Homogeniser and vacuum process plant, and method using same
Patent Information
- Application Number
- EP2023841307
- Authority / Receiving Office
- EP · EP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2022-11-07
- Filing Date
- 2023-11-07
- Publication Date
- 2025-09-17
AI Technical Summary
Existing homogenizers and vacuum process systems face limitations in throughput and hygiene, particularly in cleaning efficiency, which affects productivity and product quality in industries like food and pharmaceuticals.
A homogenizer design with a groove-like configuration at the transition from the rotor shaft to the rotor plate for smooth flow deflection, integrated rotor teeth and suction/pump blades, and a helical stator toothing to enhance throughput and cleaning ease, along with a centrifugal pump-based suction system for efficient product handling.
The design improves product throughput, simplifies cleaning, reduces turbulence, and increases the shearing effect, leading to better emulsion quality and higher oil dosage rates while maintaining low noise and energy consumption.
Smart Images
Figure 1.1
Abstract
Description
[0001] Homogenizer and vacuum processing plant and process therewith
[0002] Description
[0003] The invention relates to a homogenizer as well as a vacuum processing plant and a method for homogenizing or dispersing or generally for treating flowable products, each with such a homogenizer.
[0004] DE 102009047777 A1 discloses a homogenizer for homogenizing or dispersing flowable substances, i.e. for liquid and pasty products, with a mixing chamber with a product inlet and a product outlet and, in the mixing chamber, a rotor shaft carrying a rotor, which is rotatably mounted and can be set in rotation by means of a drive, in particular a controllable drive, and a stator which interacts with the rotor.
[0005] The rotor contains a rotor plate which sits concentrically on the rotor shaft, and on the rotor plate a rotor toothing which is arranged radially within a stator toothing of the stator to form a shear gap, so that a shear gap is formed between the rotor and the stator. Downstream of the product inlet, an axial product flow direction is defined along the rotor shaft towards the rotor plate, and from the rotor shaft a radial product flow direction is defined radially along the rotor plate between the rotor teeth and the stator teeth, from which the product can flow to the product outlet. Such homogenizers are also called rotor-stator or gear ring homogenizers, which introduce the shear energy into the product in a defined manner and promote it, i.e. drive the product flow.
[0006] Such homogenizers are used, for example, in the food industry, as well as in the cosmetics and pharmaceutical industries, to produce ketchup, mayonnaise, sauces, dressings, etc., using hot and cold processes, or to produce emulsions and suspensions for lotions, creams, gels, ointments, etc. Such homogenizers are particularly integrated into vacuum processing systems, where they are installed below a process vessel and also contain mixing / conveying blades. This configuration ensures reliable premixing and uniform wetting of dry substances in the liquid phase from the process and / or storage vessel immediately before passing through the homogenizer. A recirculation line, for example, is installed downstream of the homogenizer and guarantees the forced flow of the product back into the process vessel. This closes the product cycle and ensures vertical mixing in the process vessel.This also provides the opportunity for sample drawing and product discharge.
[0007] The designs of homogenizers and vacuum processing systems using the technology described above are widely used and generally function satisfactorily, but have long since reached their design limits, for example, in terms of throughput and oil dosing for the liquid and pasty products to be treated, which are subject to special and evolving hygiene requirements. Due to the latter, a homogenizer must be easy to clean, although the designs known in practice have significant disadvantages.
[0008] The present invention therefore aims to further improve the existing technology and, in particular, to increase the throughput and to enable fast, simple and thorough cleaning capability.
[0009] This object is achieved with a homogenizer according to claim 1 and a vacuum processing system with such a homogenizer according to claim 11 and a method according to claim 12.
[0010] Accordingly, the invention provides a homogenizer for homogenizing or dispersing or generally for treating flowable products, which comprises a mixing chamber with a product inlet and a product outlet and, in the mixing chamber, a rotor shaft carrying a rotor, which is rotatably mounted and can be set in rotation by means of a, in particular controllable, drive, and a stator cooperating with the rotor, wherein the rotor comprises a rotor plate which is seated concentrically on the rotor shaft, and on the rotor plate, a rotor toothing which is arranged radially within a stator toothing of the stator, forming a shear gap, and wherein an axial product flow direction is defined downstream of the product inlet along the rotor shaft towards the rotor plate, and a radial product flow direction is defined from the rotor shaft radially along the rotor plate and through between the rotor toothing and the stator toothing,from which the product can flow to the product outlet, wherein at the transition from the rotor shaft to the rotor plate, a groove-like design surrounds the rotor shaft, with preferably at least approximately flush transitions to the rotor shaft and the rotor plate, so that the flowable products to be treated are deflected during operation of the homogenizer from the axial product flow direction by the groove-like design, in particular continuously or via at least one slope, into the radial product flow direction.
[0011] The groove-like design at the transition between the rotor axis and the rotor plate, with its negative or concave circumferential rounding, leads to a continuous and, in particular, low-disturbance, low-blockage, and low-turbulence deflection of the product flow from the axial direction along the rotor shaft into the radial direction along the radii of the rotor plate, which optimizes product throughput. At the same time, the elimination of a kink at the transition between the rotor axis and the rotor plate avoids a dead space for the product flow, where product can accumulate. This contamination must be laboriously removed before or after each start-up of the homogenizer and also blocks the product flow at this point or disrupts it by creating turbulence. The optimization, i.e.Increasing the throughput compared to a design without the groove-like design according to the invention and saving or at least simplifying cleaning requirements leads to increased productivity of the homogenizer.
[0012] The invention thus achieves a guided, low-loss deflection of the product flow from the axial to the radial direction according to the principle of a radial pump. While in the prior art, a suction impeller arranged upstream of the rotor toothing is essentially an axial pump that conveys fluids axially, which is extremely inefficient for deflecting fluids from the axial to the radial direction. In contrast, the rotor design according to the invention creates, so to speak, a radial centrifugal pump.
[0013] Preferably, the groove-like configuration is provided on an inner ring of the rotor that protrudes axially from the rotor plate counter to the axial product flow direction, and is thus a component of the rotor and, in particular, integrally formed with the rotor plate and / or the rotor shaft. Preferably, the groove-like configuration, on the one hand, merges at least approximately flush with the rotor shaft at its radially narrowest end, and, on the other hand, extends at least approximately flush with the rotor plate.In particular, in and in conjunction with any other embodiment of the homogenizer, it can further be provided that the groove-like configuration a) is a part-circular groove with a part-circular cross-section with a constant radius, wherein the radius is in particular in the range from 10 mm to 100 mm and preferably in the range from 30 mm to 80 mm and particularly preferably in the range from 40 mm to 65 mm, or b) is a part-ellipsoidal groove with a part-ellipsoidal cross-section with a radius that changes continuously over the course of the curvature, wherein the radii of the part-ellipsoidal cross-section are in particular in the range from 10 mm to 100 mm and preferably in the range from 30 mm to 80 mm and particularly preferably in the range from 40 mm to 65 mm, or c) is a truncated cone configuration with at least one bevel in the cross-section, which is formed by at least one truncated cone.
[0014] Advantageously, it can further be provided that a mixing / conveying blade and / or a dispersing disc is / are arranged coaxially to the rotor upstream of the rotor with respect to the axial product flow direction, wherein the mixing / conveying blade is preferably drive-connected to the rotor shaft and / or the dispersing disc is arranged coaxially to the rotor shaft, wherein, if appropriate, the dispersing disc is arranged downstream of the mixing / conveying blades in the axial product flow direction.
[0015] A further preferred embodiment consists in the rotor toothing comprising individual rotor teeth arranged coaxially around the rotor shaft on a rotor tooth circle and connected to the rotor disc, and in particular integrally formed, which protrude from the rotor disc counter to the axial product flow direction. In particular, the integral design of the rotor teeth with the rotor disc provides advantages in terms of cleaning and rotor compactness.
