Solar Chili Dryer

INTRODUTION

Solar Chilli dryer project was assigned to me and Ritesh. we both are working on it together as decided in a first meeting with Kulkarni sir and Ranjeet sir in presence of Prasad sir and Mahesh sir.

DESCRIPTION

Work done by Me and Ritesh regarding this project is described as follow from the project was assigned to both.

26/10/2023

As discussed in a meeting about some different dryers which can more useful for the farmers in a khargon district in MP. Also, we discussed about some simple solution like Solar Bubble Dryer. But we can’t implement it directly that was just for reference study discussed on it.

Also, I was assigned for another two projects 1. Jamun Harvesting Lift 2. Rice Transplanter and discussed some information about that farmer. For Collection of more information regarding this topic I have to visit Dapoli. They have already made a machine for coconut harvesting. For my study to gain some new idea for project, so I have to visit Dapoli and get information about it.

27/10/2023

I meet Ranjeet sir, and tried to get contacts about Dapoli visit, we got some of them and waited for other contact that will be more helpful for us. After some time, we got the contact of Dr.Shahare sir currently HOD of Farm machinery and power, Dapoli.

On same day Ranjeet sir gave me contact and I texted Shahare sir to make call but he didn’t reply on that day and also, I was searching and reaching some research paper on solar bubble dryer to understand it’s working.

28/10/2023

As before have not more information about dryer and its some basics conceps, so i have to meet Dixit sir and get more information about it.we discussed some technical terms in drying process that made me clear about drying process. we discussed about the drying process and some parameter which are important in drying process like Temperature, Humidity, And Airflow.

30/10/2023

As my work was going on to find the research papers and study on it which contain the solar bubble dryer and different chilli drying process. But did not get some new in chilli drying but I got some specification on that solar bubble dryer that I was looking for.

In a picture shown below is Schematic diagram of solar bubble dryer.

Schematic view of the solar bubble dryer setup; (a) solar panel frame, (b) solar panel, (c) solar battery, (d) electric cable, (e) blowers (fans), (f) blower frame, (g) heating area, (h) grain, (i) outlet openings, (j) upper cover, and (k) drying floor.

1/11/2023

I found some specifications related to solar bubble dryer by GrainPro for 0.5 tons.

Components:

1. solar panel Battery (12v)
2. DC Fan (12v) 25cm dia.
3. Bubble support
4. Drying area

Material:

1. Top Transparent Cover :- UV-LDPE (Thickness 0.15mm)
2. Drying Floor :- PVC (610gsm) (Thickness 0.5mm)

After reading some of research paper found one research paper which defines thet solar bubble dryer is more effective as compared to the solar tunnel dryer and solar direct drying. link for same is given as follow. https://www.sciencedirect.com/science/article/pii/S2772427123000542

2/11/2023

For the discussion on project, we have to meet today, in meeting Ranjeet sir, Dixit sir, Prasad sir and Mahesh sir was present. Before the meeting I and Dixit sir discussed and seen together about some research paper related to the solar bubble dryer. after seeing that paper sir said that this mechanism is noting different than our solar flat plate dryer which are already, we made it. that not more different between it that solar flat plate and solar bubble dryer except fans in it.

Output for the discussion was that we have to work on dryers which we have made already and take trials on it and after we can suggest new modifications in it. it was fixed that I and Ritesh have to take the trials on dome dryer with green chilies and calculate Loss of Drying for it and also take a data for temperature and Humidity on different position in dome.

1. we have to remove the trays in the dome dryer and after removing it we have to put mesh by replacing the trays but not all trays on the last trays only.
2. Attach the fan at the top of dome which dome already have it. (220V/240V AC) for the ventilation which take air in a dome from outside.
3. Attach data loggers one at the top position and another at the lower position for the calculation of temperature and humidity difference

Task After Meeting:

1. learn to make data logger from Maels.
2. Maintain dome dryer and take trial with green chillies.

3/11/2023-4/11/2023

It has been taken 2days to complete data logger. I have learned some wiring and program changes needed to made as per requirements. Males taught the making of data logger it was new to him to make it because he told that making data logger with SD card data storage and LCD screen was 1st time for him too. so, it was time taking process for us both.

6/11/2023

Now the Data Loggers are ready and we were now able to take trial, so I and Ritesh started working on dome and making some changes in dome tryer.

• we firstly removed all the trays in the dome dryer.
• And Keeping distance of about 5cm we attached the mesh on the dome.
• we attached the data logger on top position and one at lower position which record the both temp and humidity.
• now we were ready to take trial and decide to start trial from next day. Because we did not get the chilies from market.

Two images below were showing the changes done in the dome dryer after removing of the trays in it. Lower image shows the condition of the dome before making changes that is the arrangement of the mesh on the lower surface of the dome keeping clearance of about 5cm. and upper image gives the information about the arrangement of data logger and mesh.

As we both completed the work on dome in this day and all was set start the trial, but at last as we start the fan just for checking the doesn’t on because the extension board was not working. so again, we plugged out the data loggers and fan switch and gave the extension board to Raghav sir.

7/11/2023

Today we are going to start the trail with the green 5kg of green chillis. because of the problem in extension box first task was to repair it from Raghav sir and then go further.

Mahesh sir already bought the chilli from market and we are ready for it. I and Ritesh spread the chillies in the dome with the diameter of about 65cm and Hip height of 15 cm.

And then problem was we attached the data logger display inside it which was totally wrong, because we have to see the display for current reading at the time we visit the place, again we attached it from outside of the dome, in which Mahesh sir helped us for that arrangement.

We have to start the trial at 10am but because of the extension board and wrong arrangement of data logger make us late that was fault of mine.

After all, we were ready and stared the trial at 10.10 AM in Morning. and we are going to take reading till 5.10 PM evening as Mahesh sir told us to off it at 5.10pm.

Above image represent that we laid the green chillies in the dome dryer and trial was started.

19/11/2023

As we tried in dome dryer it was failed and we didn’t get results from it. as there was not good working of data loggers and data collection was not possible. Before going for next the weight of chillies reduced in dome dryer was 4kg from 5kg. in 3days

So, In Diwali holiday Ritesh was here so he decided to make the design for dryer with discussion with Dixit Sir, Ranjeet Sir and Prasad Sir, and he worked on it.

In this design he taken a PVC pipe of 69 inch which is going in inside the dryer now he is conducting this experiment in flat plate dryer. He attached the PVC pipe to Blower by making 216 holes on the pipe. He dried 4kg chilies in it. And got 1.6 kg of chillies in 8days.

Above are the images of the Ritesh taken trial in Diwali

20/11/2023

After Diwali, I started to work with Ritesh. With the another structure of 3 pipes. Design was similar to the Ritesh done but with some changes in it and we started to work on it. I tried to make the design on AutoCAD. And I showed that to the Mahesh sir and Prasad sir after that i started working on the design.

21/11/2023

I have done design for it and we are going to make the actual structure for dryer now. Ritesh and I stared to make that design. I bought some material required for it from village. we made the design and fitted it to the flat plate dryer.

Above is the design we fitted in flat plate dryer

Design was made as follow:

1. 3 PVC pipes are taken two of 2 inch and 1 of one inch.
2. Pipe is divided into 5 equal parts
3. Taken holes in 5 different parts that’s about 1ft. with different drill bits.
4. Holes taken from smaller to bogger bits are 3.97mm,6.35mm, 7.94mm, 9.52mm, 12.70mm.
5. Attached the pipes to the connections which we have already, for making that reduction Mahesh sir helped us.

It has taken our day for making holes and fittings in it so didn’t taken trial on that day.

22/11/2023

We started the trial in Morning in presence of Prasad sir and Mahesh sir. I already bought the green chilies on evening yesterday.

Below are the images of trial we started

we weighed chilies and start to spread in the dryer

Ritesh fitting blower and I spreading chilling on pipe

Picture of green chili on trial 1st day

Trial was started at 10.15am at temp of 27^oc and weight of the chilies was 20 kg. chilies were spread mostly on the pipe and the measurement taken for the chilies volume was 5.4 x 2.4 x 0.4ft. (LxBxH). we do not have the data loggers in working condition so we didn’t connect data offer there.

23/11/2023

Blower is in ON condition and for seeing condition i visited site and taken the picture of the chilies.

Picture for the 2nd day of trial

24/11/2023

we are not having any reading taken because there were not data loggers in working condition. I with the help of Maels we started to work on data loggers and we made one data logger in condition and he said also he will make another as soon as possible.

Data loggers are not working good after repair also so I asked Dixit sir and decided to make them work on Wi-Fi and we started to make then On Wi-Fi.

Picture for the 3rd day of trial

I and Ritesh connected the data logger by 1:pm and the data loggers are in working condition. One sensor is at the centre upside in the dryer above the chilies (Device 1) and another one is in the chilies to check the temperature near chilies (Device 2).

Link for checking the reading on the datalogger on Mob/PC is https://dataloggerdryerva.web.app/

we got the data for only 2 hours only About 1:00 pm to 3:00 pm because the data logger is again not working good and also the Wi-Fi in EDP is not working.

25/11/2023

Visited the site and taken picture of the chilies and switch ON/OFF the Datalogger and again now they are in working condition and i getting data from dryer. Don’t know about that why they are working for some period and getting off that is affecting on data we getting was not continue.

27/11/2023

Data loggers are not working well and continue but some data was collected by it. we got data regarding Temperature and Humidity of one day.

