EUROPEAN ROADMAP OF PROCESS INTENSIFICATION

- TECHNOLOGY REPORT -

TECHNOLOGY: PULSE COMBUSTION DRYING

TECHNOLOGY CODE: 4.1.4

AUTHOR: Tadeusz KUDRA, CANMET Energy Technology Centre,

Varennes, QC, Canada J3X 1S6

Table of contents

1. Technology
1.1 Description of technology / working principle
1.2 Types and “versions”
1.3 Potency for Process Intensification: possible benefits
1.4 Stage of development
2. Applications
2.1 Existing technology (currently used)
2.2 Known commercial applications
2.3 Known demonstration projects
2.4 Potential applications discussed in literature
3. What are the development and application issues?
3.1 Technology development issues
3.2 Challenges in developing processes based on the
technology
4. Where can information be found?
4.1 Key publications
4.2 Relevant patents and patent holders
4.3 Institutes/companies working on the technology
5. Stakeholders
5.1 Suppliers/developers
5.2 End-users
6. Expert’s brief final judgment on the technology

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1. Technology
1.1 Description of technology / working principle
(Feel free to modify/extend the short technology description below)

The term pulse combustion (PC) originates from the intermittent (pulse) combustion of the solid,
liquid or gaseous fuel in contrast to the continuous combustion in conventional burners. Such
periodic combustion generates intensive pressure, velocity, and to certain extent, temperature
waves propagated from the combustion chamber via a tailpipe to the process volume (applicator)
such as a drying chamber. Because of oscillatory nature of the momentum transfer, pulse
combustion intensifies the rates of heat and mass transfer thus accelerates drying rates.
The controlling mechanism behind the operation of a pulse combustor is a complex
interaction between an oscillatory combustion process and acoustic waves that are propagated
from the combustor. Pulse combustion starts when fuel and combustion air are drawn into the
combustion chamber, mixed to form an explosive mixture, ignited by a spark plug, and combust
instantly in the explosion-like burning. At this moment, the air and fuel inlet ports are closed
which results in the rapid pressure raise. This pressure forces the combustion products to flow
out through the tail pipe to the dryer. As the hot flue gases flow out, the resulting outward
momentum causes the pressure in a combustion chamber to drop to the minimum so the inlet
ports open, which admits fresh fuel and air into the combustion chamber. This new charge ignites
itself due to contact with remnants of hot flue gases left in the tailpipe from the preceding cycle
which reenter the combustion chamber during the minimum pressure period. These combustion
cycles repeat at a natural frequency based on the geometry of the combustion chamber and
characteristics of the tailpipe which, along with the dryer, ensures self-sustained oscillatory
operation of the pulse combustor.

Fig. 1. Pulse combustor with flapper valves – principle of operation.

Typically, pulse combustors oscillate with frequencies that vary from 20 to 200 Hz. Pressure
oscillations in the combustion chamber of ± 10 kPa produce tailpipe velocity oscillations of
nominally ± 100 m/s and the gas jet velocity at the tailpipe exit pulsates from approximately 0 to
100 m/s. The input power for commercially available pulse combustors ranges from 20 to 1000
kW.
The major function of the pulse combustor in a drying system is to supply heat for
moisture evaporation, and to generate large-amplitude high-frequency pressure pulsations within
a drying chamber (e.g., rotary dryer), which enhances the drying rate. The advantage of a strong
oscillating hot gas jet from a tailpipe has also been taken to promote dispersion of the feed,
which is especially advantageous when drying biomaterials. Thus, in pulse combustion spray
dryers the sound energy generated in a pulse combustor is used primarily for atomization of the

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liquid feed, which accelerates convective drying due to extended surface area of the liquid spray
in addition to the thermal effect of the hot gas jet. The dryer can handle slurries (with solids up to
2 mm in diameter and up to 10 mm in length) with viscosities up to 16000 cP as well as solutions
with viscosities up to 300 cP. In pneumatic dryers, the pulse combustion allows processing of
wet, clumps-forming materials such as sawdust, corn fibers, spent grains, paper sludge with size
of up to 25 mm.

