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Procedia Engineering 205 (2017) 540–547

10th International Symposium on Heating, Ventilation and Air Conditioning, ISHVAC2017, 19-
22 October 2017, Jinan, China

Analysis on efficiency optimization of tobacco leaf flue-curing

process
Gengshuo Caoa,b
a,b, Yafeng Baocc, Chao Wudd, Yong Wanga,b
a,b*

aa
Key Laboratory
Key Laboratory of
of the
the Three
Three Gorges
Gorges Reservoir
Reservoir Region’s
Region’s Eco-Environment,
Eco-Environment, Chongqing
Chongqing University,
University, Chongqing
Chongqing 400045,
400045, China
China
b
b National
National Centre
Centre for
for International
International Research
Research of
of Low-carbon
Low-carbon and
and Green
Green Buildings,
Buildings, Chongqing
Chongqing University,
University, Chongqing
Chongqing 400045,
400045, China
China
cc
China Haisum
China Haisum Engineering
Engineering Co., Ltd, Xuhui
Co., Ltd Xuhui District,
District, Shanghai
Shanghai 200031,
200031, China
China
d
d Chongqing
Chongqing Architectural
Architectural Design
Design Institute,
Institute, Yuzhong
Yuzhong District,
District, Chongqing
Chongqing 400015,
400015, China
China

Abstract
Abstract

Tobacco
Tobacco leaf
leaf flue-curing
flue-curing process
process consumes
consumes large
large amounts
amounts ofof energy.
energy. Comparing
Comparing to to the
the traditional
traditional heating
heating approach
approach using
using coal,
coal,
the
the heating source like heat pump would be more energy efficient and environmental friendly. Using heat pump for tobacco
heating source like heat pump would be more energy efficient and environmental friendly. Using heat pump for tobacco
drying is
drying is proposed
proposed in in this
this study.
study. AA 3D
3D numerical
numerical model
model is
is established
established based
based on
on the
the theory
theory of
of heat
heat and
and mass
mass transfer
transfer in
in porous
porous
medium. Field
medium. Field measurements
measurements werewere conducted
conducted inin an
an actual
actual curing
curing barn
barn in
in Chongqing.
Chongqing. The
The effects
effects of
of wall
wall insulation
insulation performance
performance
and
and circulating
circulating air
air volume
volume were
were obtained
obtained by
by comparative
comparative analyses
analyses of
of the
the key
key parameters.
parameters. The
The feasibility
feasibility and
and energy
energy efficiency
efficiency
were
were proved by comparative analyses and experimental data. The result can help improve energy efficiency of relevant
proved by comparative analyses and experimental data. The result can help improve energy efficiency of relevant projects
projects
in agriculture
in agriculture baking.
baking.
© 2017
© 2017 The
The Authors.
Authors. Published
Published by
by Elsevier
Elsevier Ltd.
Ltd.
© 2017 The Authors.
Peer-review Published by
under responsibility
responsibility ofElsevier Ltd. committee of the 10th International Symposium on Heating, Ventilation and Air
the scientific
scientific
Peer-review under of the committee of the 10th International Symposium on Heating, Ventilation and Air
Peer-review
Conditioning. under responsibility of the scientific committee of the 10th International Symposium on Heating, Ventilation and
Conditioning.
Air Conditioning.
Keywords: Tobacco
Keywords: Tobacco flue-curing;
flue-curing; Heat
Heat and
and Mass
Mass transfer;
transfer; Wall
Wall thermal
thermal insulation;
insulation; Circulating
Circulating Air
Air volume;
volume; Energy
Energy saving
saving optimization
optimization

1. Introduction

Tobacco leaf flue-curing process consuming large amounts of energy is all-important to the quality and
availability of tobacco [1]. At present, coal is the main heat source of curing barn, occupied above 70% of the market
share in China [2]. Most curing barns adopt coal as the heat source, low efficiency (only about 20%) and severe air
pollution [3]. According to the existing research results, a variety of factors relevant to the quality of tobacco flue-

* Corresponding
* Corresponding author.
author. Tel.:
Tel.: +86-23-65120750;
+86-23-65120750; fax:
fax: +86-23-65120773.
+86-23-65120773.
E-mail address: [email protected]
E-mail address: [email protected]

1877-7058 ©
1877-7058 © 2017
2017 The
The Authors.
Authors. Published
Published by
by Elsevier
Elsevier Ltd.
Ltd.
Peer-review
Peer-review under
under responsibility
responsibility of
of the
the scientific
scientific committee
committee of
of the
the 10th
10th International
International Symposium
Symposium on
on Heating,
Heating, Ventilation
Ventilation and
and Air
Air Conditioning.
Conditioning.

