Generalized Correlations for the Estimation of Condensate Power in Flooded Cylinders

Condensate accumulated inside dryer cylinders will produce an increased power demand and eventually the inability of the dryer drive to accelerate the section. In a previous paper, these authors presented an online estimation algorithm capable of detecting the presence of condensate during a section starting. In this paper, a complete set of tests is run over two experimental cylinders covering up to 40% of cylinder volumes, and the complete set of power curves are reported and analyzed. Specifically, the presence of a combined cascading-rimming region in the medium to high condensate loads is confirmed. This combined mode modifies the pattern followed by the maximum power in the low condensate region. Using these data, high-order and simplified correlations are proposed for the estimation of condensate in flooded dryer cylinders. These new correlations increase the capacity of the online estimation algorithm to give good estimations of the condensate load present inside the dryer cylinders up to 55 mm of rim thickness.