Cooling Crystallizer Zoning for Supersaturation-Controlled Sugar Yield
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Solution Overview
Problem
Existing sugar crystallization processes face challenges in achieving high sugar yield with efficient equipment utilization, particularly in controlling supersaturation and crystal growth during the cooling process, leading to sugar losses and inefficiencies.
Innovation Solution
A cooling crystallizer design with vertically spaced cooling blocks grouped into separate cooling packages, each with its own heat exchanger, allowing for adjustable temperature differentials and flow rates to optimize crystallization conditions, and incorporating hydraulic and thermal decoupling to manage supersaturation and crystal growth.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single cooling circuit is used in existing crystallizers, then the equipment structure is simple, but the temperature control precision and crystallization optimization are insufficient
Solution Approach 1:
The cooling circuit is divided into multiple independent cooling circuits (first cooling circuit, second cooling circuit, etc.), each with its own heat exchanger and flow control. This segmentation allows independent temperature control for different crystallization stages, achieving precise temperature management while maintaining manageable system complexity through modular design
2Adaptability or versatility
If cooling blocks are fixed in a single configuration, then the equipment structure is simple, but the adaptability to different crystallization stages is limited
Solution Approach 1:
The cooling blocks are made movable along the vessel axis and can be positioned at different heights to match different crystallization stages. The blocks can also be tilted relative to each other, creating dynamic cooling zones that adapt to the progressing crystallization front, thereby enhancing versatility without excessive structural complexity
Solution Approach 2:
The cooling blocks are arranged in a stepped configuration along the vertical axis of the vessel, creating multiple cooling zones at different heights. This spatial arrangement in the vertical dimension allows simultaneous cooling at different stages of crystallization, providing adaptability through dimensional organization rather than complex mechanical adjustments
3Productivity
If the cooling process is not optimized, then the equipment size is large, but the sugar yield is reduced due to new crystal formation and supersaturation issues
Solution Approach 1:
The system optimizes sugar yield by dynamically adjusting temperature parameters at different crystallization stages through multiple independent cooling circuits. By precisely controlling temperature differentials and cooling rates in each zone, the process maintains optimal supersaturation levels that promote crystal growth over nucleation, thereby increasing sugar yield without requiring larger equipment volume
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design enhances sugar yield by optimizing crystallization conditions, preventing the formation of new crystals, and allowing for higher throughput or smaller equipment size with improved temperature control and reduced pressure loss.
Implementation Method 1
The cooling blocks are permeated by a heat transfer fluid and coupled to a heat exchanger to dissipate heat from the magma
Implementation Method 2
dissipate heat from the magma
Implementation Method 3
the physical process of crystallization allows for excellent separation of the sugar from non-sugar components
Implementation Method 4
The formation of new crystals is prevented by ensuring that certain supersaturation levels are not exceeded
Data Source
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AI summary
The invention relates to a cooling crystallizer (2.0) for saccharose magma in a vertically oriented container (2.1) which has an upper inlet (2.2) for supplying magma and a lower outlet (2.3) for discharging magma, comprising multiple cooling blocks (5.0) which are mutually spaced in a vertical direction. A heat carrier fluid flows through the cooling blocks (5.0), and the cooling blocks are coupled to a heat exchanger in order to dissipate heat from the magma, wherein multiple cooling blocks (5.0) are combined to form a cooling packet (5.1; 5.2), and the cooling packets (5.1; 5.2) are designed as separate cooling circuits with separate heat exchangers (2.1.2; 2.2.2).