Choosing Right Infrared Solution for Application

Technically advancing your traditional heaters or dryer with infrared heaters or infrared based dryers are always has been great decision or making up to quality product requirements of the market with lesser cost and time. It’s important to stop for while to understand and give critical thinking over below points:

  • What advantages will the Infrared heaters/dryers will bring along in my current process?
  • Will it help in reducing the total processing cycle time?
  • What will type of materials, which get processed? 
  • What is the physical, physiochemical property, absorptivity, Size, Microstructure and Optical Properties of material?
  • Can the existing heating/drying system be used?
  • What will be the space requirement for the new IR installation?

There could be thousands of more questions or concern points that arise can arise in your mind when you think of such changes, hence it’s very important to take help or consult experts or heating consultant or search for heating manufacturer, who is expertise in designing and building infrared based heating solution (partnering with company such as KERONE can help you with best suited IR heater/dryer for process requirements).

First and most important aspect in choosing right infrared based heating or drying solution is understand the material that to will be processed inside the Infrared heater/Infrared dryer, as every material absorbs infrared (IR) differently. The generation of heat on material takes place through the absorption and scattering of radiation. When an electromagnetic wave passes through a medium, it undergoes diffraction from the surface of a particle whose refractive index differs from that of the medium. This phenomenon is known as scattering or weakening. The scattering and absorption depends on the size form of particles, micro-structure and optical properties of material under processing and also on the wavelength of the radiation of the Infrared emitter. On the other hand the radiation absorption in material depends mainly on the water content, thickness, and physicochemical nature of the material and wavelength of the radiation.

Hence choosing the correct wavelength for the Infrared heaters is very critical. The infrared emitter which generates or radiates the desired wavelength becomes very important part of the infrared heating/drying systems. Choosing correct emitter ensures the most effective heat work that will yield reduced cycle time i.e. achieve the desired temperature very quickly. To understand the basic IR wavelength requirements it’s important to understand the Planck’s Law, the Max Planck reported that “the spectral distribution of radiation from a blackbody source that emits 100% IR radiation at a given single temperature”. According to Planck the higher the object temperature the greater the amount of IR energy will be produced

Infrared (IR) heaters for efficacious manufacturing

Manufacturing processes is changing day by day, doing business has become very challenging over time and new concepts of manufacturing process improvement had brought traditional way of production and all major and minor steps of manufacturing process under strict scrutiny. Concepts such as process improvement, lean management, Poke-yoke, Six Sigma and Just in time (JIT) have coerced manufacturer/team of experts to study and analyze the every process in terms of time required in every piece of product, space utilization factor, efficiency, economy of scale etc. Different concepts started working on different part of manufacturing processes, such as lean management and process improvement started by analyzing every necessary and unnecessary process involved in complete manufacturing process, entire manufacturing process is divided into small stages and then later every stage is further sub-divided to analyze worthiness of every single man power or machinery and all required steps are taken to improve or eliminate the process step that is not adding value to total manufacturing process and help to improve ROI.

As part of industrial manufacturing process such as heating, drying or welding those required the input process material to heat at desired process to achieve the desired quality output product. The conventional heating/drying techniques which results in required more time and energy to heat the input material, the conventional heating/drying takes longer time hence the batch size must be large as to match the future demand , this require excess inventory. The Conventional heating system heat complete chamber to achieve the desired level of heating at input material, hence this requires large amount of energy to be wasted. The conventional haters are huge in size which required larger floor space.

KERONE, itself have been manufacturing heating solution from last 40years and has witnessed the transformation in manufacturing process, hence to help our clients and society with better and more environmental friendly heating solution, we have adopted new technologies such as Infrared for heating and drying solution.

Infrared heaters/dryers uses infrared frequencies of Electromagnetic spectrum, these infrared frequencies fall just above the visible frequencies, Infrared heaters does not product heat as source but it produces heat at source i.e. material under processing. The infrared heater/dryer produces the heat by using the surface of input material, since it does not required to heat the air for transfer of heat it results in the rapid transfer of heat and causes material to get heated in very short span of time. These capabilities of Infrared heating/drying system help in achieving the more efficacious manufacturing by adding following advantages:

1)      No time is wasted in heating, hence batch sizes are small even it’s suitable for the continuous heating which ultimately no need to maintain large inventory.

