An IMS 6kW High Moisture Microwave Heating and Drying System allows processors to improve their product cost effectiveness and quality, increase production volumes, reduce equipment footprint or floor space, and improve the manufacturing environment since the system generates no dangerous NOx or SOx emissions.
Each system continuously heats and/or dries a thin sheet or bed of product as it is horizontally conveyed through a rectangular heating chamber or applicator on a specially selected microwave inert plastic modular belt.
Depending on the application and material, some products are can be dried vertically without a belt. The volumetric heating that results from the agitation of the polar molecules in the product, results in rapid, uniform heating and/or drying of the product in a fraction of the time required by a conventional dryer.
6kW High Moisture Microwave System: Materials
A high-moisture applicator consists of a cavity or oversized waveguide structure with variable attenuation capabilities. Its modular construction allows an electric field orientation that is perpendicular to the material passing through the applicator on a microwave inert belt. The result is greater absorption of power by the material.
A range of loose granular to continuous sheet materials succesfully heated or dried includes:
- Carpet
- Cereals
- Peanuts
- Textiles
- Biomass
- Pulses and Seeds
- Biodiesel Products
- Agricultural Grains
Specifications
The following are operating parameters per each 6kW High Moisture Microwave Heating and Drying System:
| Frequency: | 2450 MHz |
| Power Output: | 5 – 15 kW |
| Max. Throughput: | 132 – 396 lbs. per hour (60 – 180 kg. per hour) |
| Max. Moisture Removal: | 11 – 33 lbs. per hour (5 – 15 kg. per hour) |
| Max. Temperature: | Limited by product and belt material |
| Operating Pressure: | Atmospheric at 14.7 psig (1.0 Barg) |
| Applicator Material: | Aluminum (SS available upon request) |
| Max. Product Height: | 1 inch (25.4 mm) |
| Belt Speed: | 0 – 100 feet per minute (0 – 30 meters per minute) |
| Belt Width: | Variable to 4″ (0.10 meters) |
| Electric Air Heater: | Optional for drying application |
| Generator, Control Panel & Applicator Dimensions | |
| Length: | 3’4″ (1.03 m) 1.7″ (0.48 m) 22’4″ (6.81 m) |
| Width: | 1’9″ (0.54 m) 0’11” (0.27 m) 2’4″ (0.71 m) |
| Height: | 5’9″ (1.76 m) 1’7″ (0.48 m) 3’10″ (1.17 m) |
| Electricity (including Belt Drive Motor): | 7 – 20 kW |
| Magnetron Cooling Water: | 3 – 5.4 GPM (11 – 20 LPM) |
Major Components
Microwave Generator
Generates the microwave energy at a frequency of either 915 or 2450 MHz. The generator and its ancillary components include a magnetron, electromagnet, power supply unit, circulator (to protect the magnetron) and water load. The generator components are typically housed in a NEMA 12 floor mounted enclosure. Except for air-cooled 2 kW generators, a flow of water is required to cool the magnetron, circulator and water load.
Applicator
Contains and distributes the microwave energy around the product. It may not include exhaust fans if minimal product drying or dehydration is required. Available in aluminum as standard, the design allows the target material to pass through it uniformly on a moving conveyor belt with variable speed control. The product can then efficiently absorb the available microwave energy to achieve the desired final temperature or moisture content.
The applicator is the essence of Industrial Microwave Systems’ competitive advantage, and its design, construction and/or process application is patented. IMS has developed three applicator designs to meet and optimize most customers’ heating and drying requirements:
The Ridged Waveguide Applicator is designed as a series of modules containing specially designed waveguides arranged in a serpentine fashion. The orientation of the electric field is parallel to the direction of the product as it is conveyed through the applicator, resulting in high absorption of microwave energy by the product.
The High Moisture Applicator is an oversized waveguide structure with variable attenuation capabilities. The orientation of the electric field is perpendicular to the material as it is conveyed through the applicator, reducing the rate of power absorption across the product.
In the Linear Applicator, product moves through a single waveguide on a conveyor belt, and the power is directed along the length of the conveyor belt.
Waveguides
Microwave energy conveys from the generator to the applicator by interconnecting waveguides. These allow the generator to be located in a separate area away from the applicator at a distance of up to 30 meters (100 feet) before any significant loss of power output is experienced. Waveguides may incorporate manual tuning stubs that allow an operator to optimize microwave energy absorption of a product, dependent on its dielectric properties and temperature.
Control System
Monitors and controls the performance of the PHS, and facilitates automation programming as well as in-process adjustments of variables such as generator power output, reflected power and product exit temperature. The control system consists of a Programmable Logic Controller (PLC), a touch screen control panel, and devices for data acquisition, power monitoring, and temperature or moisture monitoring. It also incorporates process alarm features that identify, record, and assist the resolution of process control issues.
The control system is typically supplied in a water resistant NEMA 4 stainless steel wall mounted enclosure. Various input and output signals can be used to communicate and integrate with total plant automation control systems, greatly assisting with monitoring and recording overall production throughputs, temperatures, pressures, etc.
With a customer provided live internet connection, IMS technicians can connect to the systems remotely to make program changes, additions or to help troubleshoot issues.
Safety Features
Sensors constantly monitor the entire PHS for the leakage of microwave energy, and communicate with the control system for automatic shut down in the unlikely event that excessive electro-magnetic radiation or leakage is detected.
IMS planar heating systems incorporate a “choke” section at the entry and exit of each section or applicator. This reduces microwave leakage to well below industry accepted levels for safety.
To learn more about the IMS 6kW High Moisture Microwave Heating and Drying System, please contact our team.
