Note: Descriptions are shown in the official language in which they were submitted.
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MODULAR INFRARED IRRADIATION APPARATUS AND ITS
CORRESPONDING MONITORING DEVICES
FIELD OF THE INVENTION
The present invention refers to a modular infrared irradiation apparatus
which employs combustion gas and its respective monitoring devices.
Particularly, the apparatus of the present invention is direcetd to thermal
transfer operations for provide quick and efficient thermal energy transfers
at
high rates as in industrial drying operations of paper making and cellulose
industries. The irradiation apparatus comprises automation means for control
the starting and all steps of the procedure which is performed by such
equipment and permits multiple industrial applications.
BACKGROUND OF THE INVENTION
Technicians of the art, particularly those skilled in the continous fibrous
products manufacturing processes, know that a drying step (or a set drying
steps distributed along the process) is a necessary step for drying coating or
impregnating substances added to the product.
Known drying techniques employ heat transfer by direct contact between
the heat receiver and the planar and/or cylindrical heat source or by means of
hot air blowing.
The Infrared (IR) drying technique is the most preferred because the
direct contact step for heat transfer is avoided. Thus, this embodiment
normally
employed for complementary drying applications in the traditional drying steps
of the art.
For each konwn different drying step, the desired result, e.g., substrate
features, and surface and phisical properties, may differ. Therefore, in view
of
the above, a refined techinique, derived from known embodiments, which is
complemented by IR drying step is seen as the best result maker.
Recently, the use of an IR drying process has been seen as the best
alternative because such techinique is suited to several industrial
applications
and for provide solutions for old problems of the art.
The IR technique has particular features and such features make the
difference when applied to known heat irradiation apparatus of the art. The IR
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generation techniques are basically distinguished in the temperature average
and in the frequence range of the irradiating element.
In the heat irradiation apparatus production, the selection of building
materials determines the IR emission ability of such apparatus in some ranges
of frequence, i.e., metallic irradiation elements generate long and medium
waves. Ceramic irradiation elements at high temperatures generate short and
medium waves. Generally, short waves have best penetration features in
substrates in relation to long waves, and it permits that a substrate be dried
without direct contact and avoinding damage to the dried substrate surface.
The eletromagnetic energy produced at IR frequence bands, if correctly
set, will be absorved by substrate in such manner that the material will
change,
firstly in its initial state by absorbing heat and modifying its temperature.
For
volatile substances like water, the absorbed heat permits the chance of
phisical
state, from liquid to vapor, and thus the drying step occurs by evaporating
all
volatile mass contained in the substrate.
The amount of water to be evaporated from the substrate is a particular
feature of the product and depends on the manfacturing route and the final
application of such product. Therefore the intensity of thermal energy in each
case is to be particularly determined.
IR use as a final controller of remaining volatiles in the substrate, e.g.,
the substrate humidity, is an alternative that depends of the irradiation
element.
If the element is able (or not) to change the heat emission power the process
is
able to dry the substract at the desired level.
Several types of irradiation models as mentioned above are known in the
art. Most of them comprise a metallic frame which enclose irradiation elements
into metal housings, such elements are installed side by side transversally or
alongside of the process direction. The irradiation elements are positioned
near
to the substrate path and at least one plenum air and/or air/combustible gas
mixture distributor is provided.
Irradiation elements are positioned at a minimal distance from the
substrate path in order to obtain a maximum of heat transfer efficiency and
avoid unnecessary substrate distortions, e.g, cause wet bands in the substrate
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due to the temperature differences of the housings in relation to the
irradiation
elements.
Most of equipment known in the art has such minimal distance limited by
the housings. If they are closely positioned, "heat shadows" are created and
it
causes wet bands in the substrate. A good housing positioning is necessary for
avoid such shadows. By other hand, the necessary positioning reduces the
equipment radiation ability and creates an air/combustion gas stream which
makes the substrate drying difficult. Thus for avoid this problem, additional
heat
equipment is provided in order to keep a good global efficiency.
Other problems related to combustion gas mixture quality may occur.
The systems of the art generally employ a not standard combustible gas
mixture composition. Such differences can alter the burning stoichiometry at
the
irradiation elements. So, the flame can return to the inner part of the
equipment
at the plenum zone or at the gas injection tips and cause explosions and the
process is to be interrupted for repairs for long term.
