Drying and crystallizing apparatus for granules

Abstract: A drying and crystallizing apparatus for granules, which is provided in a heating tank formed in a rectangular parallelepiped with a plurality of disc-like partitions forming therebetween a plurality of partitioned spaces across a material inlet and a material outlet , the partitions being rotatably supported on a rotary shaft and provided with agitating vanes respectively, so that the granules are heated efficiently and uniformly by use of a microwave unit without variation in heating, thereby enabling the granules to be dried or crystallized in a short time.

Description: The present invention relates to a drying and crystallizing apparatus for granules, and more particularly to a drying and crystallizing apparatus for granules which are formed mainly of synthetic resin. Conventionally, granules of synthetic resin are dried, or those of petrochemical resin of crystalline synthetic resin are crystallized, in such a manner that usually a sealed processing tank is used and the granules charged therein are supplied with hot air from below. In this case, when a temperature of material becomes higher than a predetermined degree , the granules are softened and mutually fused to make difficult uniform hot-air-drying, or are oxidized at the surface, whereby they are not usable as molding material. Hence, the granules must be dried by hot air at a lower temperature than the predetermined degree , thereby creating the problem in that the time is required to that extent for drying them. The applicant directs his attention to that the granules including water content are heated from the interior by microwaves, so that such heating is convenient for dispersing the water content in the granules onto the surfaces thereof. He has proposed a granule drying and crystallizing apparatus which can dry or crystallize the granules in a short time by using the microwaves and made an application for a patent ( Patent Application No. Sho 62-314920 ). Such internal heating is very efficient, but has a problem in that variation is caused in the heating of granules in the processing tank. The problem is soluble at one side in such a manner that the granules are agitated by rotation of vanes provided in the processing tank. The use of such usual agitating vanes, however, makes not-uniform a residence time of granules in the processing tank, in other words, the time of microwave-heating the granules while staying the same, thereby creating a problem in that variation in the heating still remains. On the other hand, the heating by the microwaves is efficient to quickly reach the temperature of drying the granules, whereby they are heated earlier than dried by vaporizing the water content. As the result, the radiation of microwaves must often be interrupted not to fuse them due to an excessive high temperature during the drying. According , the problem also is created in that an expensive microwave apparatus is obliged to be idle without a full operation, which is very uneconomical. GB-A-2 110 803 discloses drying apparatus which comprises a screw-conveyor which extends axially through a shell to progress material from an inlet to a discharge portion through several treatment sections, one of which is a microwave drying section. Upstream of the microwave drying section is a steam/hot water heating section which removes the bulk of the residual moisture from the material. Downstream of the microwave drying section is a material cooling section. FR-A-2 224 268 discloses treatment apparatus which comprises a heating vessel and a drying vessel. The cylindrical heating vessel is enclosed in a steam-heated envelope and material is moved through the vessel by a number of shaft-mounted blades. Each blade comprises an arm having a plate at its free end, the plates being angled to push the material through the vessel as the shaft rotates. The drying vessel is provided with a through flow of heated air. A main object of the invention is to provide a drying and crystallizing apparatus for granules, which eliminates non-uniform heating caused by irregular reflection of microwaves and variation in the residence time of granules in the processing tank so that the granules mainly of synthetic resin can be heated by the microwaves, thereby performing continuously uniform drying or crystallization. Another object of the invention is to provide an inexpensive drying apparatus for granules, which can improve operating rates and reduce drying time. The present invention is defined in the appended independent claims. One aspect of the present invention relates to drying and crystallizing apparatus for granules, which is provided with a heating tank formed in a rectangular parallelepiped and having at one lengthwise side a material inlet and at the other lengthwise side a material outlet and with a microwave unit for radiating