Systems and methods for carbonating liquids

Abstract

The embodiments described herein relate to systems and methods for carbonating a liquid at ambient temperature. The system may include a liquid source, a carbon dioxide source, and a contactor for carbonating the liquid. The contactor may include a channel and a sparge for carbonating the liquid flowing through the channel. The system may produce a liquid with a high level of carbonation at ambient temperature. The sparge may generate micro- or nano-bubbles to enable cost-effective carbonation at ambient temperature. The bubbles may have an average diameter of 100 μm or less. The system may carbonate the liquid at a rate of 1 gram to 10 grams of carbon dioxide per liter.

Description

[Technical field]

[0001] The present disclosure relates to systems and methods for carbonating liquids, and more particularly, to systems and methods for carbonating liquids with micro- or nano-bubbles of gas (e.g., carbon dioxide) at ambient temperature. Summary of the Invention

[0002] Some embodiments are directed to a system for carbonating a liquid. In some embodiments, the system includes a liquid source, a carbon dioxide source, and a contactor for carbonating the liquid. In some embodiments, the contactor includes a first channel, a second channel, and a sparge. In some embodiments, the first channel is in communication with the liquid source, and the first channel has a first inner diameter. In some embodiments, the first channel includes a first end, a second end, and a first inlet defined in a sidewall of the first channel. In some embodiments, the second channel includes a first end in fluid communication with the second end of the first channel, and the second channel has a second inner diameter smaller than the first inner diameter. In some embodiments, the sparge is disposed at least partially within the first channel and at least partially within the second channel and is configured to generate bubbles having an average diameter of 100 μm or less. In some embodiments, the sparge is configured to provide between 1 gram and 10 grams of carbon dioxide per liter of liquid flowing through the contactor. In some embodiments, the sparge is configured to provide between 1 gram of carbon dioxide per liter of liquid and 10 grams of carbon dioxide per liter of liquid. In some embodiments, the system is configured to operate at ambient temperature.

[0003] In some embodiments, the system further includes a restrictor disposed at a second end of the first channel, the restrictor including a tapered inner surface.

[0004] In some embodiments, the sparge includes pores through which the carbon dioxide flows, hi some embodiments, the pores are located only on the portion of the sparge that is located in the second channel.

[0005] In some embodiments, the sparge includes a sealing end configured to seal a first end of the first channel, a first portion of the sparge coaxial with the first channel, a second portion of the sparge coaxial with the second channel, and a tapered end disposed within the second channel.

[0006] In some embodiments, the system is configured to carbonate the liquid with between 3 grams and 8 grams of carbon dioxide per liter of liquid.

[0007] In some embodiments, the ambient temperature is from about 4°C to about 32°C.

[0008] In some embodiments, the system is configured to carbonate between 1 liter and 10 liters of liquid per minute.

[0009] In some embodiments, the system is configured to carbonate between 200 liters and 2000 liters per minute.

[0010] In some embodiments, the system is configured to carbonate the liquid without heat treatment.

[0011] In some embodiments, the liquid is one of cola, carbonated soft drink, juice, coffee, tea, water, dairy, or a protein-based liquid.

[0012] In some embodiments, the sparge has an outer diameter that is smaller than the second inner diameter such that a sparge gap is formed between the sparge and the second channel.

[0013] In some embodiments, the system has a height of about 2 meters, a length of about 1 meter, and a width of about 1 meter.

[0014] Some embodiments are directed to a method of carbonating a liquid. In some embodiments, the method includes flowing the liquid through a first channel of a contactor at a rate of at least 1 liter to 2000 liters per minute and injecting carbon dioxide bubbles into the liquid by sparging. In some embodiments, the carbon dioxide bubbles have an average diameter of 100 μm or less. In some embodiments, the carbon dioxide bubbles are injected at a rate of 1 gram to 10 grams of carbon dioxide per liter of liquid. In some embodiments, the method includes carbonating the liquid without heat treatment.

[0015] In some embodiments, the method further comprises flowing a liquid through a second channel of the contactor.

[0016] In some embodiments, the first channel has a first inner diameter and the second channel has a second inner diameter that is smaller than the first inner diameter.

[0017] In some embodiments, the sparge is disposed at least partially within the first channel and at least partially within the second channel.

[0018] In some embodiments, the rate is between 500 liters per minute and 2000 liters per minute.

[0019] In some embodiments, the carbon dioxide is injected at a rate of 5 grams to 10 grams of carbon dioxide per liter of liquid.

[0020] In some embodiments, the liquid has a temperature of about 4°C to about 32°C.

[0021] Some embodiments are directed to a system for carbonating a liquid. In some embodiments, the system includes a contactor for carbonating a liquid flowing through the contactor. In some embodiments, the contactor includes a first channel having a first inner diameter, a second channel in fluid communication with the first channel, the second channel having a second inner diameter, and a sparge disposed at least partially within the first channel and at least partially within the second channel. In some embodiments, the sparge is configured to deliver carbon dioxide bubbles to the liquid at a rate of at least 5 grams of carbon dioxide per liter of liquid flowing through the carbonator. In some embodiments, the bubbles have an average diameter of 100 μm or less. In some embodiments, the system is configured to operate at ambient temperature.

[0022] In some embodiments, the second inner diameter is smaller than the first inner diameter.

[0023] In some embodiments, the system is configured to carbonate between 1 liter and 2000 liters of liquid per minute.

[0024] In some embodiments, the sparge has an outer diameter smaller than the second inner diameter such that a sparge gap is formed between the sparge and the second channel, the sparge gap being between 0.75 mm and 10 mm.

[0025] In some embodiments, the sparge is coaxial with the first channel and coaxial with the second channel.

[0026] In some embodiments, the sparge includes a sealing end configured to seal the first end of the first channel.

