Productivity improvement through the use of industrial microwave technologies

Microwave processing of materials is a relatively new technology advancement alternative that provides new approaches for enhancing material properties as well as economic advantages through energy savings and accelerated product development. This paper presents a state-of-the-art review of microwave technologies, processing methods and industrial applications. The characteristics of microwave interactions with materials are outlined together with the challenges that are difficult to process the materials present. To fully realise the potential benefits of microwave and hybrid processes, it is essential to scale-up process and system designs to large batch or continuous processes. This necessitates computational modelling and simulation, system design and integration and a critical assessment of the costs and benefit analysis. Impediments to industrial applications are identified and development opportunities that take advantage of unique performance characteristics of microwaves are discussed. Clearly, advantages in utilising microwave technologies for processing materials include penetrating radiation, controlled electric field distribution and selective and volumetric heating. The aim of the work presented in this paper is to help guide those interested in using microwaves to improve current materials processing. Microwave fundamentals are described to provide a brief awareness of the advantages and limitations of microwaves in the processing of materials. Furthermore, the limitations in current understanding are included as a guide for potential users and for future research and development activities. Examples of successful applications are given to illustrate the characteristics of materials, equipment and processing methods applicable to industrial microwaves. Economic considerations are described and costs are provided as guidelines in determining the viability of using microwaves for processing materials.