Another problem of the art is the employment of several feeding heat
recovery ducts. Ducts occupy a considerable space in the production plant and
it reduces a best employment of the plant space and makes a new equipment
installation difficult.
Some recent techniques employ irradiation elements made of continous
refractory ceramic plates as a radiation emitter. Such plates are designed for
cover all width of the process and are longitudinally positioned at one or
more
sections. Such arrangement comprises a limitation when the process is to be
fitted for other ends.
Such models presently satisfy IR irradiation quality and operation
maintenace necessities, but some problems are still found:
- Framed housings provide cold zones (shadows) and a bad heat distribution,
thus the irradiation element is to be positioned farer and the global
efficiency is
reduced;
- The power modulation is necessary in some cases; therefore IR emission
bands are moved to large waves region (Planck Law for Black Bodies). This
changes reduces the penetration feature of IR rays, because the way of energy
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is absorbed depends on the length of the wave emitted from the emission
element and it causes temperature gradient differences in the substrate, the
evaporation is not effected and the substrate surface is burned. Depending on
the technique an wave modulation is not possible;
- Equipments found in the art are not suited for permit sample collection from
an
open chamber and the residual oxygen content after the combustion is not
detected.
- Even all safety steps have been taken, all equipment of the art are
potentially
dangerous and an explosion hazard is possible. Irradiation elements
manufacturers of the art consider this possibility hard to occur, thus the
design
of such irradiation elements did not involve safety care.
Industries of the art need safe and low maintenance equipment for
reduce the interruption time for repairs.
SUMARY OF THE INVENTION
According to the above discussed and in view of the above mentioned
problems, the present invention provides a modular IR irradiation apparatus
which employs combustion gas and its respective integrating devices for
automatically control the air/gas mixture, for sequencing the process
starting,
for interlocking the equipment and the corresponding process. Some
modifications in the irradiation modules have been done in order to eliminate
shadow zones and to enhance gas flowability; such improvements are achieved
by means of a fibrous ceramic. The fibrou ceramic have flexible pores through
which the air/gas mixture flows and after the air/gas mixture emerges from an
escape surface an ignition means is driven and a fire line provided and kept
stable over the ceramic escape surface which acts as IR irradiation element at
high frequency bands.
This preferred embodiment permits a safe operation, because the flexible
fibrous ceramic does not resist to pressure, causing minimal intensity
explosions and provides soft fragments when exploded. The modular design
permits multiple arrangements being fitted to any drying processes, enhances
the continous irradiation element operation.
All the above objectives are achieved acorrding to the following steps:
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- Refractory flexible irradiation module comprising stopping means which are
high temperature resistant and avoid shadow zones and side losses of heat at
the burning zone in the ceramic surface;
- Employment of refractory flexible ceramic plates having flexible pores which
5 permit air/gas modulation, the flexible pores permit define the path of the
air/gas
mixture through the ceramic plate. When the flow pressure of mixture is
reduced, part of the pore automatically close and the combustible mixture is
coducted to the surface where the hot fibers are placed. The fibres keep the
combustion active at the surface, multplying IR heating effects. Ceramic
plates
of the art tend to "swallow" the flame causing an inner burning and reducing
the
efficiency of the process and/or loss of the control of the flame and
equipment
explosion.
- Sensors and measuring means are provided for monitoring all steps: Thermal
sensor- safety device applied in the lower face of each flexible fibrous
ceramic
module, more particularly fixed in the support screen of the ceramic plate and
extending to median line of such plate, for monitoring a possible heat flow
inversion due to external factors which cause the "flame swallowing". For
example, a heat reflection means positioned in front of the irradiation
element in
order to return IR energy back to the irradiation element and creating an
ressonance effect for store heat in the irradiation element and make the flow
inversion. This device avoid misemployment problems by blocking the
irradiation element. This provides an extended work life of the ceramic plate.
