INFORM April 2026

PRESERVING MEAL INFORM 29

the water, transferring it to an internal refrigerant loop which can then be heated using electrical power, and delivers thermal energy to a moving bed preheater upstream via a second water loop. This allows energy recovered during cooling to be reused for preheating the incoming meal. In this configuration the heat pump adds valuable flexibility, as the temperature differentials available in solids handling applications are often limited and difficult to leverage for energy recovery. The inclusion of the heat pump allows for the recovered energy from thermal gradients to be transferable to different streams where the thermal gradients would be otherwise incompatible. When recovered energy exceeds process demand, a dry cooler provides controlled heat rejection to maintain stable operation and system flexibility. MANAGING SOLIDS BEHAVIOR AND MOISTURE Energy recovery from solids presents challenges that differ from those encountered in liquid or gas systems. Particle size distribution, bulk density, and moisture content all influence the meal’s behavior as it passes through a heat exchanger. The influences of these properties are difficult to predict and often warrant pilot testing to verify the operability of the equipment under realistic process conditions.

We performed pilot testing at Agrifirm’s facility with a focus on exploring these practical considerations. Plate spacing in the moving-bed heat exchangers was adjusted to prevent bridging and ensure consistent downward flow. Moisture release from the product could lead to elevated humidity within the inter-particle voids causing condensation and adverse flow conditions. As a result, air management proved to be a critical factor. In the preheater, we injected warmed air to reduce the dew point within the inter-particle void space and prevent air from becoming saturated with water vapor. In the cooler, we injected dehumidified air to maintain the dew point below the temperature of the cooling water inside the pillow plates to prevent condensation directly on the exchanger plates. These measures prevented condensation and supported reliable operation across a range of conditions, fulfilling the purpose of the pilot testing FROM PILOT VALIDATION TO Following successful pilot testing, Agrifirm had a full scale system constructed. Raw soy and rapeseed meal are conveyed from ambient temperature storage to a moving-bed preheater, FULL-SCALE OPERATION

where the product is heated to approximately 70 °C using recovered thermal energy. The preheated meal is then introduced into the radio frequency unit for treatment. After processing, the meal enters a moving-bed cooler and cooled to approximately 30 °C before storage. Throughout the process, thermal energy is continuously exchanged, upgraded, and reused. Heating and cooling operate as components of a single integrated system rather than independent unit Operational results from the installation demonstrate a clear improvement in energy efficiency. Recovering thermal energy directly from solids reduces primary energy consumption and lowers the overall carbon intensity of the process. At the same time, the process meets product quality requirements. Radio frequency treatment provides consistent microbial control while preserving protein integrity and digestibility. This approach aligns regulatory compliance, nutritional performance, and energy efficiency within a single process design. operations. ENERGY PERFORMANCE AND PRODUCT OUTCOMES