I discussed with Dixit sir and our observation was that the system is not working well.

Temperature at bottom and was low than the temperature at top. we are blowing the air from outside which is not hot so there is no chance to increase the temperature of that air and hence drying cannot happen at bottom of chillies equally and on the top the direct heating was going on that’s why drying is going on but also some chillies are getting damaged.

Also working with the another project works going on.

I created the excell of that data we dicussed is attached below.

2/12/2023

We decided to make some change in dryer as this system was not working. we decide to the fan which was blowing air will change its position and use it for extracting air inside dryer out with it.

Not more changes are observed according to me that doesn’t make any big change in that system. I removed the exhaust and kept chillies for direct sun drying because they are getting damaged.

Below are some images of system i made for extraction of air from dryer.

4/12/2023

I, Prasad sir and Mahesh discussed about the result from our previous trial and that was not working well because we got the causes for it was like,

1. the air going inside or air inside the dryer is not getting heated and air circulation was not good.
2. that the main cause for drying was not happening there the air in upper surface only is getting heated. so as we have some plan for the next trial which we discussed in early discussions.

We decided to take trial in dome and and attach the PVC pipe with holes for suction of the humid air in dome .

5/12/2023

I told to dixit sir about last dicussion. Now sir told to calculate the volume of the green chillies and the dome because we needed to find the capacitty of the dome dryer we were going to use it for our next trial.

I calculated the volume of the dome and chiliies in image below.

I and Dixit sir discussed about that data and then in evening Dixit sir told me about the study that they have dome before for the drying. He told that we have to calculte the air flow for the particular weight of the chillies and we have to dry chillies at particular period too.

After that i have task to calculate the CFM of the fans we were usinf for the trials.

6/12/2023

I started the work to measure the flow rates of the fan. I used Anemometer for the measuriong of the flow rate of air.

Firstly, i calculate the CFM of the table fan and for the area of cylindrical pipe we are going to use for dome trail as for the reference and that was 1617CFM. And then i aslo calculated the CFM for the fan which we were going to use was 2784 CFM.

Following are image of calculation:

7/12/2023

I dicussed with Dixit sir again about the fan flow rates which i have calculated. Then we decided to assume some condition like 10kg of the water should we have extract from chillies per day then what energy is requirement.

Then i calculated the water removal per time required for the 10kg chillies to dry for 8 hours a day that was 20g/min should be removed then we will get the extraction of 10kg warer per day.

Then Dixit sir and I discussed about the next step that how many CFM we would required for that much removal of water. and we calculated it as follow by assuming some values:

8/12/2023

Also i calculated the CFM of the fans we have and their electricity consumption per day . i got one thing from google that made my calculation fast was the 10CFM/WATT that is we required 10watts for 100CFM.

Image regarding calculation is below:

9/12/2023

After getting the information that how many watts we fan have and how many electricity they consume and with their CFM. we can get some conclusion and now i was ready to take trial with this data. Now the number of holes is decided by i and Dixit sir that was 100 and of 6mm in diameter on pvc pipe.

I taken the material required for and made the holes in pipe of 2ft. and spacing between holes was 3cm horizontal and 9.6cm vertical.

Diagram for it is as follow:

Along this i was also working with sahil for his Ecart Sugarcane juicer project because we have complete it fast.

13/12/2023

After making holes in a pipe. I attached the pipe in a dome and fan at base to take the humid air out from the dome. also, I attached two data loggers for collection of data. one at top inside dome where the air enters to dome and another below fan from where air come out by taking moisture from chillies.

For attaching and making setup Sahil helped me.

Following are some images whiles fixing pipe and fan on Dome Dryer:

14/12/2023

Yesterday evening I bought green chilies from market and in morning I have to start the trial. As decided in discussion I have to start the trial at 10am and take reading till 6pm that will make us easy for the further discussion. Because before this trial I have calculated the CFM of the fan we have which was 600CFM and now we have the exact specifications of the fan that at which rates we are going to take air out.

Following are the images related to Trial setup:

15/12/2023

After collection of the data of 14-15/12/2023 I discussed with dixit sir in evening about the data.

And after observation of data the output was that the temperature inside the dome is reaching around 44-47  ^oc. that good for the drying we observed.

Problem regarding data collection was faced because data logger is not working well. Again, I repaired it and attached to dome.

But we need to compare the temperature and humidity of the air going inside the dome and out coming from dome.  That the sensor position for incoming air was wrong so sir told me to correct and then we will take again data and then discuses about observation.

Attaced the data observed for 2days’

16/12/2023

Changed the position of the sensor as dicussed in evening with Dixit sir and data collection was going on.

Another task was to Make a questionary for the farmers in Khargone for the empathy of the farmer drying process and their losses and Handloading information and etc. and also enquiry for the solar bubble dryer but didn’t got any contact seller for solar bubble dryer.

18/12/2023

I and Dixit sir discussed on the data for date 17/12/2023 and the data we got was working that is we got good reading from drying of chilies. And now next was to calculate how much air is pumped in a day and quantity water removed in a day by calculation of fan and by weighing of chilies at start of day and in end of day.

As we calculated the drying rate calculated by CFM of the fan was 4times more than the actual rate calculated after weiging of chillies.

19/12/2023

Again, we calculated the latent heat for the water remove per watt i.e. 1.7g and for 850g in a day. And conclusion from it was that the fan was providing only 1J of energy for drying in a day and other 440J energy was taken from atmosphere.

Then from that we calculated the air quantity should be pumped from fan that will sufficient for the drying of chilies. And we calculated the CFM was 52500CFM.

Another point was that there was the cloudy whether during trial. That why the temperature difference was positive on cloudy whether and negative in clear whether.

And next was the problem of the weighing of the chilies I was doing weight at start of day and end of day but that was disturbing the system and was rearranged all time that may affect the rate of drying. Because we decided to attach the load cells but that will take time to make so, I decided to attach weighing balance and take weight daily by it.

20-21/12/2023

As discussed, before I have to make a weighing structure for the chilies on which the chilies should be placed and that is attached to weighing balance. I made the frame required for the weighing of chilies and on which the chilies are hanged. I Made it and fixed setup in evening was ready to trial from next day.

And also, I closed the holes which are not covered by chilies because that air coming out from it was taking water with it because it doesn’t have contact with chilli and energy of fan was losing for it.

22/12/2023

As we dicussed i made the weighing stucture for the dome to take weight of the chillies and also increse the drying rate by geting free space below it.

following are images of structure made:

23/12/2023

Taken the weight of the chillies in morning was the 12kg and also in the evening and weight was 11.2kg. Hence the diference was about 800g it means 800g of water is taken out in 8 hours.

also i calculated the rate of drying for that in 8 hrs was 6.66 percent.

Data collection sheet for the same is attached:

25-31/12/2023

As the weight loss was observed was about 800-1000g per day(8hours) . As the trial was going on and i was going on leave from next day(26/12/2023 to 6/12/2023) so i told sahil to check and taking weight of the chillies for the days he was also taking it but some of them was missed by us because he was also busy with hid BSF chamber work.

and the as observaing the chilies are looking dryed i told him to take them out from dome dryer and take the final weight.

As the final weight observed was 4.68kg and in observation it was also noticed that the chillies are also got infected and damaged too.

we see in image that the most of the chilies are damaged also further sorting was dome was Pranay and DBRT students for making power of the chilli and the final weight of good chilies used for power was 2.5 kg.

8/1/2024

As Dixit sir and Prasad sir gone to Khargone (M.P) for empathy for our chili drying project. Prasad Sir made a report on empathy and visit they done. I read the report and listened audio recording done by them.

After that I discussed with sir about that and we understand that the we are assuming the loss of chili breakage about 30% was not the actual problem that we are considering it as. There is only about 2-3kg of loss(breakage) per 5 quintals. Not big problem as we were considering it.

The main problem was they are facing was the virus on chilies, plucking charges for the labors another of drying and also in rain the chilies become black because of the dew and gave less rate in market to the farmer. Then sir told me to calculate the area required for the 1kg of chillies as that farmer drying chilies in khargone.

9/1/2024

Then I calculated the area required for 1kg of chilies drying was 1sq.ft for the 1.5kg of chilies. I calculated it from the empathy report that prasad sir made in that farmers told about the area they used for drying chilies and its quantity. And farmers told they have thikness about 7-8cm at time of drying.

10/1/2024

When I was on leave one discussion was done between all DIC students, Dixit sir and Prasad sir about the empathy and next step for our project. And some calculation was done regarding the efficiency of 4m dome dryer at Nashik by comparing with we have small dryer at our Ashram and its previous trial records and we will be going to take trial on it of 500kg chilies.

Draft for the calculation is attached below:

11/1/2024

I started to search contact to the red chili vendors taken some contact from Ranjit sir and Dixit. Find out 4-5 vendors and then confirmed one who is agree to give red chili to us at our location in Nashik with transport.

Prasad sir taken lecture on Empathy and also explained for what purpose it is main process in design thinking.

12/1/2024

Taken trial on the BSF separated machine which Abhishek is doing project, i helped him in taking trials on different seive attached.

13/1/2024

Akshata had arranged one day workshop for the BSc students. So, I and Sahil taken the tour of that students.

15/1/2024

we are going to take trial on dome dryer at Nashik so we need a PP Mesh to spread chillies on it for derying. We are not using their trays for drying because that may affect their products in future. so I and Pranay gone to Pune for purchasing mesh.