[0016] Preferably, suction vanes are mounted on the rotor disk radially inside the rotor teeth and also projecting against the axial product flow direction on a suction vane circular line coaxially around the rotor shaft and are particularly integrally formed. Preferably, pump vanes are mounted on the rotor disk radially outside the rotor teeth and the stator toothing and also projecting against the axial product flow direction on a pump vane circular line coaxially around the rotor shaft and are particularly integrally formed. This configuration advantageously also contributes to simplifying and improving the cleaning options as well as improving the compactness of the entire homogenizer.The reduction of the number of components from three (separate components: suction vane, rotor and pump vane) to one advantageously leads to a reduction in the number of components, lower manufacturing, assembly, cleaning and maintenance costs as well as an improvement in hygiene. The latter is promoted not only by avoiding multiple connection points between different components on the rotor shaft and / or between each other, but also by eliminating the need for seals, such as O-ring seals, at such points. This has a positive effect on manufacturing and operating costs in addition to the advantages in terms of hygiene.
[0017] In particular, in and in connection with any other embodiment of the homogenizer, it can further be provided that the groove-like configuration a) is a part-circular groove with a part-circular cross-section with a constant radius, wherein the radius is determined by the ratio
[0018] Outer radius of the suction blades / radius of the groove and the ratio has a value of 0.2 to 5, preferably 0.4 to 3 and particularly preferably 0.5 to 1.5, or b) a partially ellipsoidal groove with a partially ellipsoidal cross-section with a radius that changes continuously over the course of the curvature, the radii being determined by the ratio
[0019] Outer radius of the suction blades / local radius of the groove and the ratio has a value of 0.2 to 5, preferably 0.4 to 3 and particularly preferably 0.5 to 1.5.
[0020] The invention also enables the manufacturing process to be significantly streamlined through the use of new, efficient manufacturing methods. In the previous production of up to three separate components, which in total require more stainless steel to be machined than for a rotor with integrated suction and pump vanes, each component had to be reclamped several times in a turning and milling machine. Both material usage and machining handling are minimized with the new rotor, and cumulative manufacturing tolerances are also eliminated. Preferably, the rotor teeth and, in particular, the suction vanes and / or the pump vanes, which together can also be referred to as the rotor blading, are designed with a flow-optimized curve. For the individual blades, i.e. the rotor teeth, suction vanes and / or pump vanes, the tooth or blade curvatures are determined based on the calculation of velocity vectors.
[0021] The curvature of the rotor teeth is preferably convex in cross-section in an end region of the flank pointing in the direction of rotation of the rotor, radially adjacent to the stator, and preferably tapers to a point in the direction of rotation of the rotor and, in particular, is free from kinks. The rotor teeth are preferably trapezoidal in cross-section. A further preferred embodiment consists in the flank of the rotor teeth pointing in the direction of rotation of the rotor, also called the leading rotor tooth flank, and if the leading rotor tooth flank itself is curved, the connecting line of the end edges of the leading rotor tooth flank, encloses a smaller angle to the radius of the rotor plate than the trailing flank of the rotor teeth and, if the trailing rotor tooth flank itself is curved, the connecting line of the end edges of the trailing rotor tooth flank.
[0022] This design specifically includes a fluidic optimization of the rotor teeth for a defined, flow-optimized product deflection into the stator. This applies not only to the leading flank of the rotor teeth in the direction of rotation of the rotor, i.e., the leading rotor tooth flank, but also to the trailing rotor tooth flank, where the product preferably no longer has to flow around any sharp rotor edge. The product flow flows toward the shear gap with largely low turbulence.
[0023] Advantageously, in the homogenizer according to the invention, the rotor teeth can be extended axially relative to the axial product flow direction and in order to increase the flow area (slot or groove area) and to match the corresponding length of the stator slots or the corresponding axial extent of the perforation of the stator ring compared to the designs in the prior art.
[0024] A further advantageous embodiment consists in the fact that the rotor teeth taper radially, in particular continuously and preferably in a curved manner, towards the sides facing the stator, i.e., toward the pressure side. This creates a dynamic pressure that increases in this direction, i.e., toward the stator and, in particular, its slots or grooves between the stator teeth, during operation of the homogenizer. This, in turn, increases the expansion of the microdroplets of the product and thus the shearing effect. In other words, the outer diameter of each rotor tooth is progressively reduced or reduced in size in the direction of rotation, so that a wedge-shaped gap is formed between the rotor teeth and the stator teeth of the stator toothing.With this structural design of the rotor teeth, an increased dynamic pressure is generated during operation of the homogenizer in the direction of the spaces between the stator teeth of the stator toothing, also called stator grooves, which increases the aforementioned expansion of the microdroplets and thus the shearing effect.
[0025] It can also advantageously be provided that the suction impeller, i.e. the individual suction vanes, are combined with individual rotor teeth, for example fused or, in particular, integrally connected by a web. In particular, every second rotor tooth is combined with a suction vane, fused or integrally connected by a web. In addition to the manufacturing advantages, this advantageously ensures that there are no gaps, joints or general spaces between the suction vanes and the corresponding rotor teeth, thus avoiding corresponding hygiene problem zones. Furthermore, this allows efficient guidance of the product in front of and, in particular, behind the suction vanes, with little turbulence and loss.
[0026] Preferably, the suction impeller of the homogenizer according to the invention is based on the principle of a centrifugal pump. This allows the product to be conveyed efficiently with a larger volume flow and at a higher pressure.
[0027] Advantageously, the new pumping vanes, i.e. the pumping vanes are extended radially outside the stator axially with respect to the axial product flow direction, in relation to the rotor teeth, compared to the designs of the prior art, which leads to an improvement in the pumping effect and an increase in the product delivery rate.
[0028] In the case of the pump vanes, the entire flank pointing in the direction of rotation of the rotor, also called the leading pump vane flank, is preferably convexly curved in cross-section, in particular tapering to a point in the direction of rotation of the rotor, and alternatively or additionally the cross-section is trapezoidal. A further preferred embodiment consists in the angle of the flank of the pump vanes pointing in the direction of rotation of the rotor, i.e. the leading pump vane flank, and if the leading pump vane flank itself is curved, the connecting line of the end edges of the leading pump vane flank, encloses a larger angle to the radius of the rotor plate than the trailing flank of the pump vanes, i.e. the trailing pump vane flank, and if the trailing pump vane flank itself is curved, the connecting line of the end edges of the trailing pump vane flank.In a further embodiment, the trailing flank of the pump vanes can be convex in cross-section, in particular over the entire cross-sectional length.
[0029] Preferably, the vane geometry of the pump vanes is aerodynamically optimized to enable optimal outflow of the product into a recirculation line or pressure line or into the product outlet, and in particular has a curved shape.
[0030] It has been shown to be advantageous and is accordingly preferred if the coverage of the stator slots or grooves by the pump vanes is reduced by reducing the number and shortening the arc dimension of the pump vanes, so that the free, undisturbed passage area through the stator or, more precisely, its stator slots is increased and pressure losses are thereby reduced.
[0031] A further preferred embodiment consists in that the stator toothing contains individual stator teeth arranged coaxially around the rotor shaft on a circular line, which preferably protrude from a stator base ring in the axial product flow direction and between which continuous stator slots are defined in the radial product flow direction.
[0032] Preferably, the stator teeth are connected at their end facing away from the stator base ring by a stator ring which forms a stator stabilizing ring, so that the stator slots are circumferentially defined between the stator teeth and axially delimited by the stator base ring and the stator stabilizing ring.
[0033] It is further preferred that the stator gearing be helical with respect to the axial product flow direction, resulting in a longer length of the stator slots or grooves compared to straight gearing, which in turn increases the flow area of the stator slots compared to straight gearing, thus achieving the advantage of an enlarged shear zone. Tests have confirmed that helical gearing results in a better droplet size distribution of an emulsion processed with the homogenizer, which suggests a better shear effect of a helical-toothed stator compared to a straight-toothed design. Tests have also shown that helical gearing has a positive effect on the shear effect.Helical gearing allows for a higher oil dosage (in kg / s) compared to straight gearing. This is due to the greater shearing effect (extensional flow) on the microscopic emulsion spheres with helical gearing than with straight gearing. Finally, experiments have demonstrated that helical gearing has a positive effect on sound intensity. Figuratively speaking, the rotor cuts into the helical stator gearing, significantly reducing pressure surges when flowing through the shear edges of the stator gearing.
