Development of an Energy-Efficient Machining Chip Dryer for Enhanced Metal Recycling

This study presents the design, analysis, and optimization of a machining chip dryer tailored for industrial environments generating substantial quantities of metal chips during turning, milling, and drilling operations. These chips are often saturated with cutting fluids such as oil or coolant, rendering them hazardous and unsuitable for direct recycling or disposal. Improperly dried chips contribute to storage challenges, corrosion, unpleasant odours, slippery work surfaces, and potential fire risks. Moreover, moisture-laden chips degrade the quality of recycled metal and elevate environmental concerns. The proposed dryer integrates three core components: a centrifugal air blower delivering hot air, a temperature-controlled heating chamber, and a conveyor mechanism ensuring uniform chip movement and consistent drying. Critical process parameters—including airflow rate, drying temperature, and conveyor speed—are optimized for enhanced performance. Computational Fluid Dynamics (CFD) is employed to model the airflow and heat distribution within the system, ensuring even thermal exposure. Response Surface Methodology (RSM) facilitates experimental design and process optimization, while Analysis of Variance (ANOVA) identifies the most influential variables. The resulting system significantly improves drying efficiency, promotes effective chip recycling, reduces energy consumption, and enhances operational safety.