DESC:[001] The present disclosure generally relates to an induction heating system of bitumen tanker discharge. Particularly it relates to induction heating system of bitumen tanker discharge for discharging of material from bitumen thanker for automotive applications.
[002] As you are aware that bitumen is one of the key products for road construction and other industrial use. This is being transported from refineries to construction sites through heavy commercial vehicle such as trucks.
[003] Bitumen is a sticky and highly viscous liquid employed in the construction industry mainly for paving applications and is used as a binder in asphalt meant for making roads, runways, parking lots and foot paths.
[004] Currently, below practice is being followed by the operators while unloading (1) unloading pump & nearby area is being heated by igniting woods which is highly risky to operator, environment & property and wrap diesel-soaked cloth around the parts and ignite it, resulting in soot and dirty deposits. Further also to perform such kind of operation, operator needs to relocate many components on vehicle as mentioned below –
• Relocating battery inside cabin
• Replacing brake pipes to metal material
• Relocation of STC to rear side
• Re-routing of wiring harness
• Relocation of fuel tank to opposite side
• Damage to property & nearby components
[005] The present subject matter solves the aforementioned and other problems by providing an electric heating system preferably inductive based for bitumen tanker unloading pump and outlet pipe in a desirable time frame. The present subject matter replaces the existing highly unsafe, unclean, exhausting and crude - open flame method of melting the bitumen that gets clogged in the unloading pump & outlet plumbing of the transporting tanker trucks with an engineered heating system. This also saves cost to customer on need of component relocation in the vehicle.
[006] The present subject matter design and develop an electric heating system preferably inductive based, for bitumen tanker unloading pump / outlet pipe for estimated time of 10-15 mins. Further this is required before engaging mechanical drive to safeguard gears / shaft by heating of coal tar in to discharge form. This solution is offering a very safe, clean, environment friendly, reliable, quick, energy efficient, user friendly and economical Heating System for melting Bitumen which is obtained by employing the induction heating technology.
[007] In one embodiment, the present subject matters relate to an electric heating induction system for bitumen tanker characterized by unloading pump and outlet pipe for estimated time of 10-15 mins before engaging mechanical drive to safeguard gears and shaft by heating of coal tar in to discharge form. The electric heating induction system for bitumen tanker of present subject matter replaces the existing highly unsafe, unclean, exhausting and crude-open flame method of melting the bitumen that gets clogged in the unloading pump & outlet plumbing of the transporting tanker trucks with an engineered heating system.
[008] The electric heating induction system for bitumen tanker further comprising atleast one induction coils held in dye molded polyamide housings of semicircular shape.
[009] In another embodiment, the present subject matter relates to a heating system comprises of two induction coils held in dye molded polyamide housings of semicircular shape. The housings are fastened on the heating pipe outer periphery and the power source/controller is placed on the top surface of this system which receives 24 V D.C. from the vehicle alternator through a switch located on the driver dashboard.
[0010] The induction controller converts this power supply to high frequency A.C. power which generates heat, owing to the inductive effect, making the pipe red hot and thus melts the clogged bitumen.
[0011] The system has following add-on features to make it safe & more reliable operation –
Timer setting
Temperature monitoring
Thermostat for automatic switching off
Relays for reliable working
[0012] The system of present invention minimize gap between heating object & induction coils so as to minimize losses & penetration depth of inductive effect. Hence shape of coil & wattage of induction controller became a paramount importance to bring maximum temperature in stipulated time.
[0013] The below calculations & derivation for Induction controller wattage demonstrate the uniqueness of present subject matter –
Ip * Np = Is * Ns
Ns = 1
Ip * Np = Is
P = Is2 * R heat generated in workpiece watts
P = (Ip * Np)2 * R
R = ? * l / A
A = ? r2
R = ? * l / ? r2
P = (Ip * Np)2 * ? * l / ? r2 P = (Ip * Np)2 * ? * ? * D / d * l
? * l / ? r2 = ? * ? * D / d * l
d = ?2 * D * r2 / l2
P = (Ip * Np)2 * ? * ? * D / d * l heat generated in workpiece watts
Asur = ? * D * l
Psur = P / Asur surface power watts/m2
Psur = (Ip * Np)2 * ? / d * l2 surface power
d = Sq. root of (2?/µ * ?) skin depth m
Psur = (Ip * Np / l)2 * 2? * ? sq.rt of (µr * f / ? * 107) surface power watts/m2
H = Ip * Np / l magnetizing force ampere.turn/m
Psur = 2? (H)2 sq.rt of (µr * f * ? * 10-7) surface power watts/m2
Energy in = Energy stored
Energy in = Psur * t * Asur
Energy in = Psur * t * ? * D * l
Energy stored = m * c * dt
Estored = (density * Vol) * c * dt Vol = ? r2 l
Estored = (? * ? r2 l) * c * dt
Psur = dt * c * ? * r / (2t)
[0014]
S.No. Symbol Parameters of the work piece Value Unit Consideration
1 Ti Initial temperature 5 deg C
2 Tf Final temperature 100 deg C
3 dt Temperature difference 95 deg C
4 D Diameter 0.1 m
5 l Length 1.0 m
6 µ Magnetic permeability 6.3 * 10-3 H/m µ = µ0µr, iron
7 µr Relative permeability 5000.0 99.8% Fe
8 ciron Specific heat of iron 450.0 J/kg degC iron
9 casphalt Specific heat of asphalt 920.0 J/kg degC asphalt
10 ?iron Density of iron 7870.0 Kg/m3 iron
11 ?asphalt Density of asphalt 2243.0 Kg/m3 asphalt
12 ? Resistivity of work piece 9.71x10-8 ohm m iron
13 d Skin depth 0.0007 m f= 10kHz
14 Qiron energy stored in iron pipe 2139269.64 J
15 Qasphalt energy stored in asphalt 1246508.89 J
16 Estored Total stored energy 3385778.53 J
17 Psur Surface power entering the cylinder 25233.19 watt/m2 t = 300 sec
18 Psur Surface power entering the cylinder 0.0001384 watt/m2 *H2
19 H Magnetizing force 13503.8911
20 H Magnetizing force 4051.1673 for 300mm lg
21 Ip Current 15
22 Np Number of turns 270
23 P Heat generated in pipe 1071.34 watts

