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Lean Drying
n todays competitive world, customers are constantly demanding higher quality, faster delivery and lower cost. For ceramic manufacturers, lean manufacturing can provide a way to achieve all three of these goals. Unfortunately, drying processes that take hours make the implementation of lean manufacturing almost impossible because they prevent that area of the manufacturing process from becoming more efficient. Combination dryers using both radio frequency (RF) technology and convection technology can solve this problem. These dryers allow ceramic manufacturers to change from older batch processes to lean, continuous processes, in some cases reducing drying times from 24 hours to 90 minutes and from 12 hours to 30 minutes. Combination RF-convection dryers also offer the added benefits of more uniform temperature gradients and moisture levels, less solids migration of sizing and additives, lower drying temperatures, and smaller equipment.
from older batch processes to lean, continuous processes by significantly reducing drying times.
by Ben Wilson, P.E., Sales Manager, PSC, Inc., A Litzler Company, Cleveland, Ohio
The difference in the end result of a dried product is shown in Figure 2. A conventionally dried product is hot and dry on the outside and cold and wet on the inside. Unfortunately, this is not efficient because the dry outer layer acts as an insulating barrier and reduces the conduction heat transfer to the middle of the product, especially with thermal insulating materials such as ceramics. This dry outer layer can cause quality problems, such as surface cracking, a skin on coatings and uneven solids dispersion due to the wicking of sizing and additives from the middle to the surface. With RF drying, the heating is from within, so there is no hot, dry outer layer. The product is heated throughoutas the water in the middle is heated, it moves to the surface. In general, because of the heat losses at the surface, radio frequency dried products are hot and dry on the inside and
Reprinted from the April 2002 issue of Ceramic Industry.
cooler and wetter on the outside. For this reason, combining these two technologiesusing RF heating to heat the inside and move the water to the surface where it is effectively removed with a welldesigned convection systemoffers significant potential benefits.
Lean Drying
times per second, which causes friction and heat. The power put into the material by dipole rotation is based on the voltage gradient in the material, the frequency of the electric field and the loss factor of the material. The relationship among these variables is complicated by the fact that the loss factor varies with both frequency and temperature. In ionic conduction, charged particles (ions) are always moving toward the opposite charged plate. Since the polarity is changing millions of times per second, these ions are constantly moving and colliding with other particles, similar to billiard balls. These collisions create friction and heat that warms the material. The power put into the material by ionic conduction is based on the voltage gradient in the material and on the conductivity of the material. In ionic conduction, frequency has no effect on the power.
Q Heat in
Losses
Hot/Dry
Hot/Dry + + Q in
Q Heat in
Wet Dry
+
Dry
+
Wet Dry
Conventional (inefficient)
Benefits of RF Drying
Because RF drying differs from conventional drying methods, it provides some significant advantages in drying materials such as ceramics. These include: Faster drying times and reduced labor costs with continuous versus batch processing. Because the energy is absorbed directly by the water throughout the product, heating and drying are faster than convection, conduction and infrared methods. This means faster cycle times and lower labor costs with a continuous process. A more uniform temperature gradient through the product due to heating from within, resulting in more consistent product quality. This uniform heating prevents a dry outer layer and provides a more uniform dispersion of sizing and additives throughout the product. This is especially important in
drying fiberglass packages. No overheating of the base ceramic material, since most materials are self-limiting, i.e., they wont heat once the material is dry. This prevents scrap product and improves product quality. Selective heating, which allows water to be heated with less heating of the base ceramic material. This improves the quality of the product through lower drying temperature. Product temperatures do not normally exceed 212F. Moisture leveling in the product, resulting in more consistent product quality and lower cost by not over-drying some areas to meet required moisture levels in others. Instant on and off power and heating, reducing costs by eliminating warm up and cool down cycles associated with conventional systems. Efficient energy usage, because the energy used is proportional to the amount of work being done (i.e. water being evaporated). This reduces costs as lower production volume will have reduced operating costs. Fewer environmental issues, as there are no combustion byproducts to exhaust. This improves quality by keeping the dryer cleaner and reduces costs by reducing permits and approvals for process emissions. Almost all of these benefits are a direct result of the unique way RF energy interacts with materials, and are therefore only attainable through the use of RF drying.
Moisture
Conventional
Radio Frequency
Time
Figure 3. Typical drying curves.
toward lean manufacturing. These combination dryers provide great synergy, where RF excels at heating uniformly within the material and pushing the moisture to the surface and convection excels at removing moisture from the surface. Whether the RF is used as a preheat, boost, finish or a full RF application, drying ceramics can be much more effective and efficient with combination RF-convection dryers.
For more information about combination RF-convection drying, contact PSC Inc., A Litzler Company, 21761 Tungsten Rd., Cleveland, OH 44117; (216) 531-3375 or (800) 538-1337; fax (216) 531-6751; e-mail info@pscrfheat.com; or visit www.pscrfheat.com.