1877-7058 © 2017 The Authors. Published by Elsevier Ltd.

Peer-review under responsibility of the scientific committee of the 10th International Symposium on Heating, Ventilation and
Air Conditioning.
10.1016/j.proeng.2017.10.413
 Gengshuo Cao et al. / Procedia Engineering 205 (2017) 540–547 541
2 Gengshuo Cao, et al. / Procedia Engineering 00 (2017) 000–000

curing which determine the availability and economic benefits of tobacco [4]. Therefore, it is essential for the
development of tobacco industry to solve the issue about low efficiency heat source and improve the quality of flue-
cured tobacco.
Heat pump drying technology has applied in agriculture, food production and industry manufacture widely with
outstanding merits of energy efficiency and environmental friendliness [5,6]. Neslihan. C et al. founded the
feasibility and economy of applying heat pump as a heat source to tobacco flue-curing [7]. P. Sun et al. applied heat
pump system, heat pump and electric hybrid system, heat pump and solar hybrid system to the tobacco leaf flue-
curing respectively and obtained good feedback [8,9]. Compared with the traditional curing barn, the energy saving
rate can reach 20% to 50% [10,11]. Therefore, the heating source like heat pump are more energy-efficient and
environmental friendly than the traditional heating approach using coal. It can play an irreplaceable and important
role in the promotion of energy sustainable utilization.
Regard to factors affecting the quality of tobacco flue curing, L. Yue et al. founded that baking method, tobacco
varieties, barn type and other factors have different effects on the quality of tobacco baking [12]. Through analyses
on temperature-humidity changing status for curing barn, H. Wang et al. discovered that the stability of the
temperature and humidity of the curing barn play an important role in the improvement of the tobacco flue-curing
quality [13,14]. At the same time, the stable temperature and humidity conditions also require that the barn have a
good thermal insulation performance and suitable circulating air volume. Therefore, it is necessary to study the
effect of circulating air volume and wall thermal insulation performance on the quality of tobacco flue-curing
process.
In this study, a 3D numerical model is established based on the theory of heat and mass transfer in porous
medium [15,16,17], where the hanging tobacco leaves in the bulk curing barn can be regarded as continuous porous
media, thus the process of flue-curing can be addressed by the model of heat and mass transfer in porous media
[18,19]. Combining theory with experiment, field measurements were conducted in an actual curing barn in
Chongqing. External conditions such as wall thermal insulation performance and circulating air volume influenced
on process were obtained by comparative analyses of the key parameters. The feasibility and energy efficiency were
proved by comparative analyses and experimental data. The result can help improve energy efficiency of relevant
projects in agriculture baking.

Nomenclature

CFD computational fluid dynamics

K wall heat transfer coefficient
E1 energy consumption before taking energy saving measures
E2 energy consumption after taking energy saving measures
ε energy saving rate

2. Methodology

The temperature and humidity distribution of the barn plays a vital role in the quality of tobacco flue-curing,
which can be affected by different external factors including baking methods, the varieties and maturity of tobacco
leaves, and the types of curing barn [5]. As the temperature and humidity environment is sensitive to the building
envelope performance and the circulating air volume, special attention has been paid to the impacts of the wall
insulation performance and circulating air volume on the quality of tobacco flue-curing. This research combined
theory with experiment as follows:

2.1. Theoretical calculation method

Based on the theory of heat and mass transfer in porous media, the process of tobacco leaves flue-curing is
regarded as a typical heat and mass transfer process in porous media. As the tobacco leaves are assumed to be virtual
continuum media from a larger scale, with internal heat and mass transfer process ignored. Thus a mathematical
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Gengshuo Cao, et al. / Procedia Engineering 00 (2017) 000–000 3

model to demonstrate the heat and mass transfer process based on a whole barn is built in this study [18]. Curing
barn physical model is established by considering the arrayed rule and size of tobacco and the exhaust outlet
(Figure.1). Each shelf of tobacco is simplified represented to a cuboid (1.05m × 0.8m × 0.1m) and all the tobacco
divides into three sheds and symmetrical distributed in the curing barn. Taking a barn ground Centre as the origin,
air supply direction as the positive X axis direction, vertical upward as the positive Z axis direction, Z and X right-
hand rule is pointing to Y axis [16].

