[Case Study] Microwave Pyrolysis with GaN Solid-State Microwave Technology

 Video of RFHIC's GaN solid-state technology utilized in Scanship's pyrolysis system.

Case Study Summary:

RFHIC partnered with Scanship, a Norweigian company that develops microwave pyrolysis systems for waste gasification.
By replacing magnetrons with RFHIC's 30kW, 900-930MHz, GaN solid-state microwave generator, known as the RIK0930K-40TG,
Scanship successfully designed stable microwave prolysis systems that efficiently convert carbon-based ship waste into valuable biofuels.

Customer:

Scanship, a subsidiary of the Norwegian company Vow ASA,
provides solutions that transform waste into valuable resources and
generate clean energy for customers in cruise, aquaculture and a
wide range of land-based industries and for utilities.
Scanship also designs and manufactures microwave-assisted
pyrolysis systems that are installed on commercial cruise ships.
These systems collect and convert the biowaste generated onboard
into valuable biofuels such as hydrogen and biochar.

Biochar produced from Scanship's microwave pyrolysis system.

Customer Pain Points:

During the development of their microwave-assisted pyrolysis system
to convert organic waste into biofuels,
Scanship initially chose magnetrons as components to generate microwaves.
They encountered the following problems during the course of system design.

     1. Inconsistent and non-uniform heating patterns

Magnetrons produce microwaves with unstable frequencies.
Factors such as temperatue changes, old usage, and power supply variations often lead to unexpected shifts in frequencies.
Additionally, magnetrons offer little control over frequencies and phase due to their fixed resonant structure. Heating patterns are significantly influenced by frequency stability and control.
Consequently, magnetrons frequently fall short in delivering consistent and uniform heating to feedstocks. 

In the case of Scanship's microwave-assisted pyrolysis system,
the magnetrons not only failed to uniformly heat the organic waste,
but also inflicted damage on delicate components due to their constantly shifting frequencies. 
This adversely affected the quality of the end products and led to increased operating costs.

     2. Short Mean Time between Failure

Magnetrons typically have short lifespans, averaging between 4,000 to 6,000 hours. They also operate under extremely high voltages, reaching up to 20Kv.
Due to these factors, users are frequently required to replace failed magnetron units, along with other connected components such as circulators, diodes, launchers, etc.
This frequent replacement not only increases operational costs but also offsets the low initial procurement costs of the magnetrons.

Scanship's microwave-assisted pyrolysis systems were designed for operation onboard cruise ships during voyages. 
The potential mid-voyage failure of magnetron units in the waste gasification system posed a critical challenge; in such instances, all operations would come to a halt until the components can be replaced on land. This interruption resulted in reduced yields and increased operating costs.

RFHIC's Proposed Solution

RIK0930K-40TG installed into Scanship's microwave pyrolysis system.

RFHIC offered a 30kW, 900 - 930MHz GaN solid-state microwave generator, the RIK0930K-40TG, as an alternative to magnetrons.
The RIK0930K-40TG is fabricated using RFHIC’s cutting-edge gallium-nitride (GaN) on silicon-carbide (SiC) technology.
The RIK0930K-40TG comes fully equipped with a 3-phase 380VAC power supply unit, a control module, and eight (8) solid-state power amplifier shelves.

Unlike magnetrons, RFHIC’s RIK0930K-40TG provides precise digital controllability of both frequency and phase.
These key features allowed Scanship to adjust the operating environment of the pyrolysis system depending on the composition of the organic waste. 
The microwave generator also achieved more uniform and consistent heating patterns, allowing the pyrolysis system to process higher volumes of waste in a shorter time.

RFHIC's Digital Control Software of the Microwave Generator

Moreover, the RIK0930K-40TG operates under much lower voltages (50V), and boasts lifetimes up to 100,000 hours.
The microwave generator is designed with eight power amplifier shelves, incorporating a redundancy feature that ensures graceful degradation.
In the event of a malfunction in one or two shelves, the microwave generator will continue to operate properly until the shelves can be replaced.

Key benefits

     1. Consistent and Uniform Heating Patterns

915MHz, 30kW microwave heat distribution model.

RFHIC's state-of-the-art GaN solid-state microwave generator was able to produce uniform and consistent heating patterns, effectively heating the organic waste produced onboard. This significantly increased the yield of both hydrogen and biochar. Moreover, by adjusting frequencies and power outputs based on the composition of the waste, Scanship found the ideal operating environment that suited their specific microwave pyrolysis requirements. 

     2. Increased System Lifetimes and Stability.

GaN Solid-State vs Magnetrons

RFHIC's GaN solid-state microwave generator had significantly longer lifetimes than magnetrons, and proved to be stable due to its low voltage characteristics.
In addition, the built-in redundancy feature, which allows the microwave generator to continue operating in case one of the power amplifier shelves fail, provided considerable flexibility in both system design and operation. This feature significantly reduced the need of replacing broken units, thereby reducing maintenance and operating costs. 

For more information about our GaN solid-state microwave generator technology, please contact us here.

About RFHIC:

RFHIC (KOSDAQ: A218410) is a global leader in designing and manufacturing GaN RF & Microwave components and systems for applications in wireless communications, defense and aerospace, and RF Energy (Industrial, Scientific, and Medical) segments. We provide industry-leading solutions for gallium-nitride (GaN) transistors, high-power solid-state power amplifiers, and high-power microwave generator systems, all within our in-house production facility. We enlighten industries with RF and Microwave advancements. To expedite a future enhanced by technological innovation - to create a better connected, safer, and stronger world for generations. Learn more at www.c0006.bizhomepass.kr.

RFHIC® is a registered trademark

Media Contact:

• Grace Cho
• RFHIC Corporation
• Manager, Global Sales & Marketing
• marketing@c0006.bizhomepass.kr