The "Vitruvius" dryer is an innovative, sustainable, and cost-effective solution designed to address the
post-harvest losses faced by small to medium-scale farmers in Bangladesh. This hybrid dryer efficiently
utilizes solar energy as the primary heat source, with an integrated biomass burner as a backup for cloudy
conditions.
The design ensures uniform drying and prevents contamination through a dedicated airflow system, a jute-
cloth moisture belt, and dust removal mechanisms. With a capacity of 1000 kg per batch, it is tailored for
local manufacturing, using readily available materials like mild steel, jute, and bamboo. Incorporating IoT
sensors for real-time moisture monitoring, the Vitruvius dryer represents a significant step towards
modernizing agriculture in Bangladesh while prioritizing sustainability and farmer affordability.
Key Performance Indicators:
• Drying Efficiency: 60-70% solar energy contribution
• Capacity: 1000 kg per batch
• Drying Time: 4-6 hours (weather dependent)
• Moisture Reduction: 22% to 14% (wet basis)
• Estimated Cost: 150,000 BDT (prototype)
1. Introduction & Design Rationale
1.1 Problem Statement
In Bangladesh, post-harvest losses of grains like rice, wheat, and maize due to improper drying account for
significant economic losses for farmers. Traditional open-sun drying is inefficient, prone to contamination,
and weather-dependent. Studies indicate that up to 15-20% of harvested grains are lost annually due to
inadequate drying facilities, directly impacting farmer income and national food security.
1.2 Design Rationale
The Vitruvius dryer was conceived to directly address these challenges by providing a controlled, efficient,
and hygienic drying environment.
Key Design Principles:
• Hybrid Heating: Bangladesh receives abundant solar irradiation (4-5 kWh/m²/day), making it the
ideal primary, zero-cost fuel source. The biomass (rice husk, straw) backup ensures continuous
operation during the monsoon or overcast days, utilizing agricultural waste that would otherwise
be discarded.
• Modular & Scalable: The design is modular, allowing farmers to start with a single unit and
expand as their capacity grows. This reduces initial capital investment barriers for small-scale
farmers.
• Localized Design: All components can be fabricated using locally available skills and materials,
ensuring ease of maintenance and repair in rural settings. This approach creates local employment
opportunities and reduces dependency on imported machinery.
• Focus on Grain Quality: Features like the adjustable sieve system and dust control directly
address the need to handle different grain types and prevent contamination, preserving grain quality
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and market value. Higher quality dried grain commands premium prices in both local and export
markets.
2. Design Description & Key Features
Silo for storage
Solar PV panel
Screw conveyor for grain disposal
Solar concentrator for heating grain
Sieve (adjustable for
Moisture removal fan
different grain types)
Dust removal fan
Venting duct
Biomass heater
Belt made
of jute cloth
for moisture
absorption
The Vitruvius is a continuous-flow, mixed-mode dryer that combines direct and indirect heating methods.
The system integrates multiple innovative features to optimize drying efficiency while maintaining grain
quality.
2.1 System Overview
As shown in the rendered visualization, the complete system consists of five major subsystems:
1. Solar collection and heating system
2. Biomass backup heating chamber
3. Grain handling and feeding mechanism
4. Multi-tier drying chamber
5. Dried grain storage silo
2.2 Key Components & Workflow
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2.2.1 Solar Air Heater & Biomass Backup
Solar Collection System:
• Large-area photovoltaic panel array (visible in the image as the angled dark blue panel)
• Estimated solar collection area: 8-10 m²
• Operating temperature range: 50-70°C
• Used to run the electric equipment’s and heating the grains
Biomass Heating Chamber: The brown box structure visible in the image houses the biomass combustion
chamber. This secondary heating system features: Rice husk/straw burner with controlled air intake,
Thermostat-controlled operation prevents overheating, Estimated thermal output: 15-20 kW
Safety Features:
• Automatic temperature monitoring
• Pressure relief valves
• Fire suppression provisions
• Emergency shutdown system
2.2.2 Grain Hopper & Screw Conveyor
The yellow cylindrical component visible in the image represents the grain feeding mechanism:
• Capacity: 1000 kg hopper volume
• Screw Conveyor: Variable speed (adjustable from 10-50 rpm)
• Material: Food-grade stainless steel auger
• Innovation: Conveyor speed can be linked to IoT moisture sensors for automated feed rate
optimization
The screw conveyor meters grain into the drying chamber at a controlled rate, ensuring optimal residence
time for complete drying without overheating.