Fig. 1. (a) 3D physical model profile; (b) Vertical view of physical model.

To choose the grid partition program, the grid generation time, calculate the cost and the factors related to the
numerical dissipation should be considered. More tightly grid partition is used to the tobacco accumulation area
(porous zone) in curing barn, and in other areas, the relatively sparse grid partition is used. The total number of gird
is 961979, and the average quality of grid is 0.65 which is acceptable for CFD use.
Based on the above model, the governing equations describing heat and mass transfer process were established
according to the law of momentum, mass and energy conservation. According to the characteristics of porous media,
the various coefficients of porous media are determined. The computational domain and parameter settings show in
Table 1. The temperature field and velocity field in the bulk curing barn is simulated by using SIMPLE arithmetic
and FLUENT software to meet the accuracy requirements while verified by experiments [16]. The influence of wall
insulation performance and circulating air volume on the temperature field and velocity field in the barn was
analyzed by changing the boundary conditions. Furthermore, the influence of flue-cured tobacco quality was
obtained.

Table 1. Fluent settings of the calculation parameter.

Computational Domain Setting Parameters
Inlet Temperature, Speed, Team volume fraction
Tobacco physical parameters, Pore rate, Stickiness resistance coefficient, Inertia
Porous media zone
resistance coefficient, Energy source term, Evaporation – Condensation UDF
Outlet Outlet pressure, Outlet temperature
Wall Heat insulation surface

2.2. Experimental method

The flue-curied tobacco quality improvement methods and expected results under different conditions were
obtained by CFD theoretical method. However, CFD numerical simulation results can only be used as theoretical
guidance. Field measurements were conducted as follow to obtain the practicability and energy saving rate of this
method.
The test site was a curing barn located in Wushan, Chongqing. The curing barn volume was 8m×2.7m×3.5m,
which is equipped with five observation windows. The flue-curing heat source is the high temperature heat pump
with heat recovery technology which model is PAXHZ120S using the refrigerant R134a as working medium. The
heating rated power of this heat pump is 8.4 KW, the nominal heating capacity is 36 KW and the heating recovery is
25 KW. Recirculation fan was two axial fans with power 750w and the total air volume is 21000m3/h. The upper
supply and bottom return was adopted as air distribution mode. The size of air inlet and air outlet were
1200mm×600mm.
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The tobacco leaf flue-curing experiment based on the above curing barn started on July 20, 2014 and till the end
of September 30, 2014 which had tested for three experiments as follows: Work condition 1 was the initial condition
of the barn which described above. Work condition 2 changed the wall thermal insulation performance by pasted 3
cm thick foam board based on work condition 1. Work condition 3 improved the air volume by changing the
recirculation fan based on work condition 2.
Under the three work conditions described above, the following experimental methods were used to test the key
parameters in tobacco leaf flue-curing process: (1) the temperature was collected every 30 minutes by the
Agilent34972A instrument and the temperature sensor was arranged in the barn according to Figure. 2; (2) the
KANOMAX intelligent environment test instrument was used to test the temperature, humidity and wind speed of
outdoor environment and removing humidity port; (3) the energy consumption was recorded per hour by electric
meter; (4) the amount of water discharged from the removing humidity port was recorded per hour to get the amount
of moisture.

Fig. 2. (a) Floor plan of thermocouple; (b) Elevation of thermocouple.

3. Numerical results and discussions

3.1. Analysis on the influence of wall thermal insulation performance

Based on above numerical model, setting the boundary conditions are K=0 and K=0.83 to analyze the influence
of wall thermal insulation performance on the temperature distribution of the barn. Among them, K=0 is assumed
that the curing barn doesn’t exchange heat with the outside environment. K=0.83 is based on the requirements of
energy conservation for the building envelope of China [20]. The distribution of temperature field in the barn was
calculated under these two conditions as shown in Figure. 3. The results are compared and analyzed as follows:

Fig. 3. Calculation results of temperature field distribution at Y=0.5m in different stages. (a) K=0, early stage of the yellow; (b) K=0.83, early
stage of the yellow; (c) K=0, early stage of fixing color; (d) K=0.83, early stage of fixing color; (e) K=0, early stage of stem-dring; (f) K=0.83,
early stage of stem-dring.
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It can be found that that there is an obvious temperature gradient on the wall side of the non-adiabatic wall
(K=0.83) with respect to the adiabatic wall (K=0) according to Figure. 3. The heat decreased during the circulation
process result in temperature gradient, which is consistent with the actual situation. Therefore, it is suggested that
put the mature tobacco leaves near the air outlet and put fresh tobacco leaves near the thermal insulated door to
improve the uniformity of the flue-cured tobacco quality. Furthermore, the wall thermal insulation performance has
an important influence on the distribution of the temperature field which has an important impact on the quality of
tobacco flue-curing. It is essential to deter-mine the economic insulation measures for making the minimum
investment in the whole life of the barn.

3.2. Analysis on the influence of circulating air volume

Essentially, the velocity field is variety which change with circulation air volume, and then affect the uniformity
of temperature field due to the coupling relationship of velocity field and temperature field. Limited space, this
paper mainly for the velocity field comparative analyses. Based on numerical model, the velocity field distribution
of Q=10000m3/h, Q=20000m3/h and Q=25000m3/h were simulated by FLUENT software under the condition of
steady state. Among them, Q=20000m3/h is the actual circulating air volume in the barn, Q=10000m3/h and
Q=25000m3/h were the boundary conditions used to study the influence of circulating air volume. The results are
compared and analyzed as follows:

Fig. 4. Calculation results of velocity profile distribution. (a) Q=10000m3/h, velocity field at Y=0.5m; (b) Q=20000m3/h, velocity field at Y=0.5m;
(c) Q=20000m3/h, velocity field at Z=1.5m; (d) Q=25000m3/h, velocity field at Z=1.5m.

According to Figure. 4, it illustrates that the velocity field and the uniformity of the temperature distribution of
the barn are improved by increasing circulating air volume and it shows that the wind speed was fast at the non-
tobacco accumulation area and decreased sharply at tobacco accumulation area. Lacking air volume will affect the
uniformity of the temperature field in the barn and thus affecting the quality of flue-cured tobacco. Excessive air
volume will cause the tobacco flue-curing process too quickly and reduce the quality of the flue-cured tobacco.
According to existing research results, the air volume required differ in all stages of tobacco leaf flue-curing process,
which is growing from the yellowing stage to the color-fixing stage and decrease from the yellowing stage to the
stem-dring stage. Therefore, it is necessary to reduce the rotate speed of recirculation fan in the stem-dring stage,
which has an important effect on the appearance quality, and flavor quality. In the promotion of tobacco flue-curing
 Gengshuo Cao et al. / Procedia Engineering 205 (2017) 540–547 545
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using heat pump, recirculation fan with infinitely variable control would be recommended. Different stage match
different air volume, it can not only reduce the operating energy consumption but also improve the aroma quality of
flue-cured tobacco.

4. Experimental results and discussions

4.1. Analysis on the influence of wall thermal insulation performance

This paper focuses on the flow field optimization of curing barn using heat pump. Therefore, we only analyze the
uniformity of the temperature distribution in the first 90 hours as shown in Figure. 5:

Fig. 5. (a) Variation of vertical temperature distribution under work condition 1; (b) Variation of vertical temperature distribution under work
condition 2; (c) Variation of vertical temperature difference; (d) Variation of horizontal temperature distribution under work condition 1; (e)
Variation of horizontal temperature distribution under work condition 2; (f) Variation of horizontal temperature difference.

During this experimental process, the heat pump has ran for 170 hours which consumed 1722 KW·h under
working condition 1 while the energy consumption was 1259.4 KW·h under working condition 2. As the heat pump
has the energy conservation technology of heat recovery, the power consumption can further reduce 170.2 KW·h
according to the actual situation. Therefore, the comprehensive energy consumption reach 1089.2 KW·h and the
total energy saving was 632.8 KW·h by increasing thermal insulation measures and using heat pump with heat
recovery technology as flue-curing heat source. The energy saving rate can be calculated by formula as follows:

E2
ε =
E1 (1)