1.2 Types and “versions”

(Describe the most important forms/versions of technology under consideration, including
their characteristic features, differences and similarities)

A pulse combustor (PC) is an integrated part of any pulse combustion dryer. Pulse
combustors may be categorized into three distinct classes according to the specific acoustic
system on which their operation depends, namely: quarter valve PC, Helmholtz PC, and
Rijke-tube PC. Without going into details, the pulse combustors consist of the inlet section,
the combustion chamber, and the tailpipe. The inlet section admits fuel and combustion air
which is burned in a combustion chamber and flue gasses exit the combustor through the
tailpipe. The inlet section is equipped either in mechanical valves or in aerodynamic valves to
prevent the flow of combustion products out of the pulse combustor through the combustor
inlet during the positive pressure phase of the pulse combustion cycle.
The mechanical valves are designed as reed valves made from thin-sheet spring-
steel, flapper valves, flapper valves that are not controlled through spring action but instead
move freely, and rotary valves of various design, which periodically seal and open the inlet
section according to the running frequency of the pulse combustor.
The aerodynamic valves have a specially designed inlet (e.g., a profiled orifice in the
inlet pipe, contoured diffuser, or a shrouding duct) in which the fluid flow characteristics act as
a physical barrier (fluid diode) to the backflow of combustion products. Such pulse
combustors are termed the valveless combustors.
Some pulse combustors may be operated in a self-aspirating mode thereby eliminating
the need for a fan to supply combustion air unless flue gases have to be diluted to reduce the
processing temperature.
To excite large-amplitude pulsations in a dryer, the pulse combustor must operate at the
same frequency as one of the natural acoustic mode frequencies of the drying chamber. Such
resonance driven drying is achieved either by a trial and error method in a pilot scale apparatus,
or by using a frequency-tunable combustor which actively follows the variations in the amplitude
of pressure pulsations in the applicator.
The pulse combustor in a drying system can be used alone, or in combination with a
conventional burner. The primary function of the pulse combustor is then to serve as a "speaker"
which excites resonant pulsations in a drying chamber thereby improving the dryer performance.
Typical configurations of pulse combustion dryers are: spray dryers, rotary dryers,
pneumatic dryers, and dryers with large-size chambers such as vertical or horizontal cylinders as
shown in Fig. 2.

Fig. 2. Basic configuration of Pulse-Dryer with valveless burner

(Designed by Pulse Drying Systems, Inc., Portland, OR, USA)

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1.3 Potency for Process Intensification: possible benefits
(In Table 1 describe the most important documented and expected benefits offered by the
technology under consideration, focusing primarily on energy; CO2 emission and costs,
providing quantitative data, wherever possible. Add other benefits, if needed).

An analysis of the reported data indicates that the pulse combustion drying, as compared to
classical (continuous) drying, enables one to:
- increase the drying rate by a factor of 1.2 to 3, depending on the configuration of
PC dryer,
- reduce unit air consumption by up to 30%,
- eliminate distribution of characteristic process parameters (e.g. temperature,
concentration, moisture content) within the dryer which improves the product quality,
- lower gas and product temperatures during processing,
- handle sticky materials which form lumps or aggregates without mechanical mixing or
disintegration,
- disperse liquids, slurries and suspensions without the need for a disk atomizer or high
pressure nozzle,
- lower air volumes discharged to the atmosphere.
Some quantitative data, which validate the generalized features, are presented in Table 1.

Table 1: Documented and expected benefits resulting from technology application

Benefit Magnitude Remarks

Higher combustion intensity
3 10000-50000 100-1000 (steady-state combustion)
(kW/m )
Higher efficiency of burning
90-99 80-96 (steady-state combustion)
(%)
Lower CO concentration in
0-1 0-2 (steady-state combustion)
exhaust (%)
Lower NOX concentration in
3 10-70 100-7000 (steady-state combustion)
exhaust (mg/m )
Higher noise level (dB) 110-130* 85-100 (steady-state combustion)
Quantitative data for a single PC spray dryer compared to a conventional spray dryer
with pressure atomizer (Mujumdar and Wu, 2004)
Lower energy consumption
in PC spray dryer (kJ/kg 3300 5501 kJ/kg H2O in conventional spray dryer
H2O)
10
Energy savings (kJ/year) 1.6 x10 PC spray dryer over conventional spray dryer
CO2 abatement (t/year) 795 PC spray dryer over conventional spray dryer
Lower capital cost ~ 4x*** Relative to conventional spray dryer
* 70 dB is reported for some novel pulse combustors
** Based on literature data (Mujumdar and Wu, 2004) and typical pulse combustion spray
dryer with 1000 kg/h of evaporative capacity operated 24/300 (Pulse Drying Systems, Inc.)
*** Estimated for 15x smaller dryer volume (Mujumdar, 2007; Chapter 53) as results from higher
evaporation intensity in PC spray dryer (Mujumdar and Wu, 2004).