microwaves onto the granules charged in the heating tank, a plurality of disc-like partitions across the material inlet and material outlet of the heating tank to form a plurality of partitioned spaces between the respective adjacent partitions, and agitating vanes which agitate the granules in the partitioned spaces between the respective partitions and transfer them to the adjacent space at the material outlet side. A driving shaft disposed in the heating tank rotates to allow the vanes to agitate the granules within the spaces between the partitions, so that even when the microwaves radiated from microwave units are irregularly reflected in the heating tank, no variation is caused in heating the granules, and since the granules in each space are sequentially transferred by rotation of the agitating vanes toward the adjacent space at the material outlet side, variation in the residence time of the granules subjected to the microwave heating in the heating tank is eliminated. Accordingly, the microwaves radiate onto the granules of synthetic resin continuously charged in the heating tank, thereby enabling the entire granules to be uniformly and continuously dried and crystallized. Another aspect of the present invention is further characterized in that separately from a sealed heating tank having a material inlet and outlet and provided with a microwave unit, a sealed drying tank is provided which has a material inlet and a material outlet and is provided with a diffusor for dehumidifying air from a dehumidifying air feeder, and between the material output of the heating tank and the material inlet of the drying tank is provided connecting means for connecting the heating tank and drying tank, so that the granules heated by the heating tank are dried in the drying tank. The granules charged in the heating tank through the material inlet are quickly heated up to an optinmum temperature to dry them by radiating the microwaves, the heated granules being discharged from the material outlet without waiting for drying, charged into the separate drying tank through the connecting means, and dried in the drying tank by the dehumidifying air from the dehumidifying air feeder. Hence, the drying capacity of the drying tank corresponds to the heating capacity of the heating tank, so that the microwave unit can always demonstrate its capacity without interrupting the microwave radiation, thereby improving its operating rate and enabling the granules to be continuously dried. The above and further objects and novel features of the inveniton will more fully appear from the following detailed description when the same is read in connection with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a schematic longitudinal sectional view of a first embodiment of a drying and crystallizing apparatus for granules of the invention. Fig. 2 is a sectional view taken on the line II-II in Fig. 1, Fig. 3 is a perspective view of part of a driving shaft provided with disc-like partitions, Fig. 4 is a view showing frequency distribution of a residence time, Fig. 5 is a schematic longitudinal sectional view of a modified example of the first embodiment of the invention, and Fig. 6 is a schematic illustration of a second embodiment of the invention, in which the principal portion thereof is shown in section. DETAILED DESCRIPTION OF THE INVENTION Referring to Figs. 1 and 2, a first embodiment of a drying and crystallizing apparatus for granules of the invention is shown, which heats, dries and crystallizes granules by a heating tank 1. The heating tank 1 comprises a top wall 11, a bottom wall 12, both side walls 13, and both end walls 14, and is formed in a rectangular parallelepiped and sealed. A plurality of microwave units 2 provided with waveguides 2a are disposed in series on the top wall 11 so that microwaves can be radiated from the waveguides 2a into the heating tank 1. A material inlet 15 is provided at one lengthwise end of the top wall 11. The bottom wall 12, as shown in Fig. 2, is downwardly semicircularly curved , so that the heating tank 1 is U-like-shaped in section with the bottom wall 12 and both the side walls 13. A material outlet 16 is provided at one lengthwise end of the bottom wall 12 reverse to the material inlet 15, a discharge pipe 18 provided with a rotary feeder 17 continuously discharging therethrough the granules is provided at the material outlet 16, and at the upper portion of the discharge pipe 18 and above the rotary feeder 17 is mounted a dehumidifying air feed pipe 19. In the first embodiment in Figs. 1 and 2, a driving shaft 3 is disposed at the center of the semicircularly bent bottom wall 12. The driving shaft 3 carries a plurality of disc-like partitions 4 for forming the plurality of partitioned spaces S therebewteen and across the material inlet 15 and material outlet 16, is supported rotatably to the heating tank 