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Tri-Phase has developed a new revoluntary ultra efficient drying technology that may be applied to a wide variety of dr

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Tri-Phase has developed a new revoluntary ultra efficient drying technology that may be applied to a wide variety of dr

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    1. I’m Steve Shivvers, President of Tri-Phase Drying Technologies We have developed a new platform drying technology that will cut drying energy costs by ½ or more.I’m Steve Shivvers, President of Tri-Phase Drying Technologies We have developed a new platform drying technology that will cut drying energy costs by ½ or more.

    2. Tri-Phase is a spin off from Shivvers Manufacturing, Corydon, Iowa, USA. Shivvers has been making grain dryers for over 40 years.Tri-Phase is a spin off from Shivvers Manufacturing, Corydon, Iowa, USA. Shivvers has been making grain dryers for over 40 years.

    4. Many industrial dryers operate in the 2000 BTU/pound of water evaporated range (4650 kJ/Kg) . We can move this down to the 500 – 600 BTU range (1160 – 1400 kJ/Kg). Lower if one wants to add the complexity of a heat pump option.Many industrial dryers operate in the 2000 BTU/pound of water evaporated range (4650 kJ/Kg) . We can move this down to the 500 – 600 BTU range (1160 – 1400 kJ/Kg). Lower if one wants to add the complexity of a heat pump option.

    5. How does it work? 1st we heat the product without doing any drying, with a counter flow heat exchanger. -- hot fluid comes in here & exits cool -- cool product enters here & exits hotHow does it work? 1st we heat the product without doing any drying, with a counter flow heat exchanger. -- hot fluid comes in here & exits cool -- cool product enters here & exits hot

    6. Then we dry the product through evaporative cooling, putting a small amount of unheated outside air in at the bottom. This is also a counter flow process. -- hot humid air then exists the top -- cool, dried product exits the bottom – no heat is lost in hot exhaust productThen we dry the product through evaporative cooling, putting a small amount of unheated outside air in at the bottom. This is also a counter flow process. -- hot humid air then exists the top -- cool, dried product exits the bottom – no heat is lost in hot exhaust product

    7. Then we reclaim most of the heat in another counterflow air to fluid heat exchanger. -- hot humid air enters here and exits cool -- cool fluid enters here and exits hot -- water condenses out -- the add some heat & around and around the process goesThen we reclaim most of the heat in another counterflow air to fluid heat exchanger. -- hot humid air enters here and exits cool -- cool fluid enters here and exits hot -- water condenses out -- the add some heat & around and around the process goes

    8. We recapture 60 – 75 % of the heat. REPEAT LAST 4 SLIDES. Let’s go over this again.We recapture 60 – 75 % of the heat. REPEAT LAST 4 SLIDES. Let’s go over this again.

    9. Here is the process diagram for the basic Tri-Phase Process. Heating Zone (a counter flow heat exchanger) Drying/Cooling Zone (a counter flow heat exchanger) Air to Fluid Heat Exchanger (a counter flow heat exchanger) Heater That is all there is to it……..actually quite simple concept. One important limitation of the basic process that I need to point out is that the points of moisture removed per pass is limited by the amount of heat one can pump into the product being dried. For most products it ends up in the 5% MC removal per pass.Here is the process diagram for the basic Tri-Phase Process. Heating Zone (a counter flow heat exchanger) Drying/Cooling Zone (a counter flow heat exchanger) Air to Fluid Heat Exchanger (a counter flow heat exchanger) Heater That is all there is to it……..actually quite simple concept. One important limitation of the basic process that I need to point out is that the points of moisture removed per pass is limited by the amount of heat one can pump into the product being dried. For most products it ends up in the 5% MC removal per pass.

    10. This is the prototype dryer that has proven the process & that multiple drying experts have written papers on. This is a rotary drum version, using indirect contact to heat the material.This is the prototype dryer that has proven the process & that multiple drying experts have written papers on. This is a rotary drum version, using indirect contact to heat the material.

    11. Here you can see the sections inside the rotary drum and the heating fluid coils.Here you can see the sections inside the rotary drum and the heating fluid coils.

    12. The efficiency of the process depends upon Operation Temperature of the Heating Fluid and the effectiveness of the three counter-flow heat exchange processes. With an approach differential of all three exchangers of 15 degree F, the green line, theory predicts about 420 to 580 BTU/pound of water evaporated. With delta T of 10 degrees F, the blue line, it is from 300 to 380 BTU/pound of water evaporated. There will be some heat losses and actual dryers will not perform quite this well.The efficiency of the process depends upon Operation Temperature of the Heating Fluid and the effectiveness of the three counter-flow heat exchange processes. With an approach differential of all three exchangers of 15 degree F, the green line, theory predicts about 420 to 580 BTU/pound of water evaporated. With delta T of 10 degrees F, the blue line, it is from 300 to 380 BTU/pound of water evaporated. There will be some heat losses and actual dryers will not perform quite this well.

    13. The basic process has a limitation of around 5 points MC removal per pass due to the limited amount of heat one can put into the wet product. This configuration overcomes this limitation by back mixing (reflux) a portion of the product. Note also that here, only dried product is flowing through the heating zone.The basic process has a limitation of around 5 points MC removal per pass due to the limited amount of heat one can put into the wet product. This configuration overcomes this limitation by back mixing (reflux) a portion of the product. Note also that here, only dried product is flowing through the heating zone.

