Control for the process of drying wet material
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Solution Overview
Problem
Existing fish meal production processes face inefficiencies in energy utilization and regulation, leading to excessive steam bleeding and slow reaction times in heat exchange mechanisms, which hinder the synchronization of energy input and material flow.
Innovation Solution
A closed system where a first dryer acting as a steam boiler generates steam to sustain the factory's energy needs, with dry air used in the secondary dryer, and sensors monitor material levels to automate energy input, ensuring continuous operation and minimizing manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If steam is bled from each component to maintain pressure, then pressure control is achieved, but energy utilization deteriorates due to excessive steam loss
Solution Approach 1:
The patent merges the heat exchange elements of multiple components (cooker, dryers, evaporators) into a single integrated heat exchange system. This allows steam to be generated once in a central boiler and distributed to all components through a common steam line, eliminating the need for separate steam generation in each component and preventing steam bleeding losses.
Solution Approach 2:
The common steam line serves multiple functions: it distributes steam to all heat exchange components, collects condensate from all components, and maintains pressure throughout the system. This multi-functional approach replaces the traditional single-function steam lines in each component.
2Adaptability or versatility
If individual heat exchange systems are used in each component, then component independence is maintained, but system complexity increases and energy efficiency deteriorates
Solution Approach 1:
The patent combines multiple independent heat exchange systems into a single integrated system with a common steam line and condensate collection system. This reduces the number of separate steam lines, valves, and condensate pumps required, thereby reducing system complexity while maintaining the ability to control each component's heat input.
3Ease of operation
If manual regulation of heat exchange is used, then system control is simple, but reaction time to energy demand changes deteriorates
Solution Approach 1:
The patent incorporates pressure sensors that continuously monitor the pressure in the common steam line and provide feedback to an automatic control system. When pressure drops below a set point, the control system automatically opens steam admission valves to increase steam generation, and when pressure rises above the set point, the valves close. This closed-loop feedback control enables rapid automatic response to pressure changes without manual intervention.
4Loss of energy
If heat recovery devices are added to re-use energy, then energy efficiency improves, but process complexity increases and proper utilization deteriorates
Solution Approach 1:
The patent recovers thermal energy from condensate by routing it through heat exchangers that pre-heat the feed water before it enters the boiler. This heat recovery system captures the thermal energy that would otherwise be discarded with the condensate and reuses it to reduce the boiler's energy demand, improving overall system efficiency.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system achieves full energy utilization and automatic operation by maintaining predefined pressure ranges and material flow, reducing energy waste and enhancing process efficiency.
Implementation Method 1
The heart of the system is a first dryer, which is also a steam boiler receiving external energy to heat up the material and generate steam
Implementation Method 2
The cooker and the first dryer are chambers having heat exchange elements for conducting heat to the chamber
Implementation Method 3
A duct leading from the upper portion of the chamber of the first dryer to the jacket of the cooker and to the jacket of the secondary dryer is used for leading steam generated in the first dryer into the heat exchange elements of the cooker and the secondary dryer
Implementation Method 4
In addition to using steam to heat the surfaces of the secondary dryer, the present invention uses dry air which is blown into the secondary dryer while removing the remaining water from the material
Data Source
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AI summary
The present invention relates to a process for continuous of drying or removing the water phase from wet material,such as organic materialand for regulating or controlling the drying mechanisms using heating and drying components in a mechanic set up for drying material. The steam generated in the pre-dryer in the process is sufficient to sustain the energy need of the system as the different components of a meal factory are set up as a closed system.