The present invention refers to a device for microwave material heating, particularly applicable to the heating of ore products, which allows eliminating the use of fossil fuels (e.g., natural gas, coal, heavy oil etc.) for the generation of heat for heating this type of material, enabling the use of microwaves for heating materials through more efficient dispersion of its electromagnetic waves.
The present invention also relates to a system that uses a heating chamber and a microwave heating method.
The process of reducing the moisture of a mining product by heating, in many cases, is highly harmful to the environment since it requires the use of fossil fuel-based fuels (e.g., natural gas, coal, heavy oil etc.) due to the way it is exploited by the mining industry today.
To reduce the environmental impacts caused by the use of such technology of CO2 emission, the development of alternative methods of reducing the moisture of the mining product has been encouraged.
Among the solutions proposed in the state of the art, the use of microwave radiation systems to reduce the moisture of mining products has aroused interest in different sectors of the mining industry.
However, performance-related problems imply large-scale implementation and operation costs for this type of solution and prevent its use from becoming more economically advantageous. For example, in a simpler solution, in which the mining product is heated by being subjected only to electromagnetic waves, the time required for heating the product and the cost of the equipment are factors that hinder the large-scale use of the technology. That is because, after studies and analyses conducted on the energy use of these devices, it could be observed that the electromagnetic waves are not adequately dispersed in the regions of interest of the ore products.
It could be observed that the heating is performed very heterogeneously, which significantly impairs the efficiency of the heating process of the material. Ideally, heating should be more evenly distributed over the entire surface of the material. Instead, the lack of dispersion in the state-of-the-art drying devices implies a longer exposure time to achieve appropriate drying of the product, and it makes the process inefficient and non-competitive in operational costs.
That occurs primarily because of an inherent design flaw in the state-of-the-art microwave heaters. When using a single chamber with multiple wave-emitting sources, an electromagnetic wave from a first source may enter the output of a second source, potentially burning out its magnetron. To avoid this situation, it is necessary to use a greater distance between the sources by increasing the size of the chamber, which, in turn, decreases the power x area ratio (kW/m2). Moreover, the emission of electromagnetic waves directly into the empty space inside the chamber does not allow an appropriate reflection and dispersion of these waves for homogeneous heating of the material of interest, further decreasing the device's efficiency.
State of the art brings some possibilities for the construction of microwave heating chambers, as seen in the US patent document U.S. Pat. No. 4,870,236. This document proposes a chamber for microwave heating of materials that uses at least a pair of cavities in which the electromagnetic wave source is arranged. The waves are reflected inside the waveguide to eventually reach the main chamber where the materials to be heated are located. However, this solution shown in U.S. Pat. No. 4,870,236 does not solve the problem of inefficient dispersion of the electromagnetic waves because the waves are distributed uncontrollably after their arrival in the chamber, resulting in the same heterogeneous dispersion observed in other state-of-the-art chambers.
Therefore, no microwave heating device can adequately disperse the electromagnetic waves in the state of the art, resulting in efficient heating of the mining product and allowing the elimination of the use of environmentally harmful combustion heat generation systems as well as a reduction of electric power and fossil fuels.
Objective one of the present invention is to provide a microwave heating device that can replace and entirely or partially eliminate the need for using fuel-burning systems to obtain heat.
Objective two of the present invention is to provide a microwave heating device that allows efficient, homogeneous dispersion of the electromagnetic waves over the product to be heated.
Objective three of the present invention is to provide a microwave heating device comprising a wall shape conducive to the dispersion of electromagnetic waves efficiently over the product to be heated.
Objective four of the present invention is to provide a microwave heating system that uses the aforementioned heating device to enable efficient, serial heating of the material of interest.
Objective five of the present invention is to provide a microwave heating method that uses the abovementioned heating device.
Objective six of the present invention is to provide a microwave heating device and system that prevents microwave leakage to the external environment, ensuring the safety of operators in the surroundings.
Objective seven of the present invention is to provide a microwave heating device and system that prevents vapors and particulates from the material under drying from entering the heating device.
In a first implementation, the present invention device comprises a main cavity defining an inner portion and an outer portion of the device, the main cavity being provided with at least one wall and being configured to receive at least one electromagnetic wave emission source, at least one wall of the main cavity comprising at least one portion bent at an acute angle formed against a vertical reference centerline of the main cavity.
In one possible configuration, the angle of inclination of the sloping portion of the main cavity wall is between 15° and 40°.
In another possible configuration, the device comprises at least one auxiliary cavity, arranged inside the main cavity and between the source and the outer portion, the auxiliary cavity enclosing an auxiliary reflection region of at least part of the electromagnetic waves generated by the source.
In another possible configuration, the auxiliary cavity has a rectangular cross-sectional profile, walls of which project from a pair of housing side walls, parallel to a vertical reference centerline of the cavity and in the direction of the outer portion.
In another possible configuration, at least one wall of the main cavity contains a permanent magnet element.
