Cylindrical Heating Systems

IMS Cylindrical Heating Systems provide a unique solution which is best utilized for the continuous thermal processing of heat and shear sensitive, high viscosity, and multiphase materials that demand precise temperature control.

Planar Heating Systems

IMS Planar Heating and Drying Systems can offer a better alternative to conventional, re-circulated hot air dryers due to the best-in-class uniformity, efficiency and thermal processing they demonstrate in many industrial processes.

Cylindrical Heating Systems

Although an IMS CHS can be used for many product and process applications, including heating, cooking/gelation, pasteurization and sterilization, its specific benefits and economic advantages are best achieved when applied to heat or shear sensitive, high viscosity and multi-phase fluids.

Planar Heating Systems

An IMS Planar Heating System has advantages over conventional dryers in two areas of their design that are intrinsically inefficient: (1) pre-heating a product to evaporative temperature, and (2) removing water from products with relatively low overall moisture content.

FAQ

What About Maintenance?

In addition to downtime for cleaning and inspection, conventional dryers and heat exchangers need periodic servicing with an expensive inventory of parts and a highly trained labor force. Apart from periodic examination for wear on the belt of a planar system or the tube in a cylindrical heater, the only part that requires maintenance on an IMS system is the magnetron.  In the event of a malfunction or misuse through incorrect operation, this can easily be replaced in less than thirty minutes.  In many cases, a magnetron can be repaired or refurbished for about two-thirds the cost of a new unit. 

Although most vendors limit their warranty to 2,500 hours, the operating life of a 915 MHz 100 kW commercial magnetron can be greater. IMS recommends that the magnetron be replaced annually or after 8,000 hours of operation, whichever is sooner.  This translates to a maintenance cost of about US$1.50 per operating hour at maximum power output.

Low power 2450 MHz magnetrons cannot be repaired, but larger units usually can be.  A typical operating life for magnetrons at this frequency is 6,000 hours.


What Are the Advantages?

Because volumetric heating is not dependent on heat transfer by conduction or convection, it is possible to use microwave heating for applications where conventional heat transfer is inadequate. One example is fluids containing particulates where the identical heating of solids and liquids is required to minimize over-processing.  Another is for obtaining very low final moisture levels for product without over-drying. 

Other advantages include:

  • Microwaves generate higher power densities, enabling increased production speeds and decreased production costs.
  • Microwave systems are more compact, requiring a smaller equipment space or footprint.
  • Microwave energy is precisely controllable and can be turned on and off instantly, eliminating the need for warm-up and cool-down.
  • Lack of high temperature heating surfaces reduces product fouling in cylindrical microwave heaters. This increases production run times and reduces both cleaning times and chemical costs.
  • Microwaves are a non-contact drying technology. IMS planar dryers in the textile industry reduce material finish marring, decrease drying stresses, and improve product quality.
  • Microwave energy is selectively absorbed by areas of greater moisture. This results in more uniform temperature and moisture profiles, improved yields and enhanced product performance.
  • The use of industrial microwave systems avoids combustible gaseous by-products, eliminating the need for environmental permits and improving working conditions.

What Are the Disadvantages?

Historically, the primary technological drawback to using microwave energy for industrial processing has been the inability to create uniform energy distribution. If uniform energy distribution is not present, wet regions of the target material are underexposed, and other regions are overexposed. This is analogous to the hot spots and cold spots generated in your microwave oven at home when heating or defrosting foods like a potato or frozen chicken.

Severe overexposure of non-uniform energy distribution may provide excessive focus of heat build up resulting in burnt material or a fire hazard. The uniformity of distribution designed into IMS microwave equipment overcomes this problem.

Another disadvantage is the depth of penetration achievable using microwave energy. This is a function of microwave frequency, dielectric properties of the material being heated and its temperature.  As a general rule, the higher the frequency, the lower the depth of penetration.


What About Safety?

Using patented applicator design geometries and unique choking mechanisms, IMS technology reduces microwave leakage from system entry and exit points to virtually non-detectable levels for both their planar and cylindrical heating systems. This poses no threat of electromagnetic radiation to the health and safety of equipment operators.  

