1. What is Flameless Catalytic Energy?

Flameless Catalytic Infrared Energy (FCIR) is generated by catalyzing natural gas or propane with a proprietary enhanced platinum catalyst. Natural gas or propane, when combined with air across the platinum catalyst, reacts by oxidation-reduction to yield a controlled bandwidth of infrared energy and small amounts of CO2 and water vapor.

2.  Why is “controlled bandwidth” important?

The key to this process is that the bulk of the radiant energy bandwidth generated is in the “far infrared” range, with wavelengths ranging from approximately 3 to 7 microns.  Water absorbs energy extremely efficiently at 3, 4.5 and 6 microns.  By directing this energy spectrum at water-containing products, evaporative energy is targeted to the water within the product.  Far infrared does not heat the air, therefore energy is transferred very efficiently to the organic matter.

3. How efficient is Catalytic Infrared for dehydrating fruits and vegetables for use as edible products, or as feedstock for nutraceuticals?

Catalytic infrared processing has proven to be compatible with a broad range of fruits, vegetables and herbs.  Examples include the production of edible dried foods with excellent flavor, texture and color, the extraction of vitamins or minerals from herbs (such as rosemary), and the production of botanicals for food, cosmetic or medicinal purposes.

Catalytic infrared energy has proven its value as an efficient and highly repeatable technology that delivers exceptional end product quality, with substantially less heat exposure, in a shorter process cycle, at lower cost, than conventional heating methods.

4. What is the cost of a Flameless Catalytic Infrared Energy system compared to conventional systems that attempt to perform the same function?

In general, equipment costs are on a par with conventional conveyor-type systems on a cost-per-conveyor area basis.  However, since drying/heating times can be greatly reduced using flameless catalytic infrared energy, it is likely that smaller equipment or more throughput (or both) can result from using a CDT catalytic infrared system.

5. How do energy costs compare between flameless catalytic infrared systems and conventional convection heating/drying systems?

A typical convection conveyor dryer or column dryer requires as much as 50 horsepower just to move heated air.  Flameless catalytic infrared energy is transferred directly to the product without the requirement to heat large volumes of air.  Therefore, horsepower requirements are greatly reduced. In typical applications, CDT’s system uses 12 - 25 horsepower to move the conveyor and operate small recirculation and ventilation fans.

Regarding fuel use, conventional convection dryers that use open flame burners or heat exchangers are much less efficient at utilizing all of the energy in the fuel when compared to the direct energy transferred using flameless catalytic infrared energy systems.  Of course this requires the proper kind of catalytic system such as developed by CDT.  Fuel costs can be reduced 30-50% in some applications due to the efficiency of the direct energy transfer and lower heat losses, which are minimized by vastly reducing the required air handling.

6. Is flameless catalytic infrared energy safe?

Flameless catalytic infrared energy is very safe.  Wavelengths generated are in the “far infrared” range, not microwaves.  And because it is flameless, catalytic systems are approved for use in environments where other systems are not, such as in dusty environments and environments where volatile compounds (alcohols, etc.) are present in the vapors generated by the heating/drying processes.

Flameless Catalytic Infrared Energy Applications in Agricultural and Food Processing

7.  Where has flameless catalytic infrared proved useful in agricultural and food processes?

We’ve developed processes to add value, improve quality and yield, and reduce operating costs in many segments of the agricultural/food processing industry.  Here are just a few examples:

• The efficient drying of rice and small grains
• Drying herbs and foods for nutraceutical extraction
• Killing stored grain insects

8.  What special food and agricultural applications are uniquely suited for CDT’s flameless catalytic infrared systems?

We’ve run extensive tests in our own laboratory and in cooperation with major universities to develop unique processes that take costs out of processing, improve the quality of the finished products, and even deliver unique new products not available through conventional processing.  Here are just a few:

• Pre-conditioning rice and other grains prior to milling - By pre-heating brown rice and wheat, for example, prior to milling, significant increases in yield, throughput and quality are possible, while reducing overall electrical energy usage.
• Stabilizing rice bran – preliminary testing has shown that by heating the surface of brown rice prior to milling, the resultant rice bran removed during the milling process is much less susceptible to rancidity for several weeks after milling.  This promising application is available for testing on your rice products.
• Puffing rice and small grains – tasty rice and grain snacks can be made by the intense application of flameless catalytic infrared energy to rice and grain under appropriate conditions.
• Disinfesting grains prior to packaging or final storage – Stored grain insects, larvae and eggs are rapidly killed by heat.   Once insects are heated to 60°C (140°F.), they quickly die.   Insects contain over 55% moisture, so the catalytic infrared targets this moisture to effectively heat the insects to lethal temperatures.  Since the grains contain much lower moisture, rapid heating of the insects, larvae and eggs occurs without significant drying of the grains.

  Here are two excellent papers related to the 3 points above:
  Simultaneous Rough Rice Drying and Disinfestation Using Infrared Radiation, presented at the American Society of Agricultural and Biological Engineers Annual Meeting.

  Hot Technology for Killing Insects: Catalytic Infrared Heaters Effective on Insects Developing in Stored Wheat, by Bhadiraiu Subramanyam, professor in the Department of Grain Science and Industry at Kansas State University.

• Dehydrating small fruits – we’ve dehydrated small fruits, such as sliced apples and strawberries, delivering high quality, shelf-stable, low water activity products of higher quality than conventionally dried fruits.
• Adding value to agricultural by-products – by-products such as grape pomace, cranberry skins, tomato skins, citrus peels, etc. can be quickly dried to stable moisture content without reducing the potency of valuable nutraceutical components such as polyphenols, and vitamin E.
• Dehydrating delicate vegetables – our processes for dehydrating broccoli and cauliflower, cut conventional process times in half and deliver high color, high flavor and aroma, while maintaining the integrity of the florets.

9.  Can I have my product or process idea tested by CDT?

Yes.  CDT provides complimentary testing to help you determine the optimum process for your application.   CDT has pilot scale and large scale testing facilities for delivering flameless catalytic infrared energy in ways designed to answer your questions about quality, capacity, operating conditions and equipment specifications.   Testing is proprietary for the customer and is protected, at the customer’s request, by non-disclosure agreements.