Here is a new drying concept called E - DRYING TECHNOLOGY. Innovative concept of drying by applying high frequency electro magnetic energy to substance.
When the material to be dried is conveyed through Microwave field, the water molecules in the material reorient constantly to align with the changing field. This movement generates heat inside water molecules and makes entire mass of water to evaporate it uniformly without heating the product externally.
Here the comparison between E drying & conventional is given:
|Conventional drying||Electromagnetic Drying Technology|
|Surface heating is not only slow, but also non-uniform with the surfaces, edges and corners being much hotter than the inside of the material.|| Fast &Uniform heating |
|Larger energy consumption.|| Energy efficient. |
|Time consumption process.||Less time consumption process.|
|Overheating of surface of material & Imperfect heating causes product rejections, wasted energy and extended process times.|| Only moisture is heated in place of heating a total mass , so no matter of overheating occurs. |
|Large ovens are slow to respond to needed temperature changes, take a long time to warm up and have high heat capacities and radiant losses.|| Low operating cost & Compact equipment size |
MW heat products directly and throughout the thickness of the product.
MW heats from within the material and does not rely on conduction. This provides uniform temperature gradient throughout the material for more consistent product quality. Binder/sizing migration is significantly reduced.
The heating rate is proportional to the amount of water in the material. As the material dries, less MW energy is absorbed, the heating rate decreases. Most materials will not overheat. This improves product quality.
Since the heating rate is proportional to the amount of moisture, wet areas heat faster than dry areas within a product. This accelerated drying continues until the moisture level is uniform throughout the product. This creates a more consistent product quality.
Different materials heat at different rates so it is possible to heat only one part of a composite material or to dry a coating without heating the substrate. This improves product quality by not heating sensitive materials.
Power and heating start and stop instantly, with a virtually no warm up or cool down time.
Energy usage is proportional to the amount of work being done. All energy goes into the work without losses to the environment. If the line is running at less than capacity, energy usage is lower. This can lower fuel costs.
There is no combustion by-products. This saves on both capital and operating costs.
Using applicator design geometries and a unique MW choking mechanism, E-drying technology reduces Microwave leakage from system entry and exit points. This poses no threat of electro-magnetic radiation to the health and safety of equipment operators.
As a further precaution, all control systems are supplied with safety interlocks that shut down power instantaneously in the event of equipment malfunction or misuse.
A common misconception is that E-drying is always more expensive than heating by conventional techniques. The actual answer depends on the application. In some cases, Microwaves can be 50% more efficient than conventional systems, resulting in major savings in energy consumption and cost.
In addition to the applications above, these units are often used as Stand-Alone Dryers. These may be the most economical solution where minimal equipment floor space or footprint is available for a new application, or when expansion of existing production facilities would require building modifications to accommodate a conventional drying system.
Not all dielectric materials have the same ability to dissipate electromagnetic energy in to thermal energy. A number of factors are involved: these include the chemical – physical characteristics of the material, its temperature and the strength and frequency of the applied electromagnetic field.
In more detail, the ability of a dielectric material to heat under an MW field is directly related to a value known as the "loss factor" of the material. So its better to send your material at our lab. We will check its property & take trial and then give you answer.
Yes its possible. There are many installations in the world where in this hybrid concept is successfully used.
It can be used for pre-drying, drying, post drying. This technology has to be suitably adopted depending upon the existing plant, economics, the moisture percentage and the quality requirement of the end product. E-dryer can works as stand alone or can be combined with existing plant.