I have calculated the mesh required that was about 405sq.ft. considering all over area of the dome. After that Prasad sir calculated the actual mesh we required for only replacing trays and that was about 390sq.ft.(119x 3.28 ft).

16/1/2024

After dicussion about different vendor for chilli purchase I and Prasad Sir decided for the vendor from Nandurbar. Then made list for our requirement for experiment mainly it was Data logger in good condition and wifi availability at location. Then done for the data logger as Suhas sir was working on it and he gave us the 4 data loggers.

17/1/2024

Worked with Sahil and Abhishek in their projects. helped sahil for making the black chamber for the pupa to pass the flies to the main breeding chamber of BSF. And helped abhishek for tighing the seive to the separator.

18/1/2024

As we are planing for the trial from 21/1/2024 so we have to dicuss some points for thr trial, so we discussed with Dixit sir,Prasad sir and other DIC students.

In that we dicussed about the position of the 4 data loggers which is as follows:

1. At exhaust (To take temp.& humidity air coming out from dome dryer)
2. Below Duct (Inlet Airfrom blower)
3. Above the chillies
4. Out side of Dome dryer

Another point was dicussed was about the thikness of the chilli layer and that was decided according to surface area we have and quantity of chillies.

Thikness was decided was:

1. Lower layer 2 inch
2. Middle layer 3 inch
3. Top layer 4 inch

19/1/2024

I and Pranay taken follow for the organizing of the program of 26th January. Handover the program responsibilities to Himansu and told him some task to do in absense of us because pranay was also coming with us to Nasik to take workshop of Chikki making at Nashik.

21/1/2024

I, Mahesh sir, Prasad sir, Pranay we leaved Pune at Night and reached Nashik. Then in morning we gone to trial location and chillies were already delivered by vendor at location. Firstly, we tighed the mesh we brought to replace tray and then we loaded chillies to dryer and it was tough work to load chillies to dryer because of its circular shape the workspace was too small that made us tough for loading chillis in it. Another problem was that quantity of the chillies was more.

I, Prasad sir, Mahesh sir and Pranay Loaded chillies to dome dryer .

Then we started the trial about 11:30 PM and data loggers exhaust and blower were working in good condition exhaust fan was running at 5 min ON per hour and blower at 55 min ON per hour.

Collection of the data was going on and Iwas Making it in a Excelsheet.

22/1/2024

As data was collected for yesterday and observation was that humidity inside the dome goes on increasing but it is not getting out.

We concluded that exhaust is only getting 5 min per hour and that’s making the big effect we observing because humid air in not getting outside that’s make the drying rate slow because air inside is not replacing by new air.

This all discussion was going on call with Dixit sir and Prasad Sir after observation of the data we getting.

After discussion in morning, we decided to increase the fan ON duration to 15 Min/hr. and then observe the data at 2PM.

We got better results from that was the humid air inside dome was coming out every 15 min/hr. but after some time again we were facing same problem was that humidity inside dryer is increasing and it was not coming out.

So, we decided to turn ON the exhaust fan for 30min/hr. and then see for the results. And observe the same result for next day.

23/01/2024

On 2pm we observed the data from data loggers and that was more effective than before because we increased the exhaust time and it taking humid air faster and replacing by new hot air and process increased the rate of drying by some difference than before.

Because of the large quantity of chillies their was some fungus was occur in some patches in chillies. Because temperature and humidity is going on incresing that made fungus to grow.

At lower layer their was more fungus affection was observed because of the more thikness at lower layer.

24/01/2024

I and Pranay observed their is more fungus was growing than yesterday we observed. so we decided to move chllies from their place and make them free that will reduce fungus affection less. And also sir told us about take a 200gm sample from each layer and take weight of same sample that we can calculate the weight reduction for the day. Because we are not able to take out the chillies everday and weight it.

So, i taken a PP Mesh of area 30x30cm of 30gm and 200gm chillies from each layer and kept them on same layer and i will take weight of that same layer everyday. i put that same yesterday i.e on 23/01/2024.

25/01/2024

I have to collect data and take the weight of three samples which i kept yesterday.

Above are images for the weight of 200gm chilli weight and 30gm weight of PP Mesh this weight is included the weight of PP Mesh. Weight was 185gm,195gm and 196gm for the Top,Middle,Lower layers respectively.

Another change was done tha duct was taken below the lower layer that air flow would be passed from the lower layer to upward direction. and removed the bricks from lower side for more air circulation but after that i and Dixit sir dicussed on it and not more changes was observed by observing the reading 30 min before and after making changes

26/01/2024

Same process was going on and i moved chillies on morning and then taken weight of that samples i kept and the weight was 166gm,178gm, 182gm.for the top,middle and lower layer respectively.

and also data collection from data logger and excel filling for data was going on.

27/01/2024

Now our call was that to take the chillies out from the dome dryer and let them dry on open ground. we taken this call because our drying process is going good indryer but it was taking time because of the large quantity. so taken this call and taken out the chillies from dryer.

The task was too tough for single person to take the 300kg chilli out but i have to di it and taken around 6 hours (9am to 2pm) to take out chillies and spread them all over ground and all wrap up. because we tighed the PP Mesh and to cut it and take chillies out was time comsuming.

Task was not only to take them out but also to weight of it and I weighed it because otherwise we cannot find the chilli dryed in last 5 days in dome dryer.

I weighed and spread the chillies on the floor and the final weight after taking chillies out from dryer after 6 days was 295kg from that lower layer 151kg, middle layer 90kg and top layer 54kg and we put 495kg chillies in dryer that means we have taken around 200kg of water in 6 days from dryer. The rate of drying was about 33kg of water remove per day.

Now data loggers ae off and all accessories was taken out by me.

Below sharing below the data collected all over 6 days excel sheet its temperature and Humidity for each day.

Also sharing below small chart for weight i have done for 3 days of 200gm chillies.

Date	Top Layer	Middle Layer	Lower Layer
23/01/2024 Initial Weight (gm)	230	230	230
24/01/2024	204	210	210
25/01/2024	185	195	196
26/01/2024	166	178	182

28/01/2024

weighed the chilies in evening and the weight was 230kg around 65kg water loss in a day. And from that 230kg Lower layer 112kg, middle layer 67kg and top layer 51kg.

29/01/2024

Weighed in the evening and weight was 179kg around 51kg water loss in a day and from that lower layer 85kg, middle layer 54kg and top layer 40kg.

30/01/2024

It was our 10 days for trials and as weighed yesterday was weight 179 kg and it’s going to take final weight because we were stopping trial today and taking chilies to Vigyan Ashram for sorting and then powder making. Final weight was 160 kg. and water removed for that day was 19 kg.

31/01/2024

Day was spend in travelling from Nashik to Pabal taking dryed chillies to Pabal.

01/02/2024

Discussion with Ranjit sir dixit sir and prasad sir about trial and its results.

We got total reduction of chilies from 495 to 160kg in 10days, At rate of 33.5kg/day.

• Trial taken for 495kg Red chilies.
• 335kg water removed in 10days at rate of 33.5kg/day (8 hours).
• Efficiency of dome was 4% instead of 11% as calculated.
• Dried chilies remain 160kg.
• We removed moisture of 67% And we have data from empathy that farmer reduce 70% moisture from chilies and then sell in market.

Date	Initial weight kg	Final Weight kg	Water removed kg
21-26/01/2024(In dome 6days)	495	295	200
27-28/01/2024(On Ground 2 days)	295	230	65
29/01/2024	230	179	51 (Thin Layer)
30/01/2024	179	160	19
		Total	335kg

From discussion we concluded that to keep area same as the famer already using i.e. 1sq.ft for 1.5kg chilies.

Construction of 3m dome and make changes problem faced loading and unloading.

02/02/2024

Issued faced at time of trial:

1. Loading and unloading
2. Humidity accumulation
3. Sorted chilies for trial
4. Length of duct.

Discussion was taken with prasad sir Dixit sir for further phase of the project.

1. 3m dome Construction.
2. Loading unloading.
3. Exhaust selection and position.

Calculation was dome for the 4m dome dryer area (Nashik) was 262. 45sq.ft

And surface area of the dome was R= 6.5ft =132sq.ft and chilies 199kg.

Again, we calculated area for 3m dome we going for construction was 247sq.ft

And surface area of dome R= 4.9ft = 75sq.ft= 112kg

5/02/2024

On Monday review meeting we dicussed about the project next what to do and we decided to make the 3m dome at campus and fixed its deadline for it will be 15 March 2024. Because it will make sense that after we can more trial on dome before rain start. and also we can get red chillies for that trials too.

I started to work for it and to find the curvature of dome to make it bend from vendors and its costing for it. That curvature for 3m dome was 2.35m(7ft length) and radius about 4.9ft.

6/02/2024

Made a presentation for dicussion with Kulkarni sir,Ranjit sir,Dixit sir about trial we taken, its result and future plans for the project.

below is the presentation made for discussion.

7/02/2024

Discussion with Kulkarnisir,Ranjit sir and Dixit sir in presence of prasad sir and Mahesh sir. we discussed about the objectives we kept to DST for the project and that was we have to give 10 live dome demo and spread this technology or concept upto 200 farmers in future.

Dicussed about future plan regarding project and output was that we have to clear the problem we were faced during trial and then to construct the dome on campus. we decided to take one more trial in this month and after that positive result construction of dome will be done.

