1 st International Congress on Drying and Sustainable Development (IC-DSD) February 28-29, 2020, Agadir (Morocco)
Innovation in Drying Technologies - Current Status and Future Needs Prof. Arun S. Mujumdar McGill University, Montreal, Canada Jiangnan University, Wuxi, China www.arunmujumdar.com Dr. Shivanand S. Shirkole National Institute of Technology Rourkela, India
Outline Introductory remarks on innovation Conventional vs. innovative drying technologies Selected recently developed technologies Why innovative ideas are slow to be adopted Closing remarks “Innovation is seeing what everybody has seen and thinking what nobody has thought.” Introduction Innovation Commercial Vs. Innovative Tech. Recently Developed Tech. Closing Remarks
Some Interesting Stats/Facts About Drying Over 10,000 materials are dried at different scales to diverse specifications starting from liquid, suspension, sludge, particulate to large discrete sheets to continuous sheets hence the need for 100 dryer types. Operating ranges- supercritical to sub-zero temperature/pressure. Mechanism of heat input include conduction, convection, and radiation, continuous, hybrid, simultaneous or sequential. Continuous or batch modes of operation. From above it is easy to see why a wide assortment of diverse dryers are needed. Introduction Innovation Commercial Vs. Innovative Tech. Recently Developed Tech. Closing Remarks
Selection of right dryer/drying system is the most baffling problem in industry Note: Novel dryers are not necessarily better. New ideas need to be tested and validated. LCA is recommended when choosing a new dryer. Introduction Innovation Commercial Vs. Innovative Tech. Recently Developed Tech. Closing Remarks
Drying Conferences IADC ADC NDC IDS IWSID/ Boston Lyon Iceland WFCFD Wuxi Montreal Thessaloniki KL Montreal (3) Beijing Trondheim Tianjin Veracruz Budapest Vadodara Mumbai (11) Birmingham Kyoto Karlstad Kolkata Sao Paolo Magdeburg Noordwijkerhout Gifu Copenhagen Hong Kong Sao Paulo IC-DSD Versailles Gold coast Bangkok (2) Prague Xiamen Penang Morocco Krakow Hyderabad Bali Introduction Innovation Commercial Vs. Innovative Tech. Recently Developed Tech. Closing Remarks
Watercolors by Prof. Arun S. Mujumdar… Imagination is more important than knowledge. -Albert Einstein
Innovation “ Innovation is the ability to see change as an opportunity-not a threat ” Introduction Innovation Commercial Vs. Innovative Tech. Recently Developed Tech. Closing Remarks
Types of Innovation Incremental Evolutionary Radial Revolutionary • High R&D cost Low cost of implementation • • Risky although RoI for Less risk • successful technologies is high More likely to be adopted • Examples: Examples: - Pulse combustion dryers - Superheated steam dryer - Flame dryers - Modified fluidized/spouted - Impingement jet superheated beds steam dryer for tissue - Hybrid dryers /newsprint - Adsorption dryer for grains - Microwave + Ultrasonic dryers (particulate drying) - Swell Drying-DIC Introduction Innovation Commercial Vs. Innovative Tech. Recently Developed Tech. Closing Remarks
Why innovative dryers involves higher risk? Lack of reliable knowledge of mechanism of heat/mass transfer in drying - no universal model for drying or dryers High development costs - nonlinearity of scale up of heat/mass transfer and quality attributes is going from lab to pilot to full scale. Dryer design and operating conditions after performance - which also depends on material properties Overall, drying is an extremely complex operation which so far has defined a universal solution. Introduction Innovation Commercial Vs. Innovative Tech. Recently Developed Tech. Closing Remarks
Why adoption rates are low from published works to industry? Over 500 dryer types are reported in literature: most are lab reports Pilot scale up is essential Research paper do not provide enough information to allow scale up by potential users. Often quality attributes cannot be scaled up resulting in expensive trials. Lack of reliable scale-up and criteria or math model for most dryers also adds uncertainty. Finally, techno economics of the novel dryer concepts is largely unknown. Results: close interaction between academia and industry is a pre- requisite for introduction of innovations. Introduction Innovation Commercial Vs. Innovative Tech. Recently Developed Tech. Closing Remarks
Motivating Factors for Innovation New product or process Higher capacities than current technology permits Better quality than currently feasible Reduced overall cost Reduced environmental impact, sustainable Safer operation; more flexibility Better efficiency Introduction Innovation Commercial Vs. Innovative Tech. Recently Developed Tech. Closing Remarks