[0034] The latter configuration is preferably further designed such that the side walls of the stator teeth, and thus of the stator slots, extend radially at every point in the circumferential direction of the stator toothing. This configuration can also be described such that the slot or groove guide lines are always perpendicular to the central axis, i.e., to the axial product flow direction. This results in a helical or twisted milling or a helical or twisted longitudinal profile of the stator slots, which is preferably produced using a 5-axis milling machine or a 3D printing method. This configuration advantageously ensures that the shearing effect remains constant over the length of the stator slots or grooves.
[0035] Alternatively, the stator toothing can be formed by a perforated stator ring, which sits coaxially on the stator base ring and contains continuous stator bores in the radial product flow direction, forming the perforation. By perforating the stator ring with bores instead of slots, the ratio of shear edges to passage area is increased compared to slots, which can have a positive effect on the formation of the emulsion.
[0036] Preferably, the stator slots or stator bores and / or spaces between the rotor teeth can be designed to taper conically in the radial product flow direction to increase the expansion of the microdroplets, which also contributes to an improvement in the shearing effect.
[0037] Furthermore, it is important for the stability (reduction of deflection and bending stresses) of the
[0038] It is advantageous and therefore preferred for the stator teeth, but also for the rotor teeth and, if applicable, the suction and / or pump vanes, if their profile or thickness is conically reinforced, so that the profile becomes slimmer towards the end of the stator teeth facing away from the stator base ring, and towards the tooth or vane ends facing away from the rotor plate of the rotor teeth and, if applicable, the suction and / or pump vanes. Particularly with the aforementioned axial extension of the teeth and, if applicable, vanes, the resulting centrifugal forces lead to greater deflection and a critical increase in bending stresses in the root area, which is counteracted by the aforementioned conical reinforcement towards the root of the aforementioned teeth and vanes.
[0039] Preferably, the number of slots or grooves in the stator is not a common multiple of the number of rotor teeth and, if applicable, pump vanes. This can significantly reduce the sound intensity, at least at individual, and especially at certain frequencies, as demonstrated in tests using a sound spectrum analyzer. As a non-limiting example from the tests, 10 rotor slots, and thus also rotor teeth, 5 pump vanes, and 27 stator slots are combined.
[0040] Yet another preferred embodiment of the homogenizer according to the invention is that the homogenizer contains a housing which widens in a helical manner around the pump vanes according to the principle of a centrifugal pump housing, so that chambers of a pump vane annular gap between a housing of the homogenizer and the pump vanes become successively larger during their rotation until they are ejected into a recirculation connection to a recirculation line or a pressure line or the product outlet (5), whereby the delivery volume advantageously increases and the internal pressure losses in the pump vane annular gap decrease.
[0041] Furthermore, a recirculation connection of the homogenizer for product discharge into a circuit for returning the product back to the homogenizer for further treatment of the rotor-stator combination is designed similarly to a centrifugal pump. The recirculation connection is formed by a pipe connection, which in particular has an oval cross-section to enable an even more optimal inlet into a recirculation line downstream of the recirculation connection. Alternatively or additionally, the recirculation connection and / or at least the area of the recirculation line adjacent to the recirculation connection are conically tapered in the flow direction.In the homogenizer according to the invention, the individual embodiments and their combinations ensure that, in particular, the return flow from the homogenizer into a further container of the vacuum processing system, into which the homogenizer is preferably integrated, is realized in the recirculation connection and / or at least the region of the recirculation line adjacent to the latter in a substantially eddy-free manner, which further improves the product throughput and the product quality.
[0042] Furthermore, it can advantageously be provided that the rotor-stator combination in the homogenizer according to the invention is designed in two or more stages, i.e., radially outside the innermost stator ring, a circular arrangement with rotor teeth is arranged, and radially outside adjacent to these, another stator ring, which can be repeated further. This would increase the shearing effect.
[0043] Finally, the object of the invention is also achieved with a vacuum processing system with a homogenizer and a method for homogenizing or dispersing or generally for treating flowable products with a homogenizer, which preferably uses one or more of the previously explained design options.
[0044] The present documents also disclose advantageous operating and manufacturing methods based on the homogenizer according to the invention and the corresponding vacuum processing system, as well as the use of such a homogenizer according to the invention and such a vacuum processing system for specific product types, products and results.
[0045] The invention will be explained in more detail below by means of exemplary embodiments with reference to the drawing, in which
[0046] Fig. 1 is a schematic side view of a first embodiment of a homogenizer,
[0047] Fig. 2 is a schematic front view of the first embodiment of the homogenizer from Fig. 1, Fig. 3 is a schematic cross-sectional view of the first embodiment of the homogenizer from Figs. 1 and 2 in the region of the rotor-stator arrangement according to the section line AA in Fig. 1,
[0048] Fig. 4 is an enlarged schematic side view of the rotor plate of the first embodiment of the homogenizer with hidden vanes / blading from Figs. 1 to 3,
[0049] Fig. 5 is a schematic longitudinal sectional view of the first embodiment of the homogenizer from Figs. 1 to 4,
[0050] Fig. 6 is a schematic perspective view of a first embodiment of a rotor of the homogenizer,
[0051] Fig. 7 is a schematic perspective detail of a second embodiment of a rotor of the homogenizer to illustrate a detail,
[0052] Fig. 8 is a schematic perspective detail of a third embodiment of a rotor of the homogenizer to illustrate a further detail,
[0053] Fig. 9 is a schematic perspective partial sectional view of a further embodiment of the homogenizer to illustrate yet another detail,
[0054] Fig. 10 is a schematic perspective view of a first embodiment of a stator of the homogenizer,
[0055] Fig. 10A is a schematic perspective view of a modification of the first embodiment of the stator of the homogenizer from Fig. 10,
[0056] Fig. 11 is a schematic perspective view of a second embodiment of a stator of the homogenizer, Fig. 12 is a schematic perspective view of a third embodiment of a stator of the homogenizer,
[0057] Fig. 13 is a schematic perspective detail of a fourth embodiment of a stator of the homogenizer,
[0058] Fig. 14 is a schematic side view of the fourth embodiment of a stator of the homogenizer from Fig. 13,
[0059] Fig. 15 is a schematic perspective detail view of the fourth embodiment of a stator of the homogenizer from Figs. 13 and 14,
[0060] Fig. 16 is a schematic detail view of a fifth embodiment of a stator of the homogenizer,
[0061] Fig. 17 is a schematic perspective detail view of the third embodiment of the rotor of the homogenizer, according to Fig. 8,
[0062] Fig. 18 is a schematic partial cross-sectional view of the third embodiment of the homogenizer from Fig. 17 according to the section line AA in Fig. 17,
[0063] Fig. 19 is a schematic partial cross-sectional view of a fourth embodiment of the homogenizer,
[0064] Fig. 20 is a schematic cross-sectional view of a fifth embodiment of the homogenizer,
[0065] Fig. 21 is a schematic cross-sectional view of a sixth embodiment of the homogenizer,
[0066] Fig. 22 is a schematic partial view of an essential detail of the homogenizer, Fig. 23A is an enlarged schematic partial side view of the rotor plate with clarification of a first variant of the first embodiment of the homogenizer with hidden vanes / blading from Fig. 4, and
[0067] Fig. 23B is an enlarged schematic partial side view of the rotor plate illustrating a second variant of the first embodiment of the homogenizer with hidden vanes / blading from Fig. 4.
[0068] The invention is explained in more detail by way of example only with reference to the exemplary embodiments and applications described below and illustrated in the individual figures of the drawings. This means that it is not limited to these exemplary embodiments and applications or to the combinations of features within an exemplary embodiment and application. Process and device features are also derived analogously from device and process descriptions.
[0069] Individual features that are specified and / or illustrated in connection with a specific embodiment are not limited to this embodiment or the combination with the other features of this embodiment, but can be combined with any other variants within the scope of what is technically possible, even if they are not dealt with separately in these documents.