1.4 Stage of development

Even though pulse combustion dryers are in the market for years (First Dehydrated Poultry
Waste Drying Site was established in 1974 by Sonodyne Industries, Newberg, OR, USA) the
design and operation of pulse combustion dryers still belongs to art rather than science,
mostly because of complex phenomena involved in pulse combustion and interaction of the
sonic waves with the drying chamber and the drying material. As a result, the trial-and-error
approach has been used by manufacturers to design a variety of commercial pulse
combustion dryers. It became a standard procedure to perform drying tests in a pilot unit to
identify drying conditions and modify the design, if needed. Such pilot units are operated by
Pulse Drying Systems (Portland, OR, USA), Novadyne Ltd. (Hastings, ON, Canada), and
TM TM
Pulse Combustion Systems (San Rafael, CA, USA). The Pulse Combustion Systems
offers toll drying service. Every university listed in Table 8 has the experimental pulse
combustion dryer, and research is oriented towards process simulation using mathematical

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models validated by experiments. The exception is National University of Singapore where
modeling and simulation is performed using data generated by others.
Note: Much research is devoted to particularities of the pulse combustion process
and to the design of pulse combustion burners. However, presenting these research topics
and listing the institutions involved is outside the scope of this report which deals only with
pulse combustion dryers.

2. Applications

2.1 Existing technology (currently used)

(Describe technology (-ies) that are conventionally used to perform the same or similar
operations as the PI-technology under consideration)
Pulse combustion dryers belong to the class of direct-heated dryers where the drying gas
consisting of fresh air, recycled air and the hot combustion gases from a burner is in direct
contact with the material to be dry. Direct firing is most commonly applied in textile industry,
paper manufacture, chemicals, and agri-food production.
Basically, pulse combustion burners can replace continuous burners in direct-heated
dryers. Examples of proven industrial applications of pulse combustors are spray dryers,
rotary dryers, fluid bed dryers and flash (pneumatic) dryers. However, the application of pulse
combustion can fit well other drying technologies such as impingement drying, drying in
impinging streams, drying in spouted bed, or conveyor belt drying.
Pulse combustion may be incorporated into a dryer at the design stage, or it may be
retrofitted to an existing dryer but in this case not all advantages of pulse combustion (e.g.
acoustic resonance) can be fully taken.

2.2 Known commercial applications

(Is the technology broadly applied on commercial scale? In which process industry sectors is
the technology most often applied: large volume chemicals – specialty chemicals & pharma –
consumer products – ingredients based on agro feedstocks? What is the estimated number
of existing applications? In Table 2 provide the most prominent examples of realized
applications and provide their short characteristics)

Based on information provided by 3 major dryer manufacturers who report on 18 pulse

combustion dryers sold to industry, the technology can be considered as commercially viable,
yet not broadly applied in view of over 150 raw materials tested in a pilot unit rated at 1
ton/hour of evaporated water, and found to be suitable for pulse combustion drying
(http://www.pulsedrying.com/experience.html). Pulse combustion dryers were positively
tested for minerals and chemicals (e.g., iron oxide, magnesium oxide, boric acid, copper
concentrate, sodium sulfate, titanium dioxide, calcium carbonate, kaolin, perlite, carbon black,
latex, detergents, coal fines, calcium carbonate, diatomaceous earth, adhesives, organic
polymers), food and agri-products (e.g., instant coffee, apple pumice, fish meal, cocoa
powder, whole eggs, corn syrup, whey, lactose, starch, gluten, animal blood, molasses),
biomaterials (e.g., soy protein, single cell protein, yeast, detergents, spirulina algae, vitamins,
antibiotics, biopesticides). Pulse combustion drying is most often applied in agri-food, large
volume and specialty chemicals, and semi-solid wastes.