In this research, E1 is 1722 KW·h and E2 is 1089.2 KW·h. Therefore, the comprehensive energy saving rate is 60 %
and energy saving effect is remarkable.
According to Figure. 5 (a-c), it illustrates that the vertical temperature difference under work condition 2 is
smaller than that under work condition 1 and the vertical temperature field is more stable by improving the wall
thermal insulation performance, which is verified the practicality of theoretical analysis method described above.
The temperature and humidity of the barn varied within a reasonable range are helpful to improve the quality of
flue-cured tobacco and reducing start-up period of heat pump, so as to improve the operation life of heat pump.
According to Figure. 5 (d-f), it shows that insulation measure can’t improve the horizontal temperature uniformity of
546 Gengshuo Cao et al. / Procedia Engineering 205 (2017) 540–547
Gengshuo Cao, et al. / Procedia Engineering 00 (2017) 000–000 7

the barn but increase the temperature difference in quite a few stages. There is evidence to suggest that lacking
circulating air volume leading to insufficient heat exchange between hot air and tobacco leaf and then the quality of
flue-cured tobacco declined. Therefore, we improved the circulating air volume by changing the recirculation fan in
work condition 3.

4.2. Analysis on the influence of circulating air volume

Fig. 6. (a) Variation of vertical temperature distribution under work condition 2; (b) Variation of vertical temperature distribution under work
condition 3; (c) Variation of vertical temperature difference; (d) Variation of horizontal temperature distribution under work condition 2; (e)
Variation of horizontal temperature distribution under work condition 3; (f) Variation of horizontal temperature difference.

During this experimental process, the electricity consumption was 1231 KW·h under work condition 3 and has
reduced 28.4 KW·h compared with work condition 2. Therefore, changing recirculation fan also has certain energy
saving effect. According to Figure. 6 (a-c), it reveals that the vertical temperature difference of the barn was further
reduced by changing recirculation fan to meet the requirements of air volume. The whole tobacco quality under
work condition 3 is better than that under work condition 2, which is verified the practicality of the theoretical
analysis method described above. In the fixing color stage (100h to 150h), the amount of moisture is large while
heat pump is fixed frequency output. Consequently, the temperature difference is larger than any other stage and the
maximum vertical temperature difference reach 3.5℃. In the stem-dring stage (150h to 170h), the temperature field
becomes uniform as the amount of moisture is less and less. Therefore, it is suggested that put the fresh tobacco
leaves on the upper shed in order to improve the quality of flue-cured tobacco. According to Figure. 6 (d-f), it
suggests that the horizontal temperature uniformity of the barn was improved by changing recirculation fan to meet
the requirements of air volume. Heat between hot air and tobacco can be fully exchanged and improve the horizon-
tal temperature distribution of the curing barn. The temperature field of the curing barn is more uniform which is
beneficial to improve the quality of flue-cured tobacco.

5. Conclusions

According to the existing research results, the quality of flue-cured tobacco can be affected by multifarious
external factors including baking methods, the varieties and maturity of tobacco leaves, the types of curing barn and
so on. This research based on the numerical model established by the theory of heat and mass transfer in porous
medium. The effects of external conditions such as the wall thermal insulation performance and circulating air
volume in the tobacco leaf flue-curing process were obtained through theoretical calculation and experimental
 Gengshuo Cao et al. / Procedia Engineering 205 (2017) 540–547 547
8 Gengshuo Cao, et al. / Procedia Engineering 00 (2017) 000–000

analysis. The key parameters in the tobacco leaf flue-curing process were analyzed and the conclusions were
obtained as following:
1. CFD numerical simulation can provide theoretical guidance for improving the quality of flue-cured tobacco
and the practicability of this method was verified by experiment.
2. The wall thermal insulation performance play an important role on the temperature field of the barn. Through
the actual measurement analysis, the comprehensive energy saving rate can reach 60% by increasing thermal
insulation measures and using heat pump with heat recovery technology as flue-curing heat source. Improving the
wall thermal insulation performance not only protect the heat pump operation by reducing start-up period of heat
pump but also increase the temperature uniformity of the barn and improve the overall quality of flue-cured tobacco.
3. The air volume of recirculation fan has a great influence on the tobacco flue-curing quality too. Lacking air
volume will affect the uniformity of the temperature field in the curing barn which isn’t conducive to tobacco leaves
drying together. High air volume is beneficial to improve the quality of flue-cured tobacco in the yellowing stage.
However, in fixing color and stem-dring stage, excessive air volume would cause the aroma constituents can’t be
maintained very well and flue-cured tobacco become dry and matte which could reduce the level of tobacco and it
economic benefits.

Acknowledgements

This work was supported by the 111 project, No. B13041.

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