Also discussed about the substrate because red chilli availiability will be less then replace it by green chillies and take trials.

8/02/2024

As dicussed firstly contact with old vendors for cheking availiability of red chillies and if not then to take costing of the green chillies. And also dicussed to increase the CFM of fan and that results to buy new fan and controll its CFM.

Visited market for taking cost of green chillies because red chillies were not available. Market for green chillies was about 40-50/kg.

we were dicussing trial for 200kg with same thikness in same dome and also to use the same trays in dome. Sahil and Abhishek bought fan of 580CFM from Pune.

9/02/2024

Taken tour of the Engg.College students from Sangammner. Also went to Shikrapur with Abhishek for material purchase of project of BSF Separator.

12-13/02/2024

Faculty Development program was conducted by Vigyan Ashram involving it attained the Empathy Lecture by Prasad sir and went with the Group of 5 teachers I and Mahesh sir was leading then for the Empathy of poultry farm and we visited to the Mayur Chaudhari’s poultry farm and empathy was done by group members that was task for them to identify problem at poultry farm and note it.

14-17/2024

From 14 to 17 working with Abhishek for BSF Project because he have timeline for project was 17/02/2024. we fixed Mesh to the ring we bought and fixed then on the GI pipe(Shaft) with the help of MS Threaded rod.

In Betweein on 16/02/2024 Taken tour of the Students from college of Home science and BCA,Loni.

19-20/02/2024

Fabrication of Pupa black box for BSF Breeding chamber with sahil.

22/02/2024

As we were discussing about our next on field trial at Nashik on green chilies and contacting with vendors for chilies. And we were planning for the trial on 23/2/2024 at Nashik so we take discussion with Dixit sir, Prasad sir and Mahesh sir for confirming plan for trial.

Discussion was done on previous problem we faced and changes we was going to do. Then length of the duct of inlet should be taken down and other changes that we made late at last trial and eliminate that mistakes and observe the trial.

Problems we was facing that Green chili is not available in market. We needed about 200kg and if available rate for that was high (75/80 per kg) we can’t take trial on that base.

26/02/2024

we contacted with the farmer in Nashik and also the vendors for green chilies but there was less availability and costing were high so we waited for some days late we know about green chili from about DBRT Student Abhishek Shinde from Nashik.

So, we decided to not take trial at Nashik because of the high cost and less availability of green chili. And we decided to take trial on wood chaff on same 1m dome we have in both condition 1^st on as it is trial on current condition of dome and 2^nd on by creating duct for heating of air and then blowing it in the dome.

27/02/2024

So, I started to working for the trial at campus and dome dryer and made the setup for trial and covered trays with black cover because Trays were cored and so I made setup and all data loggers are attached as per dissuasion with Dixit sir the position was divines as 1^st for outer atmosphere,2^nd for air outlet, 3^rd and 4^th in between the trays at different levels.

But gone I was thinking to take trial on green chili if it is available at low price and went to market in evening and I got the chili at 40/kg green chillis 10kg. that was almost half of the market price of the green chili and I taken call to take trial on this chili. So, I confirmed that and bought chilies.

Also taken a tour of the Proffessor of the MMM college of engineering,Pune.

28/02/2024

In morning I filled trays because I want to start the trial at 10am and that will take time. So, I filled trays and placed them in dome and system was set and start the trial.

Then at 10 am I started the trial.

29/02/2024

In morning we discussed about the yesterday data I collected. The sensors attached for trial was in position as below:

1. Outer (Temperature and Humidity)
2. Air out (Exhaust)Temp/Humidity
3. Upper lower tray
4. Lower tray

Another discussion was done for next steps in project was like to make some change in structure and collect the data.

we observed the data and data was showing that temperature humidity at lower layer was not high that means to be that air from that zone was not getting disturbe. To disturb that air, we packed 1^st two line of air inlet on dome cover with tape and our prediction was that will make air to disturb because air suction will be more. We said that let observe for day and then again, we will talk on next day.

01/03/2024

we discussed about the data collected on both days 28-29/02/2024 and compared both the data, conclusion was that we identified from data that air at the lower trays is not getting circulating inside dome and it was creating dead zone in dome.

Nextly, trial on green chilies was going on but prasad sir and Dixit sir talked about the changing nature of chili at every trial of it. So, I decided to take out green chilies in dome and put them in flatbed dryer to dry. And take trial on the wood chaff in dome dryer and collect data from it. Also another reason for it was availability of green chilies and increasing cost of the green chilies. Position for sensor was same as before.

And we decided to take trial on wood chaff on as it is condition of dome and then make changes accordingly.

So, I bought wood chaff and taken a proportion on 5kg wood chaff and 5 kg of water then substrate for drying was 10 kg and I have started taking trial on 10 kg wet wood chaff. After adding water to it I started trial about 3:40pm

But unfortunately, connection I have taken from EDP Department was off by 5:25pm by someone who locked department. So again at 8:00pm I started and data recording was going on.

02/03/2024

As the results from yesterday trial was not recorded. So again, trial was started on saw dust and by maintain same condition as dome working in past, without making any changes in it.

04/03/2024

As we discussed in last discussion that we have to lift dome and make the air which is getting trap at lower should get disturb and increase the temperature. And trail was started on same model. but taking out the air from exhaust pipe attached to it.

We observed that in as its is working condition of their was air accumulation and air was not getting out from dome and that may increase humidity in dome and cause fungus growth or make product inside it infect.

Now because of this change we made the water removal rate was increased and around 4.5g of water/kg of air was removing observed from data we was getting.

05/03/2024

In Moring trial was going and we have to discuss about the yesterday result but I have to take tour of the Farmer came for the BSF training program. And then at evening we discussed about the yesterday result and again we decided to make changes accordingly.

we added the center pipe and attached exhaust at Bottom and dome was as lifter as same. and plan for next day was driven.

06/03/2024

Trial result for day was the we were removing a water about 3.8g/kg of air on average. and we decided now we will test the Nashik dome on campus by replicating it on our small dome dryer at campus.

And we decided to make a duct and then it will act like the Nashik dome.

Data for the trial will be saving in excel sheet and link for same is given below:

https://docs.google.com/spreadsheets/d/1LTZjrL9OX4ecsOgip0kg8DT3V6XiN0xS/edit#gid=1417412724

08/03/2024

As discussed, before I made the duct like Nashik dome dryer which act as a heating chamber and that air is passed from pipe and pipe have holes on it and that passes from above the trays and help to improve drying rate. It was our predicted thought for that trial.

Made setup for the trial and ready to start trial on next day all connections and data loggers were attached.

09/03/2024

Trial was started and data collection for same was going on. Sensors was attached at different position like

1. Blowing air from duct.
2. Out of the dome.
3. 2^nd layer of the trays.
4. Lower layer of the dome.

following are images for trial setup and duct attachment.

10/03/2024

In morning we discussed about the data and data observed was more efficient than before that we were having results in drying. And we observed the weight loss about 2.7kg from 10kg od saw dust.  

https://docs.google.com/spreadsheets/d/1LTZjrL9OX4ecsOgip0kg8DT3V6XiN0xS/edit#gid=1417412724

Another point we missed by me was that we were talking about the replication of Nashik dome but while taking trial I was lofting dome and keeping more space from ground level to dome periphery and we observed that we decided to add exhaust fan same as fan on Nashik dome dryer and here we will use firstly only one fam and then by discussion we will increase if needed.

So, I attached one CPU fan on dome on 2^nd layer of trays.

12/03/2024

Trial was started and data collection was going on from data logger. At end of the trial the weight loss observed was about 3.2kg in 6 hours of day.

and sensors of data loggers was attached as follows:

1. Blowing air in from duct
2. Outer going air from exhaust
3. lower layer
4. Outer temperature

following the picture for trial set and exhaust attached on it

13/03/2024

 Again, trial was started because data observed showing result but we again reduced the distance between ground and dome periphery that will show some result like dome at Nashik.

At end of day weight of the saw dust was of 2.50kg that initial weight was 6.80kg and final weight was 4.50kg.

15/03/2024

Trial was started as discussed before with Prasad sir and Dixit sir and trial was starte and data recorded but data for day was not recorded because of the power cutoff and low voltage fans and data logger was off for arount 3 hrs from 11am to 2pm so i have to repeat same trial and take data on it.

Data recorded on same day was added to excel and link for it is below:

https://docs.google.com/spreadsheets/d/1LTZjrL9OX4ecsOgip0kg8DT3V6XiN0xS/edit#gid=1417412724

16/03/2024

Review was taken by Dixit sir and Prasad sir and discussed on results and for further project step we decided to dicuss in evening at 9pm.

In Discussion we calculated the water removal rate according to data and compared it to actual weight loss according to weight taken at end of day.

We also talked about the air exchange from large open space from lower portion of dome and that may create resistance for fan to suck air from dome and blow it into the duct.

And we calculated the CFM of fan was 5CFM and again we realised that we need more fans for it so we decided to make a series of the fan on surface of and that may ON/OFF by interval and can control by us that we are going to test in out next trials.

Following is image for calculation done:

17/02/2024

We discussed about trials and our on-going trial results on dome on campus with Ashok Kalbag Sir in presence of Dixit sir, Prasad sir, Ranjit sir. Ashok sir suggested sum different structure we currently using for trial. Structure was like cylinder structure and mount dome on it. That will make dome structure as a preheating chamber and in cylinder structure we will load the substrate in it.

