The fluctuation of solar radiation throughout the day presents a significant obstacle to the widespread adoption of solar dryers for the dehydration of agricultural products, particularly those that are sensitive to high temperatures, such as basil leaf drying during the winter season. Consequently, this recent study sought to address the limitations of solar-powered dryers by implementing a hybrid drying system that harnesses both solar energy and liquid petroleum gas (LPG). Furthermore, an innovative automatic electronic unit was integrated to facilitate the circulation of air between the drying chamber and the ambient environment. Considering the solar radiation status in Egypt, an LPG hybrid solar dryer has been developed to be suitable for both sunny and cloudy weather conditions. This hybrid solar dryer (HSD) uses indirect forced convection and a controlled auxiliary heating system (LPG) to regulate both temperature and relative humidity, resulting in increased drying rates, reduced energy consumption, and the production of high-quality dried products. The HSD was tested and evaluated for drying basil leaves at three different temperatures of50, 55, and 60 °C and three air changing rates of 70, 80, and 90%, during both summer and winter sessions. The obtained results showed that drying basil at a temperature of 60 °C and an air changing rate of 90% led to a decrease in the drying time by about 35.71% and 35.56% in summer and winter, respectively, where summer drying took 135–210 min and winter drying took 145–225 min to reach equilibrium moisture content (MC). Additionally, the effective moisture diffusivity ranged from 5.25 to 9.06 × 10− 9 m2/s, where higher values of effective moisture diffusivity (EMD) were increased with increasing both drying temperatures and air change rates. Furthermore, the activation energy decreased from 16.557 to 25.182 kJ/mol to 1.945–15.366 kJ/mol for the winter and summer sessions, respectively. On the other hand, the analysis of thin-layer kinetic showed that the Modified Midilli II model has a higher coefficient of determination R2, the lowest χ2, and the lowest root mean square error (RMSE) compared to the other models of both winter and summer sessions. Finally, the LPG hybrid solar dryer can be used for drying a wide range of agricultural products, and it is more efficient for drying medicinal plants. This innovative dryer utilizes a combination of LPG and solar energy, making it efficient and environmentally friendly.