On Innovation in Drying Tech- Why Slow? 1. Most innovative ideas in public domain come from academia; techno economic analysis conspicuous by absence 2. Collaboration between academia, user and vendor necessary for technology transfer. 3. Half-life /operating life of most dryer systems are long, discouraging need for replacement with better/innovative dryers. 4. Developing economies are more likely to leapfrog to new Technology then established ones e g vacuum steam drying of timber. 5. Buzz word research areas tend to attract major fraction of funding available; much less available for R&D in drying. Industrial funding has not taken up the slack for various reasons. Solution: Make R&D cost-effective by sharing knowledge, ideas, resources globally and enhance industry-academia interaction. Introduction Innovation Commercial Vs. Innovative Tech. Recently Developed Tech. Closing Remarks
Time to Commercialization From proof -of -concept to commercialization is a long tortuous nonlinear route Often it takes one to several decades; many never see successful technology transfer Superheated steam drying idea was first published in 1898 - still not common technology despite numerous advantages Pulse combustion drying concept has been around for over 6 decades but still not mainstream Impinging stream dryers also have not succeeded in commercialization Introduction Innovation Commercial Vs. Innovative Tech. Recently Developed Tech. Closing Remarks
Comparison of Conventional Vs Innovative Drying A. - Fluidized bed dryers – 30+ variants - Heat pump assisted dryers – 20+ variants - MW/RF dryers – 20+ variants - Spouted bed dryers – 20+ variants etc. B. - Very few “disruptive” technologies e.g. Vacuum superheated steam drying kiln for wood-replacing hot air kilns C. - Potential for superheated steam dryers is high but still under utilized D. - New drying technologies needed for nanoparticles, nanogels etc. E. - Use of AI not yet materialized. Introduction Innovation Commercial Vs. Innovative Tech. Recently Developed Tech. Closing Remarks
Innovative Drying Concepts: Enhancement of Drying Rates Vibration Pulsation Sonic or ultrasonic fields (e.g. Vibrated bed dryers) (e.g. Impinging streams) (e.g. pulse combustion dryers) Dielectric fields {MW, RF} Superheated steam drying (e.g. MW-assisted steam drying) (future tech.) Introduction Innovation Commercial Vs. Innovative Tech. Recently Developed Tech. Closing Remarks
Innovative Drying Concepts: Combination of Optimal Dryers in Stages • Spray + Fluid bed (Spray Fluidizer) • Filter mat (Spray + Conveyor) • Flash + Fluid Bed Innovative Drying Concepts: Combined Modes of Heat Pump • Convection + Conduction • Convection + Radiation (Concurrent or Sequential) • Convection + (MW / RF) Introduction Innovation Commercial Vs. Innovative Tech. Recently Developed Tech. Closing Remarks
Innovative Drying Concepts: Combined Unit Operation • Filter - Dryer • Dryer - Cooler - Agglomerator etc. Innovative Drying Concepts: Novel Gas / Particle Contacts • Spout - fluidized / Rotating spouted bed • Pulsed Fluid Bed • Mechanical screw conveyor spouted bed • Mechanically fluidized bed Introduction Innovation Commercial Vs. Innovative Tech. Recently Developed Tech. Closing Remarks
Innovative Drying Concepts: Miscellaneous • Spray dryer - “engineered” powders • Ohkawara Kakohiki spray bag dryer • Condebelt dryer for thick paper grades • Remaflam (for textiles) • Supercritical CO2 extraction (aerogels) • Spray-freeze drying • Carver - Greenfield process Introduction Innovation Commercial Vs. Innovative Tech. Recently Developed Tech. Closing Remarks
Selected Innovations Intermittent Drying Introduction Innovation Commercial Vs. Innovative Tech. Recently Developed Tech. Closing Remarks
Selected Innovations Intermittent Drying Introduction Innovation Commercial Vs. Innovative Tech. Recently Developed Tech. Closing Remarks
Selected Innovations Variable Pressure Drying Essential oil Extraction (volatile molecules) Swell-Drying DDS Direct Auto- Drying 3-stage spray- vaporization drying Expansion Decontamination DIC Stop thermal degradation Solvent Extraction Instant Cooling In-Situ TransEsterification De- (Biodiesel) allergenicity Cracking/depolymerizat ion of cellulose: 3 rd generation bioethanol Introduction Innovation Commercial Vs. Innovative Tech. Recently Developed Tech. Closing Remarks
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