1, perforates the heating tank 1 lengthwise and at the lower portion thereof, projects at one end at the material inlet 15 side outwardly of the end wall 14, and rotatably connects to a driving unit 20 of a motor or the like. The partitions 4 are mounted on the driving shaft 3 in relation of being spaced lengthwise thereof and at regular intervals and each provided with agitating vanes 5 for agitating the granules in each partitioned space S and conveying them to the adjacent partitioned space S at the material outlet 16 side. Also, the partitions 4 each have an outer diameter slightly smaller than an inner diameter of the semicircularly bent bottom wall 12, are disposed concentrically therewith , and form the partitioned spaces S between the respective adjacent partitions 4. The agitating vanes 5, as shown in Fig. 3, are plate-like-shaped, provided at the outer periphery of each disc-like partition 4, spaced at a phase difference of 120°, and extend in parallel to the driving shaft 3 and toward the material inlet 15. The drying and crystallizing apparatus of the invention in Figs. 1 and 2, while rotating the driving shaft 3 and partitions 4 by the driving unit 20, charges the granules into the heating tank 1 through the material inlet 15. The granules charged in the heating tank 1, while being agitated by the rotating vanes 5, are transferred to the adjacent partitioned space S . In addition, the granules are continuously charged into the heating tank 1 through the material inlet 15 and controlled to correspond to the transfer capacity of each partition 5 to an extent of covering the driving shaft 3 in each partitioned space S . The granules thus agitated and transferred to each partitioned space S are radiated by the microwaves from the microwave units 2 and heated thereby. Water content included in the granules is vapored by heating and exhausted,together with the dehumidifying air fed from the dehumidifying air supply pipe 19,outwardly of the heating tank 1 through the material inlet 15, thereby drying or crystallizing the granules. The rotary feeder 17 is driven to discharge the dried or crystallized granules outwardly through the material outlet 16. Since the granules charged in the heating tank 1, as the above-mentioned, are stepwise transferred to each partitioned space and uniformly agitated therein and then discharged, thereby enabling the variation in heating to be eliminated. Moreover, the granules agitated and sequentially transferred to the adjacent partitioned space S are reduced in variation in the residence time when they stay in the heating tank 1 so as to be heated by the microwaves. Incidentally, as shown in Fig. 3, each disc-like partition 4 is 150 mm in diameter D and spaced apart at an interval of 100 mm, each agitating vane 5 is 70 mm in length l ₁ and 300 mm in width L ₂, so that when granules of petrochemical resin of 3 to 5 mm in grain diameter are transferred at a speed of 60 kg per hour and the residence time of granules aims at 20 minutes, the frequency distribution of the residence time of granules at the material outlet 16 has been measured, thereby obtaining the result as shown in Fig. 4. The frequency distribution of the residence time is obtained in such a manner that, while keeping an amount of granules in each partitioned space S to an extent of covering the driving shaft 3, colored granules discriminated from those to be dried are charged into the heating tank 1 at a predetermined amount every predetermined time to thereby count the number of the colored granules included in the granules discharged from the material outlet 16. As seen from the measurement result shown in Fig. 4, the frequency of discharge for the target residence time of 20 minutes is maximum. In addition, when the partitions 4 are increased in number to increase the partitioned spaces S , the curve of the residence time frequency distribution is made more sharp at the peak, thereby enabling the residence time of granules to be further uniformed. Alternatively, the agitating vanes 5 may be provided at both sides of each partition 4. Furthermore, as shown in Fig.5, the agitating vanes 5 may connect the respective adjacent partitions 4, in which frameworks are formed to improve strength as a whole. It is preferred to provide the agitating vanes 5 at the outer peripheral portion of each partition 4 as in the first embodiment, which vanes may be provided radially inwardly of each partition 4. Furthermore, the agitating vanes 5 are not limited in number and configuration to those in the first embodiment. Alternatively, as shown in Fig.6, it is preferred that a drying tank may be provided independently of the heating tank 1, so that dehumidifying air is supplied to the drying tank for drying the granules. Referring to Fig.6, a heating tank 21, as the same as the heating tank 1 in the first embodiment , is formed in a rectangular