Oxygen measuring means - Continous measuring based on Zirconinum
oxide. This device collects combustion gases over the burning surface in at
least one module of refractory ceramic, for continous analysis ends,
permitting a
flame optimization a an after buring residual oxygen controlling. Such sensor
is
connected to a LPC ( Logical Program Controller) of the monitoring,
interlocking
and alarming system which is driven when the level of oxygen does not match
with the standard value. Ultraviolet (UIl) Flame detector - It is applied in
the
external face of the metallic frame, more particularly, near to the
combustible
gas inlet, for flame detection, i.e., for combustion detection in the ceramic
modules. The flexible ceramic concentrates the burning in its surface, the IR
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generation occurs basically in the short waves range, including some residue
at
the begining of the UV spectrum which is identified by the UV detector. The UV
detector is assembled as an cathode anode discharge vessel, known in the art,
inserted in a housing or specially designed device for support severe
operation
conditions. The housing have a cylindrical shape made of metallic material
provided with a lower hole and channels for better air circulation.
Refrigeration
air flows from refrigeration ribs and also from the ceramic discharging tube
of
the receptacle body of the sensor, keeping the inner pressure positive and
external particulate material entrance is avoided (the equipment can use two
UV flame detector); Bed - all flexible refractory ceramic modules and the
first
and the second plenum distribution means are positioned in the bed which is
made of metallic plates having two handles and two mirrors and botton caps
and couterventing strips. Between the handles and the bottom caps a safety
system is provided for permit an easy opening of the caps for maintenance or
for avoid bed expanding in case of explosion. The locking system permits
determine the effects of an explosion.
APPLICATIONS AND ADVANTAGES
Several advantages are achieved by means the present invention. The
novel modular IR irradiation means and its eletronic devices permit a better
control during the operation and an enhanced global efficiency for thermal
energy.
Other advantages are as follows:
- Flexible ceramic modules of the present invention permit uniform IR emission
in all burning zone, avoiding shadow zones without irradiation;
- The absence of shadow zones permits that the irradiation surface be placed
near to the substrate avoiding losses caused by air/gas streams and providing
a
collimation cavity for IR emission for avoid radiation scattering.
- Ceramic plates stopping in the irradiation modules comprise other feature of
this invention, since it meets thermal-phisical requirements and avoid energy
dispersion over the limits of burning zone edges.
- LPC can be programmed for logoff some modules when other are still active
and meet substrate width variations requirements.
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- The fiber web has some anisotropic free grade related to a particular
moviment. When the gas passage is forced through the flexible ceramic, other
pores are forced to open avoiding pore saturation, making the pores equivalent
in relation to the conduction ability of the mixture. The average pore
diameter is
automatically adjusted for keep balance between the pores. This permits a gas
volume and the power level modulation and keep the discharge rate controlled
and fitted to the minimum limit.
- The oxygen measuring means application makes possible the residual smoke
collection after the burning for continous monitoring of the residual oxygen
and
this system can detect failure in the combustible gas feeding. Other feature
of
such means is that it is able to keep a high burning efficiency and keep the
previous defined stoichiometry for obtain the desired temperature and IR band
results.
- Two retangular plenum employment as mechanical support of the modules
permits the gas mixture feeding in the modules by means modular valves or
blocking valves, when modifications and/or improvements are necessary.
- The metallic frame building having inner pressure rate and overpressure
alleviating means, meets the safety requirements as the explosionproof
equipment, providing a safe operation for workers and equipment.
DESCRIPTION OF THE DRAWINGS
The present inventio is best defined, but not limited to, according to the
drawings as follows:
Figure 1 is a perspective view of the modular heat irradiation element
provided with some irradiation modules in ready to use position and one module
in exploded view;
Figure 2 is cross sectional view of the IR irradiation element of the
present invention;
Figure 3 is exploded perspective view of a irradiation module, illustrating
all its components;
Figure 4 is a sectional view of an oversized detail of the stopping means
in the ceramic plate;
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Figures 5 and 6, illustrate, respectively, side and sectional views of the
irradiation module;
Figure 7 is a perspective view of part the bed and primary and secondary
plenum distribution ducts;
Figure 8 illustrates the entire bed with more details, in exploded
perspective, showing the positioning of the oxygen measuring means and flame
UV detectors;
Figure 9 is a cross sectional view of the bed, showing the mounting
system with safety device for alleviating the explosion;
Figure 10, is an oxygen measuring means, in a more detailed
perspective view;
Figure 11 illustrates the oxygen measuring means mounted on the IR
modular irradiation element;
Figure 12 is an exploded perspective view of the UV sensor bulbs
support housing; and
Figure 13 is sectional view of the UV flame detector of the invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the Figures, the present invention refers to a MODULAR
INFRARED IRRADIATION APPARATUS AND ITS CORRESPONDING
MONITORING DEVICES, the modular heat irradiation apparatus (1) is directed
to heat transfer operation involving elevated rates of heat to be contoinously
traferred to a receiving substrate, e.g., industrial drying process of fibrous
products as paper or cellulose (L) (Figure 2).
