Electric Heater Mixing Plenum for Process Air Reheating
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Solution Overview
Problem
Drying systems in tissue, paper, and corrugated board production face challenges with high greenhouse gas emissions, delayed temperature regulation, and imprecise energy consumption due to reliance on fossil fuel-powered combustion burners and inefficient process air recirculation systems.
Innovation Solution
The implementation of an electric heater mixing plenum system that fluidly communicates with both exhaust and makeup air inlets and a combustion heating system, allowing for efficient reheating of process air using electric heaters and reducing fossil fuel consumption, while enabling bypass functionality for maintenance and energy optimization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If combustion burners powered by fossil fuels are used to reheat process air, then the drying system can operate economically without process air recirculation systems, but greenhouse gas emissions increase significantly
Solution Approach 1:
The patent changes the energy source parameter from fossil fuel-based combustion to electric heating, fundamentally altering the heating mechanism to eliminate greenhouse gas emissions while maintaining the economic viability of process air recirculation
Solution Approach 2:
The patent substitutes the combustion-based thermal system with an electric heating system, replacing the chemical energy conversion process with direct electrical energy conversion to heat the process air
2Reliability
If combustion burners are used for reheating process air, then the drying system can maintain operation, but temperature regulation is delayed and imprecise
Solution Approach 1:
The patent implements a control system that continuously monitors temperature and adjusts electric heater power in real-time, using feedback loops to maintain precise temperature control and respond immediately to process variations
Solution Approach 2:
The patent employs dynamic control capabilities where the electric heating system can rapidly adjust its output in response to changing process conditions, enabling real-time temperature optimization without the thermal inertia limitations of combustion systems
3Productivity
If fossil fuels are used to power combustion burners, then the drying system can operate, but energy efficiency is reduced due to combustion losses
Solution Approach 1:
The patent replaces the combustion-based energy conversion system with direct electric heating, eliminating combustion losses and improving energy efficiency by converting electrical energy directly to thermal energy without intermediate chemical reactions
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 solution reduces greenhouse gas emissions, improves temperature regulation, and enhances energy efficiency by allowing for a mix of electrical and fossil fuel energy use, enabling cost-effective operation and minimizing production losses during maintenance.
Implementation Method 1
an electric heater mixing plenum configured to fluidly communicate with the air makeup inlet, wherein the electric heater mixing plenum is disposed downstream of the makeup inlet
Implementation Method 2
a combustion heating system configured to fluidly communicate with the electric heater mixing plenum, wherein the gas combustion heating system is disposed downstream of the electric heater mixing plenum
Data Source
AI summary
An exemplary process air recirculation system, and an electric heater mixing apparatus is disclosed herein. Exemplary process air recirculation systems comprise the electric heating mixing apparatus. An exemplary electric heating mixing apparatus comprises: walls defining a first chamber having a first upstream opening and a first downstream opening, and a second chamber having a first upstream opening and a first downstream opening, wherein the second chamber is adjacently disposed to the first chamber, a first inlet damper disposed at the first upstream opening, a second inlet damper disposed at the second upstream opening, and a resistance-type electric air heater disposed in the first chamber.