Polymer Drying Valve Switching for Energy Reduction
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Solution Overview
Problem
Existing methods for drying plastics require complex setups and high energy consumption due to the need for continuous regeneration of desiccants, which introduces moisture from fresh air and reduces the efficiency of the drying process.
Innovation Solution
A method and device that transition from a warm air regeneration phase to a cooling phase by recirculating air within the closed circuit, using an additional valve unit to switch from fresh air supply to air recirculation, and employing an adsorbent with a hexagonal crystal structure and high water absorption capacity to optimize the drying and regeneration process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If fresh air is supplied continuously during regeneration phase to maintain aerodynamic balance, then the system operates continuously, but moisture is introduced into the system increasing energy consumption
Solution Approach 1:
The patent implements periodic action by alternating between a first operating phase (adsorption) and a second operating phase (regeneration) for the fixed-bed adsorber. During regeneration, the system periodically introduces fresh air only when needed for cooling the adsorber, rather than continuously. This periodic operation allows the system to maintain continuous plastic drying productivity while reducing overall energy consumption by limiting fresh air intake to specific regeneration intervals rather than operating continuously with fresh air supply.
2Productivity
If the regeneration phase is shorter than the adsorption phase to ensure continuous operation, then productivity is maintained, but the system requires complex two-adsorber configuration
Solution Approach 1:
The patent applies dynamics by making the fixed-bed adsorber configuration adaptable and reconfigurable over time. Instead of requiring two simultaneous adsorbers, the system uses a single adsorber that dynamically switches between adsorption mode and regeneration mode. The cooling phase during regeneration allows the same adsorber to be prepared for the next adsorption cycle, eliminating the need for a second adsorber while maintaining continuous operation capability.
Solution Approach 2:
The patent implements discarding and recovering by temporarily discontinuing the adsorption function during the regeneration phase. The fixed-bed adsorber is discarded from its adsorption role and recovered through regeneration and cooling phases. This allows single-adsorber continuous operation by recovering the adsorber's capacity cyclically rather than requiring duplicate adsorbers to run simultaneously.
3Productivity
If desiccant water absorption capacity is utilized fully, then drying efficiency is maximized, but regeneration frequency increases reducing productivity
Solution Approach 1:
The patent applies parameter changes by modifying the operational parameters of the fixed-bed adsorber, specifically the temperature and flow conditions during different phases. During the cooling phase of regeneration, the system controls temperature and airflow to prepare the adsorber for extended adsorption operation. By optimizing these parameters, the adsorber can maintain high water absorption capacity for longer periods, reducing regeneration frequency while preserving drying efficiency.
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 simplifies the system, reduces energy consumption, and extends the adsorption phase by maintaining a consistent dew point, leading to more efficient and cost-effective plastic drying with improved energy efficiency.
Implementation Method 1
a desiccant, which is introduced into the named systems as a fixed-bed adsorber, adsorbs the moisture
Implementation Method 2
the moisture is expelled at regular intervals in a regeneration phase using hot regeneration air
Implementation Method 3
a desiccant, which is introduced into the named systems as a fixed-bed adsorber, adsorbs the moisture
Data Source
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AI summary
Method and apparatus for drying plastics by means of process air guided in a circuit (40) with a drying container (10) and an air drying device (20) which has at least two fixed bed adsorbers located in chambers (30) which are simultaneously supplied with process air during a regeneration phase and are alternately supplied with moisture-laden return air from the drying container and with dry regeneration air, wherein the regeneration phase comprises an initial warm air regeneration phase and a subsequent cooling phase.Increased energy efficiency is achieved by switching during the regeneration phase from the warm air regeneration phase to the cooling phase from a fresh air supply (100), in which fresh air is supplied to the circuit from outside, to a recirculation system in the closed circuit (40), in which the cooling air exiting the relevant chamber is recirculated within the circuit.