parallelepiped, has at one lengthwise side a material inlet 22 and at the other lengthwise side a material outlet 23, and forms at the top wall an opening of a wave guide 25 of a microwave unit 24, is provided at the opening with a partition 26 to thereby partition therethrough the interior of heating tank 21 from that of wave guide 25. The material inlet 22 connects with a material storage tank 27 through a valve 28. A return pipe 31 of a dehumidifying air supply unit 30 to be discussed below is mounted on the upper portion of one side wall of the heating tank 21 at the material inlet 22 side. An opening 34 is provided at the lower wall of heating tank 21 in the vicinity of the material outlet 23,and a punching plate 35 having a large number of orifices through which the granules cannot pass is mounted at the opening 34. Furthermore, a rotary shaft 38, on which a large number of disc-like partitions 36 provided with agitating vanes 37 are mounted , perforates the heating tank 21 and is adapted to rotate by a driving unit 39, such as a motor or the like. A drying tank 40 funnel-shaped at the lower portion and sealed is provided below the heating tank 21, a material inlet 41 is provided at the upper wall of the drying tank 40, a material outlet 42 is provided at the lower end thereof, and a discharge pipe 44 provided with a rotary feeder 43 connects with the material outlet 42. Furthermore, a conical diffuser 45 for dehumidifying air is provided at the inside lower portion of the drying tank 40 and connects with the dehumidifying air supply unit 30 through a blast pipe 46. In addition, the dehumidifying air supply unit 30 is provided with a heater ( not shown ) or the like so as to adjust the temperature of dehumidifying air blown-off into the drying tank 40. The material outlet 23 at the heating tank 21 connects with the material inlet 41 at the drying tank 40 through a connecting pipe 48 having a rotary feeder 47. In addition, separately from the connecting pipe 48, an air connecting pipe 49 is provided between the upper wall of the drying tank 40 and the opening 34 at the bottom wall of the heating tank 21, so that the dehumidifying air blown-off into the drying tank 40 returns to the dehumidifying air supply unit 30 through the air connecting pipe 49, heating tank 21, and return pipe 31. The second embodiment of the drying apparatus constructed as the above-mentioned dries the granules in such a manner that the rotary shaft 38 is driven by the driving unit 39 to rotate the agitating vanes 37 together with the disc-like partitions 36 so that the granules are heated by the microwaves while reducing variation in the residence time, and then discharged from the heating tank 21 by the rotary feeder 47 through the material outlet 23. In this case, the granules in the storage tank 27 are continuously charged into the tank 21 through the material inlet 22 to the extent that the granules are charged slightly higher than the level of rotary shaft 38 in each partitioned space S between the respective pertitions 36. Also, the microwaves from the microwave unit 24 are radiated on the granules in the heating tank 21 through the wave guide 25 to heat them up to the most suitable high temperature required for drying them with the dehumidifying air in the drying tank 40. The heated granules are sequentially discharged by the rotary feeder 47 to the connecting pipe 48 through the material outlet 23 and sequentially charged into the drying tank 40 through the material inlet 41 thereof, so that the granules are dried by the dehumidifying air which is sent from the dehumidifying air supply unit 30 and blown off through the diffuser 45, at which time the granules are dried while adjusting at need the temperature of dehumidifying air. In addition, the temperature of dehumidifying air may be raised or lowered. Then, the dried granules are sequentially discharged from the drying tank 40 by the rotary feeder 43 through the material outlet 42. Accordingly, the granules in the heating tank 21 are quickly heated by radiation of the microwaves up to the optimum temperature and then charged in the separate drying tank 40 to be dried therein by the dehumidifying air. As a result, the drying capacity of drying tank 40 corresponds to the heating capacity of heating tank 21, thereby enabling the microwave unit 24 to be operated without interrupting the microwave radiation,and its operating rate to be improved. Alternatively, the return pipe 31 connected to the heating tank 21 in this embodiment may be open in the atomosphere. Also, the air connecting pipe 49 may alternatively be omitted so as to separately supply the humidifying air to the heating tank 21 and drying tank 40. Although several embodiments have been described, they are merely exemplary of the invention and not to be constructed as limiting , the invention being defined solely by the appended claims.