[0027] In some embodiments, the sparge is a sintered sparge. [Brief description of the drawings]

[0028] The accompanying drawings, which are incorporated in and form a part of this specification, illustrate the disclosure and, together with the specification, further serve to explain the principles of the disclosure and to enable those skilled in the art to make and use the disclosure. [Figure 1] 1 illustrates a carbonator according to some embodiments. [Diagram 2] 1 illustrates a flow chart of a system for preparing carbonated beverages according to some embodiments. [Figure 3A] 1 illustrates a flow chart of a carbonator according to some embodiments. [Figure 3B] 1 illustrates a flow chart of a carbonator according to some embodiments. [Figure 4] 1 illustrates a contactor according to some embodiments for use with a carbonator. [Diagram 5] 1 illustrates water flow through a contactor according to some embodiments. [Figure 6] Illustrates a method of preparing a carbonated liquid according to some embodiments. [Figure 7] Illustrates a method of preparing a carbonated liquid according to some embodiments. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0029] References herein to "one embodiment," "an embodiment," "an exemplary embodiment," "some embodiments," and the like indicate that the embodiment being described may include a particular feature, structure, or characteristic, but all embodiments may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases do not necessarily refer to the same embodiment. Furthermore, when a particular feature, structure, or characteristic is described in connection with one embodiment, the impact of such feature, structure, or characteristic on other embodiments, whether or not explicitly described, is intended to be within the knowledge of one of ordinary skill in the art.

[0030] Carbonated beverages are often made by injecting carbon dioxide into a liquid. These carbonation methods typically use a thermal treatment (e.g., chilling) during carbonation. For example, existing methods require the liquid to be chilled before or after carbonation because the carbonation process is enhanced at lower temperatures. Otherwise, there is a limit to the degree of carbonation possible if not chilled. This is because lower temperatures allow for carbonation (i.e., dissolution of carbon dioxide into the liquid) at the required rate by ensuring the appropriate solubility required for the product. If the temperature is too high, existing processes do not allow for higher carbonation levels that are practical or economical. Although chilled carbonated liquids can be filled into containers, the liquid must be warmed to room temperature before further processing (e.g., labeling, packaging, storage, transportation, etc.).

[0031] Chilling and warming require significant capital expenditures for equipment and real estate, such as cooling equipment (e.g., chillers) and warming equipment (e.g., tunnel warmers). This equipment can use significant amounts of space, utilities, and water, and existing systems require significant operating costs. Existing methods of carbonating liquids at a rate of 600 L / min require approximately 42 kW of energy input for every 1° C. change in temperature. For example, chilling from 15° C. to 5° C. and then warming back to 15° C. requires approximately 840 kW of energy input. Additionally, existing systems that do not use chilling before carbonation have limited compatibility with standard beverage production machinery, cannot be retrofitted to existing systems, and are not compatible with highly carbonated liquids (e.g., carbonated soft drinks such as cola and seltzer).

[0032] Additionally, existing methods are unable to achieve high dissolution rates without adding excess carbon dioxide to the liquid, which can waste large amounts of carbon dioxide during the carbonation process and result in inconsistent product quality.

[0033] The embodiments described herein overcome these and other challenges by providing, among other benefits, systems and methods for non-thermal carbonation of liquids. Additionally, the embodiments described herein use smaller air bubble sizes to increase dissolution rates and enable room temperature carbonation. For example, the air bubbles can be microbubbles or nanobubbles. The embodiments described herein enable non-thermal carbonation of liquids without adversely affecting the attributes (e.g., taste, color, shelf life, etc.) of the resulting carbonated beverage. Additionally, the embodiments described herein can be used in a variety of applications, including manufacturing lines for production-scale operations to single-serve operations (e.g., homebrew systems and fountain dispensers). The embodiments described herein can also improve the consistency of the final product and reduce wasted carbon dioxide by enabling a full dissolution approach to carbonation. In an embodiment, the carbonation system 30 can include a contactor 200 configured to provide non-thermal carbonation of liquids using smaller air bubble sizes.

[0034] FIG. 1 illustrates a carbonator according to some embodiments. For example, the carbonator 100 may include a contactor 200, a pump 300, a melt pipe 400, a restrictor valve 500, and an isolation valve 600. The carbonator 100 may be sized to allow for retrofitting in a production-scale system (e.g., system 1 shown in FIG. 2). For example, the carbonator 100 may have a width of about 1 meter, a length of about 1 meter, and a height of about 2 meters. The size of the carbonator 100 allows for the retrofitting of an existing system with a carbonator disclosed herein (e.g., the carbonator 100). In some embodiments, the carbonator 100 is a retrofit carbonator for replacing an existing carbonation system.

[0035] FIG. 2 illustrates a flow chart of a system for bottling or canning carbonated beverages. For example, system 1 may include a gas source 10, a liquid source 20, a carbonation system 30, a filling system 40, and a packaging system 50. In some embodiments, gas source 10 is a source of carbon dioxide, nitrous oxide, nitrogen, or mixtures thereof. In some embodiments, liquid source 20 is a source of beverage liquid. In some embodiments, liquid source 20 includes one or more of water, juice, dairy, sweeteners, and flavorings. In some embodiments, liquid source 20 includes water. In some embodiments, liquid source 20 includes water, sweeteners, and flavorings. In some embodiments, liquid source 20 includes cola. In some embodiments, carbonation system 30 includes equipment for carbonating liquid from liquid source 20. In some embodiments, carbonation system 30 includes a carbonator (e.g., carbonator 100) that produces carbonated liquid. In some embodiments, the filling system 40 includes equipment for filling containers (e.g., bottles or cans) with carbonated liquid. In some embodiments, the packaging system 50 includes equipment for capping and labeling containers prior to dispensing. In some embodiments, the carbonator 100 is used in a homebrew system, where the filling system 40 fills bottles, glasses, or cups at home. In some embodiments, the carbonator 100 is used in a fountain dispenser, where the filling system 40 fills cups at the point of sale.

