The 100kW Liquid Heating System by Industrial Microwave Systems is a unique solution for pumpable foods, beverages, biomaterials, and fluids. By uniquely applying high-intensity electromagnetic energy, it solves the problem of “hot spots” associated with traditional surface heating technologies. It is often used in pasteurization and sterilization processes.
Applications & Processes
This IMS In-Line Microwave Liquid Heating System is particularly effective for the thermal processing of high-value, heat and/or shear sensitive, high viscosity, and multi-phase foods. Typical products processed with this system include:
- Salsa
- Surimi
- Soy milk
- Fruit purees
- Pasta sauces
- Meat slurries
- Cheese sauces
- Particulate soups
- Vegetable purees
- Poultry emulsions
- Coffee-based drinks
- Tomato-based products
- Dairy-based foods and desserts
Each system heats a single or multi-phase product as it is pumped through a microwave-transparent heating tube located in the center of the cylindrical heating chamber or applicator. The volumetric heating that results from the agitation of the polar molecules in the product means that no hot tube sidewalls are required for heat transfer.
As a result, an IMS 100kW Liquid Heating Microwave System allows processors to improve their product cost effectiveness and quality, reduce equipment footprint or floor space, and in some cases create new or enhanced pumpable products. This is due to the cool wall surface temperature of the microwave heating tube, combined with the minimal residence time and uniform ultra-rapid heating of the product. This combination is achieved without the fouling, maintenance and replacement part costs associated with conventional hot surface heat exchangers.
100kW Microwave Liquid Heating System: Technical Specifications
The following specifications are operating parameters per module:
| Frequency: | 915 MHz |
| Power Output: | 75 – 200 kW |
| Max. Throughput: | 10 GPM (2500 kg. per hour) |
| Max. Temperature: | 302°F (150°C) |
| Max. Pressure: | 150 psig (10.5 Barg) |
| Applicator Material: | Stainless Steel |
| Product Tube: | PTFE with Ceramic Pressure Sleeve (other FDA approved materials available) |
| Tube Size: | 1.5″ – 2.5″ (38 mm – 63 mm) |
| Standard Tube Fitting: | Stainless Tri-Clamp Ferrule |
| Generator, Control Panel & Applicator Dimensions | |
| Length: | 6’0″ (1.83 m) 2’8″ (0.81 m) 2’9″ (0.84 m) |
| Width: | 2’6″ (0.76 m) 0’9″ (0.23 m) 2’0″ (0.61 m) |
| Height: | 9’3″ (2.82 m) 4’0″ (1.22 m) 8’2″ (2.49 m) |
| Electricity: | 90 – 240 kW |
| Magnetron Cooling Water: | 27 GPM (100 LPM) / 100kW Generator |
100kW Liquid Heating Microwave System: Integrated Components
The following components are integrated in our system:
Product Heating Tube
Allows material to be pumped through the IMS heater where the product absorbs microwave energy that is available in a well defined cylindrical geometric region. This “microwave inert” tube is typically made out of food grade Teflon and/or ceramic material. It is specially selected and designed to ensure it does not heat up by absorbing electromagnetic energy while meeting the required operating temperature & pressure requirements of the process system.
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 that surrounds the product heating tube using unique patented designs and geometries within a focusing structure. Available in aluminum or 304 stainless steel. Its design allows the target material to pass through a uniform microwave field, and efficiently absorb the available microwave energy. The applicator is the essence of Industrial Microwave Systems’ competitive advantage, and its design, construction and/or process application is patented.
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. Wave guides 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 system, and facilitates automation programming as well as in-process adjustments of variables such as generator power output, power reflections 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 monitoring. It also incorporates process alarm features that identify, record, and assist the resolution of process control issues. The control system is typically in a water resistant NEMA 4 stainless steel wall mounted enclosure. Various input and output signals can 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 system 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. Every IMS 100kW liquid heating system incorporates a unique “choking” section at the entry and exit to the applicator that reduces microwave leakage to well below industry accepted levels for safety. Operator safety shrouds are available for most industrial applications.
Design Codes
Each liquid heating system design conforms with design codes specified by various US government and industry regulatory authorities. These include the Occupational Safety and Health Administration (OSHA), the National Electric Code (NEC), the National Electrical Manufacturers Association (NEMA), the Food and Drug Administration (FDA), 3-A Sanitary Standards, Incorporated (3-A), the National Sanitation Foundation (NSF) and the US Department of Agriculture (USDA).
Materials
- Multiple Pump Designs
- Hold Tubes
- Product Cooling Heat Exchanger
- Conveyors
- Hoppers
- Mixers
- Blenders
Process Design Specifications
IMS designs and supplies Liquid Heating Systems in 915 and 2450 MHz frequencies. Calculation of the required power output, optimum magnetron frequency, applicator design and selection of product heating tube are determined by:
- A brief description of the type, physical and chemical properties of the pumpable fluid.
- Maximum particle size if the fluid is not homogeneous.
- The mass per hour of material pumped and thermally processed, expressed in kilograms or pounds.
- The thermal properties of the material, namely specific gravity, specific heat and average viscosity.
- The dielectric or microwave absorption properties of the material.
- The required product entry and exit temperatures.
- The maximum design/ test temperatures and pressures required.
- Available space, namely footprint and height.
Curious to learn more about the 100kW In-Line Liquid Heating Microwave System? Talk to the experts!
