Induction Heated Roller Drying Belt for Sludge
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Solution Overview
Problem
Existing sludge drying apparatuses face inefficiencies due to heat conduction limitations, energy losses, large footprint, temperature control issues, and prolonged heating and cooling times, which affect the drying process and product quality.
Innovation Solution
The use of a rotatable roller with induction heating elements on both the interior and exterior surfaces, along with porous metal belts to enhance heat transfer and moisture evaporation, eliminating the need for thermal fluids and allowing for precise temperature control and faster heating and cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If thermal oil is used as heating medium in roller drying apparatus, then heat can be conducted to the sludge, but heat loss occurs during recirculation through piping and boilers, leading to energy inefficiency
Solution Approach 1:
The patent extracts and eliminates the thermal oil recirculation system (including boilers, piping, and pumps) from the drying apparatus. Instead, induction heating elements are directly integrated into the roller structure to generate heat on-demand at the drying surface, removing the source of heat loss during thermal fluid recirculation.
Solution Approach 2:
The patent replaces the mechanical thermal fluid circulation system with an electromagnetic induction heating system. Induction heating elements generate electromagnetic fields that directly induce currents in the roller, converting electrical energy to thermal energy locally without requiring physical heat transfer through pipes and boilers.
2Temperature
If thermal oil recirculation system is used, then heating can be maintained, but large pumps and piping are required, resulting in large footprint
Solution Approach 1:
The patent removes the bulky thermal oil recirculation infrastructure (large pumps, extensive piping networks, and boiler systems) from the apparatus. The heating function is achieved through compact induction heating elements embedded in the roller, dramatically reducing the spatial footprint while maintaining heating capability.
Solution Approach 2:
The patent changes the heating mechanism from thermal fluid-based conduction to electromagnetic induction heating. This parameter change allows for localized heat generation within the roller structure itself, eliminating the need for external heating infrastructure and reducing overall apparatus footprint.
3Device complexity
If single boiler source is used for thermal oil heating, then system is simplified, but drying temperature cannot be accurately controlled and varied at different drying stages
Solution Approach 1:
The patent segments the heating system into multiple independent induction heating zones along the roller length, each controlled by separate power supplies. This allows different sections of the roller to operate at different temperatures simultaneously, enabling precise temperature control at various drying stages without requiring a complex centralized thermal oil system.
Solution Approach 2:
The patent implements dynamic temperature control through independently adjustable induction heating zones. Each zone can be activated or deactivated and its power level adjusted in real-time based on the drying requirements of different sludge layers, providing flexible and accurate temperature management throughout the drying process.
4Quantity of substance
If thick sludge is processed in roller dryer, then treatment capacity increases, but moisture escape route becomes longer, reducing drying efficiency
Solution Approach 1:
The patent applies local quality by concentrating heating energy at the sludge-roller contact interface through induction heating elements embedded in the roller surface. This creates a high-temperature zone precisely where moisture needs to be evaporated from the sludge, enabling effective drying of thicker material layers without requiring heat to conduct through the entire sludge thickness from a single surface.
Solution Approach 2:
The patent transitions from surface-only heating to volumetric heating by embedding induction heating elements within the roller structure. This allows heat generation throughout the roller thickness, creating temperature gradients that penetrate deeper into thick sludge layers and facilitate moisture removal from the interior, not just the surface.
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 increases the efficiency of the drying process, enables the processing of thicker sludge, reduces energy consumption, and allows for accurate temperature control, resulting in faster heating and cooling times, thus improving the quality and capacity of the drying apparatus.
Implementation Method 1
a plurality of heat induction elements arranged to induce heat in the first belt to heat the substance
Implementation Method 2
heating the substance to remove fluids from the substance
Implementation Method 3
the first belt urges via its first side, the substance towards a portion of an exterior circumferential surface of the roller
Data Source
AI summary
The present invention provides an apparatus 100 for drying a substance 190, the apparatus 100 comprising at least one roller 121 rotatable about a central axis; a first belt 112 having a first side 112′ and a second side 112″, the first side 112′ of the first belt 112 adapted to receive the substance 190; and a plurality of heat induction elements 123 arranged to induce heat in the first belt 112 to heat the substance 190, where in operation, the first belt 112 urges via its first side 112′, the substance 190 towards a portion of an exterior circumferential surface of the roller 121, and the substance 190 is heated to remove fluids from the substance 190.