The improvement of the design and operation of energy conversion systems is a theme of global concern. As an energy intensive operation, industrial agricultural product drying has also attracted significant attention in recent years. Taking a novel industrial corn drying system with drying capacity of 5.5 t/h as a study case, based on existing exergoeconomic and exergetic analysis methodology, the present work investigated the exergetic and economic performance of the drying system and identified its energy use deficiencies. The results showed that the average drying rate for corn drying in the system is 1.98 g_water/g_{dry matter} h. The average exergy rate for dehydrating the moisture from the corn kernel is 345.22 kW and the exergy efficiency of the drying chamber ranges from 14.81% to 40.10%. The average cost of producing 1 GJ exergy for removing water from wet corn kernels is USD 25.971, while the average cost of removing 1 kg water is USD 0.159. These results might help to further understand the drying process from the exergoeconomic perspective and aid formulation of a scientific index for agricultural product industrial drying. Additionally, the results also indicated that, from an energy perspective, the combustion chamber should be firstly optimized, while the drying chamber should be given priority from the exergoeconomics perspective. The main results would be helpful for further optimizing the drying process from both energetic and economic perspectives and provide new thinking about agricultural product industrial drying from the perspective of exergoeconomics.

The online measurement of moisture content for grains is an essential technology to realize real-time tracking and control, improve drying quality and reduce energy consumption of the drying process. To improve the measurement accuracy and reliability of the dynamic measurement process as well as expand the application scope of the device, the present work constructed an experimental equipment for determining dynamic resistance characteristics of a single grain. The relations between moisture content and real-time resistance waveform were revealed, and an analytical calculation method of peak value and peak area of waveform was proposed, which correctly revealed the electrical measurement properties of grain. The results demonstrated that the gap width between the electrodes had large influence on the sensor’s performance. Moreover, an online measuring device was developed based on the experimental analysis and calculation method, and the test results in both lab and field for different grains showed that online real-time absolute measurement error are within ±0.5% in the varied moisture content (10–35%w.b.) and the temperature (−20–50 °C). The main results and the developed device might provide technical support for developing intelligent grain drying equipment.

Uncontrollable ambient conditions are the main factors limiting the self-adaption control of an industrial drying system. To achieve the goal of accurate control of the drying process, the influence of the ambient conditions on the drying behavior should be taken into consideration when modeling the drying process. Present work introduced an industrial drying system with a loading capacity of 50 t, two artificial neural network prediction models with (IANN) and without (OANN) considering the ambient conditions were established using artificial neural network modeling approach. The ambient conditions on the moisture content (MC), exergy efficiency of the heat exchanger (η_ex,h) and specific recovered radiant energy (Er) of the drying process were also investigated. The results showed that the η_ex,h and Er increase with the increase of ambient temperature while the drying time decrease with the increase of the ambient temperature. The IANN model has a better prediction performance that that of OANN model. An optimal architecture of 9-2-12-3 artificial neuron network model was developed and the best prediction performance of the artificial neural network (ANN) model were found at a training epoch number of 30, and a momentum coefficient of 0.4, where the coefficient of determination of moisture content, exergy efficiency of heat exchanger, and the specific recovered radiant energy, respectively are 0.998, 0.992, and 0.980, indicating that the model has an excellent prediction performance and can be used in engineering practice.

Energy consumption performance evaluation of an industrial grain dryer is an essential step to check its current status and to put forward suggestions for more effective operation. The present work proposed a combined IRCC dryer with drying capacity of 4.2 t/h that uses a novel drying technology. Moreover, the existing energy–exergy methodology was applied to evaluate the performance of the dryer on the basis of energy efficiency, heat loss characteristics, energy recovery, exergy flow and exegetic efficiency. The results demonstrated that the average drying rate of the present drying system was 1.1 g_water/g_{wet matter} h. The energy efficiency of the whole drying system varied from 2.16% to 35.21% during the drying process. The overall recovered radiant energy and the average radiant exergy rate were 674,339.3 kJ and 3.54 kW, respectively. However, the average heat-loss rate of 3145.26 MJ/h indicated that measures should be put in place to improve its performance. Concerning the exergy aspect, the average exergy rate for dehydration was 462 kW and the exergy efficiency of the whole drying system ranged from 5.16% to 38.21%. Additionally, the exergy analysis of the components indicated that the combustion chamber should be primarily optimized among the whole drying system. The main conclusions of the present work may provide theoretical basis for the optimum design of the industrial drying process from the viewpoint of energetics.

An online corn moisture content measurement device would be a key technology for providing accurate feedback information for industrial drying processes to enable the dynamic tracking and closed-loop control of the process. To overcome the problem of large measurement error caused by the characteristics of the corn flow state and the pore distribution when a parallel plate capacitor is applied to the online moisture content measurement process, in this study, we summarized the constraint conditions of the sensor’s structure parameters by mathematical modeling and calculated the optimal sensor design size. Moreover, the influence of porosity variation on moisture content measurement was studied by using the designed sensor. In addition, a mathematical model for calculating corn moisture content was obtained for the moisture content range of 14.7% to 26.4% w.b., temperature of 5 °C to 35 °C, and porosity of 38.4% to 44.6%. The results indicated that the fluctuation in the online moisture content measurement value was obviously reduced after the porosity compensation. The absolute error of the measured moisture content value was −0.62 to 0.67% w.b., and the average of absolute values of error was 0.32% w.b. The main results provide a theoretical basis and technical support for the development of intelligent industrial grain–drying equipment.

Online detection of impurities content in the corn deep-bed drying process is the key technology to ensure stable operation and to provide data support for self-adapting control of drying equipment. In this study, an automatic approach to corn image acquisition, impurity classification and recognition, and impurities content detection based on machine vision technology are proposed. The multi-scale retinex with colour restore (MSRCR) algorithm is utilized to enhance the original image for eliminating the influence of noise. HSV (Hue, saturation, value) colour space parameter threshold is set for image segmentation, and the classification and recognition results are obtained combined with the morphological operation. The comprehensive evaluation index is adopted to quantitatively evaluate the test results. Online detection results show that the comprehensive evaluation index of broken corncobs, broken bracts, and crushed stones are 83.05%, 83.87%, and 87.43%, respectively. The proposed algorithm can quickly and effectively identify the impurities in corn images, providing technical support and a theoretical basis for monitoring impurities content in the corn deep-bed drying process.