[0070] Identical reference numerals in the individual figures and illustrations of the drawings designate identical or similar components, or components with identical or similar functions. The illustrations in the drawings also clearly identify features that are not provided with reference numerals, regardless of whether such features are described below. On the other hand, features included in the present description but not visible or illustrated in the drawings are also readily understandable to a person skilled in the art.
[0071] Figs. 1 to 5 schematically show, in side, front, cross-sectional, partial detail, and central longitudinal sectional views, a first embodiment of a homogenizer 1 for homogenizing or dispersing, or generally for treating flowable products, wherein Fig. 3 shows a cross-sectional view along section AA in Fig. 1. The homogenizer 1 contains a mixing chamber 3 contained in a housing 2 with a product inlet 4 and a product outlet 5, and in the mixing chamber 2, a rotor shaft 7 carrying a rotor 6, rotatably mounted and set in rotation by means of a, in particular controllable, drive (not shown), and a stator 8 interacting with the rotor 6.
[0072] As Figures 1, 2, 3 and 5 show in particular, in this first embodiment of the homogenizer 1, in addition to the product inlet 4, there is a product outlet 5 and product outlets 5a and 5b as well as four further product inlets 4a, 4b, 4c and 4d, through which, for example, during an initial filling, individual components of the product to be treated can be filled from corresponding storage containers (not shown). Furthermore, in addition to the product outlet 5, which leads, for example, into a process container (not shown), from where the product, for example,can also be fed back to the product inlet 4 of the homogenizer 1 after another treatment in the circuit, two further product outlets 5a and 5b are provided, by means of which remaining product can be drained from the mixing chamber 3 of the homogenizer 1 after completion of the processing of the product in order to be able to clean the mixing chamber 3 and the other components contained therein and to prepare it for the processing of another product.
[0073] The rotor 6 contains a rotor plate 9, which sits concentrically on the rotor shaft 7, and on the rotor plate 9 a rotor toothing 10, which is arranged radially within a stator toothing 12 of the stator 8, forming a shear gap 11. Downstream of the product inlet 4, an axial product flow direction L is defined along the rotor shaft 7 towards the rotor plate 9 (see also Fig. 22), and a radial product flow direction R is defined from the rotor shaft 7 radially along the rotor plate 9 and between the rotor toothing 10 and the stator toothing 12, from which the product can flow to the product outlet 5.
[0074] At the transition from the rotor shaft 7 to the rotor plate 9, a groove-like configuration 13 surrounds the rotor shaft 7, with at least approximately flush transitions to the rotor shaft 7 and the rotor plate 9, so that the flowable products to be treated are continuously deflected from the axial product flow direction L into the radial product flow direction R by the groove-like configuration 13 during operation of the homogenizer 1, as is separately illustrated in the illustration in Fig. 22. The groove-like configuration 13 at the transition between the rotor axis 7 and the rotor plate 9, due to its negative or concave circumferential rounding, leads to a continuous and, in particular, low-disturbance, congestion- and turbulence-free deflection of the product flow according to the arrow S from the axial direction L along the rotor shaft 7 into the radial direction R along the radii of the rotor plate 9, which optimizes the product throughput.At the same time, the elimination of a kink at the transition between rotor axis 7 and rotor plate 9 eliminates dead space for the product flow, where product can accumulate and cause stagnation or disruption due to the formation of turbulence. This achieves a guided, low-loss deflection of the product flow from the axial direction (L) to the radial direction (R) based on the principle of a radial pump or a radial centrifugal pump.
[0075] In Fig. 4, in an enlarged schematic side view of the rotor plate 9 of the first embodiment of the homogenizer 1 with hidden vanes / blading from Figs. 1 to 3, the groove-like configuration 13 from the rotor shaft 7 to the rotor plate 9 is illustrated. The groove-like configuration 13 is a part-circle groove 13a with a part-circle cross-section with a constant radius, wherein the radius is in particular in the range of 10 mm to 100 mm and preferably in the range of 30 mm to 80 mm and particularly preferably in the range of 40 mm to 65 mm. Alternatively, the part-circle groove 13a with a part-circle cross-section with a constant radius can be determined by the ratio
[0076] Outer radius of the suction blades / radius of the groove and the ratio has a value of 0.2 to 5, preferably 0.4 to 3, and particularly preferably 0.5 to 1.5. Each of these configurations can be realized in any embodiment in combination with, but also without, any of the other features disclosed herein that go beyond the combination of features in claim 1. This means, in particular, that the dimensional and ratio specifications can be combined with the combination of features in claim 1 without restriction and without any other further developments.
[0077] A first variant of the first embodiment of the homogenizer 1 from Fig. 4 is illustrated in Fig. 23A in an enlarged schematic partial side view of the rotor plate 9 by dashed lines as a groove-like configuration 13 in the form of a partially ellipsoidal groove 13b with a partially ellipsoidal cross-section with a radius that continuously changes over the course of the curvature, wherein the radii of the partially ellipsoidal cross-section are in particular in the range from 10 mm to 100 mm and preferably in the range from 30 mm to 80 mm and particularly preferably in the range from 40 mm to 65 mm. Alternatively, the partially ellipsoidal groove 13b with a partially ellipsoidal cross-section with a radius that continuously changes over the course of the curvature can be determined by the ratio
[0078] Outer radius of the suction blades / local radius of the groove, and the ratio has a value of 0.2 to 5, preferably 0.4 to 3, and particularly preferably 0.5 to 1.5. Each of these configurations can be implemented in any embodiment in combination with, but also without, any of the other features disclosed herein that go beyond the feature combination in claim 1, as an alternative to a version with a part-circle-like groove. This means, in particular, that the dimensional and ratio specifications can be combined with the feature combination of claim 1 without restriction and without any other further developments.
[0079] A second variant of the first exemplary embodiment of the homogenizer 1 from Fig. 4 is illustrated in Fig. 23B in an enlarged schematic partial side view of the rotor plate 9, illustrated by dashed lines as a groove-like configuration 13 in the form of a bevel 13c formed by at least one truncated cone. Several successive different bevels 13c can also form the groove-like configuration 13 as partial chords of an imaginary partially circular groove, formed by corresponding successive truncated cones (not shown). Each of these configurations can be realized in any embodiment in combination with, but also without, any of the other features disclosed herein that go beyond the combination of features in claim 1, as an alternative to a version with a partially circular or partially ellipsoidal groove.
[0080] The groove-like configuration 13 is provided on an inner ring 14 of the rotor 6, which protrudes axially from the rotor plate 9 counter to the axial product flow direction L, and is thus a component of the rotor 6 and, in particular, is formed integrally with the rotor plate 9. Preferably, the groove-like configuration 13, on the one hand, merges at least approximately flush with the rotor shaft 7 at its radially narrowest end and, on the other hand, terminates at least approximately flush with the rotor plate 9.
[0081] Mixing / conveying blades 15 and a dispersing disk 16 are arranged upstream of the rotor 6 with respect to the axial product flow direction and are arranged coaxially with the rotor 6. The mixing / conveying blades 15 are drive-connected to the rotor shaft 7, and the dispersing disk 16 is arranged coaxially with the rotor shaft 7, with the dispersing disk 16 being arranged downstream of the mixing / conveying blades 15 in the axial product flow direction L.
[0082] In this first exemplary embodiment of the homogenizer 1, as can be clearly seen in the schematic enlarged and perspective detailed illustration of Fig. 1, the rotor toothing 10 contains individual rotor teeth 17 arranged coaxially around the rotor shaft 7 on a rotor tooth circle and connected to the rotor plate 9, and in particular integrally, which protrude from the rotor plate 9 opposite to the axial product flow direction L. Above all, the integral design of the rotor teeth 17 with the rotor plate 9 results in advantages in terms of cleaning and compactness of the rotor 6.