Table 2. Industrial-scale applications of the Technology (existing and under

realization)
Year
Company - Short Production
of
Sector Process/Product characteristic capacity/Pl Reported effects
applic
name/type of application ant size
ation
Altair Pulse Two dryers,
Better powder than
Nanotechnologies combustion each
produced in
(Reno, Nevada, spray drying to releases 0.4
Fine conventional spray
USA). Lithium- produce large GJ, giving 2007
chemicals dryer (solid spheres
compound particles quantities of evaporation
with narrow size
used in the electric nanosized and rate of 72
distribution)
car batteries. uniform particles kg/h

5
 Three Large increase in
Pulse
dryers, evaporative
combustion
Large each efficiency and
Canaan Fertilizers, spray drying of
volume releases 3 throughput; ability to
Vereeniging, South fertilizers 2006
chemicals GJ and handle
Africa derived from
evaporates inconsistencies in
chemical plant
500 kg/h of the feed material.
byproducts.
water
One dryer Improved powder
Pulse
Berghausen with a heat quality, reduced
combustion
Corporation, release of 1 energy consumption
spray drying of
Agri-food Cincinnati, Ohio, GJ and 2003 by 17-36%,
food additives
USA evaporates increased dryer
and flavourings.
160 kg/h of throughput.
water
Evaporation
Specialty Valveless pulse
rate 5 kg/h,
chemicals combustion
initial
and Not specified spray drying of 2007 Not specified
moisture
pharma Chinese
content 85-
products medicinals
98% wb
Evaporation
Specialty
Valveless pulse rate 0.5
chemicals
combustion kg/h, initial
and Not specified 2005 Not specified
spray drying of moisture
pharma
medical supplies content
products
98% wb
Ocean Proteins, Valveless pulse
2 t/h of
Inc. (Charleston, combustor with Powdery product of
Agri-food evaporated 1980
Oregon, USA). Fish horizontal drying superior quality.
water
meal chamber
Two valveless Can handle versatile
Tektronix, Inc. pulse feed 15-25% solids
Large 2 t/h of
(Beaverton, OR, combustion (aluminum, iron,
volume evaporated 1981
USA). Electro - burners in a calcium ferrite,
chemicals water
chemical waste. horizontal drying copper, nickel,
chamber. silicates etc).
Valveless pulse
Nuclear Metals, The only known
combustor.
Large Inc. (Concord, MA, 1 t/h of nuclear application of
Material is fed to
volume USA). Radioactive evaporated 1985 PC. Allows isolation
the divergent
chemicals depleted uranium water and control of
nozzle of the
oxide. hazardous waste.
burner
An efficient process
National
for simultaneously
Starch&Chemical Valveless pulse
dispersing,
Corporation combustor with
Agro-food NA NA pregelatinizing and
(Bridgewater,NJ, horizontal post-
drying to produce
USA). Cold water drying chamber
granular starch of
swelling starch.
superior quality.
NA – not available because of confidentiality agreement

2.3 Known demonstration projects

(Are there any demonstration projects known related to the technology under consideration?
In which process industry sectors are those projects carried out: large volume chemicals –
specialty chemicals & pharma – consumer products – ingredients based on agro feedstocks?
In Table 3 provide the short characteristics of those projects.)

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Pulse combustion drying is already commercialized thus demonstrated in industrial scale.
However, pilot units can be regarded as demonstration projects. Hence, the following units
can be listed:
TM
Pulse Combustion Systems (San Rafael, CA, USA) operates two pulse combustion spray
dryers:
* PCS Model P-0.1 is a pilot scale dryer used for testing and development work.
5
It releases 10 kJ of thermal energy and evaporates up to 18 kg/h of water.
* PCS Model P-1 is used for scale-up demonstrations and for custom-ordered drying
6
of up to 180 kg/h of evaporated water and releasing 10 kJ of thermal energy.

The PCS Model P-0.1 is also used by Degussa-Hüls AG in Hanau-Wolfgang, Germany for
product and process development (colorants, pharmaceutical intermediates, polymers, silica,
pigments, catalysts and other industrial goods).

Table 3. Demonstration projects related to the technology (existing and under

realization)
Short characteristic
Aimed
of application
Who is carrying year of
Sector investigated, Reported effects
out the project applicati
including product
on
name/type
•

2.4 Potential applications discussed in literature

(Provide a short review, including, wherever possible, the types/examples of products that
can be manufactured with this technology)
Drying of organic and inorganic materials from the groups of Industrial and agricultural wastes
and by-products, Foods, Chemicals and Minerals. Moisture content in the feed is practically
unlimited as the feed consistency extends from liquids (solutions and suspensions) through
pastes to wet solids with size from micrometers to centimeters. Final moisture content in the
product can be as low as 2% . The residence time in the region of high gas temperature
(~1200°C) is in the order of milliseconds so continuing flash evaporation keeps the product at
low temperature, typically around 50-60°C.

