Design of Enhanced Virtual Reality Training Environments for Industrial Rotary Dryers Using Mathematical Modeling

Source abstract

Rotary dryers are widely used in industry for their ease of operation in processing large volumes of material continuously despite persistent challenges in energy efficiency, cost-effectiveness, and safety. Addressing the need for effective operator training, the purpose of this study is to develop virtual reality (VR) environments for industrial rotary dryers. Visual and behavioral aspects were considered in the methodology for developing the environments for two application cases—ammonium nitrate and low-rank coal drying. Visual aspects considered include the industrial-scale geometry and detailed components of the rotary dryer, while behavioral aspects were governed by mathematical modeling of heat and mass transfer phenomena. The case studies of ammonium nitrate and low-rank coal were selected due to their industrial relevance and contrasting drying characteristics, ensuring the versatility and applicability of the developed VR environments. The main contribution of this work is the embedding of validated mathematical models—expressed as ordinary differential equations—into these environments. The numerical integration of these models provides key process variables, such as solid temperature and moisture content along the rotary dryer, thereby enhancing the behavioral realism of the developed VR environments.