The present invention further addresses a device for microwave material heating, comprising a main cavity, defining an inner portion and an outer portion of the device, the main cavity being provided with at least one wall, the main cavity being configured to receive at least one source of electromagnetic wave emission, where, in at least one wall of the main cavity, a permanent magnet element is arranged.
The present invention further refers to a method of microwave material heating that uses a device comprising a main cavity defining an inner portion and an outer portion of the device, the main cavity being provided with at least one wall, the main cavity being configured to receive at least one source of electromagnetic wave emission, the method comprising the stage of:
In one possible configuration, the method comprises at least one of the stages of:
The present invention further addresses a system for microwave material heating comprising a conveyor of material to be heated and a material feeding zone on the conveyor, the system comprising a material heating zone, the material feeding zone being arranged prior to the material heating zone, the material heating zone comprising at least one microwave heating device such as the aforementioned.
In one possible implementation, the system comprises dielectric material plates arranged on the conveyor and a plate heating zone, the material feeding zone being arranged in between the plate heating zone and the material heating zone, the plate heating zone comprising at least one microwave heating device such as the one above.
The present invention further addresses a system for microwave material heating comprising at least one device for microwave material heating, such as the aforementioned, and at least one microwave containment housing surrounding at least one device.
In one possible implementation, the system comprises a conveyor of a material to be heated and a material feeding zone over the conveyor, the system comprising a material heating zone, the material feeding zone being arranged before the material heating zone, the material heating zone comprising at least one microwave heating chamber, comprising at least one microwave heating device.
In another possible implementation, at least one microwave containment housing is arranged around at least one microwave heating chamber.
In another possible implementation, at least one microwave containment housing is a Faraday cage.
In another possible implementation, at least one microwave containment housing extends over at least a portion of a belt conveyor.
In another possible implementation, the system additionally comprises at least one sealing plate adapted for sealing a lower opening of the main cavity.
In another possible implementation, at least one sealing plate is a Teflon plate.
The present invention will be further described below based on an example of execution represented in the drawings.
The figures show:
In this implementation of
However,
Thus, the state of the art cannot offer a device, chamber, or system for microwave material heating that is efficient enough to replace the use of fuel-burning heat generation.
To solve this problem, the present invention device 1 is provided in a first implementation shown in
In a first implementation of the present invention device 1 shown in
More specifically, the device 1 in its first implementation comprises a main cavity 10, defining an inner portion 2 and an outer portion 3 of the device 1 and being provided with at least one wall 11. The main cavity 10 is configured to receive at least one electromagnetic wave emission source 30, which preferably emits electromagnetic waves with a wavelength between 122 mm and 328 mm and a frequency in the range between 2450 and 915 MHz, and this range may change substantially depending on the desired application.
In this first implementation, at least one wall 11 of the main cavity 10 comprises at least one portion bent at an acute angle T formed against a reference vertical centerline Y of the main cavity 1. The housing further preferably comprises an upper wall 12 housing the source 30, more preferably arranged perpendicularly to the centerline Y.
The centerline Y is an imaginary guiding line that cuts vertically through the housing 10 from its center in a side view in a mirrored bipartite arrangement. Each side wall 11 projects at an acute angle T against this centerline Y in a direction away from the centerline Y, so that the housing 10 configures a substantially conical or “bi-pyramidal horn” shaped form. The angle T is preferably between 15° and 40°, more preferably between 20° and 30°, and more referentially 28°. More preferably, the present invention device 1 may comprise two pairs of side walls 11 arranged perpendicularly to each other two by two, configuring a substantially pyramidal shape.
The use of a main cavity 10 provided with a side wall 11 having an acute angle T of inclination allows a more efficient reflection of the electromagnetic waves emitted by the source 30 in the direction of dispersion of the waves onto the material to be heated. In this way, a homogeneous temperature gradient is obtained, as seen in
In this way, a more efficient dispersion level than that seen in state-of-the-art chambers and cavities is obtained through this first implementation, increasing the power x area ratio (kW/m2) and making its application feasible, for example, in the field of ore product heating, which becomes clear by simple comparison between
In agreement with this first implementation of device 1, a microwave material heating method is further provided that comprises the stage of:
A second implementation of the present invention can be seen in
In this second implementation, the device 1 comprises at least one auxiliary cavity 20 arranged inside the main cavity 10 and in the intermediate between the source 30 and the outer portion 3. The auxiliary cavity 20 boundaries an auxiliary region 6 for reflection of at least part of the electromagnetic waves generated by the source 30 to allow further reflection of said waves and to ensure greater dispersion of said waves on the material to be heated.
The auxiliary cavity 20 preferably comprises a rectangular cross-sectional profile of which walls 21 project from a pair of side walls 11 of the housing, parallel to a vertical centerline Y of reference of the cavity 10 and in the direction of the outer portion 3, configuring a substantially “cube” or “box” shape. The side walls 11 of the housing may be angled or not angled, configuring a “bi-pyramidal horn” shape or still others, such as simply rectangular or square.