[0036] FIG. 3A illustrates a flow chart of a carbonator 100 according to some embodiments. The carbonator 100 may include a liquid inlet 101, a gas inlet 111, a contactor 200, and a dissolution pipe 400. In some embodiments, the contactor includes a first channel 201, a second channel 221, and a sparge 241. In some embodiments, a gas (e.g., carbon dioxide) flows from a gas source 10 to the gas inlet 111. In some embodiments, a liquid (e.g., water) flows from a liquid source 20 to the liquid inlet 101. As shown in FIG. 3A, the liquid may flow through the liquid inlet 101 to the first channel 201, from the first channel 201 to the second channel 221, and from the second channel 221 to the dissolution pipe 400. In some embodiments, the liquid flows at a flow rate of about 0.02 L / min to about 2000 L / min (e.g., about 0.2 L / min to about 6 L / min, about 1.5 L / min to about 6 L / min, about 3.5 L / min to about 75 L / min, about 7.5 L / min to about 20 L / min, about 3 L / min to about 15 L / min, or about 150 L / min to about 1000 L / min). In some embodiments, the carbonator 100 is used in a homebrew beverage system and the liquid flows at a flow rate of about 0.2 L / min to about 6 L / min (e.g., 1.5 L / min to about 6 L / min). In some embodiments, the carbonator 100 is used in a production scale system and the liquid flows at a flow rate of about 150 L / min to about 1000 L / min. In some embodiments, the liquid flows at a rate of about 400 L / min to about 600 L / min (e.g., about 450 L / min to about 500 L / min). In some embodiments, the liquid flows at a rate of about 475 L / min. In some embodiments, the liquid flows at a rate of about 1000 L / min to about 1500 L / min (e.g., about 1100 L / min to about 1300 L / min, or about 1150 L / min to about 1200 L / min). In some embodiments, the liquid flows at a rate of about 1180 L / min.

[0037] 3A, gas may flow through gas inlet 111 to sparge 241, from sparge 241 to first channel 201 or second channel 221, and from first channel 201 or second channel 221 to dissolution pipe 400. In some embodiments, gas flows from sparge 241 to both first channel 201 and second channel 221. In some embodiments, gas flows from sparge 241 to only one of first channel 201 or second channel 221. In some embodiments, gas flows from sparge 241 to only second channel 221. As gas flows from sparge to first channel 201 or second channel 221, the gas mixes with the liquid flowing through first channel 201 or second channel 221 to form a liquid / gas mixture. The liquid / gas mixture then flows from the second channel 221 to the dissolution pipe 400 where the gas dissolves in the liquid.

[0038] 3B illustrates a flow chart for a carbonator 100 having two or more contactors 200. In some embodiments, the carbonator 100 can have one or more (e.g., two or more, or three or more) contactors 200. In some embodiments, the carbonator 100 can have multiple carbonators operating in parallel. In some embodiments, the carbonator 100 can have multiple carbonators operating in series.

[0039] For example, the carbonator 100 may include a liquid inlet 101, a gas inlet 111, a first contactor 200a, a second contactor 200b, and a melt pipe 400. In some embodiments, as shown in FIG. 3B, the carbonator 100 includes two contactors (e.g., a first contactor 200a and a second contactor 200b) operating in parallel. In some embodiments, the first contactor 200a and the second contactor 200b are the same contactor. In some embodiments, the first carbonator 200a and the second carbonator 200b are different contactors.

[0040] In some embodiments, the carbonator 100 can include two contactors (e.g., contactors 200a and 200b) that can operate simultaneously. In some embodiments, one of the two contactors 200a and 200b can be turned off to adjust the flow rate through the carbonator 100. For example, in some embodiments, the contactor 200a can operate while the contactor 200b is turned off. In some embodiments, each contactor 200a and 200b includes a valve configured to allow or prevent flow through the contactors 200a and 200b. This can allow for easy adjustment of the flow rate. In some embodiments, each contactor (e.g., contactors 200a and 200b) operates at the same flow rate or different flow rates. For example, in some embodiments, the liquid can flow through the contactor 200a at a first rate and through the contactor 200b at a second rate. In some embodiments, the first rate is equal to the second rate. In some embodiments, the first rate is different from the second rate. In some embodiments, the gas (e.g., carbon dioxide) can flow through each contactor at the same rate or at different rates. For example, in some embodiments, the liquid can flow through contactor 200a at a first rate and through contactor 200b at a second rate. In some embodiments, the first rate is equal to the second rate. In some embodiments, the first rate is different from the second rate. In some embodiments, the gas can flow through only one of the contactors 200a or 200b.

[0041] 4 illustrates a contactor used in a carbonator according to some embodiments. Contactor 200 may include a first channel 201, a second channel 221, a sparge 241, and a restrictor 261. In some embodiments, first channel 201 includes a first end 203, a second end 205, a liquid inlet channel 207, and a liquid inlet opening 209. In some embodiments, second channel 221 includes a first end 223, a second end 225, and an outlet 227. In some embodiments, sparge 241 includes a sealing end 243, a sparge end 245, a gas inlet 247, and a gas channel 249.

[0042] In some embodiments, the second end 205 of the first channel 201 and the first end 223 of the second channel 221 are coupled together such that the first channel 201 and the second channel 221 are in fluid communication. In some embodiments, the first channel 201 is in fluid communication with the liquid inlet channel 207. In some embodiments, liquid flows through the liquid opening 209 and through the liquid inlet channel 207 into the first channel 201.

[0043] In some embodiments, first channel 201 and second channel 221 each have an inner diameter. In some embodiments, first channel 201 has an inner diameter of about 15 mm to about 40 mm (e.g., about 20 mm to about 35 mm or about 25 mm to about 30 mm). In some embodiments, first channel 201 has an inner diameter of about 20 mm.

[0044] In some embodiments, the second channel 221 has an inner diameter of about 10 mm to about 25 mm (e.g., about 11 mm to about 20 mm or about 12 mm to about 16 mm). In some embodiments, the second channel 221 has an inner diameter of about 14 mm. In some embodiments, the inner diameter of the first channel 201 is larger than the inner diameter of the second channel 221. In some embodiments, the inner diameter of the first channel 201 is the same as the inner diameter of the second channel 221.

[0045] The contactor 200 may include a sparge 241. As shown in FIG. 4, the sparge 241 may be at least partially disposed within and coaxial with the first channel 201 and the second channel 221. In some embodiments, the sparge 241 is at least partially disposed within the first channel 201. In some embodiments, the sparge 241 is at least partially disposed within the second channel 221. In some embodiments, the sparge 241 is at least partially disposed within both the first channel 201 and the second channel 221. In some embodiments, the sparge 241 is coaxial with the first channel 201. In some embodiments, the sparge 241 is coaxial with the second channel 221. In some embodiments, the sparge 241 is coaxial with both the first channel 201 and the second channel 221.

