Hybrid Can Dryer Heating for Lower Emissions and Energy Waste
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Solution Overview
Problem
Conventional can drying systems are energy intensive, wasteful, and produce harmful emissions, with direct gas-fired burners requiring fresh air input for combustion, leading to environmental pollution and operational inefficiencies.
Innovation Solution
A hybrid heating system combining a gas burner and an electrical heating element, controlled by a system that switches between modes to optimize energy use, reducing the need for fresh air input and minimizing harmful emissions, while utilizing electrical heating for efficient and sustainable drying.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a direct gas-fired burner is used for heating air in the can dryer, then high temperature heating is achieved, but harmful emissions are produced and fresh air input is required leading to energy waste
Solution Approach 1:
The patent combines a gas burner and an electrical heating element into a hybrid heating system. The gas burner provides high-temperature heating when needed, while the electrical heating element can operate independently to eliminate harmful emissions. This merging allows the system to achieve high temperature heating without consistently producing harmful emissions, as the electrical element can be used during periods when emissions are problematic.
Solution Approach 2:
The control system dynamically adjusts the operating parameters of the heating system by switching between gas burner-only mode, electrical element-only mode, and combined mode. This parameter change allows optimization of the heating process based on real-time conditions, reducing harmful emissions while maintaining effective drying temperatures.
2Temperature
If a direct gas-fired burner is used for heating air in the can dryer, then high temperature heating is achieved, but energy efficiency deteriorates due to fresh air input requirements
Solution Approach 1:
The hybrid system merges gas and electrical heating capabilities, allowing the system to use the more energy-efficient electrical heating element during periods when high fresh air input is required. This reduces the energy waste associated with heating large volumes of fresh air, as electrical heating can maintain temperatures without requiring the same level of oxygen supply.
Solution Approach 2:
The control system changes operational parameters by switching between gas and electrical heating based on energy efficiency considerations. When fresh air input is high and energy efficiency is compromised, the system transitions to electrical heating mode, optimizing energy usage while maintaining the required heating temperature.
3Productivity
If high temperature hot air is used to evaporate water film from cans, then drying effectiveness is improved, but energy consumption increases
Solution Approach 1:
The heating system transitions from a static gas-fired-only approach to a dynamic hybrid system that can adapt between gas and electrical heating based on real-time drying requirements. This dynamic operation allows the system to use electrical heating during phases where high temperature is less critical, reducing overall energy consumption while maintaining drying effectiveness when high temperature is necessary.
Solution Approach 2:
The control system implements parameter changes by adjusting the mix of gas and electrical heating based on the drying process requirements. When rapid evaporation is needed, high-temperature gas heating is used; when lower-temperature sustained heating suffices, electrical heating is employed, optimizing the balance between drying effectiveness and energy consumption.
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
The hybrid system reduces energy costs, minimizes harmful emissions, and optimizes resource use by reusing condensed water, enhancing operational efficiency and sustainability.
Implementation Method 1
Natural gas 12 and combustion air 13 are fed into a direct fired gas burner 3 that burns natural gas 12 in a combustion chamber 4. The energy released heats the air flowing around the combustion chamber 4 to a desired operating temperature.
Implementation Method 2
an electrical heating element; a heating chamber structured to heat cans using air heated by the gas burner and/or the electrical heating element
Implementation Method 3
a circulation system structured to move air from the gas burner and the electrical heating element to the heating chamber
Implementation Method 4
The energy in the hot air is used to raise the temperature of the incoming containers and evaporate the water off the metal surfaces.
Implementation Method 5
The energy in the hot air is used to raise the temperature of the incoming containers and evaporate the water off the metal surfaces.
Implementation Method 6
The energy in the hot air is used to raise the temperature of the incoming containers and evaporate the water off the metal surfaces.
Data Source
AI summary
A heating system for use with a can dryer or oven includes a gas burner, an electrical heating element, a heating chamber structured to heat cans using air heated by the gas burner and/or the electrical heating element, a circulation system structured to move air from the gas burner and the electrical heating element to the heating chamber, and a control system structured to selectively control the gas burner and the electrical heating element to switch between a first mode where the gas burner and the electrical heating element are active and both heat air provided to the heating chamber and in a second mode where the gas burner is inactive and the electrical heating element is active.