[0014] Although the present disclosure is described in terms of certain preferred embodiments and examples, other embodiments and examples will be apparent to those of ordinary skill in the art, given the benefit of this disclosure, including embodiments and examples that do not provide all of the benefits and features set forth herein, which are also within the scope of this disclosure. It is to be understood that other embodiments may be utilized, without departing from the true spirit and scope of the present invention.
[0015] It is to be understood that other embodiments of the present disclosure will become readily apparent to those skilled in the art from the following detailed description, wherein it is shown and described only various embodiments of the disclosure by way of illustration. Accordingly, the drawings and description are to be regarded as illustrative in nature and not as restrictive.
[0016] It would become abundantly clear to a person in the art, after reading this specification that the present subject matter also provides an electric heating induction system for bitumen tanker characterized by unloading pump and outlet pipe for estimated time of 10-15 mins before engaging mechanical drive to safeguard gears and shaft by heating of coal tar in to discharge form effectively and without departing from the spirit of the present subject matter. While the subject matter may be susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and have been described herein. Alternate embodiments or modifications may be practiced without departing from the spirit of the present subject matter. The drawings shown are schematic drawings and may not be to the scale. While the drawings show some features of the subject matter, some features may be omitted. Alternatively, in some other cases some features may be emphasized while others are not. Further, the methods disclosed herein may be performed in manner and/or order in which the methods are explained. Alternatively, the methods may be performed in manner or order different than what is explained without departing from the spirit of the present subject matter. It should be understood that the subject matter is not intended to be limited to the particular forms disclosed. Rather, the subject matter is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the subject matter.

Yours Faithfully

ANIL KUMAR PANDEY
(IN P/A 2359)
AGENT FOR THE APPLICANT(S)

,CLAIMS:We claim:

1) An electric heating induction system for bitumen tanker characterized by unloading pump and outlet pipe for estimated time of 10-15 mins before engaging mechanical drive to safeguard gears and shaft by heating of coal tar in to discharge form.
2) The electric heating induction system for bitumen tanker as claimed in Claim 1, wherein said system replaces the existing highly unsafe, unclean, exhausting and crude-open flame method of melting the bitumen that gets clogged in the unloading pump & outlet plumbing of the transporting tanker trucks with an engineered heating system.
3) The electric heating induction system for bitumen tanker as claimed in Claim 1 further comprising atleast one induction coils held in dye molded polyamide housings of semicircular shape.
.

Yours Faithfully

ANIL KUMAR PANDEY
(IN P/A 2359)
AGENT FOR THE APPLICANT(S)