After discussion we noted all points and that will be useful for us in future while discussion of dome structure and construction at Ashram.

19/02/2024

As we decided in discussion before and trials was planned. Now last trial was conducted with one exhaust fan now I have to take trial with 4 exhaust fans on periphery of dome and fabricate it.

On same day I made an exhaust fan series and attached fan the dome and next day I will start trial.

20/03/2024

4 exhaust fan was attached and trial on 4 exhaust fan was started and minimum distance between ground and dome surface.

At end of the day final weight of the saw dust was 4kg loss i.e from 10 kg to 6kg and that was the maximum water loss we obtained in 6hrs and on dome dryer.

22/03/2024

Efficiency table was made for last 5 trial actual 6 trials was conducted for one trial was not calculated.

following is the table for changes made in dome and its calculated effeciency according to it.

Sr.No.	Changes	Weight loss from 10kg (Saw dust in Kg)	Efficiency (%)
1.	Dome structure as it is but attaching pipe to exhaust to take out humid air faster	2.56	22.3
2.	Duct was created like Nashik dome and Distance from ground is increased.	2.7	23
3.	One exhaust fan was attached and duct was as it is, and distance was same as before from ground level (Large)	3.2	28
4.	One exhaust fan was attached and duct was as it is, and distance was reduced from ground level (Less)	2.9	25
5.	4 Exhaust fan was attached and minor distance between ground and dome periphery.	4	35

23/03/2024

We have taken trial on another dome behavior like that how it works when it is packed from all side and only air intake from small holes on dome periphery.

We predicted that drying rate will be obviously less than previous trial because there was no other option for air to take in from outside

Then final weight of the saw dust at evening was noted was 7.3kg means that only 2.7kg water loss in day and we got 4kg water loss for last trial.

Hence proved that we can’t keep dome fully packed that reduce air exchange rate and drying will be less.

24/03/2024

Discussion was done between dixit sir, Prasad sir and all DIC Members. And output from that was we concluded was to repeat trial that we already made change to reverify the trials and after that we take discussion for further dome construction on champs. That verification makes surer for it.

25/03/2024

As discussed, repeat trial was started with 4 exhaust fan on dome surface maintaining minimum distance between dome and ground level and data collection for it was going on.

Final weight of the saw dust was taken and that was 6kg from 10kg that was 4kg loss same as previous trial and efficiency for it calculated was 35%

26/03/2024

As discussed, repeat trial was started with 4 exhaust fan on dome surface maintaining maximum distance between dome and ground level and data collection for it was going on.

Final weight of the saw dust was taken was 5.4kg from 10kg that was 4.6kg loss same as previous trial and efficiency for it calculated was 40%

27/03/2024

Trial with One Exhaust fan with minimum distance from ground level (5cm) was taken.

Final Weight of the saw dust observed was 6.4 from 10 kg. and Water loss recorded was 3.6kg.

28/03/2024

Trial with One Exhaust fan with Maximum distance from ground level (10cm) was taken.

Final Weight of the saw dust observed was 7.2 from 10 kg. and Water loss recorded was 2.8kg.

29/03/2024

Duct Created as Nashik Dome and repeat trial was taken on it by incresing distance from dome periphery and ground surface about 10cm.

weight loss at end of day was 3kg from 10kg of saw dust

30/03/2024

Made some changes for taking humid air out from exhaust attached pipe that will makw path for humid air to come out from dome. and trial was taken on and data was recorded.

Weight loss at end of day was 2.6 from 10kg of saw dust.

Also discussion took place between DIC members and Amey Kulkarni as he was available on campus we taked about our trial and he noticed some errors in our in going trials and told about the counter happening between Inlet air and Outlet air in dome.

and Another topic discussed was from where we can take hot air from lower surface of the ground or from upper surface of ground. and we decided to take it from upper surface of dome because that will be convient for us and less air counter will happen their.

31/03/2024

Another trial was decided including in these 6 trials was, trial on Dome structure as it is. Trial was taken before also but weight for it was not taken.

Final weight was taken at end of the day after trial stopped. The weight loss was 2.7kg from 10kg of saw dust. And efficiency for it was calculated was 23%.

Following is the table for both trials and changes done accordingly on 1m dome dryer. with their efficiency and weight loss for trail and change made.

Sr.No.	Changes	Weight loss from 10kg (Saw dust in Kg) 1st Trial	Weight loss from 10kg (Saw dust in Kg) 2nd Trial	Efficiency (%) for 1st Trial	Efficiency (%) for 2nd Trial
1.	Dome structure as it is but attaching pipe to exhaust to take out humid air faster	2.56	2.6	22.3	22.64
2.	Duct was created like Nashik dome and Distance from ground is increased.	2.7	3	23	25.5
3.	One exhaust fan was attached and duct was as it is, and distance was same as before from ground level (Large)	3.2	2.8	28	24.5
4.	One exhaust fan was attached and duct was as it is, and distance was reduced from ground level (Less)	2.9	3.6	25	31
5.	4 Exhaust fan was attached and minor distance between ground and dome periphery.	4	4	35	35
6.	Dome as it is	–	2.7	–	23

4 Exhaust fan was attached and minor distance between ground and dome periphery. WEIGHT LOSS 4.6kg

08/04/2024

Drawn 2D sketch of the Nashik dome on solid work with dimensions that can be used in further discussion of the dryer constructions.

In between this time i was working on BSF Separator. I and Mahesh sir changed tha mesh of outer cylinder of the separator and also fabricated new hopper and flange for separator.

13/04/2024

Now we are moving to construction stage of the dome dryer at champus we have collected the data for verification and we observed and got feel for constructuion of new dome dryer at campus.

1^st discussion was done, and we were going to it was by calculating the surface area of 1m dome was 0.785m^2. which have water remove rate of 4kg/day with 4 small exhaust fans about CFM of 60-70.

Then we calculated the surface area for the 4m dome that we will be going to construct, that was 12.56m². and water remove rate calculated by comparing 1m dome was 64kg/day. We assumed that to dry 200kg chilli then that chilli will be 56kg after drying then we were going to remove 144kg water from chillies. And at rate of 64kg per day then we will be required max. 3days to dry chillies.

            As we before talked with Kalbag sir, Kalbag sir, Dixit sir And Prasad sir about the structure was that to use dome as a cap/preheating chamber only and put it on a cylindrical shape and trays in cylindrical shape for drying of chillies.

Taking it forward we started discussion and as we have reference of Nashik dome which we made hemisphere and that will be mounted on cylinder.

We got task on it was like how much area of dome ids exposure to sun between drying time that we considered from 10am to 4pm. Accordingly we will cut the dome section which is not more use and then we can decide the height of our cylinder and duct.

Nextly, we discussed about the cylinder we going to design its area by assuming it as 1m length and 4m diameter, also by considering the duct space for it as 24 cm diameter.

We calculated the area for us was 36.86m². i.e. 396ft². And in that area chilli required will be 264kg as per empathy at Khargone farmer dry chilli on area of 1ft² for 1.5kg. and we were talking about the 5 layers in cylinder that we calculated we can put 52kg of chillies per layer of the cylinder.

14/04/2024

I have calculated the area which is not exposture to sun when sun is at the top of dome dryer that was around 1ft from the dome pheriphery. and that was found in the solidworks light projection mode. this all was for 3m solid dome and now i have to calculate for the 4m dome that lenght will be little more increase.

20/04/2024

Next dicussion was carried on same day that was on the area exposture and energy absorbed by cutting down area which is not expose to sun and for the duct diameter.

we dicussed that at 35% efficiency of the dome dryer we get energy capture at 12 pm rhat will define the increse in temperature inside the dome. and we will try to keep that temperature not more that 70degree celcius. then we have to decide the retaiontion time for it and that will be decided according to the CFM of fan.

According to it we will search and buy the particular CFM Fan from market and duct diameter will be depend on the diameter of fan we will going to puchase.

That’s out clear logic for deciding CFM of fan and Diameter of duct in Dome dryer.

Then after dicussion i have to calculate the energy vaule for that surface according to the 35% efficiency. and them CFM of fan will be fixed.

21/04/2024

As we discussed before I have calculated the energy exposure at surface of the dome and that was m². And energy exposure is about 546.56*10⁶ J. And energy efficiency was taken as 35% then energy which is going to be utilizes is 191296000J.

Then with the help of energy I have and temperature difference ids taken 35^oc taken from outer temperature will be 35 and inside we will increase to 70 ^oc. I have calculated the CFM value of the fan and that will be 629CFM.

22/04/2024

we dicussed about the design of the dryer.

We discussed about the loading and unloading of the substrate in dome if we working on existing dome structure like Nashik that was not good to work, we concluded.

As we discussed before we talked about the cylindrical shape structure at base and done structure upon it as a preheating chamber and cylindrical structure holds the tray and drying substrate in it. We have to make 4 parts of the cylinder which can be taken off and that will make easy to load and unload by removing trays. According to that each will have 5 fans on each layer of tray and no. of fans will 20 for 4sides.

Again, we discussed about tray system and after talking about different idea on it like taking tray out like drawer.  Slighting the tray for unloading, in that we have increase again height of cylinder. So, we dropped it. And final decision was to make 8 parts of the trays each in 45^o and attach that trays to one central axis for each tray that will guide for trays only and each tray will rest on next trays below to it by giving stand to it below it.

Also weld mesh will be used for the trays of 1inch*1inch. Now I have the conceptual design of the dome and I have to take it on SolidWorks or on paper and make a bill of material for it.

