Simulation of microwave thin layer drying process by a new theoretical model

•A new model was developed and validated to simulate microwave drying.•Moisture diffusion along material layer was ignored under intensive microwave.•An optimal layer thickness exists in microwave thin layer drying.•The temperature gradient has different orientation in hot air and microwave drying.

Various methodologies have been proposed in literature on modeling microwave drying process. However, in these methodologies moisture diffusion is normally considered in the presence of intensive microwave energy. In the present study, a new theoretical model was developed to simulate microwave drying of thin layer particulate solids, based on the consideration that moisture diffusion along material layer could be ignored due to rapid evaporation under intensive microwave energy. The model was solved numerically by using finite difference method and validated against experimental data. Results indicated good agreement between the model and experimental data, thus providing confidence in the modeling approach. For the system investigated in this study, it was demonstrated that an 80% reduction in drying time was achieved with approximately fivefold increase in microwave power (109-543 W). Furthermore, it was also demonstrated that the drying rate was the maximum corresponding to the optimal layer thickness in microwave thin layer drying process. Qualitative analysis explained the optimal thickness phenomenon using principles of heat and mass transfer. Finally, the validated model was used to predict moisture and temperature distributions along the entire material layer.