According to the present invention and Figures 1 and 2, the modular heat
irradiation apparatus basically comprises a metallic frame or bed (2) which is
designed for receive a number of irradiation modules (7), according to process
width and in such manner to receiver distribution and support ducts, priamary
plenum (3p), secondary plenum (3s) which possesses gas/ar (G) mixture
feeding outlets (3a) to the modules (7).
The employment of two plena having rectangular shape (3p and 3s)
serve as mechanic support fo the modules (7) in order to position them in such
manner to permit the gas/air mixture (G) feeding in the modules (7) by means a
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modulation/blocking valve (VL) coupled to the primary plenum (3p) or blocking
free directly coupled to the secondary plenum (3s). The module presents an
unique mixture (G) inlet (4) whit can be positioned aligned to the primary
plenum (7v) or secondary plenum (7d), depending on the final application which
can be defined by turning the module 180° and by opening passageway
(3a) of
the primary plenum (3p).
Such procedure can be accomplished even after the original assembling
be concluded when a modification is necessary or when powe control is to be
installed.
Plena (3p, 3s) are fed,firstly by the primary (3p) employing at least one
side duct (G), which is further used by the secondary (3s) by means of an
inner
joint (JR) which is optionally and restricting means (Figure 7).
The bed (2) is made of two mirror joining (LI/LC) having lower laterals (LI)
and axle type fixing supports (4) (Figure 1) which are fixed to the processes
by
means of locking bearings (M), permitting adjsutment of the equipment angle at
the moment of the installation in relation to substrate flow direction (L).
Also, the bed has the upper side (LS) comprising lateral channels for
alleviating thermal dilatation (AD) and resist to temperature variations
between
the upper edge and the lower edge and receiving refractory material (MR) to
the
irradiated IR, in order to define one irradiation cavity(CR), joined the
frontal
face, which is provided with irradiation modules (7). Such modules (7) are
trasnversally positioned to the longitudinal axle of the bed (2) and arranged
side
by side in order to define a regular planar surface. The bed is further closed
by
metallic caps (6) which description will be provided after.
The mirror (EI) of the bed (2) (Figure 1 ) is provided with sealing air inlet
duct (AS) for keep the inner cavity of the equipment pressurized and
refrigerated; such air inlet has an independent feeding and is directed to
avoid
entrance and storing not desired materials and gases in the cavity, protecting
the frame against gas losses. The pressurized air is directed to UV system
refrigeration and venturi system, both detailed in the present appliation.
Irradiating modules (7) can be made in variable dimensions and width,
and according to Figures 3,4,5 and 6 each one of the irradiation modules(7) is
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made of metallic mafierial base receiver(8), containing a feeding hole (9),
positioned and not centrallized in relation to the surtace of such base, for
aligning with other plenum support (3p13s) at the moment of the mounting, just
inversing the module according to the plenum. The mounting at the side of the
5 plenum (3p or 3s) is achieved employing a stopping ring (11) fitted to the
feeding hole (9), which ring permits a good positioning of the module when the
fixation occurs over the distribution plena (3p, 3s) and each module (7) is
fixed
in the plena by screws restraining pins (P).
The base (8) receives at its free edge, a screen (12) containing holes
10 (12a) having suitable dimensions and shapes, in the lower face of the
screen
(12) are fixed at least two sets of sensors of thermal flow (14)
interconnected by
the electronic circuit (13); such sensors extend over the screen to deep
contact
the penetration layer of the ceramic (15) where the sensors are axed thereto.
