Regarding the efficiency of the presented hybrid dryer, a
same amount of air is introduced through the lower part and drying time of less than a day can be expected. This design
through 2 inlets, the air is distributed considerably better, improves the 5 days it takes a regular solar dryer to finish a
generating a vortex-type turbulent flow like that of figure 9, batch of coffee by inducing a continuous flow of hot air like
but this time distributed along all geometry. From these two a mechanical dryer. The improvement over a regular
images it is safe to say that the inclusion of the distribution mechanical dryer is that the work volume of the solar dryer is
pipes will benefit the homogenous drying of the coffee by maintained, surpassing the amount of coffee the regular
exposing every tray to a more even amount of hot air. mechanical dryer can dry at a time. In other words, this
design basically converts a solar dryer into a big but low-cost
mechanical dryer. And the distribution pipes provide an aid
V. FINAL DESIGN in homogenizing the air flow throughout the system making
the drying rate similar in all grains.
A. Of the distribution pipes
Regarding the design of the pipes, after several tests it VI. ACKNOWLEDGMENTS
was determined that the best design for the correct To the Research Directorate of the Universidad Peruana
distribution of air inside the coffee drying chamber can be de Ciencias Aplicadas for the support provided to carry out
seen in Figure 12. this research work UPC-EXPOST-2022-1

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