Segmented Disc Dryer with MVR and Scrapers
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Solution Overview
Problem
Existing steam dryers face issues with material build-up on heating surfaces, frequent cleaning needs, structural heaviness, high energy consumption, and inefficiency due to gas presence in the heat exchange system, limiting their continuous use and energy economy.
Innovation Solution
A dryer apparatus with a chamber divided into multiple sections, using cylindrical or semi-cylindrical disc-shaped heat exchange elements connected to separate jackets for efficient steam distribution and mechanical vapor recompression (MVR) technology to increase steam temperature, combined with scrapers for material stirring and gas venting, allowing for efficient heat exchange and reduced energy usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional steam dryers use a steam heated jacket and rotor with hollow flights, then material can be dried, but material builds up on heating surfaces requiring frequent cleaning
Solution Approach 1:
The heating surface is segmented into multiple disc-shaped heat exchange elements arranged in sections, with scrapers that can access and clean each segment. This segmentation allows for more effective scraping coverage compared to traditional continuous jackets, preventing material build-up in hard-to-reach areas.
Solution Approach 2:
The scrapers are designed to automatically clean the heat exchange surfaces during the drying operation itself, without requiring separate cleaning cycles. The scrapers work in conjunction with the rotating discs to continuously remove material buildup, making the system self-maintaining during operation.
2Productivity
If traditional steam dryers use a steam heated rotor with hollow flights, then material can be dried, but the structure becomes heavy and expensive
Solution Approach 1:
The heavy rotor structure with hollow flights is replaced by stationary disc-shaped heat exchange elements. The material movement function is transferred to scrapers mounted on a lightweight central axis, eliminating the need for a heavy rotating rotor while maintaining drying capability.
Solution Approach 2:
The mechanical rotor system is replaced with a combination of stationary discs and scraper-based material movement. This substitution reduces mechanical complexity and weight while achieving the same material processing function through a different mechanical approach.
3Use of energy by moving object
If MVR technology is used to increase steam pressure and temperature, then energy economy improves, but heating surfaces must be larger to handle the limited pressure increase
Solution Approach 1:
The heating system is divided into multiple disc-shaped heat exchange elements arranged in sections, which increases the total heat exchange surface area in a compact configuration. This segmented approach allows for larger effective heating surface without proportionally increasing the device footprint.
Solution Approach 2:
The heat exchange surfaces are arranged in a multi-dimensional configuration with discs positioned at different heights and angles within the chamber. This spatial arrangement maximizes the heating surface area utilization and improves steam distribution efficiency across all surfaces.
4Productivity
If steam is fed into a traditional evaporation apparatus, then evaporation can occur, but gases accumulate in the middle part reducing heat exchange capacity
Solution Approach 1:
The evaporation chamber is divided into multiple sections with disc-shaped heat exchange elements in each section. Gas vent openings are provided in the discs, allowing gases to escape from each section independently. This segmented design prevents gas accumulation that would otherwise block heat exchange surfaces.
Solution Approach 2:
The disc structures act as intermediaries between the steam supply and the material being processed. The vents in the discs provide pathways for gas escape while maintaining the heat exchange function, mediating between the need for steam contact and the need to remove gases.
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 solution provides a more efficient and energy-economic drying process with reduced risk of material burning, lower energy consumption, and improved heat exchange efficiency by utilizing separate jackets and MVR technology, enabling smaller heating surfaces and easier control of the drying process.
Implementation Method 1
uses high pressure fans in a duct to increase the pressure and the temperature of the steam before introducing it back into the system
Implementation Method 2
heat exchange surfaces makes control of drying problematic
Implementation Method 3
a steam heated jacket throughout
Implementation Method 4
removal of the water phase from material... is usually done by an evaporation process
Data Source
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AI summary
The present invention relates to a new device, a system and a method for both cooking and drying or removing the water phase from material. The device of the present invention has a large area for heat exchange and scrapers which stir the material in the container rather than transferring it around in circles.