Speed-Modulated Fan for Energy-Efficient Malt Drying
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Solution Overview
Problem
Existing malt drying processes in Darren systems are inefficient in terms of energy consumption, as they rely on fixed fan speeds and do not optimally utilize the available drying time, leading to suboptimal electrical energy usage.
Innovation Solution
Implementing a speed modulation of fans based on real-time monitoring of grain moisture content, ambient humidity, and weather forecast data, allowing for dynamic adjustment of fan speeds to optimize the drying process within a specified maximum drying time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If fixed fan speeds are used in drying systems, then the drying process is simple to operate, but electrical energy consumption is high and drying time is not optimally utilized
Solution Approach 1:
The patent applies dynamics by transitioning from fixed fan speeds to variable fan speeds that adapt to drying conditions. The system dynamically adjusts fan speed based on real-time monitoring of grain moisture content, ambient humidity, and weather forecasts, allowing the drying process to optimize energy consumption while maintaining effectiveness throughout the drying cycle.
Solution Approach 2:
The patent implements feedback mechanisms by continuously monitoring grain moisture content, ambient humidity levels, and weather forecast data. This feedback information is used to dynamically adjust fan speed, creating a closed-loop control system that optimizes electrical energy consumption based on actual drying progress and environmental conditions.
2Productivity
If fixed fan speeds are used, then the system is easier to operate, but the available drying time is not fully utilized leading to inefficient energy usage
Solution Approach 1:
The patent applies preliminary action by incorporating weather forecast data into the drying process planning. The system uses forecasted ambient humidity and temperature information to proactively adjust fan speeds before conditions change, optimizing drying time utilization in advance rather than reacting to conditions after they occur.
Solution Approach 2:
The system continuously monitors drying progress and environmental conditions, using this feedback to dynamically adjust fan speeds. This real-time feedback mechanism ensures that the available drying time is fully utilized by adapting the drying rate to match actual conditions, maximizing productivity without requiring complex manual intervention.
3Loss of time
If fan speed is increased to reduce drying time, then productivity improves, but electrical energy consumption increases significantly
Solution Approach 1:
The patent resolves this contradiction by making fan speed dynamic rather than fixed. The system adjusts fan speed throughout the drying process based on real-time moisture content monitoring and environmental conditions, using higher speeds only when necessary to meet drying targets, thereby optimizing the balance between drying time and energy consumption.
Solution Approach 2:
The patent applies parameter changes by varying fan speed as a controllable parameter throughout the drying process. Instead of maintaining a constant high speed, the system changes fan speed parameters based on drying progress and environmental conditions, achieving the desired drying time reduction without proportionally increasing 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
This approach enables significant electrical energy savings by optimizing fan speed and extending the use of the available drying time, while ensuring the desired moisture content of the malt is achieved, thus improving the overall energy efficiency of the malt drying process.
Implementation Method 1
a fan (3) for passing an air mass flow (4) through a drying material bed (2.1) of the green malt (2)
Implementation Method 2
Hot air flows through the material to be dried from below, thus removing the moisture
Implementation Method 3
an air stream, in particular a warm air stream, flows through the green malt (2)
Data Source
Figure 1
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AI summary
In a method of energy-efficient drying of green malt (2) in a kiln (1) with the aid of a speed-modulated ventilator (3) for passage of a mass flow of air (4) through a drying material bed (2.1) of the green malt (2), it is envisaged that the drying is conducted over a defined maximum kiln-drying time (tmax). Detected for this purpose are a cereal moisture content (Hg) and a cereal mass (Mg) of a cereal (2.2) which, after softening (5) and germinating (6), forms the basis for the drying material bed (2.1) of the green malt (2). Also detected are an ambient air humidity (Hl) of ambient air (7) used for the mass flow of air (4) and a number of weather forecast data (W1, W2) at least with regard to the ambient air humidity (Hl), and, during the drying, a drying material moisture content (Ht) of the green malt (2) down to a defined limit (Gt), wherein, on the basis of the cereal moisture content (Hg), the cereal mass (Mg), the ambient air humidity (Hl), the number of weather forecast data (W1, W2) with regard to the ambient air humidity (Hl) and based on the drying material moisture content (Ht) of the green malt (2), modulation of the speed of the ventilator (3) is undertaken so as to achieve and/or comply with the defined maximum kiln-drying time (tmax).