The upper and lower surfaces of the auxiliary cavity 20 are open to pass the electromagnetic waves provided by the source 30. Other cross-sectional profiles may be used for the construction of the auxiliary cavity 20, depending, for example, on the shape of the main cavity 10, the type of material to be heated, or the desired application.
The auxiliary region 6 for reflecting electromagnetic waves is bounded by the walls of chamber 20 and by its upper and lower apertures. Such a region 6 is intended to reflect the electromagnetic waves in a pattern that disperses them into a region of interest. In this way, a homogeneous heating of the material is obtained.
In agreement with the second implementation of device 1 disclosed above, a method is provided for microwave heating of material comprising the stage of:
Having presented the first and second implementations of the present invention device 1, a third possible implementation involves joining the first and second implementations to obtain a device 1 of particular efficiency, thereby joining the wall shape 11 and auxiliary cavity 20 features to promote even more homogeneous and efficient dispersion of electromagnetic waves.
In agreement with this third implementation of the present invention, it is explained that the methods tied to the first and second implementations can be united into a single method for particularly efficient microwave material heating, which comprises the stage of:
After presenting these three possible implementations of the present invention device 1, features of the device 1 that can be applied to any of the implementations are presented below, on an optional basis, to obtain different beneficial effects in its functionality and use.
Optionally and applicable in any of the aforementioned implementations, the device 1 may comprise, in at least one wall of the main cavity 10, a permanent magnet element 22, for example, comprising ferrite or neodymium. This magnet 22 is intended to change the course of at least part of the electromagnetic waves, specifically the magnetic waves, emitted by the source 30, to complement the dispersion of the waves on the product of interest. The magnet 22 may be, for example, arranged on the bent portions of the walls 11 of the device 1, and at different heights to obtain different electromagnetic wave course change effects depending on the desired application.
To better understand the effects of including the magnet in the present invention device 1, it can be explained that electromagnetic waves are composed of electric and magnetic waves, which propagate orthogonally. When the magnet is applied to the present invention device 1, the north pole magnetic wave is attracted by the south pole magnet, to the direction of the wall, reflecting and changing the path of the magnetic wave. The north pole magnet attracts the south pole wave, reflecting and changing the trajectory of the magnetic wave.
Accordingly, any of the aforementioned methods may further comprise a stage of:
In each implementation, the device 1 mentioned herein may also comprise a projection 13 arranged on the lower portion of its wall or walls 11 and preferably projected parallel to the vertical reference line Y, more preferably enveloping the entire perimeter of the main cavity 10, such as a “skirt.” This projection 13 is intended to prevent electromagnetic waves from exiting externally to the perimeter of the cavity.
Therefore, the present invention device 1, in its implementations shown herein, is capable of efficiently dispersing the electromagnetic waves emitted by the source 30, either by their reflection from the inclined walls of the main cavity 10, or by their reflection in the auxiliary cavity 20, thus allowing homogeneous heating of the material of interest and ensuring the feasibility of using electromagnetic waves for heating/drying products. Particularly, the present invention device 1 is advantageously applicable to chambers for heating/drying of ore products since they allow to replace the use of heat generators by burning fuels such as coal, natural gas, and heavy oil, bringing relevant advantages from the ecological point of view.
Accordingly, the present invention also refers to a chamber 100 for microwave material heating by comprising a device such as the aforementioned in any of its implementations. As seen in
Additionally, the present invention also refers to a system 200 for microwave material heating that comprises a chamber 100, such as the aforementioned. The system 200 is illustrated in a preferred, but not mandatory, the configuration in
Optionally, the system 200 comprises dielectric material plates 202 (i.e., material plates with a high dielectric property) arranged on the conveyor 201 and a plate heating zone C, wherein the material feed zone B is arranged in the intermediate between the plate heating zone C and the material heating zone A. Further, the plate heating zone C comprises at least one chamber 100, such as the aforementioned.
Preferably, but not necessarily, the conveyor 201 is a grid conveyor, and the dielectric material plate 202 is composed of refractory material with high dielectric property, which may be, for example, silicon carbide, manganese dioxide (MnO2) or (CaMn7O12) compounds, or barium titanate.
In a possible implementation of the system of the present invention, the same may be employed on a belt conveyor TC, as illustrated in
Still referring to the aforementioned implementation, since the belt conveyor may traverse diverse regions where there will not necessarily be a control of the personnel circulating in the surroundings of the heating system, it becomes necessary to implement microwave containment measures to prevent the microwaves from leaving the system and reaching the surrounding personnel. In such a scenario, the present invention's heating system may comprise at least one microwave containment housing G around the devices 1. Preferably, the microwave containment housing G functions as a Faraday cage, as illustrated in
Optionally, as shown in
Optionally, as shown in
An example of a preferred implementation having been described, it is to be understood that the scope of the present invention covers other possible variations and is limited only by the content of the appended claims, therein including possible equivalents.
Number | Date | Country | Kind |
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102020012185-5 | Jun 2020 | BR | national |
132021004301-5 | Mar 2021 | BR | national |
Filing Document | Filing Date | Country | Kind |
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PCT/BR2021/050262 | 6/16/2021 | WO |