[0083] Furthermore, in this first exemplary embodiment of the homogenizer 1, also best seen in Fig. 6, suction vanes 18 are attached to the rotor plate 9 radially inside the rotor teeth 17 and also protrude against the axial product flow direction L, on a suction vane circular line coaxially around the rotor shaft 7 and are in particular formed integrally. Furthermore, in this first exemplary embodiment of the homogenizer 1, also best seen in Fig. 6, pump vanes 19 are attached to the rotor plate 9 radially outside the rotor teeth 17 and the stator toothing 12 and also protrude against the axial product flow direction L, on a pump vane circular line coaxially around the rotor shaft 7 and are in particular formed integrally.
[0084] This design also advantageously contributes to simplifying and improving cleaning options, as well as improving the compactness of the entire homogenizer. Reducing the number of components from three (separate components: suction vane, rotor, and pump vane) to one advantageously leads to a reduction in the number of components, lower manufacturing, assembly, cleaning, and maintenance costs, and improved hygiene. The latter is facilitated not only by avoiding multiple connection points between various components on the rotor shaft 7 and / or between them, but also by eliminating the need for seals, particularly O-ring seals, at such points. This has a positive impact not only on hygiene but also on manufacturing and operating costs.
[0085] In particular, the one-piece design of rotor plate 9 with rotor teeth 17, suction vanes 18, and pump vanes 19 allows the manufacturing process to be significantly streamlined through the use of new, efficient manufacturing methods. Previously, the production of up to three separate components, which required more stainless steel to be machined than a rotor with integrated suction and pump vanes, required each component to be re-clamped several times in a turning and milling machine. Both material usage and machining handling are minimized with the new rotor, and cumulative manufacturing tolerances are also eliminated.
[0086] The rotor teeth 17 as well as the suction vanes 18 and the pump vanes 19, which together can also be referred to as blading 20 of the rotor 6, are designed with a fluidically optimized curvature in that the tooth or vane curvatures are determined on the basis of the calculation of velocity vectors.
[0087] The curvature of the rotor teeth 17 is convex in cross-section in an end region 21 of the flank pointing in the direction of rotation D of the rotor 6, which is referred to as the leading rotor tooth flank 22 of the rotor teeth 17, and preferably tapers to a point in the direction of rotation D of the rotor 6, and in particular is free of kinks, as is illustrated by the partially schematic illustration in Fig. 7, in which the product flow achieved in this region is also represented by the arrow S1. As can be clearly seen from the further partially schematic illustration in Fig. 8, the rotor teeth 17 are trapezoidal in cross-section. Furthermore, also with reference in particular to Fig. 8, the rotor tooth flank 22 of the rotor teeth 17 leading in the direction of rotation D of the rotor 6 encloses a smaller angle to the radius of the rotor plate 9 than the essentially opposite trailing rotor tooth flank 23 of the rotor teeth 17.Furthermore, also with reference in particular to Fig. 8, if the leading rotor tooth flank 22 itself is curved, the connecting line of the end edges of the leading rotor tooth flank 22 forms a smaller angle to the radius of the rotor plate 9 than the connecting line of the end edges of the trailing rotor tooth flank 23.
[0088] The product flows achieved are also shown in Fig. 8 by arrows S2, S3 and S4.
[0089] This design includes, in particular, a fluidic optimization of the rotor toothing 10 for a defined, flow-optimized product deflection into the stator 8. This affects not only the leading flank of the rotor teeth 17 in the direction of rotation D of the rotor, i.e., the leading rotor tooth flank 22, but also their rearward flank, i.e., the trailing rotor tooth flank 23, where, preferably, no sharp rotor edge needs to be surrounded by the product. The product flow flows toward the shear gap 11 (see Figs. 3 and 5) with largely low turbulence.
[0090] A further embodiment consists in that, as Fig. 9 illustrates, the rotor teeth 17 taper in particular continuously and preferably curvedly towards their sides facing the stator 8, i.e. towards the pressure side, which, during operation of the homogenizer 1, creates a dynamic pressure that increases in this direction, i.e. towards the stator 8 and in particular its slots or grooves between stator teeth, which in turn increases the expansion of the microdroplets of the product and thus the shearing effect. In other words, the outer diameter of each rotor tooth 17 is increasingly reduced or made smaller in the direction of rotation D, so that a wedge-shaped shear gap 11 is formed between the rotor teeth 17 and the stator teeth of the stator toothing 12.With this design of the rotor teeth 17, an increased back pressure is generated during operation of the homogenizer toward the gaps between the stator teeth of the stator toothing 12, also called the stator grooves, which increases the aforementioned expansion of the microdroplets and thus the shearing effect. The product flow into the wedge-shaped shear gap 11 is represented by arrows S5.
[0091] 3, 6 and 8, the suction impeller, i.e. the individual suction vanes 18, are combined with individual rotor teeth 17, for example fused and in particular integrally connected or in particular integrally connected by a web 24. In particular, every second rotor tooth 17 is combined or fused with a suction vane 18 or integrally connected by a web 24. In addition to the manufacturing advantages, it is advantageously achieved that there are no gaps and joints or general spaces between the suction vanes 18 and the corresponding rotor teeth 17, and corresponding hygiene problem zones are avoided. Furthermore, this enables efficient guidance of the product in front of and in particular behind the suction vanes 18 with little turbulence and loss.
[0092] Preferably, the suction impeller, i.e. the suction vanes 18, of the homogenizer 1 is based on the principle of a centrifugal pump. This allows the product to be conveyed efficiently with a larger volume flow and at a higher pressure. With reference in particular to Fig. 6, the entire flank of the pump vanes 19 pointing in the direction of rotation of the rotor, also called the leading pump vane flank, is convex in cross-section, in particular tapering to a point in the direction of rotation of the rotor 6, and alternatively or additionally the cross-section is trapezoidal. Furthermore, the angle of the flank of the pump vanes pointing in the direction of rotation of the rotor 6, i.e. the leading pump vane flank 25, to the radius of the rotor plate 9 encloses a larger angle than the trailing flank of the pump vanes 19, i.e. the trailing pump vane flank 26.Furthermore, if the leading pump vane flank 25 itself is curved, the angle of the flank of the pump vanes pointing in the direction of rotation of the rotor 6, the connecting line of the end edges of the leading pump vane flank 25, forms a larger angle to the radius of the rotor plate 9 than the connecting line of the end edges of the trailing pump vane flank 26.
[0093] In a further embodiment, the trailing flank 26 of the pump vanes 19 can be convex in cross section, in particular over the entire cross-sectional length.
[0094] Preferably, the blade geometry of the pump blades 19 is aerodynamically optimized to enable optimal outflow of the product into a recirculation line, and in particular has a curved shape of the leading pump blade flank 25.
[0095] With reference to the schematic perspective representations in Figs. 10, 10A, 11 and 12, further embodiments of the homogenizer 1 in connection with the stator 8 are explained in more detail below.
[0096] Thus, in a first embodiment of the stator 8 of the homogenizer 1 according to Fig. 10, the stator toothing 12 has individual stator teeth 27 arranged coaxially on a circular line around the rotor shaft 7, which protrude from a stator base ring 28 in the axial product flow direction L and between which continuous stator slots 29 are defined in the radial product flow direction R. Fig. 10A shows a modification of this with an additional stator ring 30, which forms a stator stabilizing ring 30, so that the stator slots 29 are circumferentially defined between the stator teeth 27 and axially delimited by the stator base ring 28 and the stator stabilizing ring 30. In a second embodiment of the homogenizer 1 according to Fig.11, the stator teeth 27 are connected at their end facing away from the stator base ring 28 by a stator ring 30, which forms a stator stabilizing ring 30, so that the stator slots 29 are circumferentially defined between the stator teeth 27 and axially delimited by the stator base ring 28 and the stator stabilizing ring 30. Furthermore, it is provided that the stator toothing 12 is a helical toothing with respect to the axial product flow direction L, which results in a longer length of the stator slots 29 or grooves compared to a straight toothing, which in turn increases the flow area of the stator slots 29 compared to a straight toothing, thus achieving the advantage of an enlarged shear zone 11.Tests have confirmed that helical gearing results in a better droplet size distribution of an emulsion processed by the homogenizer 1, which suggests a better shear effect of a helical-toothed stator 8 compared to a straight-toothed design. Tests have further shown that helical gearing has a positive effect on the shear effect. Helical gearing enabled a higher oil dosage (in kg / s) compared to straight gearing, which is due to the fact that with helical gearing, the shear effect (extensional flow) on the microscopically small emulsion spheres is greater than with straight gearing. Finally, tests have demonstrated that helical gearing has a positive effect on sound intensity.The rotor 6 cuts, figuratively speaking, into the oblique stator toothing 12 and thus pressure surges when flowing through the shear edges of the stator toothing 12 are noticeably reduced.