[0046] A variety of factors can affect the performance of the contactor 200. These factors include, among others, the sparge gap, the pressure within the contactor, and the velocity of the fluids (i.e., gas and liquid) flowing through the contactor. Each of these is discussed in detail below.

[0047] As illustrated in FIG. 5, the sparge 241 may be positioned in the first channel 201 and / or the second channel 221 to form a sparge gap 229 between a surface 251 of the sparge 241 and a wall of the contactor (e.g., wall 222 of the second channel 221). In some embodiments, the sparge gap 229 may be formed by an annular space between the sparge 241 and an outer wall of the contactor, as illustrated in FIG. 5. The size of the sparge gap 229 may affect the performance of the carbonator 100. For example, if the sparge gap 229 is too small, the pump required to move fluid through the gap may be too large. Furthermore, if the sparge gap 229 is too small, it may be impractical to manufacture or clean. And if the sparge gap 229 is too large, the liquid flow rate may be too low. In some embodiments, the size of the sparge gap 229 is a distance 231. In some embodiments, distance 231 is between 0.5 mm and about 15 mm (e.g., between about 0.75 mm and about 10 mm, between about 0.75 mm and about 4 mm, between about 2 mm and about 4 mm, or between about 6 mm and about 8 mm). In some embodiments, distance 231 is between about 2 mm and about 4 mm. In some embodiments, distance 231 is about 0.75 mm. In some embodiments, distance 231 is about 1 mm. In some embodiments, distance 231 is about 4 mm.

[0048] Sparge 241 may be comprised of pores disposed in at least a portion of sparge 241 through which gas flows. Sparge 241 may have a pore size of about 0.1 μm to about 30 μm (e.g., about 0.2 μm to about 20 μm, about 0.5 μm to about 10 μm, or about 1 μm to about 3 μm). In some embodiments, sparge 241 has a pore size of about 2 μm.

[0049] In some embodiments, the sealed end 243 of the sparge 241 seals the first end 203 of the first channel 201. The sparge 241 may include a gas inlet 247 at the sealed end 243. In some embodiments, gas (e.g., carbon dioxide) flows through the gas inlet 247 into the gas channel 249. As the gas flows into the sparge 241, the gas exits through a wall (e.g., surface 251) of the sparge 241 and bubbles into the liquid flowing through the first channel 201 and / or the second channel 221. The sparge 241 may have a length of about 75 mm to about 500 mm (e.g., about 75 mm to about 150 mm, about 150 mm to about 450 mm, about 200 mm to about 400 mm, or about 150 mm to about 300 mm). In some embodiments, the sparge 241 has a length of about 75 mm. In some embodiments, the sparge 241 has a length of about 150 mm. In some embodiments, the sparge 241 has a length of about 300 mm. The sparge 241 may have a diameter of about 5 mm to about 300 mm. In some embodiments, the sparge 241 has a diameter of about 5 mm to about 20 mm (e.g., about 10 mm to about 15 mm or about 12 mm to about 13 mm). In some embodiments, the sparge 241 has a diameter of about 12.7 mm. In some embodiments, the sparge 241 has a diameter of about 50 mm to about 300 mm (e.g., about 100 mm to about 200 mm). The sparge 241 may have a sparge area. As used herein, the sparge area is the area through which gas can pass and bubble from the sparge into the liquid. For example, the sparge area of ​​the sparge 241 shown in FIG. 4 may be calculated according to the following formula: Sparge area = 2πrl where r = sparge radius, and l = sparge length. In some embodiments, the sparge area of ​​sparge 241 is about 4000 mm 2 ~ approx. 15,000mm 2 (For example, about 5000 mm 2 ~about 7000mm 2 Or about 11,000 mm 2 ~ approx. 13,000mm 2 In some embodiments, the sparge area is about 6000 mm 2In some embodiments, the sparge area is about 12,000 mm 2 It is.

[0050] FIG. 5 illustrates the flow of fluids through a contactor according to some embodiments. FIG. 5 shows a portion of the contactor 200, including the wall 222, the sparge gap 229, the sparge 241, the sparge surface 251, the liquid 1000, and the gas 1100. FIG. 5 illustrates the effect of fluid velocity on bubble size. For example, as illustrated in FIG. 5, a higher fluid velocity results in the bubbles separating from the surface 251 of the sparge 241 sooner, resulting in a smaller bubble size. For example, arrow 1001 represents a first fluid velocity, arrow 1002 represents a second fluid velocity that is faster than the first fluid velocity, and arrow 1101 represents the gas flow. As illustrated in FIG. 5, a higher fluid velocity (arrow 1002) results in a greater number of smaller bubbles compared to a lower fluid velocity (arrow 1001). Example 1 shows carbonation at various fluid velocities. In some embodiments, the fluid velocity in the contactor 200 is between about 0.5 m / sec and about 12 m / sec (e.g., between about 0.6 m / sec and about 10.5 m / sec or between about 0.5 m / sec and about 5 m / sec). In some embodiments, the fluid velocity is at least 1.5 m / sec.

[0051] The sparge 241 may deliver carbon dioxide bubbles on the order of micrometers or nanometers. The smaller bubbles used in some embodiments disclosed herein result in sufficiently fast carbonation at ambient temperatures to allow for economic viability. For example, Table 1 below shows the number of bubbles and total surface area of ​​the gas bubbles at different bubble diameter sizes for a 1 microliter volume of gas.