In addition to the materials tested by the dryer manufacturer and listed in Point 2.2, pulse
combustion spray dryer was found advantageous over conventional spray dryer for silicon-
based non-oxide ceramics (solid spheres and doughnuts giving higher density when
compacted) and zirconium-based powders (narrow size distribution and no undesirable
alteration to the product) (J.A. Rehkopf. Pulse combustion spray drying.
http://www.pulsedry.com/downloads/index.php). Pulse combustion drying of solid wood (T.
th
Kudra, A.G. Buchkowski, J.A. Kitchen. 1994. Pulse-combustion drying of white pine. Proc. 4
IUFRO Int. Wood Drying Conference, Rotorua, New Zealand. pp. 396-403), and thick-grade
paper (Patterson T., Ahrens F., Stipp G. High performance impingement paper drying using
pulse combustion technology. TAPPI Engineering Conference, Chicago, May 11-15, 2003)
offered higher drying rates than continuous combustion. Simulation of pulse combustion spray
drying and experiment validation with a common salt solution proved a possibility to dry highly
heat sensitive materials (Z. Wu, A.S. Mujumdar. A parametric study of spray drying of a
solution in a pulsating high-temperature turbulent flow. Drying Technology 24(6): 751-761,
2006)

3. What are the development and application issues?

3.1 Technology development issues
(In Table 4 list and characterize the essential development issues, both technical and non-
technical, of the technology under consideration. Pay also attention to “boundary” issues,
such as instrumentation and control equipment, models, etc.) Also, provide your opinion on
how and by whom these issues should be addressed)

7
Table 4. Technology development issues
How and by whom
Issue Description
should be addressed?

Modeling of R&D carried out at

pulse For effective scale-up it is necessary to develop universities and research
combustion reliable mathematical models that are validated centers in cooperation
drying and by detailed measurements of the flow and with providers of PC
developing temperature fields. burners and dryer
scale-up rules manufacturers.
Based on acoustic resonance, pressure waves
generated in the pulse combustor can favorably
be amplified in the drying chamber but the Advanced research at
Matching the operating frequency of the combustor must universities and research
combustor with match one of natural acoustic modes of the centers on frequency -
the dryer dryer. Because the frequency spectrum of the tunable pulse
dryer changes with the variations with the dryer combustors.
load, the combustor should be altered
accordingly to attain resonance-driven drying.
A complex interaction exists between the burner Applied research
and the material load in a drying chamber, performed by researchers
Active control of which affects the sonic wave patterns and on pilot-scale and
pulse operation of pulse burners. Pressure, demonstration units that
combustion temperature and/or humidity sensors could be are made available for
used to modulate via actuators fuel flow, air flow testing by dryer
and material feed. manufacturers.
Engineering and design
The modules of the drying system could easily
conceived by dryer
Design of the be shipped to the end-user and assembled on
manufacturers in
modular system the working site. It would be easy and
consultancy with
inexpensive to replace worn parts.
researchers.

3.2 Challenges in developing processes based on the technology

(In Table 5 list and characterize the essential challenges, both technical and non-technical, in
developing commercial processes based on the technology under consideration. Also,
provide your opinion on how and by whom these challenges should be addressed)

Table 5. Challenges in developing processes based on the technology

How and by whom

Challenge Description should the challenge be
addressed?

Studies on sound
High noise level of about 110-130 dB is inherent generation and
in pulse combustion. Low noise level of 70 dB is propagation as well as
Noise reduction claimed for novel pulse combustors. 50 dB is sound suppression by
claimed 3 m from the combustor with sound design of a drying
suppression. chamber. Joint work of
scientists and engineers.
Selection of materials
having better properties,
Pulse combustors operate at high temperatures.
modification to the design
Thermal resistance and strength of materials of
to reduce volumetric
Mechanical construction is crucial for long-term operation.
expansion, thermal
reliability Mechanical reliability of moving parts such as
shock, and mechanical
valves is needed, especially for combustors with
stress. R&D at
multiplicity of valves.
universities and research
centers.