2.2.3 Multi-Tier Drying Chamber with Jute Belt
The central white structure houses the core drying chamber, featuring:
Drying Bed Configuration:
• Three-tier cascading system with adjustable perforated sieves
• Each tier: 1.2m × 1.5m drying surface
• Total drying area: 5.4 m²
• Grain layer thickness: 3-5 cm per tier
Innovative Jute Moisture Belt: A continuous belt made of locally sourced jute cloth runs beneath the
grain bed, actively absorbing moisture. This traditional material proves highly effective:
Adjustable Sieve System:
• Perforation sizes: 3mm (rice), 5mm (wheat), 8mm (maize)
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2.2.4 Forced Airflow System
The red components visible in the cross-section represent the dual-fan system creating optimal air
circulation:
Moisture Removal Fan:
Dust Removal Fan:
3. Technical Specifications & Analysis
3.1 Key Specifications
Parameter Specification
Capacity 1000 kg/batch
Grain Types Rice, Wheat, Maize
Initial Moisture Content 22% (wet basis)
Final Moisture Content 14% (wet basis)
Drying Time 4-6 hours (variable)
Primary Heat Source Solar (60-70% contribution)
Backup Heat Source Biomass (Rice husk/straw)
Power Requirement 1.5 kW (fans and controls)
Power Source Options 220V AC / Solar PV
Footprint 6m × 4m × 4.5m (H)
Design Software SolidWorks 2022
3.2 Engineering Calculations
3.2.1 Heat Energy Requirements
To calculate the total energy required for drying 1000 kg of paddy rice from 22% to 14% moisture content:
Moisture Removal Calculation:
Initial moisture: 22% (wet basis)
Final moisture: 14% (wet basis)
Initial dry matter = 1000 × (1 - 0.22) = 780 kg
Final dry matter = 780 kg (unchanged)
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Final total mass = 780 / (1 - 0.14) = 907 kg
Water to be evaporated = 1000 - 907 = 93 kg ≈ 80-100 kg (accounting for handling losses)
Energy Calculation:
Qtotal = Qsensible + Qlatent + Qgrain
Where:
Qsensible = mwater × Cpwater × ΔT
Qsensible = 80 × 4.18 × (60-30) = 10,032 kJ
Qlatent = mwater × hfg
Qlatent = 80 × 2450 = 196,000 kJ
Qgrain = mgrain × Cpgrain × ΔT
Qgrain = 1000 × 1.8 × (50-30) = 36,000 kJ
Qtotal = 10,032 + 196,000 + 36,000 = 242,032 kJ ≈ 240 MJ
Energy Sources:
• Solar contribution (65%): 156 MJ
• Biomass contribution (35%): 84 MJ
• System efficiency (60%): Total input required ≈ 400 MJ
3.2.2 Airflow Requirements
Using psychrometric analysis for air at 30°C ambient, heated to 60°C:
Moisture Carrying Capacity:
At 30°C, 70% RH: Humidity ratio = 0.019 kg water/kg dry air
At 60°C, 30% RH: Humidity ratio = 0.040 kg water/kg dry air
Moisture removal per kg air = 0.040 - 0.019 = 0.021 kg water
Total air required = 80 kg water / 0.021 = 3,810 kg dry air
Air density ≈ 1.1 kg/m³
Volume = 3,810 / 1.1 = 3,464 m³
For 5-hour drying: Flow rate = 3,464 / (5 × 3600) = 0.19 m³/s
Design Flow Rate: 0.5 m³/s (with safety factor of 2.5 for efficiency losses and continuous operation)
3.2.3 Solar Collector Sizing
Solar Irradiance in Bangladesh:
• Average: 4.5 kWh/m²/day
• Peak hours: 5-6 hours
• Peak irradiance: 800-900 W/m²
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Collector Area Calculation:
Energy from solar: 156 MJ = 43.3 kWh
Collection time: 5 hours
Required input (accounting for 40% collector efficiency): 43.3 / (5 × 0.4) = 21.7 kW peak
Collector area = 21,700 W / 800 W/m² = 27 m²
Practical design: 10 m² flat plate + 8 m² concentrator = 18 m² effective area
(Difference compensated by biomass backup)
3.3 Simulation Results
3.3.1 Computational Fluid Dynamics (CFD) Analysis
CFD simulations performed in Ansys Flow Simulation validate the airflow pattern design:
Key Findings:
• Velocity Distribution: Uniform air velocity (1.5-2.0 m/s) across 95% of drying bed area
• Temperature Distribution: Maximum variation of ±3°C across grain bed
• Pressure Drop: 220 Pa across the three-tier system (within fan capacity)
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• No Stagnant Zones: Complete air coverage ensures uniform drying
3.3.2 Thermal Analysis
Thermal finite element analysis (FEA) of the biomass combustion chamber:
Results:
• Maximum Wall Temperature: 320°C (combustion chamber)
• External Surface Temperature: <50°C (with insulation)
• Heat Transfer Efficiency: 75% (from combustion to air)
• Hot Spots: Identified near burner inlet, addressed with additional ceramic lining
Safety Validation:
• All structural components remain below 60% of yield strength at operating temperatures
• Thermal expansion joints accommodate temperature variations
• Insulation requirements: 50mm rock wool or 75mm bamboo matting
4. Material Selection & Sustainability Impact
4.1 Material Selection Matrix
Component Primary Alternative Justification & Sustainability Impact
Material
Main Frame Mild Steel Stainless Steel Durable, low-cost, locally available.
(Galvanized) 304 Galvanization provides 15-20 year corrosion
resistance. Recyclable at end of life.
Drying Mild Steel Sheet Aluminum Cost-effective for large panels. Paint finish
Chamber (1.5mm) alloy provides additional protection.
Body
Drying Sieves Perforated SS SS 316 Food-grade, abrasion resistant, easy to clean.
304 Prevents contamination and rust. Expected
lifespan: 10+ years.
Moisture Belt Woven Jute Cotton canvas Eco-innovation. Biodegradable, highly
Cloth absorbent (40% moisture capacity), supports
local jute industry. Replacement cost: minimal.
Insulation Bamboo Rock Wool Bamboo is sustainable, locally abundant, zero
Matting carbon footprint. Thermal conductivity: 0.055
W/mK. Rock wool offers higher efficiency
(0.035 W/mK) but higher cost.
Solar Aluminum Polycarbonate Aluminum is lightweight, corrosion-resistant.
Collector Frame + Glass Glass provides optimal solar transmittance
(>90%). Fully recyclable.
Ducting Galvanized Aluminum Rust-proof, lightweight, easy to fabricate
Steel locally.
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Biomass Mild Steel + Refractory High temperature resistance. Ceramic lining
Chamber Ceramic Lining Brick protects steel from direct flame contact.
Storage Silo Concrete Steel Cost-effective for large volume storage.
(Grade M20) Provides thermal mass and moisture barrier.
Lifespan: 30+ years.
Fasteners Galvanized SS Fasteners Standard sizes available locally. Prevents
Bolts/Nuts corrosion and simplifies maintenance.