26/04/2024

As I was working to make SolidWorks design of the trays and dome. I was using software for it and will make to learn me too. I drawn some trays and dome design in solid works as follows.

Discussion with Dixit sir and Prasad sir we discussed about the next steps for the project when I have to take Bill of material for go for material purchase and listed some work procedure for it.

Firstly, I have work to take bill of material then take dome at Pune office to Pabal by dismantling it.

Also to take a discussion regarding about the opening of the air inlet at top of dome. That we didn’t discuss before.

27/04/2024

Discussions regarding dryer to construct at campus was almost done except discussion for air inlet to dome and we are now going to start the construction. I have dome some drawing of dome on SolidWorks but that are not good for fabrication.

We decided to make a CAD model of it first that will take out perfect bill of material and make ease to fabrication by drawing and other. So, Prasad sir will make a CAD model as we discussed and I will help him with my ongoing learning in Solidworks.

14/05/2024

I was learning solid work software by practicing some drawing on it. Also drawn some parts of the sugarcane juice machine as prasad sir given task to take dimension and make CAD in SolidWorks so I take dimensions and different parts of sugarcane juicer machine.

20/05/2024

I started to work on the solidworks to make the design of nashik dome and i have designed some different parts of it was dome outer structure dome duct and pile for blowing air in it. i am now in a learning phase and that will help to design in solidworks so i am practicing that drawing in it.

25/05/2024

As we discussed about the design of the dryer that was as in two parts 1^st will be the upper dome structure which will work as a preheating chamber and 2^nd will be the drying area which includes tray structure and trays mounted on it. so we have to use the dome structure at top and also going to use excisiting dome on champus.

01/06/2024

Dome structure is taken to the ground and its maintaines was done. that was not in use so some parts was not in good condition that was welded.

05/06/2024

Material required for dryer was confirmed and bill of material was ready and that was going accoeding to the new design of dryer.

following is the Design of dryer and final bill of material to purchase. Bill of material may be change according to maerial add or less from list.

06/06/2024

Material required for tryas and tray strucutre was purchased and we stardted for making of the strucutre and trays cutting for tryas and structure was done and welding for it was started according to drawing.

Two DBRT studensts Mallikarjun and Nivrutti were working with us in project fabrication work on contract basis. also they were learning.

07/06/2024

Cutting was and Noe welding was going on and both were working on it. Rolling of the tubes for some strucutre curve shape we done that with the help of rolling machine and some central and side pillers was finised on same day.

Marking was done in front of DIC Hostel for dryer that place was finalised which will be cover sunlight all over day with and shadow barries.

11/06/2024

Material Purchase From pune included surface fans and exhaust fan and wheels for the tray structure.

12/06/2024

Dome structure was lifted by 1ft from each side for making it more stable on side pillers.

13/06 2024

Tray structure was fabricated Malikarjun and Nivrutti both was working on it and trays and its strucutre was ready.

14/06/2024

we lifted dome on the pillers in morning and it was loking stable so we decided to keep it on 4 only instide of 8. and another was vendor for wrapping paper on dome was came and that task was over for us upper section is going to be covered.

following are some images related to tasks done.

15/06/2024

Trays was ready but we have to fix the mesh on it by welding so we started to cut and fixing it on trays.

16-20/06/2024

we got some delay, due to the exams of the Mallikarjun and Nivruti (DBRT students) was going on.

Trays structure is ready and fixing mesh on tray work was going on it and we was fixing mesh on it. On other hand Prasad sir and Mahesh sir was working on the dome position fixing and its land level.

we have already taken dome to the place and facing some issue for it because of uneven land .

Following are some images related to work between that days.

21-25/06/2024

Now trays were ready and need to paint so we started to paint them.

Then we fixed the duct paper and exhaust fan which we going to blow hot air from preheating chaber which we where going to create. so i and Mahesh sir fixed the duct paper and the also fixed the upper paper.

Made the stands for the fan fixing on the surface of the dome and our drying part.

26-29/06/2024

we Fixed the duct paper and dome surface paper but we have to stick that paper and make a air tight preheating chamber, on 28th we sticked the paper and also attached the surface paper too. Now the dome was Looking complete, all cover and air tight.

Before covering all we fixed the exhaust fan. duct will be fixed later on according to dicussions carried on field.

30/06/2024

Discussion was carried out regarding the positions of the data loggers in dome for the data collection and the future trials plans. During dicussion we discussed about different air flows and how fan reacts on that condition and we concluded for the 3 data collection points was first at top of the dome, second at bottom of the preheating chamber and third will be below the fan that is in drying part.

we decided to fix two data logger in preheating chamber, we thought in chamber their will zones created so we have to find air temperature and humidity at that positions. and third below fan that will give us data about at what temperature and humidity is getting into drying part.

and also we dicussed about that futher changes during trials like which temperature air we should drop down and which will be most effect that we will do during the trials on saw dust.

Data will be recorded for almost 3-4 days and then we will dicuss about the trials on sawdust.

2/07/2024

After attaching data logger i taken data and i have taken data from 2 datalogger because i was not able ON Fan because its creating vaccum in the preheating chamber and which create resistance for fan to flow air reduce the fan speed. and decided to take data on only 2 data logger.

After getting some data we discussed about it and we decided to change the interval data to 1minute and that will give changing temperautre and Humidity in it.

04/07/2024

I attached the 3^rd data logger in center because that was necessary, I was not getting the center reading because that was out third zone and I was missing that for it and that will make difference for it.

Now there was 3 data collection point Top, Center and at Bottom. And that was collected for 2 days and then we were moving to measure the light intensity and locking for lux measurement and conversion it in energy. And count it total energy produced and energy used.

09/07/2024

In Morning we discussed about the data collected by me in last two days in last discussion we concluded to calculate and find the energy by light intensity and another one by temperature rise in different section of the dome. And that different energies will gives the information about the total energy we are harvesting from the dome, also we can calculate the efficiency of it but we were not looking for it now. Because we were going to calculate the efficiency of dome on the weight loss basis and its drying rate for it will define its efficiency.

We discussed about the data I have collected that was good and calculation was already done for it and I compiled all in a excel sheet. Following is the excel link uploaded on goggle drive.

https://docs.google.com/spreadsheets/d/1J_jvxTOFriozcjbmgtLfumDjOVQ-tn6i/edit?gid=1511496667#gid=1511496667

Then we were looking for the inlet air holes for the structure and discussion carried on regarding that and so we discussed on two different concepts of the air inlet.

 From that 1^st was to take a air from the pre heating chamber and pass it from the duct to the drying part where trays are there and then that air will bounce back by taking moisture from substrate and same air will be taken up again in preheating chamber and circulation start and at a same point when there will be higher humidity there then we will activate the peripheral fans that will take more humidity air out and their will be some pocketing happen and that replace their new air in it.

2^nd was to give inclined duct from the base of duct to the middle or up above that was conclusive for us. Working was in way like when exhaust start it will make vacuum after starting the fan. So, we can’t keep that on for long time may be fan get damage due to more resistance on it. we decided to give the long pipe for air inlet inclined on the central pillar. That give the benefit to us that hot air will not pass back from the pipe.

That was our discussion on and we concluded about the 2^nd conceptual method. Then I was looking for the pipe length and surface area of fan and other factors.

10/07/2024

As we dicussed before about the pipes for air inlet and then we calculated the surface area of fan according to it divide it in 4 parts and then we decided the pipe of 7″ diameter pipe of 6ft we will require and we have to buy same.

firstly we were looking for the only two inlets but we didn’t got the pipe in market which was require about 13-14″ and if available its cost and time for order was taking time so decided to make it with this 7″ pipes.

On other hand i was working to make the tracks for the sliding of the trays to take them out and in for loading and unloading.i started to cut the MS sheetbut after we desided to cut it on Plasma cutter and also we have take trial on it because it was just repired and not tested any on it.

13/07/2024

we cut the traks for sliding for trays on plasma cutter. and after cutting bended them and it was ready to fix.

14/07/2024

Fixed the track under dome. Manas and i placed thec the track and that was good in working condition.

15/07/2024

Pipes For inlet was brought on 13th Aug and we fixed the track first and then we started to fix the pipes and made holes at specific placed we decided according to the center, hole in exact opposite direction at 4 corners. and we started to work on it. I,Prasad sir and Mahesh sir fixed the pipe and as discussed they were placed inclined and that will help us to not get out the Hot air inside dome(Preheating chamber) and we tighed it uunder the heating chamber. That was difficult task to do because we got temp about 60 degree and we was working in same condition. Mahesh sir got in the heating chamber, only way to enter was to dismental fan enter from same hole.

Following are some image related to pipes attached inside preheating chamber.

18/07/2024

Ranjeet sir and I discussed about some calculations regarding Polyhouse, in that we have to find out the total energy we were harveshting polyhouse and from that what we are using. i understand and taken some from him about polyhouse and stated some calculations.

21/07/2024

Iwas facing some problems regarding same calculation of the polyhouse so for that I discussed it with Dixit sir and we concluded it by assuming some data because we don’t have good recorded data from that we done some calculation then discussed with ranjit sir.