    14. This configuration uses the process diagram we just saw. It will dry any flowable particulate that will flow down through the ducts when in it’s fully dried condition. -- we modify a mixed flow tower dryer to become our product heat exchanger -- use a Shivvers Dri-flo for the drying/cooling chamber -- use a commercially available heat exchanger -- assemble the system together for a Tri-Phase dryer We back mix the fully dried exit product -- exits here, goes into the product heat exchanger here -- mixes with incoming wet product here as it enters the drying chamber Note that only fully dried product is flowing thru the product heat exchanger, allowing this configuration to be used for many products.This configuration uses the process diagram we just saw. It will dry any flowable particulate that will flow down through the ducts when in it’s fully dried condition. -- we modify a mixed flow tower dryer to become our product heat exchanger -- use a Shivvers Dri-flo for the drying/cooling chamber -- use a commercially available heat exchanger -- assemble the system together for a Tri-Phase dryer We back mix the fully dried exit product -- exits here, goes into the product heat exchanger here -- mixes with incoming wet product here as it enters the drying chamber Note that only fully dried product is flowing thru the product heat exchanger, allowing this configuration to be used for many products.

    15. Here are just a few of the drying applications for the configuration we just looked at.Here are just a few of the drying applications for the configuration we just looked at.

    16. An example application is the drying of DDGS in a corn ethanol plant. We continue to use the typical 1st stage dryer rotary drum dryer handling the very wet product. We can do a lot of back mixing and handle 38 – 40 % MC coming out of a single stage dryer as in Option B. Or less back mixing and handle 20 – 22 % MC as in Option A.An example application is the drying of DDGS in a corn ethanol plant. We continue to use the typical 1st stage dryer rotary drum dryer handling the very wet product. We can do a lot of back mixing and handle 38 – 40 % MC coming out of a single stage dryer as in Option B. Or less back mixing and handle 20 – 22 % MC as in Option A.

    17. For a corn ethanol plant, they can discard their existing fully functional 2nd and 3rd stage rotary drum dryers. Replace them with a Tri-Phase system. Gives 3 year payback based on energy savings alone.For a corn ethanol plant, they can discard their existing fully functional 2nd and 3rd stage rotary drum dryers. Replace them with a Tri-Phase system. Gives 3 year payback based on energy savings alone.

    18. Here, for a 50 million gallon per year corn ethanol plant, they can save $1,360,000/year if fuel cost is $7/MMBtu.Here, for a 50 million gallon per year corn ethanol plant, they can save $1,360,000/year if fuel cost is $7/MMBtu.

    19. Uniform low product temperatures ……….180 F or lower if you want ……….preserves excellent quality. Minimal emissions due to low operating temperatures. Uniform low product temperatures ……….180 F or lower if you want ……….preserves excellent quality. Minimal emissions due to low operating temperatures.

    20. One key fact that I want to point out is that many different types of dryers may be modified to utilize the Tri-Phase process. Then I list them. This allows the process to be used to dry many, many different types of products. One key fact that I want to point out is that many different types of dryers may be modified to utilize the Tri-Phase process. Then I list them. This allows the process to be used to dry many, many different types of products.

    21. Here is another variation on the basic process. Here we take the exhaust air, extract heat from it at A, and feed it back into the system. There are various points in the system where the heat may be added, such as at 1 or 2. A relatively small heat pump capacity is required, due to the low overall heat requirements of the system. Also gives zero exhaust emissions.Here is another variation on the basic process. Here we take the exhaust air, extract heat from it at A, and feed it back into the system. There are various points in the system where the heat may be added, such as at 1 or 2. A relatively small heat pump capacity is required, due to the low overall heat requirements of the system. Also gives zero exhaust emissions.

    22. Here is another major variation of the process. Where we use solid media………think of ceramic pellets with iron fillings embedded. Here we are heating the product with the hot solid media, and drying & cooling the mixture simultaneously. Since we can vary the ratio of solid media to wet product, this allows removing large moisture contents per pass as we can pump a lot of heat into the mixture. This diagram also shows a heat pump option on it. Here is another major variation of the process. Where we use solid media………think of ceramic pellets with iron fillings embedded. Here we are heating the product with the hot solid media, and drying & cooling the mixture simultaneously. Since we can vary the ratio of solid media to wet product, this allows removing large moisture contents per pass as we can pump a lot of heat into the mixture. This diagram also shows a heat pump option on it.

    23. Here is a physical implementation of the solid media process, using a modified rotary drum as the drying/cooling chamber. This version is well suited for the drying of biomasses such as manures and municipal waste sludge.Here is a physical implementation of the solid media process, using a modified rotary drum as the drying/cooling chamber. This version is well suited for the drying of biomasses such as manures and municipal waste sludge.

    24. Multiple pending patents. Our first patent has been granted.Multiple pending patents. Our first patent has been granted.

    25. Multiple drying experts have written papers on the process. Visit our website to read the papers.Multiple drying experts have written papers on the process. Visit our website to read the papers.

    26. We are looking for the right facility to install the 1st commercial DDGS dryer at. We seek partners who would like to help us further develop the technology for various applications. Involvement of universities are welcomed. We seek to partner with or license to interested OEM Dryer Manufacturers. We are looking for the right facility to install the 1st commercial DDGS dryer at. We seek partners who would like to help us further develop the technology for various applications. Involvement of universities are welcomed. We seek to partner with or license to interested OEM Dryer Manufacturers.

    27. Again, here is a table showing the energy use of typical dryers. Most of your dryers probably operate in the 1400 to 2000 BTU/pound of water evaporated range. We can move this down to the 500 – 600 BTU range.Again, here is a table showing the energy use of typical dryers. Most of your dryers probably operate in the 1400 to 2000 BTU/pound of water evaporated range. We can move this down to the 500 – 600 BTU range.

    28. Thank You.Thank You.

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