8
 An advanced R&D is
Increased Deliberate or spontaneous variations in fuel- to- needed on the
stability of air ratio can result in shut down of some combustion process and
combustion combustors. design of pulse
combustors.
Simulation studies on
performance and
The presently manufactured pulse combustor
operation of pulse
The use of dryers are fueled by natural gas, propane,
combustion dryers fired
energy sources diesel oil. An interesting option appears to be
with various fuels can be
other than fossil the use of biogas and other renewable gaseous
done by scientists
fuels and liquid fuels, as well as pulverized solid fuels
whereas field tests can
such as lignite or wood residues.
be performed by dryer
manufacturers.
The challenge is how to
aggregate a multiplicity of
Typical pulse convection dryers use one or two
miniaturized pulse
large capacity burners. It appears that favorable
combustors to fulfill
hydrodynamic and thermal effects can be
Micro-pulse drying requirements
achieved when using a set of multiple small
combustors without affecting the
pulse combustors to dry large sheet-type
operated as an operation and
materials (e.g., paper ) or moving beds (e.g.,
aggregate performance of individual
"Jet Zone" fluid bed dryer described in
pulse combustors.
Handbook of Industrial Drying, A.S. Mujumdar
Computer simulation
(Ed), CRC Press, 2007, p. 491.
should provide optimum
arrangement.

4. Where can information be found?

4.1 Key publications
(Provide the list of key publications in Table 6)
Table 6. Key publications on the technology
Publication type
(research
Publication Remarks
paper/review/bo
ok/report)
Book
T. Kudra, A.S. Mujumdar. Advanced Drying
ISBN:0-8247- Chapter No 14
Technologies. 2002. Marcel Dekker, Inc. NY.
9618-7
Book
A.S. Mujumdar (Ed.) Handbook of Industrial
rd ISBN:1-57444- Chapter No 20
Drying. 3 ed. 2007. CRC Press. Boca Raton,FL.
668-1
T. Nomura, N. Nishimura, T. Hyodo, Y. Tago, H.
Hasebe, T.Kashiwagi. 1989. Heat and mass Drying rate, pulsed vs.
transfer characteristics of pulse-combustion steady flow, heat
Research paper
drying process. Drying'89, A.S. Mujumdar, M. transfer, flow
Roques (Eds), Hemisphere Publ. Corp. NY. pp. visualization.
543-549.
T. Kudra, A.G. Buchkowski, J.A. Kitchen. 1994.
th Drying kinetics,
Pulse-combustion drying of white pine. proc. 4
Research paper gaseous emissions,
IUFRO Int. Wood Drying Conference, Rotorua,
pulsed vs. steady flow.
New Zealand. pp. 396-403.
Effect of drying
I. Zbicinski, I. Smucerowicz, C. Strumillo, J.
chamber on PC
Kasznia, J. Stawczyk, K. Murlikiewicz. 1999.
characteristics (noise,
Optimization and neural modeling of pulse Research paper
emissions, amplitude
combustors for drying applications. Drying
and pressure
Technology 17(3): 609-633.
oscillations).

9
 Theoretical and
C. Strumillo, I. Zbicinski, I. Smucerowicz, C.
experimental studies of
Crowe. 1999. An analysis of pulse combustion Research paper
pulse combustion
drying system. Chem. Eng. Proc. 38: 593-600.
spray dryer.
Hydrodynamics, heat
P. V. Akulich, P. S. Kuts. 2000. Studies on pulse
and mass transfer,
combustors and their applications to drying. Proc. Research paper
novel design of
MIF-2000 Heat and Mass Transfer Minsk Forum. (in Russian)
tangential pulse
Minsk, Belarus. Vol. 9, pp. 3-11.
combustor.
Heating of brass
X. D. Liu, C. W. Cao, Z. H. Lang. 2001. Heat
sphere and drying of
transfer between materials and unsteady airflow
Research paper refractory clay particles
from a Helmholtz type combustor. Drying
to determine heat
Technology 19(8): 1939-1948.
transfer coefficient.
I. Zbicinski, M. Benali, T. Kudra. 2002. Pulse Concise overview of
combustion: an advanced technology for efficient Review paper major issues in pulse
drying. Chem. Eng. Technology 25(7): 687-691. combustion drying.
A mathematical model
P.S. Kuts, P.V. Akulich, N.N. Grinchik, C. was formulated and
Strumillo, I. Zbicinski, E.F. Nogotov. 2002. solved numerically to
Modeling of gas dynamics in a pulse combustion determine pressure,
chamber to predict initial drying process Research paper temperature, viscosity
parameters. Chemical Engineering Journal 86: and velocity profiles
25-31. along the combustion
chamber and at the
outlet from a tailpipe.
An overview of major
I. Zbicinski. 2002. Equipment, technology,
issues illustrated
perspectives and modeling of pulse combustion Review paper
literature and author's
drying. Chem. Eng. Journal 86: 33-46.
results.
Pressure, velocity and
T. Kudra, M. Benali, I. Zbicinski. 2003. Pulse temperature profiles,
combustion drying: aerodynamics, heat transfer heat transfer
Research paper
and drying kinetics. Drying Technology 21(4): coefficient, drying
629-655. rates, noise, gaseous
emissions.
Theoretical and
A. S. Mujumdar, Z. H. Wu. 2004. Pulse experimental studies
combustion spray drying. Topics in Heat & Mass on heat and mass
Research paper
Transfer. G.H. Chen, S. Devahastin, B. N. Thorat transfer in a PC spray
(Eds). IWSID-2004, Mumbai, India. pp. 79-91. dryer. Comparison with
conventional dryer.