[0052] [Table 1]

[0053] As shown in Table 1, 1 μL of gas with a 10 μm bubble diameter has 125 times the total surface area of ​​1 μL of gas with a 1.24 mm bubble diameter. And, it has been discovered that such an increase in gas / liquid contact area under higher pressure compensates for the elevated temperature and makes cold carbonation economically viable. Thus, a gas with a 10 μm bubble diameter should dissolve 125 times faster than a gas with a 1.24 mm bubble diameter. In some embodiments, the sparge 241 generates gas bubbles having an average diameter of about 0.001 μm to about 100 μm (e.g., about 0.01 μm to about 75 μm, about 0.1 μm to about 50 μm, about 1 μm to about 25 μm, or about 30 μm to about 50 μm). In some embodiments, sparge 241 produces gas bubbles having an average diameter of about 50 μm or less (e.g., about 25 μm or less or about 10 μm or less). In some embodiments, sparge 241 produces gas bubbles having an average diameter of about 10 μm to about 50 μm.

[0054] The contactor 200 may include a restrictor 261 disposed at the second end 205 of the first channel 201. In some embodiments, the restrictor 261 has a central opening through which fluid can flow from the first channel 201 to the second channel 221. In some embodiments, the restrictor 261 includes a tapered inner surface to accommodate the difference in inner diameter between the first channel 201 and the second channel 221, as shown in FIG. 4. In some embodiments, the central opening of the restrictor 261 has a diameter at the first end that is equal to the inner diameter of the first channel 201. In some embodiments, the central opening of the restrictor 261 has a diameter at the second end that is equal to the inner diameter of the second channel 221. In some embodiments, the restrictor 261 allows for a transition from the larger size of the first channel 201 to the smaller size of the second channel 221. This helps to increase the velocity within the contactor 200 while preventing recirculation as the flow path narrows.

[0055] The liquid may flow through the first channel 201 and the second channel 221 around the sparge 241. As the liquid flows through the first channel 201 and the second channel 221, gas is injected from the sparge into the liquid to create a liquid / gas mixture. In some embodiments, the sparge 241 includes a sparge end 245. In some embodiments, the sparge end 245 is tapered as shown in FIG. 4. In some embodiments, the sparge end 245 has a blunt end. In some embodiments, the sparge end 245 minimizes the formation of turbulence and recirculation zones in the liquid / gas mixture flowing around the sparge 241 as the liquid / gas mixture passes through the sparge and recombines in the second channel 221. In some embodiments, after passing through the sparge and recombining, the liquid / gas mixture flows through the outlet 227. In some embodiments, the liquid / gas mixture flows through the outlet 227 to the dissolution pipe 400, as discussed in more detail below. As shown throughout the examples, systems according to some embodiments were able to consistently achieve carbonation of greater than 7 g / L (e.g., greater than 8 g / L) across a range of factors.

[0056] The sparge 241 can deliver gas to the liquid at a predetermined rate. In some embodiments, the sparge 241 delivers gas to the liquid at a rate of about 60 g / sec to about 100 g / sec (e.g., about 70 g / sec to about 90 g / sec, or about 80 g / sec to about 85 g / sec). In some embodiments, the sparge 241 delivers gas to the liquid at a rate of about 84 g / sec. In some embodiments, the sparge 241 delivers gas to the liquid at a rate of about 1 mol / sec to about 3 mol / sec (e.g., about 1.5 mol / sec to about 2.5 mol / sec, or about 1.75 mol / sec to about 2.25 mol / sec). In some embodiments, the sparge 241 delivers gas to the liquid at a rate of about 1.9 mol / sec.

[0057] In some embodiments, the sparge 241 is a sintered sparge. Sintered sparges are typically specified to function over a particular areal gas flow rate. The "areal gas flow rate" used is the amount of gas that appears per unit time per unit sparge surface area. If the areal gas flow rate is too high, the bubbles will not effectively dissolve in the liquid because they will grow too large before separating or coalesce before dissolving. If the areal gas flow rate is too low, only the lowest pressure drop pores will show gas flow, which can adversely affect performance. As shown in Example 2, systems according to some embodiments were able to consistently achieve carbonation of more than 7 g / L (e.g., more than 8 g / L) regardless of the areal gas flow rate.

[0058] The contactor 200 may be configured to operate with an inlet gas pressure of at least 5 bar (e.g., at least 15 bar). In some embodiments, the contactor 200 operates with an inlet gas pressure of about 0.5 bar to about 30 bar (e.g., about 5 bar to about 20 bar, about 5 bar to about 15 bar, about 8 bar to about 10 bar, about 15 bar to about 20 bar, about 20 bar to about 24 bar). In some embodiments, the contactor 200 operates with an inlet gas pressure of about 20 bar. In some embodiments, the contactor 200 operates with an inlet gas pressure of about 24 bar. In some embodiments, the contactor 200 operates with an inlet gas pressure of about 28 bar. Example 3 illustrates carbonation at various inlet gas pressures. In some embodiments, the carbonator 100 is used in a homebrew beverage system and the inlet gas pressure is from about 4 bar to about 24 bar (e.g., from about 5 bar to about 15 bar or from about 8 bar to about 10 bar). In some embodiments, the carbonator 100 is used in a production scale system and the inlet gas pressure is from about 4 bar to about 30 bar. Example 4 illustrates the gas pressure after sparging.

[0059] Carbonation in the contactor may be accomplished at ambient temperature. For example, carbonation at ambient temperature may refer to carbonating the water at its inlet water temperature without heating or cooling. Additionally, carbonation at ambient temperature may refer to carbonation at the dew point of the environment in which carbonation occurs. Carbonation at dew point has the added benefit of preventing liquid from accumulating behind the label after the container is filled and labeled. Carbonation in the contactor 200 may be accomplished at ambient temperature. Additionally, as used herein, ambient temperature refers to the temperature of the environment in which the contactor 200 is located. In some embodiments, the ambient temperature is between about 4° C. and about 32° C. In some embodiments, the contactor 200 carbonates the liquid without heat treatment. In some embodiments, the contactor 200 carbonates the liquid at ambient temperature and without heat treatment. In some embodiments, the contactor 200 carbonates the liquid without heating and without cooling the liquid. In some embodiments, the contactor 200 carbonates the liquid at a temperature of about 4° C. to about 30° C. (e.g., about 4° C. to about 20° C., about 10° C. to about 30° C., about 10° C. to about 20° C., about 15° C. to about 30° C., about 18° C. to about 28° C., or about 20° C. to about 25° C.). In some embodiments, the contactor 200 carbonates the liquid at a temperature of about 10° C. to about 20° C. In some embodiments, the contactor 200 carbonates the liquid at a temperature of about 18° C. In some embodiments, the contactor 200 carbonates the liquid at a temperature of about 20° C. In some embodiments, the contactor 200 carbonates the liquid at a temperature of about 25° C. In some embodiments, the contactor 200 carbonates the liquid at a temperature of about 28° C. The flexibility of carbonation at ambient temperatures benefits the carbonation system. For example, influent water temperatures may vary across geographic locations and even within the same location depending on a variety of factors including seasonal weather. This not only eliminates the need for heat treatment and associated equipment, but also allows the same carbonation system and the same operating conditions to be used across a variety of locations. Example 5 illustrates carbonation at various temperatures.

