Thermodynamic Drying Control via Post-Combustion Heat Recovery
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Solution Overview
Problem
Existing drying plants face challenges in controlling temperature and volume flow of thermal post-combustion facilities, leading to inefficient energy use and unsteady behavior, which limits their controllability and energy savings potential.
Innovation Solution
A thermodynamically controlled drying plant with adjustable temperatures and volume flows, utilizing a system with a thermal post-combustion facility, heat exchanger, and combustion chamber, where the exhaust gas is variably heated and mixed with fuel for controlled combustion, and the resulting clean gas is used to heat the drying tunnel, with a cold bypass for regulating inlet temperature and fuel input, allowing for dynamic control of combustion chamber temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the exhaust gas temperature is increased to improve drying efficiency, then the drying performance is improved, but the energy loss increases and emission management becomes more difficult
Solution Approach 1:
The patent applies parameter changes by dynamically adjusting the exhaust gas temperature and volume flow rate as controllable parameters. The system modifies these parameters in real-time to optimize drying efficiency while maintaining energy efficiency and emission control, resolving the contradiction between high drying performance and energy loss.
Solution Approach 2:
The patent implements dynamics by introducing a dynamic control system that continuously adapts the thermal post-combustion facility operation. The control unit adjusts temperature and flow parameters based on real-time conditions, enabling the system to maintain optimal drying efficiency without excessive energy loss, thus resolving the static contradiction between productivity and energy consumption.
2Power
If the volume flow of clean gas is increased to improve heating capacity, then the heating performance is improved, but the controllability and stability of the system deteriorates
Solution Approach 1:
The patent applies feedback by implementing a control unit that receives real-time data on clean gas volume flow and temperature. This feedback mechanism allows the system to automatically adjust the thermal post-combustion facility operation to maintain stable and controllable heating capacity, resolving the contradiction between high power output and system reliability.
3Use of energy by moving object
If the temperature of the thermal post-combustion facility is increased to reduce energy consumption, then the energy efficiency is improved, but the unsteady behavior increases and controllability worsens
Solution Approach 1:
The patent applies dynamics by implementing dynamic control of the thermal post-combustion facility temperature. Rather than operating at a fixed high temperature, the system dynamically adjusts the temperature to maintain energy efficiency while ensuring operational stability through real-time adaptation to changing conditions.
Solution Approach 2:
The patent applies feedback through a control system that monitors the thermal post-combustion facility operation and adjusts parameters to maintain stable operation at energy-efficient temperatures. This feedback mechanism prevents unsteady behavior while preserving energy efficiency, resolving the contradiction between energy savings and operational stability.
4Stability of the object's composition
If the drying plant operates at high energy consumption to ensure stable temperature, then the temperature stability is improved, but the energy cost increases significantly
Solution Approach 1:
The patent applies dynamics by replacing static high-energy operation with dynamic temperature control. The system adjusts the thermal post-combustion facility and heat exchanger operation dynamically to maintain temperature stability only when necessary, reducing energy consumption while preserving temperature control where required for drying quality.
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
This approach enables precise control of energy flow and temperature, optimizing energy use, reducing energy consumption, and allowing for flexible operation, achieving significant energy savings and improved emission management.
Implementation Method 1
heated in a heat exchanger by the clean gas from a thermal post-combustion facility
Implementation Method 2
burned in a combustion chamber of the thermal post-combustion facility in at least one flame
Implementation Method 3
the clean gas is used to heat the drying tunnel
Data Source
AI summary
The invention relates to a drying system (T) according to FIG. 1 for drying goods to be dried (LTG), comprising—a drying tunnel (TT), —a line (LAG) for exhaust gas (AG) containing (VOC) out of the drying tunnel (TT), —a controlled fan (GBL) for further transporting the exhaust gas (AG) to a heat exchanger (WT), —a heat exchanger (WT) for heating the exhaust gas (AG) using the clean gas (RG), —an exhaust gas line (LAG) downstream of the heat exchanger (WT) for further transporting the exhaust gas (AGWT) to a burner (BR) in a combustion chamber (BK) of a thermal post-combustion system (TNV), —a cold bypass (BP) which bypasses the heat exchanger (WT) and which can be regulated using an electronically controlled controller (R), —a fuel line (LEG) for a fuel (EG) to the burner (BER), —a clean gas line (LRG) for transporting the clean gas (RG) out of the combustion chamber (BK) to the heat exchanger (WT) in order to cool the exhaust gas (AG), —a clean gas line (LRG) for conducting the clean gas (RG) from the heat exchanger (WT) to the heat consumers (WA), —a heater (HZTT) for heating the drying zone (TT) by means of the heat consumers (WA), and —a clean gas line (LRG) for conducting the clean gas (RGD) to a stack (K). The invention also relates to a drying method and a method for a thermodynamic regulation (TDR).