4.2 Relevant patents and patent holders

(Provide the list of relevant patents in Table 7. Under “remarks” provide, where applicable,
the names/types of products targeted by the given patent.)
Table 7. Relevant patents
Remarks, including
names/types of
Patent Patent holder
products targeted by
the patent
Construction for Pulse Jet Combustor Acquired from inventors by
Design to be of
Dehydration Section. US 4,624,635. Pulse Drying Systems, Inc.
universal application
(1986). Portland, OR
Pulse Combustion Drying Apparatus Acquired from inventors by
Drying of various
For Particulate Materials. US Pulse Drying Systems, Inc.
particulate materials
4,637,794. (1987). Portland, OR
Pulse Jet Combustor Dehydration Acquired from inventors by
Design to be of
Cone Construction. US 4,640,682. Pulse Drying Systems, Inc.
universal application
(1987). Portland, OR

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Pulse Combustion Drying Apparatus Acquired from inventors by
Design to be of
For Particulate Materials. USA Pulse Drying Systems, Inc.
universal application
4,695,248. (1987). Portland, OR
Feed System For Particle Drying Acquired from inventors by
Design to be of
Pulse Jet Combustors. US 4,695,249. Pulse Drying Systems, Inc.
universal application
(1987). Portland, OR
Elevated Temperature Dehydration
Acquired from inventors by
Section For Particle Drying Pulse Jet Design to be of
Pulse Drying Systems, Inc.
Combustion Systems. US 4,701,126. universal application
Portland, OR
(1987).
Pulse Combustion Process for the
National Starch & Chemical
Preparation of Pregelatinized Starch
Company, Plainfield, NJ
Starches. US 4,667,654. (1987).
Pulse Combustion Process For The
National Starch & Chemical
Preparation of Pregelatinized Starch
Company, Plainfield, NJ
Starches. US 4,859,248. (1989).
Foods and other
Pulse Combustion Fluidizing Dryer. Jetsonic Processors, Ltd.
products; drying in inert
US 4,395,830. (1983). Los Altos, CA
atmosphere
Spray drying of foods,
Pulse Combustion Drying System. US Bepex Corporation, dairy products, flavors,
5,252,061. (1993). Minneapolis, MN chemicals, polymers,
pharmaceuticals

4.3 Institutes/companies working on the technology

(Provide the list of most important research centers and companies in Table 8)

Table 8. Institutes and companies working on the technology

Institute/Company Country Remarks

Heat and Mass Transfer Institute Experiments on pneumatic

(ITMO), Belarus Academy of dryer with novel pulse
Minsk, Belarus
Sciences. Prof. P.V. Akulich combustor having conical
(akul@hmti.ac.by) chamber and tangential tailpipe.
Engineering College, China
Agricultural University. Prof. Pulse combustion spray drying,
Beijing, China
Xiangdong Liu liquid atomization in PC tailpipe
(xdliu@cau.edu.cn)
Department of Mechanical
Simulations of pulse
Engineering, National University
Singapore combustion drying in spray
of Singapore. Prof. Arun. S.
dryers and spouted bed dryers
Mujumdar (mpeasm@nus.edu.sg)
Faculty of Process and Experimental studies and
Environmental Engineering, Lodz modeling of pulse combustion
Technical University. Prof. I. Lodz, Poland spray drying and studies on
Zbicinski interaction of PC with drying
(zbicinsk@mail.p.lodz.pl) chamber.
Theoretical and experimental
Department of Hydraulics and studies on resonance frequency
Heat Engineering, Tambov State in pulse combustors heating
Tambov, Russia
Technical University. Prof. V.I. chambers of large volumes.
Bichenok (lvi@gidra.nnn.tstu.ru) Design calculations for swirl-
type pulse combustor.
Pulse Drying Systems, Inc. Sam Manufacturer; testing of various
Duncan, President Portland, OR, USA materials in a pulse combustion
(sgnduncan@pulsedrying.com) dryer rated at 1 ton/h