Following are images related to the same calculations:

22/07/2024

Now i have to start the data collection on the dome dryer, for that i need the timmer to operated the fan so, i taken the timmer from the agriculture section from aquaponic sytem for 1 day and attached it to the fan and trial was started. Below is the link of data collection done.

data.xlsx

23-29/07/2024

started to work on the script for the video, Poster and video recording for the program on 29-30 july for exhibition. firstly written the script for the dryer and then checked out it from Dixit sir, sir added some require information which we have to get to public and then sarted to prepare on it.

Manas and i shooted the video and editing for it was started and after editing it was posted on Youtube 27/07/2024.

Below id the link for the video recorded: https://youtu.be/oGUGRVu7hrI?si=EE6-bn690geaAcYC

On Exhibitions day many school students visited and some students was activity asking questions regarding dryer and drying process, that was quite interesting to interactions with students.

30/07/2024

On same day Many colleges visited which inscludes the students from colleges and UG,PG students some students from Pysics background was taking insterest about out thinking in projects and acting accordinglu. i was explaining about the journey for the project and view and future plans on project.

some organizations was visiting taken contact of us as they were interested about drying and want to take it also in the small area in Maharashtra. where the red chilli production is.

Most efficient feedback for us was from the Dr. Kalbag which we noted it as IMP because we have dicussed priviously on dryer with him and as he have given the idea of dome and cylindrical shape and base we worked on it and made this dome.

also he suggested some air circulation methods for the hot air and we have taken it we will try them as our trials we go on.

2/08/2024

As rain was going on it was worst condition to analays the woring of dryer and take reading. it was littlepause for it. on other hand we have some inquiry for the heatpump dryer. so i and Dixit sir started to work on some calculation regarding that heatpump dryer on side data collection was going on. But facing issues regarding that was like data was going recorded by dataloggers but it was not uploading web page so that was not good recording on that day.

03/08/2024

Calculations for heatpump dryer we done but we defined some Q1,Q2,Q3 and Q4 .

Q1,Q2,Q4 – Heat lost by circulating air and Q3- Heat gained by Compressor.

Assumptions:

Temperature: 20 degree Relative Humidity: 85% Specific Humidity: 12.42g/kg of air

 Temperature: 5 degree Relative Humidity: 100 % Specific Humidity: 5.74g/kg of air

Difference In SH: 6.68g/kg of air

Q1= (1000-12.42)*1.005*15= 14887.7j

Q2= (6.68*540*4.18)= 15078j

Q3= to be find Energy to compress 1kg of air (KW*Seconds)

Q4= (1000-5.74)*1.005*15= 14988.4j

So, to find delta T

Q1+Q2=(1000-5.74)*1.005*Delta T

Delta T= 29965.7/1009.8= 30degree

Total temperature rise 30+20=50 degrees

Then at 50 degree relative humidity will be 6% as calculated online

Then,

50°temp RH 6% SH 5.749/ kg of air

50temp  RH 75% SH71.2 g/ kg of air. Gain water = 65.5 g/kg of air.

 65.5 * 540 * 4.18 = 147846.6J

147846.6 = (1000 * 1 * 5) * Delta*T “

Delta*T = 147846.6/1005

Delta*T = 147 deg – 50 deg

 Delta*T = 97%

And that will be not possible we are not going to tske temperature at 97 degrees

similarly, we can calculate it for different temperature and find exact what temp we want for drying.

10/08/2024

Also, we are talking about the data loggers are getting data to us and we have some doubt regarding the Humidity sensor so we were trying to do calculations and predict according to data from temperature only. So again, we have done some calculation regarding humidity finding with help of outside and inside temperature we know.

Following is the image related to calculations we done to find relative humidity.

13/08/2024

We discussed about the data collected on last 4 days including present day and we got the difference between temperature at top and temperature at botton have difference of 4 degrees.

So, we calculated energy use at this time and we got the Q as 131.7KJ then we found that this energy will evaporate 58.35g of water per min. Then if we consider 6hrs daily then it will take 21kg of water out.  

Now for the 200kg of red chili by remaining 30% moister in it from its original moisture, total water we have remove will be 140kg. If we are removing 21kg of water per day then for 140kg it will take 6 days approx. and that the same no. matching to the drying period for the farmer at Khargone. We realize that we have reduce this period and we started to learn some term like drying force. And correlate with these ongoing calculations.

And all this trial and readings are taken when exhaust fan is ON for 2 min and OFF for 1 Min

Following is the Image related to Calculations done during discussions:

16/08/2024

As discussed before i changed some fan setting ,that 1min ON and 2Min OFF it means exhaust fan will keep blowing hot air for 1min and off for 2 min. this was my hyposthesis don’t know how it will work that i thought if this time interval is kept may be the air inside heating chamber will gwt more higher temperature and after blowing that air below may be increase the drying rate.

This all will be concluded after discussion of this data collected for 2-3 days.

Link For the collection going on: https://docs.google.com/spreadsheets/d/1cMg8RyTZ9s5GL7YhI-idDDMMcI6aNCf9/edit?usp=sharing&ouid=114000356462010155997&rtpof=true&sd=true

08/09/2024

As I was on the emergency leave from 22/08/2024 to 08/09/2024, there was pause for the project work. But data logging was going on, due to sudden rain there was problem for recording data logger they got wet and they were off for a long time.

But yesterday Mahesh sir started the data loggers but again due to lose connection, data of all 3 points was not recorded we only recorded the bottom and outside temperature only.

Today in morning I started the data loggers and started the data collection.

10/09/2024

Discussion carried out with Dixit sir on the raw data collected on previous date. We discussed about he the temperature rise and similarly we are getting the delta of 5 degree and that was good result we are looking for and hoping that will give better result on trials. Fan timing was 2 min OFF and 1 min ON.

We also calculated the energy we are getting for the water removal rate. Talked about the comparison between normal dryer with electric heater, Heat pump dryer and our solar dryer that can helpful for us we can point out that how our dryer is efficient t but also by economical side also have less investment.

And as now climate was looking good for the trials and we also decided to take trials on saw dust and collect data on it that will give us the data and we can predict foe the red chilies in further.

Following is the link for the data we talked on:

https://docs.google.com/spreadsheets/d/17GuOC_x6XrRxOokHpDbtqu5T_K7e_VqJ/edit?gid=1657307814#gid=1657307814

13/09/2024

As discussed in last discussion to start trial with saw dust. 215kg of saw dust was bought from market and in Night all setup for the trial was ready including data logger positions attachment of duct for conveying hot air from chamber to drying section.

At night with help of DBRT students and Panit, Mahesh sir we loaded the 200 kg saw dust in trays. Each Tray contains 5 kg of saw dust and thickness of that was about 5cm.

14/09/2024

3 data loggers were attached which collecting data from Top, Bottom and Outer temperature. And In morning about 10 am trial was started.

In Evening we weighted the saw dust we got the loss in weight about 16kg which was in 6 hours and we concluded that we are removing 2.6kg of water per hour from dryer. that was result according to the precalculated water loss was 21kg per day from red chillies and we are getting it to 16 kg.

Following are images while unloading of the saw dust for weighing it.

Excel Made for Data Collection and Trial Link:

https://docs.google.com/spreadsheets/d/15IzgbayS-Cvd1TuOFZjXeC71NZX6u3P96pzIl8qqu84/edit?gid=0#gid=0

15/09/2024

As trial was completed on 200 kg of saw dust and we taken a discussion in presence of Dixit sir, Mahesh sir and all DIC Interns.

Firstly, we discussed about the loss we got in a day was 16 kg which was good and we are probably close to calculated water loss per day.so we moved on to further discussion. Now my concern was we didn’t get the same result we calculated was because of the paper we put on trays and on which we speeded the saw dust. The temperature of the air was good and we were getting that but air flow we predicted that it will travel from bottom to top between the mesh for the chilies. And for saw dust we put sawdust on paper. So, we didn’t get the result.

Then we discussed about the substrate and what will replace the saw dust, we talked about the clothes, rice husk, cotton threads and other. At final we decided to take trial with Bajaria straws because that was easily available and free of cost, we are getting it.

Also, we increased the number of data loggers at different point we thought that air is going to displace from bottom of dome and we added another data logger at same place.

We continued the discussion and discussed about the fan and its position and also the air flows how can we execute it. in air flow we discussed about the manifold making on each tray or at ground from duct, also by sealing duct from base and then making holes on duct facing to the trays at different levels.

16/09/2024

In morning with DIC interns and some fellow we brought the bajara straws and we have to remove its leaves and cut the steam in size of the chilies.

We started to remove it and some we removed the leaves but we were not able to complete it by 200 kg because it was taking lots of time for it. after some time, we realize it will not work and after contacting with Dixit sir we stopped and we decided to work on saw dust only and work on the pocketing happening in dome.

After the substrate was cancelled for the verification, I taken the weight of 500g of that bajra steam and deeded then for half hour and got the result that they absorb the water about 450g which was similar to its weight.

Then I discussed about it with Dixit sir, we already stopped it but then also discussed about its property of substrate and that was it will not remain same at all time but saw dust will be same for every trial we conduct bajra steam will start decompose after multiple trials so we stopped that and continue trial with saw dust.

18/09/2024

As discussed, we decided to continue trials on saw dust and I started the trial of 200kg of saw dust again with the proportion of 100kg saw dust and 100kg water mixed with it.

