Method and apparatus to process grain process grain received from a dryer
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Solution Overview
Problem
Conventional grain drying and cooling processes face challenges in achieving complete moisture removal and energy efficiency, often requiring multiple silos and rigorous operational control, with issues like moisture condensation and high energy consumption.
Innovation Solution
A method and apparatus for slow, deferred, and continuous cooling and moisture extraction of grain using a single tower, where grain is loaded, rested, cooled, and dried through intermittent ventilation, with a transition zone for heat and moisture exchange controlled by temperature sensors and a controller, preventing condensation and optimizing energy use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional drying systems use multiple silos with deferred slow cooling to achieve complete moisture removal, then drying effectiveness is improved, but device complexity and operational difficulty increase
Solution Approach 1:
The patent combines multiple silos into a single silo by dividing it into multiple vertically stacked drying zones (first drying zone, second drying zone, third drying zone, and cooling zone). Each zone performs a specific function, and together they achieve the drying effectiveness previously requiring multiple separate silos. The grain moves sequentially through each zone within the same structure, integrating multiple functions into one unified system.
Solution Approach 2:
The single silo is segmented into distinct functional zones: a first drying zone with first drying air inlets, a second drying zone with second drying air inlets, a third drying zone, and a cooling zone. Each zone has specific air inlet positions and drying characteristics, allowing independent control of drying parameters in different sections while maintaining a compact single-silo structure.
2Manufacturing precision
If conventional systems use rigorous operational control to maintain necessary stages, then drying quality is improved, but ease of operation deteriorates
Solution Approach 1:
The system utilizes the grain's own residual heat to drive the drying process. The grain exits the dryer at high temperature (40-70°C) and uses this heat naturally to evaporate moisture in the first drying zone without requiring external heating. The grain's temperature gradually decreases as it moves through subsequent zones, providing self-regulating thermal energy for drying and cooling operations, thereby reducing the need for complex external temperature control systems.
Solution Approach 2:
The patent implements a control system that monitors grain temperature and moisture content at different zones and adjusts air flow rates and drying parameters accordingly. The controller receives data from sensors measuring grain conditions and automatically regulates the drying process to maintain optimal parameters, reducing the need for manual intervention and specialized training while ensuring consistent drying quality.
3Productivity
If grain is cooled quickly after drying, then processing speed is improved, but grain quality deteriorates due to condensation and heterogeneous drying
Solution Approach 1:
The system employs periodic alternating drying and cooling cycles within the silo. Grain moves through the drying zones where moisture is removed, then enters the cooling zone where temperature is reduced. This periodic alternation between drying and cooling phases allows gradual temperature reduction that prevents condensation while maintaining continuous processing flow, ensuring homogeneous drying and high grain quality.
Solution Approach 2:
The grain undergoes preliminary drying in the first drying zone using its own residual heat before entering subsequent zones. This preliminary action removes the majority of excess moisture early in the process when the grain is hottest, preventing later condensation issues. The gradual temperature reduction through controlled zones ensures homogeneous drying throughout the grain mass before final cooling.
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 homogeneous and effective drying, reduces energy consumption, and improves grain quality by maintaining a controlled transition zone for efficient moisture migration and heat transfer, allowing for continuous processing without the need for multiple silos.
Implementation Method 1
moisture inside the grain moves towards the external surface of the grain
Implementation Method 2
the grain is cooled and dried by intermittent forced ventilation with air at a ventilation temperature
Implementation Method 3
extraction of the grain's residual moisture
Data Source
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.