[0060] After flowing through the contactor 200, the liquid / gas mixture may flow through a dissolution pipe 400 to allow the carbon dioxide to dissolve into the liquid. In some embodiments, a pump 300 pumps the liquid / gas mixture from the contactor 200 to the dissolution pipe 400. The dissolution pipe 400 may be used to control the residence time of the liquid / gas mixture. For example, the longer the dissolution pipe 400, the longer the residence time. In some embodiments, the dissolution pipe 400 has a length of about 3 meters to about 20 meters (e.g., about 4 meters to about 7 meters, about 9 meters to about 11 meters, or about 13 meters to about 16 meters). In some embodiments, the dissolution pipe 400 has a length of about 4.7 meters, about 6.5 meters, about 10.5 meters, or about 14.5 meters. As used herein, "residence time" is the amount of time that the liquid spends in the dissolution pipe 400 after exiting the contactor 200 and before reducing the pressure for filling or dispensing. In some embodiments, the liquid / gas mixture has a residence time in the dissolution pipe 400 of about 0.1 seconds to about 10 seconds (e.g., 1 second to about 9 seconds, about 2.8 seconds to about 7.8 seconds, about 2 seconds to about 4 seconds). In some embodiments, the liquid and gas mixture has a residence time of about 3 seconds. As shown in Example 6, at residence times of 2.7 seconds or more, all of the carbon dioxide was dissolved in the liquid. Example 7 illustrates the relationship between dissolution pipe diameter and dissolution pipe length. For example, considering the standard dissolution time, a smaller pipe diameter corresponds to a longer pipe to dissolve all of the carbon dioxide.

[0061] Carbonator 100 may produce carbonated liquid. Sparge 241 may be configured to provide from about 1 gram to about 10 grams (e.g., from about 3 grams to about 8 grams or from about 5 grams to about 10 grams) of carbon dioxide per liter of liquid flowing through contactor 200. In some embodiments, sparge 241 is configured to provide at least 5 grams (e.g., at least 7 grams or at least 8 grams) of carbon dioxide per liter of liquid flowing through contactor 200. In some embodiments, the carbonated liquid exiting carbonator 100 may have a carbon dioxide concentration of from about 1 gram to about 10 grams (e.g., from about 5 grams to about 10 grams) of carbon dioxide per liter of liquid flowing through contactor 200. In some embodiments, at least 5 grams (e.g., at least 7 grams or at least 8 grams) of carbon dioxide per liter of liquid flowing through contactor 200. In some embodiments, the carbonated liquid has a carbon dioxide concentration of at least 5 grams per liter of liquid. In some embodiments, the carbonated liquid has a carbon dioxide concentration of at least 7 grams per liter of liquid. In some embodiments, the carbonated liquid has a carbon dioxide concentration of at least 8 grams per liter of liquid.

[0062] Carbonator 100 may produce carbonated liquid at a rate of 1 L / min to 2000 L / min. In some embodiments, carbonator 100 produces carbonated liquid at a rate of about 1 L / min to about 10 L / min (e.g., about 2 L / min to about 8 L / min or about 4 L / min to about 6 L / min). In some embodiments, carbonator 100 produces carbonated liquid at a rate of about 200 L / min to about 2000 L / min (e.g., about 400 L / min to about 1000 L / min or about 500 L / min to about 750 L / min). In some embodiments, carbonator 100 produces carbonated liquid at a rate of about 500 L / min. In some embodiments, carbonator 100 produces carbonated liquid at a rate of about 600 L / min.

[0063] As shown through the examples, the systems and methods according to some embodiments can result in complete dissolution of carbon dioxide in the liquid. In contrast to existing systems, this allows for a "complete dissolution" approach when carbonating a liquid. This means that a controlled and precise amount of gas can be added during carbonation to completely dissolve before moving on to further processing (e.g., filling, capping, labeling). In some embodiments, at least 97% of the carbon dioxide dissolves in the liquid. In some embodiments, 100% of the carbon dioxide dissolves in the liquid.

[0064] In some embodiments, all of the carbon dioxide is dissolved in the liquid before it leaves the dissolution pipe 400. This may be accomplished, for example, by incorporating the proper ratio of liquid and carbon dioxide from the liquid inlet 101 and gas inlet 111, respectively. Additionally, this may be accomplished by maintaining the pressure in the contactor 200 and dissolution pipe 400 at an equilibrium pressure where the carbon dioxide not only dissolves but also remains dissolved. In some embodiments, a control system controls the flow of carbon dioxide and liquid such that the proper ratio is maintained. In some embodiments, the liquid pressure from the liquid inlet 101 and the carbon dioxide pressure from the gas inlet 111 are maintained at about 1 bar to about 20 bar (e.g., about 1 bar to about 5 bar) higher than the discharge pressure. In some embodiments, the pressure drop across the contactor 200 is about 1 bar.

[0065] In some embodiments, the control system controls the temperature, pressure, and flow rate of the various streams. In some embodiments, the control system controls the pressure and flow rate of the carbon dioxide entering the contactor 200. In some embodiments, the control system controls the pressure and flow rate of the liquid entering the contactor 200. In some embodiments, the control system controls and monitors the mass and volumetric flow rates of the fluid exiting the dissolution pipe 400 to ensure that these values ​​are equal to the inlet mass and volumetric flow rates of the liquid and carbon dioxide.