2)       Since heat is generated as source itself, so it does not and no air is heated it results in lower energy consumption and it makes it green solution.

3)      As it heats the surface of input material and air temperature is not required to maintain so it does not require large chamber size, hence infrared heaters offer better floor space utilization.

4)      Zoning within the continuous infrared heating system allows not implementing different heating arrangements.

Infrared heaters/dryer had helped the manufacturers to achieve the great level of saving in terms of cost, time and space and makes the manufacturer to produce competitive product.

Things that should be mind while selecting heater

  • There are a horde of things that can affect on the right heating/drying system you business or home need. For instance
  1.  Location and Environmental condition
  2. The availability of space,
  3.  the measure of protection in your dividers and roof,
  4. Type of process
  5.  Input to Heater/dryer and desired output
  6. and how to utilize the heating system
  • All the Above factors have an effect on deciding the right size, Type and technology that will suit your business process needs.
  • Proper sizing is critical. Having a furnace that is excessively small will mean it needs to work additional hard to keep heat the input material, wasteful fuel and bringing on the furnace to destroy sooner.
  • Then again, a furnace that is excessively large will need more control mechanism and manual interference otherwise may destroy the input to be processed
  •  Annual Fuel Utilization efficiency rating also plays important role to tell how better the heater is using the fuel and what are its losses, it helps in getting how much heat is produced by unit of fuel.
  • Automotive controls that helps smart fuel utilization and temperature control for proper speeding at with lesser fuel utilization.
  • Speed and Temperature relation while selecting conveyor based heating system.
  • Ask experts such as KERONE, help its clients by consulting which heating system will suit their requirement best, from its extensive in heating and cooling segment irrespective of vertical you are operating

Application of Infrared in Drying Process

Infrared:
Infrared is an electromagnetic radiation having a wavelength just greater than that of the visible light spectrum but less than that of microwaves. Infrared radiation has a wavelength from about 800 nm to 1 mm, and is emitted particularly by heated objects.
Drying Process:
Drying is a process that consists of the subtraction of water or other solvents material by the process of heating the material and evaporating the content. This process is often used before packaging the final product. To be considered “dried”, the final product must be solid, in the form of a continuous sheet (e.g., paper), long pieces (e.g., wood), particles (e.g., cereal grains or corn flakes) or powder (e.g., sand, salt, washing powder, milk powder).
Infrared in Drying:
One approach to enhance drying operations is to include or use infrared energy. Infrared energy could be produced by electric or gas infrared heaters or emitters. Every energy source has preferences and disservices. Regularly, gas infrared frameworks are more lavish to purchase on the grounds that they oblige security controls and gas-taking care of gear, however they frequently are less costly to run in light of the fact that gas typically is less expensive than power. Gas infrared is regularly a decent decision for applications that oblige a considerable measure of energy. Items, for example, nonwoven and material networks are cases where gas frequently is a decent decision.
Gas IR heaters create an infrared wavelength that is promptly ingested by the water in the sheet. This prompts a higher temperature and a drying proficiency build that can’t be copied by conduction and convection temperatures alone.
By difference, electric infrared is likely better for delicate substrates, for example, film and certain fabrics, where great control and consistency is needed. Electric infrared heaters might be separated into different, independently controlled temperature zones with tolerances as tight as +/ -1Of.
Both electric and gas infrared typically are controlled by thermocouple feedback control loops that regulate the electrical power or fuel mixture going to the infrared heaters. For more precise control, temperature feedback from the product using an optical pyrometer is used.
The IR heating system for the process of drying is depicted in the below picture

Where to find help in selection of Best Infrared heater?
The experts such as KERONE with the team of experts can help with the best suited Infrared heaters for your process need. For details visit www.kerone.com .