Method and apparatus to process grain received from a dryer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional grain drying and cooling processes face challenges in achieving efficient and homogeneous drying while reducing energy consumption and preventing moisture condensation, particularly in maintaining the pace with continuous dryers and requiring rigorous operational control.
Innovation Solution
A method and apparatus for slow, deferred, and continuous cooling and moisture extraction of grain in a single tower, utilizing a transition zone with controlled ventilation and extraction to facilitate heat and moisture migration, preventing condensation and improving grain quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional drying procedures are used with continuous operation and cooling sections, then drying capacity is maintained, but energy consumption increases and drying homogeneity deteriorates
Solution Approach 1:
The patent applies preliminary action by creating a rest zone before the cooling section where grain is held at elevated temperature to allow internal moisture migration to the surface. This preliminary moisture redistribution enables more efficient subsequent drying and cooling, reducing overall energy consumption while maintaining productivity through continuous operation.
Solution Approach 2:
The drying system is segmented into distinct functional zones: a rest zone for moisture migration, a drying zone for moisture removal, and a cooling zone for temperature reduction. This segmentation allows each zone to perform its specific function optimally, improving overall drying homogeneity and energy efficiency.
2Loss of time
If grain is cooled immediately after drying, then processing time is reduced, but moisture condensation occurs and grain quality deteriorates
Solution Approach 1:
The patent applies preliminary action by establishing a rest zone where grain is held at controlled temperature and humidity conditions before cooling. This preliminary treatment allows moisture to redistribute and equilibrate, preventing sudden condensation during subsequent cooling while maintaining continuous processing flow.
Solution Approach 2:
The system controls temperature and humidity parameters through the rest zone transition, gradually adjusting grain moisture content and temperature before cooling. This parameter control prevents harmful condensation by ensuring grain is properly conditioned for the temperature drop, maintaining grain quality without extending processing time.
3Manufacturing precision
If multiple silos with deferred slow cooling systems are used, then drying homogeneity improves, but device complexity increases
Solution Approach 1:
The patent merges the rest zone, drying zone, and cooling zone into a single integrated continuous system. This consolidation achieves the drying homogeneity of multiple separate silos while reducing device complexity by eliminating the need for multiple independent units and their associated control systems.
Solution Approach 2:
The system maintains continuous grain flow through all zones without interruption, ensuring constant useful action. This continuous operation achieves homogeneous drying results while simplifying the system compared to batch processing in multiple silos, as the continuous flow allows for more straightforward design and operation.
4Reliability
If rigorous control is implemented to maintain necessary stages, then process reliability improves, but operational complexity increases
Solution Approach 1:
The process is segmented into distinct zones with clearly defined functions (rest zone, drying zone, cooling zone), each with specific control parameters. This segmentation simplifies operational control by allowing operators to manage each zone independently with standardized procedures, maintaining reliability without requiring complex overall system management.
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 achieves more homogeneous and effective drying with reduced energy consumption, preventing moisture condensation and enhancing grain quality by controlling the transition zone's movement and temperature within the tower.
Implementation Method 1
moisture inside the grain moves towards the external surface of the grain
Implementation Method 2
extraction of the grain's residual moisture
Implementation Method 3
ventilated with a weak renewed flow of air to complete the drying process
Implementation Method 4
the residual heal contained in the grain upon leaving the dryer is used to complete the drying
Implementation Method 5
cold air is introduced into the bottom section, in order to cool the grain before it is extracted from the dryer
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A method of processing grain from a dryer includes maintaining a transition zone within a volume of received grain, the transition zone being a cross section of the volume of the received grain that is at a same temperature, by cooling and drying the received grain; and extracting cooled grain.