Claims: A drying and crystallizing apparatus for granules, comprising: (a) an elongated heating tank (1; 21) having at one lengthwise side thereof a material inlet (15; 22) and at the other lengthwise side a material outlet (16; 23), and (b) microwave units (2; 24) for radiating microwaves on said granules charged into said heating tank (1; 21) through said material inlet (15; 22), characterized in that: (c) an agitating unit which is housed in said heating tank for agitating said granules comprises: (c-1) a driving shaft (3; 38) which is disposed horizontally at the lower part of said heating tank; (c-2) a plurality of disc-like partitions (4; 36) which are supported and rotated by said driving shaft (3; 38), said partitions being perpendicular with the axis of said driving shaft and being spaced apart from each other for providing in said heating tank (1; 21) a plurality of partitioned spaces across said material inlet (15; 22) and material outlet (16; 23); and (c-3) agitating vanes (5; 37) mounted on each of said partitions, for agitating said granules in the rotational direction in each of said partitioned spaces, whereby said granules charged into said heating tank (1; 21) are received and agitated in the rotational direction of said agitating vanes (5; 37) in each of said partitioned spaces and whereby, when there arises a difference of elevation between a level of granules in a partitioned space at the material inlet side and a level of granules in an adjacent partitioned space at the material outlet side, with said granules being fed into and/or discharged from the heating tank (1; 21), the difference of elevation causes the granules agitated in the partitioned space at the material inlet side to overflow into the adjacent partitioned space at the material outlet side and thereby said granules charged into said heating tank (1; 21) are transferred to said material outlet (16; 23) while they are agitated in said each of said partitioned spaces. A drying and crystallizing apparatus for granules according to claim 1, wherein said heating tank (1) is provided with a bottom wall (12) semicircular in section, each of said disc-like partitions (4) has a diameter smaller than an inner diameter of said bottom wall (12), said driving shaft (5) is disposed at the axis of said bottom wall (12) and said partitions (4) are disposed concentrically with said bottom wall (12). A drying and crystallizing apparatus for granules according to claim 1, wherein said heating tank (1) is provided at the material output side with dehumidifying air supply pipe (19). A drying and crystallizing apparatus for granules, comprising, (a) an elongated heating tank (21) having at one lengthwise side thereof a material inlet (22) and at the other lengthwise side a material outlet (23), and (b) microwave units (24) for radiating microwaves on said granules charged into said heating tank (21) through said material inlet (22), characterised in that: (c) an agitating unit which is housed in said heating tank for agitating said granules (41) comprises: (c-1) a driving shaft (38) which is disposed horizontally at the lower part of said heating tank; (c-2) a plurality of disc-like partitions (36) which are supported and rotated by said driving shaft (38), said partitions being perpendicular with the axis of said driving shaft and being spaced apart from each other for providing in said heating tank (21) a plurality of partitioned spaces across said material inlet (22) and material outlet (23); (c-3) agitating vanes (37) mounted on each of said partitions, for agitating said granules in the rotational direction in each of said partitioned spaces, whereby said granules charged into said heating tank (21) are received and agitated in the rotational direction of said agitating vanes (37) in each of said partitioned spaces and whereby, when there arises a difference of elevation between a level of granules in a partitioned space at the material inlet side and a level of granules in an adjacent partitioned space at the material outlet side, with said granules being fed into and/or discharged from the heating tank (21), the difference of elevation causes the granules agitated in the partitioned space at the material inlet side to overflow into the adjacent partitioned space at the material outlet side and thereby said granules charged into said heating tank (21) are transferred in order to said material outlet (23) while they are agitated in said each of said partitioned spaces; (d) a drying tank (40) for drying said granules heated in said heating tank (21), said drying tank (40) being provided at the upper portion with a material inlet (41) through which said granules are received, at the lower portion with a material outlet (42) and at an intermediate portion with a diffuser (45) for dehumidifying air; and (e) connecting means (48) for connecting said material outlet (23) at said heating tank (21) with said material inlet (41) at said drying tank (40). A drying and crystallizing apparatus for granules according to claim 4, wherein said heating tank (21) is formed in a rectangular parallelepiped and provided at one lengthwise side thereof with said material inlet (22) and at the other lengthwise side with said material outlet. A drying and crystallizing apparatus for granules according to claim 5, wherein said heating tank (21) is provided with a bottom wall semicircular in section, each of said disc-like partitions (36) having a diameter slightly smaller than an inner diameter of said bottom wall and being disposed concentrically with said bottom wall. A drying and crystallizing apparatus for granules according to claim 4, wherein between said drying tank (40) and said material outlet (23) at said heating tank (21) is interposed an air connecting pipe (49) for supplying into said heating tank (21) a portion of the dehumidifying air blown into said drying tank (40).

Inventors: HAYASHI RYUTARO, ISHIKAWA KANZO, YOSHIMOTO AKIRO, HAYASHI, RYUTARO, ISHIKAWA, KANZO, YOSHIMOTO, AKIRO
Applicants: KAWATA CO LTD, KAWATA CO., LTD
Application year: 1989
Main classification: B29B13
IPC codes: F26B17, B29B13, F26B3