The sensors are interconnected to an electronic device (14a), which is
connected to the LPC central, not shown.
At the upper face of the screen (12) is positioned a porous flexible
refractory ceramic plate (15), in which median part, under the central line
(Y)
(Figure 6), the thermal flow sensors (14) are kept positioned. The housing
deep
is determined at moment of the mounting.
Each refractory flexible ceramic plate (15) (Figure 4) is made of sealing
means (S) which are high temperature resistant and arranged in thin ceramic
housings (16) and placed at the side faces of the ceramic plate by means of a
high temperature resistant elastomer (17) layer(Figure 4) which is able to
penetrate between the parts (15, 16) in order to produce and anchoring
phenomena, adhering to said parts and avoiding lateral dispersions (D) of
combustible gas in the ceramic plate through the screen holes (12a) by
stopping them. This keeps the burning zone restricted to the face (D1) in the
surface of the ceramic plate (15).
The block comprising the flexible refractoryceramic plate and the thin
ceramic housings (16) are fixed to the screen (12) by means of an elastomer
layer (17) suited to high temperatures, complementing the sealing means of the
irradiation modules (7) and producing a flexible joint which supports natural
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vibrations which occur during the operation of the equipament and fit
different
materials possessing very thermal dilatation coefficients, i.e., the different
ceramic materials and the metallic carcass.
One of this features of the refractory ceramic plate (15) is the flexible
pores (see detail A in Figure 3), where the fiber positioning (F) kept ready
to
move (~, due to forced passage of gas (G); this free movement feature permits
a dynamical distribution of the gas flow through the pores {R) of the fibrous
structure, thus making the pores open and/or closed when necessary,
depending on the use condition and keeping the balance between them. The
gas volume flowing through the ceramic plate is able to be modulated and the
emission power of the irradiation element is indirectly modulated by varying
the
combustible gas volume (G), but keeping active the discharge rate of the pores
compatible to the combustion rate, therefore, the flame is stably positioned
at
the first layers (D1) of the flexible ceramic.
Other feature of the flexible ceramic (15) is that even under mechanical
erosion the above mentioned properties are maitained, because the above
described phenomena, which keeps the flame balance, occurs in the
surroundings of the fire line, i.e., at the first 3mm to 5 mm deep of the
flexible
refractory ceramic plate. Erosion or removal of part of such surface material
does not modify the flame balance which always occurs at the surface (D1) of
the ceramic plate independently of the surface shape.
Another property of the ceramic plate associated to the flexibility feature
and not affected by erosion, as stated above, is the ability of the
irradiation
element resist to dropping contamination, e.g., ink dorps in a continous
painting
process of paper. The drop material at the surface of the irradiation surface
can
be easily removed by mechanic procedures of scratching or abrasion avoiding
other cleaning procedures and the system is quickly restored.
The bed (2) (Figures 1,2 and 8) as previously stated, is made of lower
side metallic plates (LI) having angular flaps (18a), closing mirrors, blind
mirror
(EC) and instrument mirrors (EI) having holes suited to the devices to be
fixed
therein and botton caps (6) having side flaps {6a) a closing flaps (22 and
P1);
such side plates (LI) are alterned with counterventing channels {21) while the
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botton caps (6) have one flap (22) at one side fixed by engaging to one of the
LI
flaps (18), and at the other side, the flap is fixed by means of screws (P1),
therefore is provided one safety devide between the lower side plates (LI) and
the bottom cap (6), the particular geometry feature of the caps permits that
the
flaps (18, 22) be easily unlocked offering an escape area for gases, in the
case
of internal explosion, the cap (6) is fixed to the structure by means of the
screws
(P1) for permitting the removal of the cap for maintenance ends.
Modular heat irradiation apparatus (1) is equiped with automatic lighting
devices and monitoring means, which are interconnected to the LPC, not
shown, such devices comprise the trigger (CT) and sensors of thermal flow
(14), oxygen measuring means (23), and the UV sensor (Figure 13), better
detailed ahead.
Automatic lighting system comprises the assembling of some trigger
electrodes (CT). The lighting is produced by inonizing the air by using a high
tension source which discharges over the bed (2). The triggers are mounted in
a number which is enough for permit the lighting of the irradiation element
even
part of such triggers are disabled.
