Powder and bulk solids manufacturers can incur high energy rates due to the nature of production. From industrial dryers to rotary kilns, there are several pieces of essential equipment that consume high volumes of energy. When the material has an improper moisture content, it can lead to extended use of this equipment and higher energy rates. Implementing a hydration sensor can help reduce energy costs, and improve product quality.
Powders and Bulk Solids Energy Use
There are many necessary equipment pieces in the powders and bulk solids industries that use high amounts of energy. Large industrial dryers are mainly used in the powders and bulk solids industries. This thermal processing of heating, drying and cooling is vital to the production process which usually uses pneumatic conveying to transport materials. Pneumatic conveying utilizes air pressure to transport, which also uses energy for compressed air. Mechanical engineering is used in the manufacturing processing for mixing, blending and the reduction of size of the product to ensure uniform consistency. Indirect heating dryers use large amounts of energy to process the materials and guarantee their characteristics are at correct levels for the end user. Many powders and bulk solids manufacturers are concerned with reducing energy costs and energy efficiency is a constant area of focus and improvement throughout the industry. Industrial dryers can generate energy bills that can reach thousands of dollars each month. By optimizing the dryer with known moisture value before and after the drying process, the user has the potential to save large amounts of money instantly. The energy consumption used by the pneumatic conveying process is influenced by aspects such as the production line design, line speed and the air velocity being used.
High Energy Use Equipment
The powder and bulk solids industries rely on several key types of equipment to produce high-quality products. Unfortunately, much of this equipment uses high levels of energy. This drives up costs and reduces revenue. Combining several of these equipment pieces on the line can have major effects on energy consumption.
Pneumatic Conveyors
Pneumatic conveyors use compressed air or suction to transport powders and bulk solids through pipelines. This can be energy intensive, depending on the distance the material needs to travel and flow rate. Accessing clean and compressed air does not come at low costs.
Rotary Kilns
Rotary kilns are used for processing materials in high temperatures. They function with constant heating and rotation, which needs large amounts of energy for use. Rotary kilns are popular for use with very fine powders.
Tumble Blenders
Tumble blenders are used for mixing and blending products. These are large industrial machines that use significant amounts of energy to operate. The longer the material needs to blend, the more energy that is consumed.
Dryers
Dryers are used to remove moisture from products. They consume a substantial amount of energy. Measuring the moisture content before and after the dryer allows the user to know the exact temperature and amount of time needed. This allows the dryer to be as efficient as possible, while using the least amount of energy.
Bucket Elevators
Bucket elevators are used to lift and transport bulk materials. The elevator consists of several buckets that are continuously moving powders and bulk solids. This method can use a large amount of energy, depending on the distance and speed of the line.
How MoistTech Aids in Reducing Energy Costs
MoistTech’s sensors aid in reducing energy costs by enabling real-time moisture monitoring, which allows for immediate process adjustments and optimizing dryer and oven control. This can lead to reduced fuel consumption and waste. The IR-3000 sensor uses Near-Infrared (NIR) technology to measure the moisture content of materials. Having real-time feedback permits the operator to instantly perform process adjustments to minimize energy consumption and waste while also enhancing product quality. The IR-3000 is guaranteed not to drift, and it will never need re-calibration. It can catch out-of-tolerance readings quickly. Thanks to contactless measurements, there is no waste from samples. There are several benefits to using a hydration monitor, such as energy consumption savings and product improvement.
Real-Time Moisture Monitoring
MoistTech’s IR-3000 sensor provides continuous, on-line moisture measurements. This gives operators instant feedback on moisture levels in various materials. Other hydration monitors require line downtime, which delays production.
Optimize Drying Processes
By accurately monitoring moisture content, operators can optimize drying processes. When material is over-dried or under-dried, it can lead to energy waste. The IR-3000 lets operators see precise moisture data for an optimized drying process.
Precision Oven and Dryer Control
The real-time data from IR-3000 sensors allow for precise control of ovens and dryers. Lower energy consumption and a higher-quality product can be achieved by ensuring the materials are dried to
Reduced Fuel Consumption
By optimizing drying and other processes, the IR-3000 can significantly reduce fuel costs associated with heating and drying. Equipment can consume high volumes of energy. When the moisture content is monitored, it can cut back on fuel consumption since the equipment will not need to operate longer than necessary.
Minimize Waste
The NIR3000 prevents over-drying and under-drying. This minimizes waste and rework, which further contributes to cost savings. Wasted product can have a significant impact on revenue.
Enhanced Product Quality
Precision moisture control ensures consistent product quality that can lead to higher yields. It can also reduce costs that are associated with rework and scrap. Use a moisture measurement sensor to boost the quality of powders and bulk solids.
Contact MoistTech Today
Add a hydration sensor to your line to start reducing energy costs. Contact MoistTech today for a quote. Our team of experts can answer any questions you may have regarding moisture measurement.