Modular Drying System With Rotary Impellers for Clogging Control
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Solution Overview
Problem
Existing dryers for solid materials and liquid-solid mixtures face issues such as clogging, lumping, and drying disturbances, leading to frequent shut-downs and inefficiency, particularly in handling waste from fisheries, aquaculture, and disposed foods, with a need for improved energy efficiency.
Innovation Solution
A modular drying system with features like a closed-loop gas duct, condenser, rotary impeller, and honeycomb structure to ensure uniform air flow, combined with a bypass duct for humidity control, and a modular design allowing for multiple drying chambers, enhancing energy efficiency and preventing clogging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional dryers are used for solid materials and liquid-solid mixtures, then drying function is provided, but clogging and lumping occur leading to frequent shut-downs
Solution Approach 1:
The drying chamber is divided into multiple zones with different air injection patterns and impeller configurations. The system segments the material flow path and uses multiple disintegrators to break up lumps at different locations, preventing clogging throughout the drying process
Solution Approach 2:
The system employs dynamically adjustable air injection rates, impeller speeds, and disintegrator rotations that can be optimized for different material properties and drying stages. This dynamic control prevents material from staying too long in any one location, reducing clogging risk
2Use of energy by moving object
If conventional drying processes are used, then drying is achieved, but energy efficiency is poor
Solution Approach 1:
The system maintains continuous material movement through the drying chamber using impellers and disintegrators, ensuring all material receives consistent drying treatment without stagnation. The continuous air flow through the closed-loop system maximizes heat transfer efficiency and minimizes energy loss
Solution Approach 2:
The system optimizes drying parameters including air temperature, air flow rate, material residence time, and chamber pressure to achieve efficient drying. The closed-loop gas duct allows precise control of air composition and temperature throughout the drying process
3Ease of manufacture
If simple dryer design is used, then ease of manufacture is improved, but handling and operation difficulty increases
Solution Approach 1:
The impellers serve multiple functions: they advance material through the drying chamber, distribute drying air uniformly, and prevent material settling. The disintegrators simultaneously break up lumps and redistribute material. This multi-functionality reduces the need for separate components while improving operational reliability
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 system effectively prevents clogging, maintains a stable fluidized bed for efficient drying, reduces energy consumption, and increases condenser efficiency, enabling continuous operation with reduced maintenance.
Implementation Method 1
a condenser arranged in the gas duct
Implementation Method 2
The heat exchanger comprises, in a traditional manner, a housing accommodating numerous lamellas and fins interconnected by cooling liquid pipes
Implementation Method 3
a heater for heating drying air before entering the drier housing
Implementation Method 4
a fan for blowing air into the drier housing
Implementation Method 5
the honeycomb structure exhibits numerous adjacent flow channels, arranged with the longitudinal axis substantially aligned with the flow direction in duct, arranged to make the air flow to the heater more homogenous and non-wavy near the wall
Implementation Method 6
operating the impellers or dis-integrators, which together with air flow maintains a fluidized bed of solid material or solids and liquid mixture being dried
Data Source
AI summary
Modular system of drying humid material, comprising a drier housing having a material inlet and outlet, a drying gas inlet and outlet, a particle separator downstream of drier housing. Drier housing comprises drying chambers. The system further comprises an air fan, and a heater. A gas duct connecting drying gas inlet and drying gas outlet defines a closed loop. A condenser is arranged in gas duct. Drying chambers comprises a rotary impeller means, and drying gas inlets. A dried-hot product cooler comprising a housing having a dried-hot product inlet, a cooled dried product outlet, a cool air supply means, and a fan arranged to draw cooled air through dried hot product in cooler.