Drying Heat Recovery Loop for Latent Heat and Condensate Reuse
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Solution Overview
Problem
Existing manufacturing processes for drying materials with liquid content are resource-intensive and environmentally detrimental due to the disposal of latent heat and evaporated liquids, leading to inefficiencies and high costs.
Innovation Solution
A method and system for recovering thermal energy and liquids by evaporating a portion of the liquid content, condensing vapor to recover gas and latent heat, and recirculating these resources for reuse in the drying process, with optional external utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If thermal energy and evaporated liquid are disposed of in prior art drying processes, then the drying process can be completed, but valuable resources (thermal energy, liquid, gas) are wasted and cannot be reused
Solution Approach 1:
The patent implements a heat recovery system that captures thermal energy from exhaust gas flows and condenses evaporated liquid, converting previously discarded resources into reusable materials. The system includes heat exchangers that transfer thermal energy from exhaust gases to incoming fresh air or process water, and condensation units that recover liquid from vapor phase, directly addressing the waste of thermal energy and liquid resources in conventional drying processes
Solution Approach 2:
The recovered thermal energy and condensed liquid are fed back into the drying process system. The heat recovery system creates a closed-loop feedback mechanism where exhaust gas thermal energy heats incoming air or process water, and condensed liquid is returned to the material or process stream, thereby reducing the need for additional energy input and fresh liquid supply
2Reliability
If large amounts of water and energy are used in traditional drying processes, then the material can be dried effectively, but manufacturing costs increase and environmental impact worsens
Solution Approach 1:
The system recovers condensed liquid from the exhaust gas stream and returns it to the process, reducing water consumption. The heat recovery exchangers capture thermal energy that would otherwise be lost, reducing the quantity of energy required to maintain drying effectiveness
Solution Approach 2:
The heat recovery system operates continuously alongside the drying process, constantly capturing thermal energy from exhaust gases and transferring it to incoming streams. The liquid recovery system continuously condenses and returns evaporated liquid, maintaining a continuous cycle of resource utilization that reduces overall water and energy consumption
3Productivity
If thermal energy is provided to evaporate liquid from material, then drying occurs, but the latent heat carried by vapor is lost when vapor is discharged
Solution Approach 1:
The system utilizes phase transition by condensing the vapor phase back to liquid phase in a heat recovery exchanger. This condensation process releases the latent heat that was absorbed during evaporation, allowing the thermal energy to be recovered and reused. The phase change from vapor to liquid is the mechanism that enables latent heat recovery
Solution Approach 2:
The latent heat contained in vapor is recovered through condensation in the heat recovery system. The condensed liquid and released thermal energy are returned to the process, converting what would be discarded waste into valuable reusable resources
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
Reduces the overall resource consumption and manufacturing costs by recycling thermal energy, gas, and liquid, enabling a more sustainable and efficient drying process.
Implementation Method 1
providing thermal energy to evaporate at least a portion of the liquid from the material
Implementation Method 2
recovering at least most or essentially all of the vapor carried by the gas flow to obtain recovered liquid and recovered gas flow by condensing the at least most or essentially all of the vapor content in the gathered gas flow
Implementation Method 3
recovering the thermal energy used for evaporation and the latent heat of vapor carried by the gas flow by heat exchanging and condensing
Implementation Method 4
recovering the thermal energy used for evaporation and the latent heat of vapor carried by the gas flow by heat exchanging and condensing to obtain recovered thermal energy
Data Source
AI summary
A method for recovering thermal energy in a material drying process, the method comprising, providing a material to be dried comprising a liquid content, providing thermal energy to evaporate at least a portion of the liquid from the material, providing a drying gas flow to carry the vapor of the evaporated liquid and the related latent heat from the material, gathering the gas flow carrying the vapor and the latent heat, recovering at least most or essentially all of the vapor carried by the gas flow to obtain recovered liquid and recovered gas flow by condensing the at least most or essentially all of the vapor content in the gathered gas flow, recovering the thermal energy used for evaporation and the latent heat of vapor carried by the gas flow by heat exchanging and condensing to obtain recovered thermal energy by the heat exchanging and condensing, recirculating at least a portion of the recovered thermal energy as the thermal energy used for evaporation and/or recirculating at least a portion of the recovered gas flow as the drying gas flow, and/or recirculating at least a portion of the recovered liquid to the material to be dried comprising a liquid content.