[0066] Carbonator 100 may be scaled up or down based on the desired production rate. For example, in some embodiments, carbonator 100 may include a larger or smaller contactor (e.g., contactor 200). Also, in some embodiments, carbonator 100 may include more than one contactor (e.g., contactor 200). In some embodiments, carbonator 100 includes at least two contactors (e.g., at least three contactors). In some embodiments, carbonator 100 includes two contactors operating in parallel, as shown in FIG. 3B.

[0067] FIG. 6 illustrates a method of making a carbonated beverage according to some embodiments. In some embodiments, method 2000 includes steps 2100, 2200, and 2300. In step 2100, a liquid may be prepared. In some embodiments, the liquid is prepared in a liquid source 20. In some embodiments, the liquid is a non-carbonated beverage liquid. In step 2200, the liquid may be carbonated with carbon dioxide to form a carbonated liquid. In some embodiments, the liquid may be carbonated with carbon dioxide bubbles having an average diameter of less than 50 μm. In step 2300, the carbonated liquid is filled into a container (e.g., a bottle or a can).

[0068] FIG. 7 illustrates a method of carbonating a beverage according to some embodiments. In some embodiments, method 3000 includes steps 3100, 3200, 3300, and 3400. In step 3100, a non-carbonated liquid may flow through a first channel (e.g., first channel 201). In step 3200, carbon dioxide may be injected into the liquid to form a liquid / gas mixture. In step 3300, the liquid / gas mixture may flow through a second channel (e.g., second channel 221). In step 3400, carbon dioxide may be injected into the liquid / gas mixture. In some embodiments, in steps 3200 and 3400, the carbon dioxide has an average diameter of less than 50 μm.

[0069] Although the methods and systems described herein are discussed in connection with larger scale beverage production and filling, it should be understood that the systems may be used in smaller scale applications. In some embodiments, the systems disclosed herein may be scaled down for carbonation in a post-mix environment, for example, for use in homebrew beverage applications, or for use in beverage dispensing machines (e.g., fountain dispensers). Smaller scale applications may use the same techniques described above. Additionally, in some embodiments, smaller scale applications such as homebrew beverages and beverage dispensing machines may pre-cool liquids to accommodate consumer preferences for chilled beverages. Exemplary homebrew systems are described in U.S. Application No. 16 / 348,107, filed May 7, 2019, U.S. Application No. 16 / 658,790, filed October 21, 2019, and U.S. Application No. 63 / 310,874, filed February 16, 2022. Each of these applications is incorporated herein by reference in its entirety.

[0070] In contrast to existing beverage dispensing systems that use pre-chilled and post-chilled water circuits to achieve carbonation levels, the embodiments disclosed herein allow for a full dissolution approach as described above. In contrast to existing systems that over-carbonate, full dissolution allows for efficient carbonation at homebrew or beverage dispensing machine scale with little or no carbon dioxide loss. This means fewer carbon dioxide canisters are needed for the same amount of carbonation. The full dissolution approach also improves accuracy and allows carbonation levels to be changed quickly, which is not possible with existing systems. This allows for high carbonation levels in homebrew and fountain systems. EXAMPLES

[0071] Example 1 In one experiment, carbonation was evaluated at various fluid rates. Table 2 shows the fluid rates tested and the maximum carbonation obtained. In this experiment, the liquid was water and the gas was carbon dioxide.

[0072] [Table 2]

[0073] Furthermore, testing showed that all gas entering the contactor was dissolved in the liquid. Thus, the embodiments disclosed herein enable high carbonation levels over a range of fluid velocities.

[0074] Example 2 In one experiment, carbonation was evaluated at various area flow rates. Table 3 shows the area flow rates tested and the maximum carbonation obtained. In this experiment, the liquid was water and the gas was carbon dioxide.

[0075] [Table 3]

[0076] Furthermore, testing showed that all gas entering the contactor was dissolved in the liquid. Thus, the embodiments disclosed herein enable high carbonation levels over area flow rates.

[0077] Example 3 In one experiment, carbonation was evaluated at the gas pressure entering the contactor. Table 3 shows the gas pressures tested and the maximum carbonation obtained. In this experiment, the liquid was water and the gas was carbon dioxide.

[0078] [Table 4]

[0079] Thus, the embodiments disclosed herein enable high carbonation levels across a range of gas pressures.

[0080] Example 4 In one experiment, carbonation was evaluated at various total system pressures and post-sparge gas pressures. Table 4 shows the total system gas pressures after sparging and the maximum carbonation obtained. In this experiment, the liquid was water and the gas was carbon dioxide.

[0081] [Table 5]

[0082] Thus, the embodiments disclosed herein enable high carbonation levels across a range of post-sparge gas pressures.

[0083] Example 5 In one experiment, carbonation was evaluated at various liquid temperatures entering the contactor. Table 5 shows the liquid temperatures tested and the maximum carbonation obtained. In this experiment, the liquid was water and the gas was carbon dioxide.

[0084] [Table 6]

[0085] Additionally, testing has shown that at least 97% of the gas entering the contactor is dissolved in the liquid. Thus, the embodiments disclosed herein enable high carbonation levels across a range of liquid temperatures.

[0086] Example 6 In one experiment, carbonation was evaluated at various residence times. Table 6 shows the residence times tested and the maximum carbonation obtained. In this experiment, the liquid was water and the gas was carbon dioxide.

[0087] [Table 7]

[0088] Furthermore, testing showed that all gas entering the contactor was dissolved in the liquid. Thus, the embodiments disclosed herein allow for high carbonation levels over residence time.

[0089] Example 7 In one experiment, the relationship between the diameter and length of the dissolution pipe and the time to complete dissolution was evaluated. Total maximum carbonation at various gas pressures. The results are shown in Table 7 below. The table shows the various diameter and length combinations that result in a complete dissolution time of 3.8 seconds.

[0090] [Table 8]

[0091] Therefore, the dimensions of the dissolution pipe may be modified to ensure complete dissolution of carbon dioxide in the water.

[0092] As used herein, when the term "about" is used in describing a value or an end point of a range, the disclosure should be understood to include the specific value or end point referred to. As used herein, the term "about" can include ±10%.