5. Cost Estimation & Implementation Plan
5.1 Detailed Cost Breakdown (Prototype)
Category Component Quantity Unit Cost Total
Cost
Structural Mild Steel Sheet (1.5mm) 45 m² 350 15,750
Steel Angle (50×50mm) 40 m 180 7,200
Galvanized Bolts/Nuts Set - 2,500
Solar System Solar Air Heater Panels 2 units 12,000 24,000
PV Panels (optional) 300W 15,000 15,000
Mechanical Axial Fans (2 units) 2 4,500 9,000
Screw Conveyor Assembly 1 8,500 8,500
SS Perforated Sheets 6 m² 850 5,100
Drying System Jute Cloth Belt 15 m 120 1,800
Biomass Burner 1 6,000 6,000
Ceramic Lining Set - 3,500
Insulation Rock Wool/Bamboo Mat 25 m² 250 6,250
Ducting Galvanized Ducts 12 m 350 4,200
Cyclone Separator 1 3,500 3,500
Storage Concrete Silo Materials Set - 8,000
Electronics Temperature Sensors 4 800 3,200
Moisture Sensors 2 4,500 9,000
Microcontroller + Display 1 set 6,000 6,000
Wiring & Controls Set - 4,500
Miscellaneous Paint, Sealants, etc. - - 3,000
Material Subtotal 145,000
6. Innovation: IoT Integration & Automation
6.1 Smart Monitoring System
The Vitruvius dryer incorporates an optional IoT module that transforms it from a passive dryer into an
intelligent, self-optimizing system.
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6.1.1 Sensor Network
Moisture Sensors (2 units):
• Location: Grain inlet and outlet
• Technology: Capacitive moisture sensing
• Range: 10-30% moisture content
Temperature Sensors (4 units):
• Locations: Ambient air, heated air, drying chamber (3 levels), exhaust
• Type: PT100 RTD sensors
• Range: -10°C to 100°C
Airflow Sensor (1 unit):
• Location: Main air duct
• Technology: Hot-wire anemometer
7. Conclusion
7.1 Design Achievement Summary
The Vitruvius hybrid grain dryer successfully addresses the critical challenge of post-harvest grain loss
in Bangladesh through an innovative combination of renewable energy, local materials, and smart
technology. The design achieves all primary objectives:
Technical Performance:
• ✓ Efficient moisture removal (22% to 14% in 4-6 hours)
• ✓ Uniform drying (±3°C temperature variation)
• ✓ Contamination prevention (closed system with dust filtration)
• ✓ 1000 kg batch capacity suitable for small-medium farmers
Sustainability:
• ✓ 60-70% renewable energy utilization
• ✓ Carbon-neutral biomass backup
• ✓ Biodegradable jute moisture belt
• ✓ Local material sourcing (>90% domestic content)
Economic Viability:
• ✓ Affordable prototype cost (~230,000 BDT)
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• ✓ Mass production target: 155,000 BDT per unit
• ✓ ROI < 2 years for typical farmer
• ✓ Creates local manufacturing jobs
Innovation:
• ✓ First-of-kind jute cloth moisture absorption system
• ✓ IoT integration for smart monitoring
• ✓ Hybrid energy system optimized for tropical climate
• ✓ Modular, scalable design
7.2 Comparative Advantage
Compared to existing solutions in the Bangladesh market:
Feature Traditional Sun Imported Mechanical Vitruvius
Drying Dryers
Capital Cost Zero 500,000-800,000 BDT 230,000 BDT
Operating Cost Zero 5,000-8,000 BDT/ton 500-800
BDT/ton
Weather 100% 0% <20%
Dependency
Contamination Risk Very High Low Very Low
Local Serviceability N/
Submitted By:
1. Sanjidul Islam
IMechE Student Affiliate No.: 80657187
Rajshahi University of Engineering and Technology, Bangladesh
2. Md. Fahim Al Azad
IMechE Student Affiliate No.: 80790721
Rajshahi University of Engineering and Technology, Bangladesh
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