[0097] Alternatively, the stator toothing 12 according to the third embodiment shown in Fig. 12 can be formed by a perforated stator ring 31, which sits coaxially on the stator base ring 28 and contains stator bores 32 extending through in the radial product flow direction, forming the perforation. By perforating the stator ring 31 with bores 32 instead of slots 29, the ratio of shear edges to passage area is increased compared to slots 29, which can have a positive effect on the formation of the emulsion.
[0098] Returning to the second embodiment of the homogenizer 1 according to Fig. 11 with the closed helical stator toothing 12, as the schematic representations in Figs. 13, 14 and 15 (Fig. 15 is a view along section line HH in Fig. 14) illustrate, the side walls 33 of the stator teeth 27 and thus of the stator slots 29 run radially at every point in the circumferential direction of the stator toothing 12. This configuration can also be described as the slot or groove guide lines always being perpendicular to the central axis, i.e., to the axial product flow direction L (Fig. 22), as illustrated in the schematic representation in Fig. 13. This results in a helical or twisted milling or a helical or twisted longitudinal profile of the stator slots 29, which is preferably produced by means of a 5- or more-axis milling machine or a 3D printing method.This design advantageously ensures that the shearing effect remains constant over the length of the stator slots or grooves 29.
[0099] In a fourth embodiment of the homogenizer 1 according to Fig. 16, the stator slots 29 or stator bores 32 are designed to taper conically in the radial product flow direction to increase the expansion of the microdroplets, which also contributes to an improvement in the shearing effect.
[0100] Furthermore, it is advantageous and therefore preferred for the stability (reduction of deflection and bending stresses) of the stator teeth 27, but also of the rotor teeth 17 and, if applicable, the suction 18 and / or pump vanes 19 (Figure 6), if their profile or thickness is conically reinforced, so that the profile becomes slimmer against the flow direction L. Especially with an axial extension of the teeth 17 and 27 and, if applicable, vanes 18 and 19, as already mentioned, the centrifugal forces that occur lead to greater deflection and a critical increase in bending stresses in the root area, which is counteracted by the aforementioned conical reinforcement towards the root of the aforementioned teeth 17 and 27 and vanes 18 and 19, which is schematically illustrated in Figure 17 and in Figure 18, which shows a section along the line AA in Figure 17, using the example of the rotor teeth 17.
[0101] Preferably, the number of slots or grooves of the stator 8 is not a common multiple of the number of rotor teeth 17 and, if applicable, pump vanes 19. This allows the sound intensity to be significantly reduced, at least at individual and, in particular, specific frequencies, as demonstrated in tests using a sound spectrum analyzer. Merely as a non-limiting example from the tests, another corresponding embodiment of the homogenizer 1 combines ten rotor slots and thus also rotor teeth 17, five pump vanes 19, and twenty-seven stator slots 18.It has been shown to be advantageous, and is correspondingly preferred in a further embodiment of the homogenizer 1, if the coverage of the stator slots or grooves 29 by the pump vanes 19 is reduced by reducing the number and shortening the arc length of the pump vanes 19, so that the free, undisturbed passage area through the stator 8, or more precisely its stator slots 29, is increased, thereby reducing pressure losses. A schematic representation of this is shown in Fig. 19.
[0102] Yet another preferred embodiment of the homogenizer 1 according to the invention, with reference to the schematic representation of Fig. 20 (here, for example, a circular instead of helical widening), is that the homogenizer 1 contains a housing 2 which widens in a helical manner around the pump vanes 19 according to the principle of a centrifugal pump housing, as the schematic representation of yet another embodiment of the homogenizer 1 illustrates, so that chambers of a pump vane annular gap 34 between a housing 2 of the homogenizer 1 and the pump vanes 19 become successively larger during their rotation until they are ejected into a recirculation connection 35 to a recirculation line (not shown), whereby the delivery volume advantageously increases and the internal pressure losses in the pump vane annular gap 34 decrease.
[0103] Furthermore, a recirculation connection 35 in the form of the product outlet 5 of the homogenizer 1 for product discharge into a circuit (not shown) for returning the product back to the homogenizer 1 for further treatment of the rotor-stator combination is designed similarly to a centrifugal pump. The recirculation connection 35 is formed by a pipe connection, which in particular optionally has an oval cross-section to enable an even more optimal inlet into a recirculation line (not shown) downstream of the recirculation connection 35. Alternatively or additionally, the recirculation connection 35 and / or at least the region of the recirculation line 35 adjacent to the latter is conically narrowed in the flow direction. Fig. 21 shows an illustrative example of this.
[0104] In the homogenizer 1 according to the invention, the individual embodiments and their combinations ensure that, in particular, the pumping power from the homogenizer 1 into a further container of the vacuum processing system (not shown), into which the homogenizer 1 is preferably integrated, is realized in the recirculation connection 35 and or at least the region of the recirculation line 35 adjacent to the latter in a substantially turbulence-free manner, which further improves the product throughput and product quality.
[0105] Furthermore, it can advantageously be provided that in the homogenizer 1 according to the invention, the rotor-stator combination is designed in two or more stages, i.e., radially outside the innermost stator ring, there is again a circular arrangement with rotor teeth 17 and, adjacent to them radially outside, another stator ring, which can be repeated further. This would increase the shearing effect.
[0106] Advantageously, in the homogenizer 1 according to the invention, the rotor teeth 17 can be extended axially relative to the axial product flow direction L to increase the flow area (slot or groove area) and to match the corresponding length of the stator slots 29 or the corresponding axial extent of the perforation of the stator ring 31 compared to the prior art designs. Likewise, with respect to the rotor teeth 17, the pump impeller, i.e., the pump impellers 19 radially outside the stator 8, can also be extended axially relative to the axial product flow direction L compared to the prior art designs, which leads to an improvement in the pumping effect and an increase in the product flow rate.
[0107] The homogenizer 1, which preferably uses one or more of the previously explained design options, can be part of a vacuum processing system (not shown).
[0108] Furthermore, the present documents disclose correspondingly advantageous operating and manufacturing methods based on the homogenizer 1 according to the invention and the corresponding vacuum processing system, as well as the use of such a homogenizer 1 according to the invention and such a vacuum processing system for specific product types, products and results, which will be readily apparent to the person skilled in the art from the individual or multiple design options shown in the drawing and explained above.
[0109] Below, some further details, possibilities, examples, and applications of the homogenizer 1 and the vacuum processing system with such a homogenizer 1 are provided for understanding and explanation, without the invention being limited to individual or specific embodiments. Such homogenizers 1 are not limited to use as components or parts of vacuum processing systems, but can also be designed as stand-alone units or immersion homogenizers, or used as DIL (= inline dispersers). A suspended design of the homogenizer 1 in a process vessel without a circulation line is also possible.
[0110] In particular, such homogenizers 1 are designed to meet the requirements of the food industry, such as the production of ketchup, mayonnaise, sauces, dressings, etc. as a hot and cold process, as well as the cosmetics and pharmaceutical industry, such as the production of high-quality emulsions and suspensions for lotions, creams, gels, ointments, etc.
[0111] In vacuum processing systems, the homogenizer 1 is often advantageously installed below the process vessel of the vacuum processing system. This configuration ensures reliable premixing and even wetting of the dry substances in the liquid phase from the process and / or storage vessel immediately before passing through the homogenizer 1. The gear-ring homogenizer 1 applies the shear energy to the product in a defined manner and conveys it. The recirculation line is located downstream of the homogenizer 1 and guarantees the forced flow of the product back into the process vessel. This closes the product cycle and ensures vertical mixing in the process vessel. It also offers the possibility of sampling and product discharge. In the process vessel, a scraper agitator prevents product from adhering to the inner wall of the process vessel during the heating and cooling phases.Furthermore, it effectively supports macro-mixing of the product in the process vessel. An integrated vacuum system assists the drawing of liquid and dry ingredients into homogenizer 1. Furthermore, the precise control of the process vacuum can influence the product quality and characteristics.
