Process analysis and optimization of open-width fabric continuous drying based on numerical simulation

Abstract

As an indispensable part of textile processing, the fabric drying process has a great impact on product quality and overall energy consumption. To reveal the characteristics of the continuous drying process of various fabrics and optimize process parameters for improving productivity and saving energy, a finite element model is built to simulate the continuous fabric drying process, and an optimization method is applied to optimize process parameters based on the model. Specifically, a finite element model is first built; the model can predict distribution of water content and surface temperature of three kinds of fabric in the continuous drying process under different process parameters. The model is then verified by experiments, and the experimental results agree well with the numerical results: The mean absolute errors of distribution of water content and surface temperature of fabrics are 4.22% and 2.15℃, respectively. The numerical results indicate that wind velocity, wind temperature, and fabric velocity have a significant influence on the drying rate and surface temperature of fabrics in the continuous drying process, which, however, are not affected obviously by initial water content. It is also found that under the same initial and technological conditions, the drying rate and surface temperature of fabrics in the continuous drying process are lower than those in the intermittent drying process. Second, the Taguchi method is applied to design continuous fabric drying schemes, considering the interaction effect of technological parameters on the drying process. The numerical model is then applied to simulate these schemes, and the TOPSIS method is applied to analyze and compare these numerical results. The optimal technological parameters are determined; the optimal parameters can help to save energy by about 27.8 % and enhance energy efficiency by about 16 % in the continuous drying process. It is worth noting that the interaction effect of fabric velocity and wind temperature on the continuous drying process is more significant than their independent effects.