IMS heaters and dryers are designed to operate at a level of electromagnetic emission that is twenty times more stringent than the IEEE/ANSI standard. As a further precaution, all IMS control systems are supplied with safety interlocks and leakage detectors that shut down power instantaneously in the event of equipment malfunction or misuse.


What About Economics?

A common misconception is that microwave heating is always more expensive than heating by conventional techniques.  The actual answer depends on the application and local utility costs.  In some cases, microwaves can be more efficient than conventional systems, resulting in major savings in energy consumption and cost.

When used as a Pre-Dryer in combination with conventional gas or oil heated air dryers, IMS microwave systems allow overall production capacities to be increased by 25 to 33%. 

This is because the pre-dryer:

  • Preheats moisture to the evaporative temperature.
  • Can help to equalize the moisture level of product before the conventional dryer.

With current energy costs, the return on capital invested in an IMS pre-dryer has been as low as 12 to 24 months.

When used as a Post-Dryer in combination with conventional gas or oil-heated dryers, IMS microwave systems are more efficient than conventional dryers at achieving final moisture levels of less than 20%.  This is because the lower the moisture level, the more difficult it is to drive moisture from the center of material to the surface by conventional heat conduction and convection processes. 

An IMS post-dryer provides:

  • Uniformity of moisture control and surface temperature of the final product.
  • Higher production efficiency due to increased process speeds.
  • Improved product quality resulting from reduced surface temperatures, compared with conventional post-dryer designs.

Return on capital invested in an IMS post-dryer has been as low as from 12 to 24 months.

In addition to the applications above, IMS planar units are used as Stand-Alone Dryers.  These may be the most economical solution where minimal equipment floor space or footprint is available for a new application, or when expansion of existing production facilities would require building modifications to accommodate a conventional drying system.

In the case of Heating a pumpable fluid using an IMS Cylindrical Heating System, the production cost of providing sensible heat transfer from microwave energy is totally dependent on the local cost of utilities than can vary by a factor of five throughout North America.  As a rough guide, this cost is expected to be approximately one third higher than using steam in a conventional heat exchanger. 

However, this is offset by several factors, including:

  • The reduced capital investment in steam boilers, steam trains, condensate collection and water treatment plant.
  • The ability to use high power densities enables microwave heaters to substantially increase production rates.
  • Uniform energy distribution minimizes fouling depositions in even the most viscous products.  This is particularly important with thermally sensitive materials such as chemical polymers, food ingredients, nutraceuticals, biotech products & pharmaceuticals.
  • For multiphase food products, hold times are greatly reduced using IMS high temperature heaters, as the equilibration of hot and cold spots is virtually instantaneous. This is because the difference in their temperatures is minimal, unlike conventional heaters. Smaller hold tubes also reduce capital investment and operating costs for system pumps.
  • With volumetric heating of multiphase products, solids loadings of 70% or higher can be processed since the carrier fluid is not used as the primary heat delivery medium.
  • The shorter residence times achievable with microwave heating improve product quality. Compared to conventional heating, IMS heated food products tend to retain a higher percentage of flavors and nutrients.

Before designing any commercial microwave heating or drying system, IMS recommends working with its customer to prepare a customized Economic Value Analysis based on the actual process specifications required.  Contact us for further details.


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IMS is a subsidiary of Laitram, L.L.C., a privately held technology company headquartered in New Orleans, LA. Since acquisition in 2003, Laitram has enabled IMS to expand its business activities in a variety of industries, including chemicals, food processing, industrial products, nonwovens and textiles. For further details on Laitram, L.L.C., please visit its website at www.laitram.com.

IMS has located its Development and Product Test center in Morrisville, North Carolina, close to Raleigh Durham airport and the Research Triangle Park area. It is a leading designer of innovative, patented microwave systems for continuous flow manufacturing processes that require rapid and uniform heating and drying. IMS commercial operations are managed from Laitram’s corporate offices in New Orleans.

 
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