[0112] Numerous tests were carried out with the homogenizer 1 according to the invention with the following results:
[0113] The tests carried out have shown that by optimising the homogeniser
[0114] 1 a significantly higher oil dosing rate (mayonnaise was tested) can be achieved. The - TI -
[0115] The oil dosing rate is a significant time factor in mayonnaise production. It was determined that the new rotor design and obliquely slotted stator achieved the best results compared to state-of-the-art designs, especially those without the groove-like design 13.
[0116] For example, using a homogenizer 1 with a 158 mm outer circumference of the pump vanes 19, an oil dosing rate of up to 3.04 kg / s was achieved, compared to 1.21 kg / s without the inventive design. The droplet distribution under the microscope was comparable to state-of-the-art designs. Furthermore, various products such as 80% mayo, 30% cold-swelling mayo, and 30% cold-swelling mayo could be produced, with no significant differences in the various viscosities.
[0117] Regarding sound emissions, qualitative measurements showed that the homogenizer 1 according to the invention is quieter during an emulsification process compared to state-of-the-art designs. A further sound spectrum analysis showed that the obliquely slotted stator has a generally significant dampening effect on the sound intensity at certain frequency points.
[0118] In the case of water, a significant increase in flow rate was measured, depending on the speed by a factor of 1.3 to 3, with a simultaneous increase in pressure by a factor of approximately 1.1. This is accompanied by a virtually unchanged electrical power consumption of the homogenizer drive.
[0119] In this respect, all this shows a significant increase in efficiency of the homogenizer 1 according to the invention, as summarized below:
[0120] Number of stator components: 1
[0121] Number of rotor components: 1 (rotor-pump wheel) Pumping capacity (flow rate, pressure): significantly increased Shear energy input: significantly increased Motor power requirement: equal to lower Noise emission: equal to lower Emulsion quality: equivalent Hygiene: better Specific energy consumption for produced batch: significantly lower Eco-balance: significantly better
[0122] Flow optimization: significantly better Manufacturing quality of components: significantly improved Mayo oil dosing rate [kg / s]: significantly improved
[0123] Furthermore, the present documents disclose correspondingly advantageous operating and manufacturing methods based on the homogenizer 1 according to the invention and the corresponding vacuum processing system and variants, as well as the use of such a homogenizer 1 according to the invention and such a vacuum processing system for specific product types, products and results.
[0124] The invention is presented merely by way of example with reference to the exemplary embodiments in the description and the drawings and is not limited thereto. Rather, it encompasses all variations, modifications, substitutions, and combinations that a person skilled in the art can derive from the present documents, particularly within the scope of the claims and the general representations in the introduction to this description, as well as the description and drawings of the exemplary embodiments, and can combine with their expert knowledge and the state of the art. In particular, all individual features and design options of the exemplary embodiments can be combined with one another, such as a rotor with teeth and perforation holes alternating around the circumference.
[0125] List of reference symbols
[0126] 1 homogenizer
[0127] 2 housings
[0128] 3 Mixing chamber
[0129] 4 Product inlet
[0130] 4a, b, c, d Product inlet
[0131] 5 Product outlet
[0132] 5a, b Product drain
[0133] 6 Rotor
[0134] 7 Rotor shaft
[0135] 8 Stator
[0136] 9 rotor plates
[0137] 10 Rotor gearing
[0138] 11 Shear gap
[0139] 12 Stator teeth
[0140] 13 hollow groove-like design
[0141] 13a Partially circular fillet with a part-circular cross-section with a constant radius
[0142] 13b Partially ellipsoidal groove with partially ellipsoidal cross-section with in the course of the
[0143] Curvature of continuously changing radius
[0144] 13c Truncated cone design with at least one slope in cross-section formed by at least one truncated cone
[0145] 14 inner ring
[0146] 15 mixing / conveying blades
[0147] 16 Dispersing disc
[0148] 17 rotor teeth
[0149] 18 suction blades
[0150] 19 pump vanes
[0151] 20 blading
[0152] 21 end area of 17
[0153] 22 leading rotor tooth flank 23 trailing rotor tooth flank
[0154] 24 jetty
[0155] 25 leading pump vane flank
[0156] 26 trailing pump vane flank
[0157] 27 stator teeth
[0158] 28 Stator base ring
[0159] 29 stator slots
[0160] 30 stator ring
[0161] 31 perforated stator ring
[0162] 32 stator holes
[0163] 33 side walls
[0164] 34 Pump vane gap
[0165] 35 Recirculation connection
[0166] D Direction of rotation
[0167] L axial product flow direction
[0168] R radial product flow direction
[0169] S Product flow
[0170] Sl, 2, 3, 4 product flow
[0171] S5 Product flow
Claims
Claims 1. Homogenizer (1) for homogenizing or dispersing or generally for treating flowable products, comprising a mixing chamber (3) with a product inlet (4) and a product outlet (5) and, in the mixing chamber (3), a rotor shaft (7) supporting a rotor (6), rotatably mounted and capable of being set in rotation by means of a drive, in particular a controllable drive, and a stator (8) cooperating with the rotor (6), wherein the rotor (6) comprises a rotor plate (9) which is concentrically mounted on the rotor shaft (7), and a rotor toothing (10) on the rotor plate (9) which is arranged radially within a stator toothing (12) of the stator (8) to form a shear gap (11),and wherein an axial product flow direction (L) is defined downstream of the product inlet (4) along the rotor shaft (7) towards the rotor plate (9), and a radial product flow direction (R) is defined from the rotor shaft (7) radially along the rotor plate (9) and between the rotor toothing (10) and the stator toothing (12), from which the product can flow to the product outlet (5), wherein at the transition from the rotor shaft (7) to the rotor plate (9), a groove-like configuration (13) surrounds the rotor shaft (7), preferably with at least approximately flush transitions to the rotor shaft (7) and the rotor plate (9), so that the flowable products to be treated are deflected from the axial product flow direction (L) by the groove-like configuration (13), in particular continuously or via at least one slope, into the radial product flow direction (R) during operation of the homogenizer (1).
2. Homogenizer (1) according to claim 1, wherein the groove-like configuration (13) at the transition between the rotor axis (7) and the rotor plate (9) consists of a negative or concave circumferential fillet, and / or wherein the groove-like configuration (13) is provided on an inner ring (14) of the rotor (6) that projects axially from the rotor plate (9) against the axial product flow direction (L) and is thus a component of the rotor (6) and in particular integral with the rotor plate (9) and / or the rotor shaft (7) and preferably on the one hand at its radially narrowest end at least approximately flush with the rotor shaft le (7) and on the other hand runs at least approximately flush into the rotor plate (9), and / or wherein the groove-like configuration (13) a) is a part-circular groove (13a) with a part-circular cross-section with a constant radius, wherein the radius is in particular in the range from 10 mm to 100 mm and preferably in the range from 30 mm to 80 mm and particularly preferably in the range from 40 mm to 65 mm, or b) is a part-ellipsoidal groove (13b) with a part-ellipsoidal cross-section with a radius that changes continuously over the course of the curvature, wherein the radii of the part-ellipsoidal cross-section are in particular in the range from 10 mm to 100 mm and preferably in the range from 30 mm to 80 mm and particularly preferably in the range from 40 mm to 65 mm, or c) is a truncated cone configuration (13c) with at least one bevel in cross-section, which is formed by at least one truncated cone is formed.Homogenizer (1) according to claim 1 or 2, wherein a mixing / conveying blade (15) and / or a dispersing disk (16) is / are arranged upstream of the rotor (6) with respect to the axial product flow direction (L) coaxially to the rotor (6), wherein the mixing / conveying blade (15) is preferably drive-connected to the rotor shaft (7) and / or the dispersing disk (16) is arranged coaxially to the rotor shaft (7), wherein optionally the dispersing disk (16) is arranged downstream of the mixing / conveying blades (15) in the axial product flow direction (L).Homogenizer (1) according to one of the preceding claims, wherein the rotor toothing (10) contains individual rotor teeth (17) which are arranged coaxially around the rotor shaft (7) on a rotor tooth circular line and are connected to the rotor plate (9) and are in particular integral, and which protrude from the rotor plate (9) counter to the axial product flow direction (L), wherein furthermore suction vanes (18) are preferably attached to the rotor plate (9) radially inside the rotor teeth (17) and likewise protruding counter to the axial product flow direction (L) on a suction vane circular line coaxially around the rotor shaft (7) and are in particular formed integrally, and / or pump vanes (19) are attached to the rotor plate (9) radially outside the rotor teeth (17) and the stator toothing (12) and likewise protruding counter to the axial product flow direction (L) on a pump vane circular line. circular line coaxially around the rotor shaft (7) and are in particular formed integrally, wherein furthermore in particular the groove-like configuration (13) a) is a part-circle-like groove (13a) with a part-circle-like cross-section with a constant radius, wherein the radius is determined by the ratio Outer radius of the suction blades / radius of the groove and the ratio has a value of 0.2 to 5, preferably 0.4 to 3 and particularly preferably 0.5 to 1.5, or b) a partially ellipsoidal groove (13b) with a partially ellipsoidal cross section with a radius that changes continuously over the course of the curvature, the radii being determined by the ratio Outer radius of the suction blades / local radius of the groove and the ratio has a value of 0.2 to 5, preferably 0.4 to 3 and particularly preferably 0.5 to 1.
