Turbofan Drying Installation for Granular Polymer Materials
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional drying installations for granular polymer materials, such as those based on polyethylene terephthalate (PET) or polyamide (PA), face inefficiencies in energy usage due to the high energy required to move process gas, often necessitating the use of multiple blowers which are complex to manage and maintain.
Innovation Solution
A drying installation utilizing a turbofan as the movement unit for the process gas, which allows for higher rotational speeds and more efficient energy use, reducing energy input by up to 50% and simplifying control and installation compared to conventional blower systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional blowers are used to move process gas in the drying installation, then the system can operate with standard flow rates, but the energy consumption increases significantly (20-40% of total energy) and the system complexity increases when multiple blowers are required
Solution Approach 1:
The patent applies parameter changes by transitioning from conventional blower operation parameters to turbofan operation parameters. The turbofan operates at higher rotational speeds with a different impeller geometry optimized for high-speed rotation, enabling it to move the same or greater volumes of process gas with significantly lower energy input compared to conventional blowers operating at lower speeds.
Solution Approach 2:
The patent replaces the conventional blower system with a turbofan system that copies the essential function of moving process gas through the drying installation. The turbofan is a proven technology from other industries (such as aerospace and HVAC) that is adapted for this specific drying application, bringing established efficiency benefits to the polymer drying process.
2Quantity of substance
If multiple blowers are used in parallel to achieve required gas flow rates, then the necessary flow capacity is met, but the device complexity and maintenance requirements increase
Solution Approach 1:
The patent merges the functions of multiple conventional blowers into a single turbofan unit. The turbofan's high-speed capability and efficient gas-moving performance allow one unit to replace what would traditionally require two or more blowers operating in parallel, thereby simplifying the overall system architecture, reducing the number of components, and lowering maintenance requirements while maintaining or improving the required process gas flow rate.
3Speed
If conventional blowers are used, then the system operates with standard rotational speeds, but the energy efficiency is reduced and the system requires more complex control arrangements
Solution Approach 1:
The patent fundamentally changes the operational parameters of the gas movement system by adopting a turbofan that operates at high rotational speeds (typically 10,000-30,000 rpm compared to the much lower speeds of conventional blowers). This parameter change in rotational speed, combined with the turbofan's optimized impeller design, results in superior energy efficiency for moving the process gas through the drying installation.
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 use of a turbofan in the drying installation significantly enhances energy efficiency, reduces energy consumption, and allows for simpler operation and maintenance, while enabling higher flow rates with a single unit, thus optimizing the drying process for granular polymer materials.
Implementation Method 1
a turbofan (16) which is provided to move the process gas along the supply circuit towards the hopper (2). The turbofan (16) comprises a motor (16a) and an impeller (16b) which is directly coupled to the motor (16a)
Implementation Method 2
The turbofan (16) is configured to operate up to a maximum number of revolutions per minute of 12,000 rpm, more preferably of 15,000 rpm
Implementation Method 3
the supply circuit (10) may comprise a heating unit (20) which is configured to heat the process gas
Implementation Method 4
there is provided a dehumidification unit (18) which is configured to reduce the humidity content of the process gas up to predefined values
Implementation Method 5
a hopper (2), inside which the granular polymer material is dried. The turbofan (16) is configured to supply the process gas into the hopper (2) at a flow rate which is predefined
Data Source
AI summary
A drying installation for granular polymer material includes a hopper, in which the granular polymer material is dried, and a supply circuit for a process gas which is provided to dry the granular polymer material. The drying installation also includes a turbofan which is able to rotate an impeller of the turbofan at a speed of at least 7000 rpm and which is provided to move the process gas along the supply circuit towards the hopper.