Trial was started in Morning about 10am and continued till 5pm evening. No. Of data Logger was increased initial and they are as following Position:

Data Logger	Position
1	Dome Bottom
2	In Duct
3	Top of Dome
4	Outside (Near Pipe)
5	Top Tray
6	Central Tray

At the End of trial total weight was taken and that was 168 kg which was great because at stage we didn’t fix any exhaust fan on periphery for remove of humid air this all results we are getting only cold air remove by pocketing only and loss of water from saw dust was 32kg which was 5.3 kg of water remove per hour in six hours.

Initial Weight: 200(100kg Saw dust+ 100kg water)

Final Weight: 168kg

Water loss: 32kg (5.3kg per hour in 6 hours)

Link for data Recoeded in Trial: https://docs.google.com/spreadsheets/d/15IzgbayS-Cvd1TuOFZjXeC71NZX6u3P96pzIl8qqu84/edit?gid=0#gid=0

21/09/2024

Raised the discussion on trials I have taken and for the next of plan of action and trials setup.

In presence of Ranjit sir, Dixit sir, Prasad sir and Mahesh sir we discussed about the trial and another replacement for the paper with another purported material which will help to pass air from it and help for the drying of the product.

Water loss rate was good and that’s why we started to work for further trial and design of different experiment that will take us for the further better decision for development of dryer until last product.

We discussed and set the procedure of the next week and trials was as below:

1^st trial will with the change paper with the purported cloth

2^nd will be by making just holes on the periphery of the dome (Drying section).

3^rd will be by attaching of the fan on same holes.

That will result to how can we adjust the fan ON/OFF and also, we can decide the no. of fan required.

22/09/2024

As decided to replace black paper we taken the puporated transparent cloth. I cut them in to the 40 trays size and that will placed on trays and then on that drying material will be placed. Also, Priyanla Madam and Dhanraj helped for the cutting of that trays size cloth.

23/09/2024

As yesterday I cut down that trays cloth and in Morning with the all DIC Interns i loaded thae trial saw dust in to the dryer and trial rading was started from 10Am and data recoeding was started.

As of now data logging positions was same but one data logger was not working good so i have given to akash but that was done by him also it was delaying work from him and i started the trials i was getting outer temperture readings.

Following are some images related to loading of the dryer with sawdust in Morning:

27/09/2024

Their was continues rain for last 4 days that that was good condition for drying. and on same day their was small stop by rain so, i decided to take out that saw dust but when i gone their to take it out that was full wet as it is so, i decided to give one more day not to take it out.

Below is the image representing of no drying happen in last 4 days as it was wet.

Along 3rd trials on going i was guiding Interns in their projects and assignments too.

Also for the ghraphical representation for the trials and dome working done some drawing and then that will be used for the maual and documentations works.

30/09/2024

It was almost 6 days for the trial and sawdust was not drying so I taken decision to take it out, trial again with new sawdust and start trail.

So, I taken out the saw dust in morning. And also, I weighted that but there was not difference between weight.

01/10/2024

Because of the last trial was good due to rain. So again, I decided to repeat trial with 100 kg of sawdust and 100 kg of water and then observe the result because now we have replaced the paper with the perforated cloth (Sadi). So, I keep both mixture in evening next morning I loaded that 200kg with the help of all DIC Students.

On Same day I weighted it with the help of DBRT Student Tushar and the final weight was 176kg and weight loss was 24 kg, that was less that before taken trial water loss was 32kg. thought was there was some clouds present during trial.

As trials was decided in last discussion and nextly we are planning for the trial with holes on the periphery of the dome and then by fixing fans on same.

For making holes on periphery, I have to raise the discussion and discuss with Dixit sir, Prasad sir.

08/10/2024

After the previous trial we talked about the trial and taken discussion and in discussion we decided to make holes on the dome paper as we decided the experiment flow before also.

So, I made the holes on the periphery of the dome of 1cm diameter and made totally 16 holes each tray contain 2 holes and position of the holes was decided on the bases of the air flow that is wet air will rise up and that will get out from that holes was hypothesis.

Trial was started with 206 kg of sawdust which was already wet and moisture was not removed from it. Another 30 kg water was added in it and 35 kg of wet saw dust left after the loading of the sawdust.  

Data Loggers position was as below:

Data Logger No	Position
2	Bottom Duct
3	Top
4	Bottom Dome Tray
5	Top Dome Tray

Final Result at the end of the day when the saw dust weighted was 170kg which was recorded weight loss was 30kg.

Following is the data recorded for trial:

https://docs.google.com/spreadsheets/d/15IzgbayS-Cvd1TuOFZjXeC71NZX6u3P96pzIl8qqu84/edit?gid=0#gid=0

9/10/2024

After trial I and prasad sir discussed about the result but while discussion prasad sir told that if we use the old sawdust which is already used for trial that will affect the next trial result because it will not have more water holding capacity because it contains water already in it.

So, we decided to take the new sawdust and repeat the same trial. And that data will be considered according to designed experiment.

11/10/2024

With help of the interns I bought the 210 kg of the saw dust for next two trial which will be on the holes and after the fan attachment. As trials was planned in future plans.

Also, we discussed with the Tejaswini and Nivedita in their calculations regarding polyhouse and fan pad system required form the BSF chamber and polyhouse efficiency. That will be on the blog of Tejaswini.

13/10/2024

As discussed before I repeated the trial and started the trials in morning with help for the loading of the DIC interns and fellows.  

In trial proportion was 100 kg of sawdust with 100kg of water added in it. And 16 holes on the periphery of dome and it was covered. Data logger position was similar as previous trial.

On same day trial was not ended because there was almost cloudy so I didn’t remove the saw dust and repeated it was next day and all data recording was for 6 hours the day. So, trials were for 2 days.

And on same day weighted at evening weight was 146kg left then water removed was 54kg in 2 days hence water remove rate was 27kg per day. According to the previous calculation 21kg water loss per day was estimated. But currently we are not getting the total input energy. so we again discussed on the input energy we need we talked about the measurement of the light intensity with the sensor which was made by one of out DIC Intern who made the that device. May be that device was dismantled. Nextly, I started to work on it.

Following is the link for data collected during trial:

https://docs.google.com/spreadsheets/d/15IzgbayS-Cvd1TuOFZjXeC71NZX6u3P96pzIl8qqu84/edit?gid=0#gid=0

18/10/2024

Attended the Annual Monsoon Workshop with Suhas sir at SPPU,Pune. Workshop was organized by IMSP (Indian Metrological Society Pune Chapter) Mainly include the 3 sessions in which different presentation and software used for the rainfall and Landside predictions and its use was presented by different IMD head and Scientists. 1^st was Features of SW monsoon and Predictions. 2^nd was unusual weather extremes and landslides and 3^rd was panel discussion on topic Weather and climate extremes: unlocking solutions through research and development.

We represented the Poster of our AIML Project for Polyhouse that how we are studying the data and collecting it with Help of AI.

19/10/2024

As discussed before in the design experiment the next trial discussion was raised and we was getting same pattern in drying so we decided to attach the fan at the base of the tray structure from that we will get benefit for drying the lower layer and pattern can break and drying rate will increase.so, we zero down to attach 8 fan on base of the tray structure and repeat trial and then further discuss the result of trial.

22/10/2024

As talked before I brought saw dust from market on 21 and by adding 100kg od saw dust and 100kg of water in it soaked and in morning with help of DIC Interns loaded sawdust to dryer and trial was started with 8 fans at base of trays connection and wiring for fans was done on previous night.

23/10/2024

In morning we opened the trays but there was not water loss and all trays are wet as loaded so I decided to continue trial for same day and trial continued. Pattern for drying was same only 1^st tray was drying but lower trays are as wet as loaded.

Following are some images realted to tray taken out and trial was continued because of not drying.

24/10/2024

In Morning sawdust was taken out similarly, There was not more water loss was seen final weight was taken and total weight loss was 50.18kg in two day 22-23/10/2024. Trial setup was 8 fans attached at last tray and they were continue ON for Max.6 hours. And weight was around 25 kg per day and 4.1 kg per hour observed. Also the weight for the 2 tray structure was taken and that weight was also showing for indiviual trays as 1st and 2nd trays have less weight and 3-4-5 trays have more weight that shows weight of sadust decrese from top to bottom.

Tray No.	Tray Structure 1 (kg)	Tray Structure 2 (kg)
1	3.90	4.22
2	3.80	4.16
3	4.10	4.28
4	3.97	4.18
5	2.65	3.41

Temperature and Humidity data recorded during trial uploaded in excel and its link is given below:

https://docs.google.com/spreadsheets/d/15IzgbayS-Cvd1TuOFZjXeC71NZX6u3P96pzIl8qqu84/edit?gid=0#gid=0

26/10/2024

We discussed the last trial observation was not good at drying water loss was only 25kg per day we are not got better result on attachment of fan and making holes on the periphery also. Now we started moving toward next move decided before to attach fan on the periphery and take trials so we discussed and decided to attach only 4 fans first at periphery and then then talk about the result plan further.

28/10/2024

As discussed, fans were attached on the periphery of the drying chamber and already 8 fans were attached on the base of the trays. Now total no of fans was 12 and they are going to operate continue 6 hours of trial. we will put them on timer in future we also planning for it.

Again, 200kg of saw dust was loaded and trial was started on same day.

In evening we weighted the total sawdust and weight was amazing we got the best result till now was 40 kg water loss in a day. Almost 6.6kg per hour.

29/10/2024

Along with this trials, I and prasad sir working for the dryer material purchase and other for the Workshop at Khargone in december 8-9, we made the bill of material and some of the orders like paper,Dome(4m) alredy placed.