5. Homogenizer (1) according to claim 4, wherein the rotor teeth (17) and in particular also optionally the suction vanes (18) and / or the pump vanes (19), which together can also be referred to as blading (20) of the rotor (6), are designed with a fluidically optimized curvature, in that preferably for the individual teeth or vanes, i.e. the rotor teeth (17), suction vanes (18) and / or pump vanes (19), the tooth or vane curvatures are determined on the basis of the calculation of velocity vectors, wherein preferably the curvature of the rotor teeth (17) in an end region (21) of the flank (22) pointing in the direction of rotation (D) of the rotor (6) is convex in cross-section and preferably tapering to a point in the direction of rotation of the rotor and in particular without kinks,and / or wherein the rotor teeth (17) are preferably trapezoidal in cross-section, and / or wherein the flank (22) of the rotor teeth (17) pointing in the direction of rotation of the rotor (6), also called the leading rotor tooth flank (22), and if the leading rotor tooth flank (22) itself is curved, the connecting line of the end edges of the leading rotor tooth flank (22), encloses a smaller angle to the radius of the rotor plate (9) than the trailing flank (23) of the rotor teeth (17) and if the trailing rotor tooth flank (23) itself is curved, the connecting line of the end edges of the trailing rotor tooth flank (23), and / or, wherein the rotor teeth (17) preferably taper radially towards their sides facing the stator (8), ie towards the pressure side, in particular continuously and preferably curved, or the outer diameter of each rotor tooth (17) is increasingly reduced or made smaller in the direction of rotation, so that a wedge-shaped tapered gap is formed between the rotor teeth (17) and the stator teeth (27) of the stator toothing (12), and / or wherein preferably the suction vanes, ie the individual suction vanes (18), are combined with individual ones of the rotor teeth (17), such as in particular fused or by a web (24) are integrally connected, wherein in particular every second rotor tooth (17) is combined or fused with a suction vane (18) or is integrally connected by a web (24). Homogenizer (1) according to claim 4 or 5, wherein in the case of the pump vanes (19), the entire flank pointing in the direction of rotation of the rotor (6), also the leading pump vane flank (25), is convexly curved in cross-section, in particular tapering to a point in the direction of rotation (D) of the rotor (6), and alternatively or additionally the cross-section is trapezoidal, wherein furthermore preferably the angle of the flank of the pump vanes pointing in the direction of rotation (D) of the rotor (6), i.e. the leading pump vane flank (25), and if the leading pump vane flank (25) itself is curved, the connecting line of the end edges of the leading pump vane flank (25), to the radius of the rotor plate (9) encloses a larger angle than the trailing flank of the pump vanes, i.e. the trailing pump vane flank (26), and if the trailing pump vane flank (26) itself is curved, the connecting line of the end edges of the trailing pump vane flank (26), and / or wherein preferably the trailing flank (26) of the pumping vanes (19) is convex in cross-section, in particular over the entire cross-sectional length, and / or wherein preferably the vane geometry of the pumping vanes (19) is optimized in terms of flow technology so that an optimal outflow of the product into a recirculation line or pressure line or into the product outlet (5) is enabled, and in particular has a curved shape, and / or wherein the coverage of the stator slots or grooves (29) by the pumping vanes (19) is reduced by reducing the number and shorter arc measure of the pumping vanes (19), so that the free, undisturbed passage area through the stator (8) or more precisely says whose stator slots (29) are enlarged and pressure losses are thereby reduced. Homogenizer (1) according to one of the preceding claims, wherein the stator toothing (12) contains individual stator teeth (27) arranged coaxially on a circular line around the rotor shaft (7), which preferably protrude from a stator base ring (28) in the axial product flow direction (L) and between which continuous stator slots (29) are defined in the radial product flow direction (R), or wherein the stator toothing (12) is formed by a perforated stator ring (31) which sits coaxially on the stator base ring (28) and contains continuous stator bores (32) in the radial product flow direction (R) which form the perforation, wherein preferably if necessary.the stator teeth (27) are connected at their end facing away from the stator base ring (28) by a stator ring (30) which forms a stator stabilizing ring (30), so that the stator slots (29) are defined circumferentially between the stator teeth (27) and axially limited by the stator base ring (28) and the stator stabilizing ring (30), wherein furthermore preferably the stator toothing (12) is a helical toothing with respect to the axial product flow direction (L), and / or wherein preferably the side walls (33) of any of the stator teeth (27) and thus of the stator slots (29) extend radially at every point in the circumferential direction of the stator toothing (12), wherein further preferably the stator slots (29) or stator bores (27) and / or spaces between the rotor teeth are designed to narrow conically in the radial product flow direction (R). Homogenizer (1) according to one of claims 4 to 7, wherein the profile or the thickness of the stator teeth (27), rotor teeth (17) and optionallySuction (18) and / or pumping vanes (19) are conically reinforced, so that the profile becomes slimmer in the direction of the end facing away from the stator base ring (28) at the stator teeth (29) and at the tooth or vane ends facing away from the rotor plate (9) at the rotor teeth (17) and optionally suction (18) and / or pumping vanes (19), and / or wherein preferably the number of slots or grooves of the stator (8) is not a common multiple of the number of rotor teeth (17) and optionally pumping vanes (19). Homogenizer (1) according to one of claims 4 to 7, wherein the homogenizer (1) contains a housing (2) which widens in a helical manner around the pump vanes (19) according to the principle of a centrifugal pump housing, so that chambers of a pump vane annular gap (34) between a housing (2) of the homogenizer (1) and the pump vanes (19) become successively larger during their rotation until they are ejected into the product outlet (5) or a recirculation connection (35) to a recirculation line or a pressure line or the product outlet (5).Homogenizer (1) according to one of the preceding claims, wherein a recirculation connection (35) of the homogenizer (1) for product discharge into a circuit for returning the product back to the homogenizer (1) for further treatment is designed downstream of the rotor-stator combination similar to a centrifugal pump, wherein preferably the recirculation connection (35) is formed by a pipe connection, which in particular has an oval cross-section, and / or preferably the recirculation connection (35) and / or at least the region of the recirculation line adjacent to the latter is conically narrowing in the flow direction, and / or wherein the rotor-stator combination is designed in two or more stages. Vacuum processing system with a homogenizer (1), wherein the homogenizer (1) is designed according to one of the preceding claims.Method for homogenizing or dispersing or generally for treating flowable products using a homogenizer (1), wherein the homogenizer (1) is designed according to one of the preceding claims.