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 Manufacturer of pulse
combustion spray dryers.
Pulse Combustion Systems.
Testing and toll drying of
James A. Rehkopf, President San Rafael, CA, USA
various materials in dryers with
(jrehkopf@pulsedry.com)
evaporation rate of 18 and 180
kg/h
Manufacturer of pulse
Novadyne Ltd. Alan Buchkowski,
combustion pneumatic dryers,
Manager. Hastings, ON, Canada
testing of various materials.
(novadyne@nexicom.net)
Burner duty 300 kW.
Pultech Corporation. Atsuyosi Manufacturer of pulse
Kubota, President Kobe City, Japan combustion spray dryer with
(qq2x8rr9k@jupiter.ocn.ne.jp) valveless burner.

5. Stakeholders
5.1 Suppliers and developers
(Provide the list of key suppliers/developers in Table 9)

Table 9. Supplier and developers

Institute/Company Country Remarks

Manufacturer of pulse
Pulse Drying Systems, Inc. Sam
combustion dryers with
Duncan, President Portland, OR, USA
evaporation rates of 1 t/h and 2
(sgnduncan@pulsedrying.com)
t/h (www.pulsedrying.com).
Manufacturer of pulse
Pulse Combustion Systems.
combustion spray dryers with
James A. Rehkopf, President San Rafael, CA, USA
evaporation rate of up to 900
(jrehkopf@pulsedry.com)
kg/h (www.pulsedry.com)
Novadyne Ltd. Alan Buchkowski,
Manufacturer of pulse
Manager. Hastings, ON, Canada
combustion pneumatic dryers.
(novadyne@nexicom.net)
The company fabricated an
Shandong Tianli Drying
Jinan, Shandong, PR experimental pulse combustion
Equipment Co., Ltd.,
China dryer for China Agricultural
(lishengxiaoyao@yahoo.com)
University.
Manufacturer of pulse
combustion spray dryer with
Pultech Corporation. Atsuyosi valveless burner. Evaporation
Kubota, President Kobe City, Japan rate from 25 to 4000 kg/h.
(qq2x8rr9k@jupiter.ocn.ne.jp) Smaller dryers available for
specialty materials.
(www.pultech.co.jp)

5.2 End users

(Describe the existing and potential end-users, other than those already listed in Table 2)

Starmet Corporation in Concord, MA, USA. Drying of radioactive uranium waste. Pulse
combustion dryer of Pulse Drying Systems, Inc. 21 years on site.

Brinkerhoff-Signal Corp. in Denver, CO, USA. Drying of waste drilling mud from oil drilling in
Alaska. Pulse combustion dryer of Pulse Drying Systems, Inc. 20 years operational.

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Thiele Kaolin in Sandersville, GA, USA. Drying of kaolin clay, Pulse combustion dryer of
Pulse Drying Systems, Inc. One year on site for product development.

Geosone, Inc. Peru, Drying of brewers yeast and brewers grains. First stainless steel mobile
unit of Pulse Drying Systems, Inc, with evaporation rate of 2 ton/hr. 12 years in operation.

Note: Only existing end-users are listed as the manufacturers do not disclose potential
customers because of confidentiality. The application list of pulse combustion dryers delivered
by Pultech Corporation (Japan) comprises 20 entries from year 1994 to 2007 with evaporation
rates from 0.5 to 6500 kg water/h for foods, ceramics, pharmaceuticals, and IT materials. No
details are given, however.

6. Expert’s brief final judgment on the technology

(maximum 5 sentences)

Pulse combustion drying is a promising, energy efficient and environmentally friendly

technology for various types of materials including minerals, chemicals, foods, as well as
industrial/municipal wastes and by-products. This technology appears to be suitable for drying
of heat-sensitive biomaterials, nutraceuticals and functional foods if direct contact with flue
gases is permissible in a country of application. In spite of several dryer types on the market,
the number of commercial applications is however relatively low, possibly due to lack of the
scale-up and design rules made available to the dryer manufacturers. Such rules should
follow from profound understanding of the complex transport processes taking place in the
system configured of the pulse combustor and the drying chamber. Further studies, both
theoretical and experimental performed by interdisciplinary scientists and practitioners are
needed to establish process mechanisms, formulate mathematical models and to simulate
various design options for particulate materials to be dried.

_____________________

Acronyms

wb wet basis (kg water/kg wet material)

NA not available
PC pulse combustion

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