[0093] It should be understood that the "Description of Embodiments" section, and any other sections, are not intended to be used to interpret the scope of the claims. The other sections may set forth one or more, but not all, example embodiments of the disclosure as contemplated by the inventor, but are in no way intended to limit the scope of the disclosure and the appended claims.

[0094] The present disclosure has been described above with the aid of functional building blocks illustrating the implementation of certain functions and relationships thereof. The boundaries of these functional building blocks have been arbitrarily defined herein for convenience of description. Alternative boundaries may be defined so long as the specified functions and relationships thereof are appropriately performed.

[0095] The foregoing description of specific embodiments will enable others to easily modify and / or adapt such specific embodiments to various applications by applying knowledge by those skilled in the art, without undue experimentation, and without departing from the general concept of the present disclosure, making the general nature of the present disclosure fully apparent. Such adaptations and modifications are therefore intended to be within the meaning and range of equivalents of the disclosed embodiments, based on the teaching and guidance presented herein. It is to be understood that the language or terminology used herein is for the purpose of description, not limitation, and thus the language or terminology used herein should be interpreted by those skilled in the art in the light of the teaching and guidance.

[0096] The above examples are illustrative of the present disclosure, but are not intended to be limiting. Other suitable modifications and adaptations of the variety of conditions and parameters normally encountered in this field, which will be obvious to those skilled in the art, are within the spirit and scope of the present disclosure.

[0097] The breadth and scope of the present disclosure should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents.

Claims

1. 1. A system for carbonating a liquid, comprising: A liquid source; A source of carbon dioxide; a contactor for carbonating the liquid, the contactor comprising: a first channel in communication with the liquid source, the first channel having a first inner diameter and including a first end, a second end, and a first inlet defined in a sidewall of the first channel; a second channel having a first end in fluid communication with the second end of the first channel, the second channel having a second inner diameter smaller than the first inner diameter; a sparge disposed at least partially within the first channel and at least partially within the second channel, the sparge configured to generate bubbles having an average diameter of 100 μm or less and configured to provide carbon dioxide to the second channel at a rate of 1 gram to 10 grams of carbon dioxide per liter of the liquid flowing through the contactor; The system, wherein the system is configured to operate at ambient temperature.

2. The system of claim 1 , further comprising a restrictor disposed at the second end of the first channel, the restrictor comprising a tapered inner surface.

3. The system of claim 1 , wherein the sparge comprises pores through which carbon dioxide flows.

4. The system of claim 3 , wherein the pores are located only on a portion of the sparge that is located in the second channel.

5. The sparge is a sealing end configured to seal the first end of the first channel; a first portion of the sparge coaxial with the first channel; a second portion of the sparge coaxial with the second channel; a tapered end disposed within the second channel.

6. The system of claim 1 , wherein the system is configured to carbonate the liquid to between 3 grams and 8 grams of carbon dioxide per liter of liquid.

7. 10. The system of claim 1, wherein the system is configured to carbonate at a temperature of about 4°C to about 32°C.

8. 10. The system of claim 1, wherein the system is configured to carbonate between 1 liter and 10 liters of the liquid per minute.

9. 10. The system of claim 1, wherein the system is configured to carbonate between 200 and 2000 liters per minute.

10. The system of claim 1 , wherein the system is configured to carbonate the liquid without heat treatment.

11. The system of claim 1 , wherein the liquid is one of cola, carbonated soft drink, juice, coffee, tea, water, dairy, or a protein-based liquid.

12. 2. The system of claim 1, wherein the sparge has an outer diameter smaller than the second inner diameter such that a sparge gap is formed between the sparge and the second channel.

13. 10. The system of claim 1, wherein the system has a height of about 2 meters, a length of about 1 meter, and a width of about 1 meter.

14. 1. A method for carbonating a liquid, comprising the steps of: flowing said liquid through a first channel of a contactor at a rate of between 1 liter per minute and 2000 liters per minute; injecting carbon dioxide bubbles into the liquid by sparging, the bubbles having an average diameter of 100 μm or less, the carbon dioxide bubbles being injected at a rate of 1 gram to 10 grams of carbon dioxide per liter of the liquid; The method wherein the method carbonates the liquid without heat treatment.

15. further comprising flowing the liquid through a second channel of the contactor; The method of claim 14 , wherein the first channel has a first inner diameter and the second channel has a second inner diameter that is smaller than the first inner diameter.

16. The method of claim 15 , wherein the sparge is disposed at least partially within the first channel and at least partially within the second channel.

17. The method of claim 14, wherein the rate is between 500 liters per minute and 2000 liters per minute.

18. 15. The method of claim 14, wherein the carbon dioxide is injected at a rate of 1 gram to 10 grams of carbon dioxide per liter of the liquid.

19. The method of claim 14, wherein the liquid has a temperature of from about 4°C to about 32°C.

20. 1. A system for carbonating a liquid, comprising: a contactor for carbonating the liquid flowing through the contactor, the contactor comprising: a first channel having a first inner diameter; a second channel in fluid communication with the first channel, the second channel having a second inner diameter; a sparge disposed at least partially within the first channel and at least partially within the second channel, the sparge configured to deliver carbon dioxide bubbles to the liquid at a rate of at least 1 gram of carbon dioxide per liter of the liquid flowing through the carbonator, the bubbles having an average diameter of 100 μm or less; The system, wherein the system is configured to operate at ambient temperature.

21. 21. The system of claim 20, wherein the second inner diameter is smaller than the first inner diameter.

22. 21. The system of claim 20, wherein the system is configured to carbonate at least 1 liter to 2000 liters of the liquid per minute.

23. 21. The system of claim 20, wherein the sparge has an outer diameter smaller than the second inner diameter such that a sparge gap is formed between the sparge and the second channel, the sparge gap being between 0.75 mm and 10 mm.

24. 21. The system of claim 20, wherein the sparge is coaxial with the first channel and coaxial with the second channel.

25. 25. The system of claim 24, wherein the sparge comprises a sealing end configured to seal a first end of the first channel.

26. 21. The system of claim 20, wherein the sparge is a sintered sparge.

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