Thermal flow sensor (14), which position has been previously detailed, is
the responsible for monitoring de heat flow inversion, since each sensor (14)
monitores a maximum temperature differential between the median line (Y) of
each ceramic plate (15) and the temperature of the feeding gas of the module,
the verification occurs at the LPC for turn the equipment off when the
differential
is greater than maximum permitted limit, this would indicate thermal flow
inversion, i.e., the flow is returning to the gas plenum and probably an
explosio
would occur. The thermal flow sensor is also used to indicate an erosion
process in the ceramic plate and the replacement of such plate is necessary.
The Oxygen measuring means (23) (Figuras 10 and 11 ) employ, a
sensor (26) based on Zirconium oxide, which is positioned in one device
containing a temperature controlled chamber (26) (temperature control system
not inidicated), and such device is formed by five tubular bodies (27, 28, 30,
31
and 33) welded (29) one to the other, the set (23) is fixed by a holder (34)
positioned in the inner flap of the upper side (LS). An extension is fixed to
the
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tubular body (28) forming a venturi type system (30), the tube (30) having the
greatest diameter conducts the sealing pressurized air inside the bed to
outside.
When the sealing air passes between the tube (30) and the broader section of
the tube portion (31 ) it is accelerated in order to effect vacuum inside the
portion
(31 ) and in the body (28), providing a vacuum chamber, while the collector
tube
(33) conducts the smokes collected in the inner part of the chamber (28). The
collection tip (35) is coupled to the upper portion of the tube (33) and holes
and
the concetrating flaps (37) are provided in the lower part (36) of such tip.
The
lighting system also employs the the tip (35) as ground contact for discharge
the
trigger.
The oxygen measuring means (23) is applied near to the burning zone,
(D1) in order to continuous analyze the combustion of the irradiation element,
optimizing the burning and controlling the amount of residual oxygen after the
combustible burning. Such sensor is connected to the LPC of the monitoring
system. Parameters of operation are adjusted in view of the desired
application
and the kind of combustible gas is used.
UV detector (24) (illustrated in Figure 1 and more detailed in Figures 12
and 13) can be double assembled, i.e., two flame detector (24) can be for each
irradiation element (Figura 1 ), each detector has an UV sensor bulb which is
commecially available and its respective encapsulating system (39) installed
inside the cooling system (40) extending to collimation cavity of IR emission
(CR) by a ceramic bulb {47) restricting and protecting the sight of the bulb
and
the sight field against obstructing clouds of vapor from the process or
against
UV emissions from other external sources. UV sensors (24) are positioned at
the external side of the the instrument mirror (EI), more particularly fixed
to the
supports (44) which are fixed by tubes which are employed to conduct the
pressurized sealing air inside the support tube fromthe irradiation element
(4) to
the cooling body (40).
Each set of UV detector {24) additionally comprise a cooling body (40)
having ribs (41 ) at its external face in order to provide cooling channels
for keep
the internal housing chamber (42) of the sensors (38, 39) cool; such
protection
comprises a lower hole (43) which is coupled to the metallic box type support
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(44) through which cooling air and connection wires of the electronic
excitation
and monitoring (called flame relay) are conducted.
The ceramic protector tube (47) is fixed to the cooling body (40) by the
flange (45) which possesses inner tips as restraining means (46) of such tube
(47).
A skilled person will see that the scope of the present invention is novel:
irradiation modules, the monitoring performed by the sensors and measuring
means via discrete electronic controls or t_PC, the modular heat irradiator
and
its improved shape, a high efficiency of the heat transfer between the
irradiating
surface and the receiving substrate, the equipment designed for being easily
adapted in any industrial process and all benefical effect achieved by this
means which permit remarked improvements in the volatile removal from
substrates, particularly wet removal from paper ou cellulose drying processes
and the invention concept which permits a long term use of the equipment of
the present invention and reducing maintenance interruptions.
Even the above mentioned invention be detailed for offer a better
understanting, the same is not limited to the revealed applications or
particular
details presently revealed.
Other embodiments and variations of the present scope is intended as
belonging to the present invention.
