Cross-Flow Spiral Freezer Layout With Internal Return Gas Cooling
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Solution Overview
Problem
Existing spiral refrigeration systems suffer from inefficiencies due to unused space in return ductwork, leading to reduced cooling capacity and increased bulk and cost, as the return gas conveyance occurs externally rather than within the product processing zone.
Innovation Solution
A dual-pass cross-flow spiral heat transfer system where the return gas flow occurs within the product processing zone, utilizing a bifurcated pathway created by a drum and conveyor belt to ensure efficient gas usage, allowing for continuous recirculation and reduced structural material needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If return gas conveyances are placed externally in single pass systems, then the system structure is simpler to implement, but the system loses cooling capacity and increases bulk and footprint area
Solution Approach 1:
The patent merges the return gas conveyance function with the product processing zone by having the return conveyor belt carry products through the region where cooled gas returns to the freezer. This eliminates the need for separate external return ductwork while simultaneously utilizing the return gas flow for additional cooling of products, thus resolving the contradiction between structural simplicity and cooling capacity efficiency.
Solution Approach 2:
The return conveyor belt serves multiple functions: it transports products through the processing zone and simultaneously acts as a heat exchange surface for the returning cooled gas. This multi-functionality allows the system to maintain structural simplicity while maximizing cooling capacity utilization, as the same structural element performs both transport and heat transfer roles.
2Ease of manufacture
If external return gas conveyors and ductwork are used in single pass systems, then the system is easier to construct, but the bulk and footprint area increase reducing cost-effectiveness
Solution Approach 1:
The patent combines the return gas conveyance pathway with the product processing pathway by using the return conveyor belt to carry products through the return gas region. This integration eliminates the need for separate external ductwork structures, thereby reducing the overall footprint area while maintaining construction feasibility through the use of existing conveyor infrastructure.
Solution Approach 2:
The patent transitions from a horizontal external ductwork arrangement to a vertical three-dimensional configuration where the return conveyor belt passes through the freezer chamber. This dimensional change allows the system to utilize vertical space for gas conveyance rather than requiring additional horizontal footprint area, thus reducing the overall system footprint while maintaining ease of construction.
3Device complexity
If single pass systems are used, then the system design is simpler, but cooling capacity is reduced due to inefficient use of process volume
Solution Approach 1:
The patent implements a dual-pass continuous system where cooled gas is utilized twice: first in the primary cooling zone and then again in the return zone where it cools additional products on the return conveyor belt. This continuous utilization of cooling capacity eliminates waste and maximizes the productivity of the refrigeration system while maintaining a relatively simple design through the use of existing conveyor infrastructure.
Solution Approach 2:
The patent recovers the cooling capacity of the return gas that would otherwise be wasted in single-pass systems. By directing the cooled return gas through the return conveyor belt pathway, the system recovers additional cooling potential, thereby increasing overall productivity without significantly increasing design complexity.
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 configuration reduces the overall system size, power consumption, and cryogen usage by approximately 50%, achieving a 35% power reduction and 15% cryogen efficiency improvement compared to single-pass systems, while maintaining effective heat transfer.
Implementation Method 1
a gas such as cryogen is directed by fans to flow among the products to be cooled
Implementation Method 2
The gas flow is bifurcated by the drum to flow along a first pathway and a second pathway
Data Source
AI summary
A heat transfer system for refrigeration and/or heating of products includes a housing having an internal chamber, a baffle, a spiral pathway around the baffle, a gas flow pathway and a blower to circulate gas along the gas flow pathway. The baffle separates the chamber into upper and lower portions. The spiral pathway includes an upper spiral pathway within the upper portion, and a lower spiral pathway within the lower portion. The gas flow pathway includes an upper gas flow pathway across the upper spiral pathway and a lower gas flow pathway across the lower spiral pathway in which gas flow in the upper and lower gas flow pathways defines a circulation loop. The width of the upper gas flow pathway and upper spiral pathway are similar, and the width of the lower gas flow pathway and lower spiral pathway are similar.