Vibrating Frame Microwave Heat Treatment for Granular Products
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing heat treatment processes for drying solid granular products, such as agri-food products, face challenges including uneven drying, difficulty in controlling final moisture levels, complex cleaning procedures, risk of fires, and lack of adaptability for small quantities or controlled atmospheres, particularly due to the use of conveyor belt tunnels with infrared radiation or hot air.
Innovation Solution
A microwave-based heat treatment process using a vibrating frame with microwave generators and controlled atmosphere capabilities, including inlet and outlet plugs to prevent microwave leaks, allows for rapid and uniform dehydration, easy cleaning, and adaptability in product support profiles, ensuring efficient energy use and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conveyor belt tunnel with infrared radiation or hot air is used for drying, then the product can be heated and water evaporated, but the drying homogeneity remains unsatisfactory and controlling the final moisture rate is difficult
Solution Approach 1:
The drying chamber is divided into multiple zones with independent temperature control and multiple infrared heating panels positioned at different locations. This segmentation allows different regions to operate at optimal temperatures for their specific drying stage, improving overall homogeneity while maintaining high productivity.
Solution Approach 2:
Different regions of the drying chamber are equipped with heating panels of varying power and positioning to create localized temperature zones. The front zone uses lower temperature for initial drying, while the rear zone uses higher temperature for final moisture removal, ensuring uniform drying throughout the product batch.
2Productivity
If a conveyor belt tunnel is used for heat treatment, then continuous processing is possible, but the cleaning remains complicated due to numerous components and limited accessibility
Solution Approach 1:
The flexible conveyor belt is completely removed from the system. Products are conveyed using a rigid metal belt with standardized components that can be easily detached and cleaned. This extraction of the problematic flexible belt eliminates the cleaning accessibility issues while maintaining continuous processing capability.
Solution Approach 2:
The metal conveyor belt serves multiple functions: product support, heat conduction, and easy disassembly for cleaning. The standardized metal components can be removed and placed in a cleaning station, allowing the same structure to fulfill both processing and maintenance requirements efficiently.
3Power
If infrared heating surfaces are placed close to the product for effective heating, then heating efficiency improves, but water vapor and microparticles deposit on the surfaces and soil them
Solution Approach 1:
The infrared heating panels are mounted on adjustable mechanisms that allow dynamic positioning. During operation, panels are positioned close to the product for efficient heating. During cleaning cycles, panels are retracted or tilted away from the product path, preventing contamination while maintaining heating efficiency when needed.
4Quantity of substance
If a tunnel kiln is used for heat treatment, then large quantities can be processed, but the adaptability for small quantities or controlled atmospheres is lacking
Solution Approach 1:
The drying chamber volume and atmospheric composition are dynamically adjustable. The system can operate with the full chamber for large batches or with reduced volume for small quantities. Gas flow rates and compositions can be dynamically changed to provide controlled atmospheres (including inert gases like nitrogen) when required, while maintaining high capacity operation when standard atmosphere suffices.
5Manufacturing precision
If the entire tunnel area is brought up to temperature for heat treatment, then uniform heating is achieved, but energy consumption is significant and delays occur
Solution Approach 1:
The heating system is segmented into multiple independently controlled zones along the drying chamber. Only the zones currently occupied by product batches are activated, rather than heating the entire tunnel. This segmentation maintains heating uniformity within each zone while dramatically reducing overall energy consumption and eliminating delays from heating empty sections.
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 process achieves rapid and uniform dehydration with increased water migration speed, improved energy efficiency, and enhanced safety, allowing for quick product changes and operation in controlled atmospheres, reducing energy consumption and minimizing contamination risks.
Implementation Method 1
subject said granular product to the action of microwaves
Implementation Method 2
subject the support to the action of means of advancing translation by vibrations
Implementation Method 3
evaporate the water contained
Data Source
Figure 1~2
Figure 3
AI summary
The object of the invention is a heat treatment process for a wet granular product which consists of the following successive steps: - placing the granular product on a support, - subjecting said granular product to the action of microwaves, and - subjecting the support to the action of means of translational advance by vibrations, simultaneously with the subjection to the action of microwaves. The invention also covers the device for implementing the process.