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Ferrite's ImageWave™ technology concentrates the microwave energy field in the area around the material to be dried, further increasing the energy efficiency of the system. This technology is proprietary and unique to our microwave equipment partner, The Ferrite Company.

A New, But Mature Technology

Developed shortly after World War II as an outgrowth of radar technology, thousands of high power industrial microwave systems are in daily use around the world. Primary applications are the preparation of human foods, such as cooking foods and tempering frozen meat and butter. They are also widely used in the production of engineered wood products. Cellencor was the first to recognize the unique potential of microwave technology for biofuel production and to bring these solutions to the industry.

Producing Better Animal Feeds

Conventional gas dryers have internal temperatures of 500°F to 1100°F which results in significant damage to protein and amino acids in the DDG/ DDGS. In the Cellencor process, temperatures do not exceed 200°F, so the full nutritional goodness of the DDG/DDGS is preserved.

Additionally, Cellencor's patented enzyme enhancement process can further enrich the DDG/DDGS' nutritional value. Microwave energy breaks down the structure of cellular walls which enhances the activity of enzyme additives. The result is animal feed with higher available energy. In the future, Cellencor plans to offer enzyme mixes tailored for microwave activated feed enhancement.

This process does not shake, bake, burn, or grind your DDG/DDGS. The result is a product that can command a premium price.

System Safety

Systems are engineered to the strictest OSHA and HHS standards for microwave leakage and are continuously computer monitored using numerous safety interlocks and sensors.

Microwave components are all stainless steel and are FDA approved for human food processing. Microwave energy is non-ionizing (i.e., not radioactive).

It has been well established that microwave processing can destroy e coli, listeria, and certain other harmful microorganisms.

Reliability

Microwave systems are relatively uncomplicated with few moving parts and low operating temperatures. There are systems installed over 30 years ago which are still in daily use. Because many components are redundant, if a component goes off-line (a microwave generator, for example) the line can automatically adapt and continue to operate with a slightly reduced throughput. The primary consumables are magnetron tubes and conveyor belts. The Ferrite Company provides 24/7 field service across the US and around the world.

The Cellencor Standard Drying Module

Cellencor has developed a standard baseline 1.2 megawatt drying module which is convenient for planning and estimating installations. In practice, each module can be customized to make it larger or smaller if needed. Typically, multiple modules will be installed side by side in order to provide the processing capacity required.

A simplified block diagram of the system is shown below.

The wet cake (WDG) is transported on a 54" wide Lexan belt through a series of drying cells. Each drying cell is fed microwave energy from four or more 100-kilowatt microwave generators via special conduits called "waveguide". The DDG/DDGS is completely dried in one pass through the line.

Warm, moist air exhausted from the drying cells is passed through an optional condenser. This cools the air and removes a significant amount of water which can be returned to the plant as process and/or makeup water. The pre-heater, which uses heat recovered from the microwave generator cooling system, provides warm dry air to the drying cell air intakes.

A computer controls and monitors every aspect of system operation including process rates and drying levels. The operator can change to any drying profile within minutes.

A near-infrared (NIR) scanner continuously monitors the temperature and moisture content of the dried product to provide feedback to the computer control system. This saves energy and produces a highly consistent product.

Physical Dimensions

In order to maximize space utilization, the microwave generator cabinets are typically installed on a mezzanine above their associated drying cells. Each module is approximately 50 feet long, 10 feet wide (including side access space) and 20 feet tall. It simplifies material handling if multiple units are placed side by side so they are all loaded and unloaded from the same ends. In general, three or four microwave lines can be comfortably installed in the space provided by the removal of an average size rotary kiln dryer.

Plant Installation

Installing microwave drying modules is fairly straightforward. An environment protected from the elements is necessary. A customized material handling system (using conveyors, slide gates, and/or diverters) brings wet cake directly from the plant centrifuge. Another conveyor system transports the dry product to DDG/DDGS load-out or storage.

Utility connections must be provided for electricity and water. The exhaust air processing depends on whether or not a condenser is used, and the exhaust vapor characteristics of the material processed.

Containerized GetMax™ Option

The Ferrite Company offers GetMax™, a complete system pre-installed in two standard 40 foot shipping containers. One container holds the microwave generators and the other holds the drying cells. The containers may be stacked vertically. The maximum power rating is one megawatt, 20% less than a standard Cellencor line. This option may be attractive when there is no space in existing buildings, or for temporary or mobile applications.