In-Line Cryogen Injection Cooling With Dual-Sensor Flow Control
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Solution Overview
Problem
Conventional methods for rapid chilling of liquid food products, such as sauces, are limited by the responsiveness of modulating control valves and PID control loops, which cannot effectively manage the rapid cooling process, leading to temperature control issues and inefficiencies.
Innovation Solution
An in-line direct cryogenic cooling method and apparatus that injects cryogen directly into the fluid while adjusting the flow rate of the fluid based on downstream temperature measurements, using a controller to maintain a constant temperature difference between sensors, eliminating the need for modulating control valves and improving process stability and cryogen efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a modulating control valve with PID control loop is used to control cryogen flow, then temperature control is attempted, but the control system is too slow to respond to rapid changes in sauce and cryogen quality conditions
Solution Approach 1:
The patent replaces the mechanical modulating control valve system with a constant-opening valve combined with an electronic control system that adjusts cryogen flow rate electronically. This substitution eliminates the mechanical lag and responsiveness limitations of traditional valve-based control, enabling rapid adjustment to changing process conditions while maintaining reliable temperature control.
Solution Approach 2:
The patent changes the control parameter from valve opening position to electronic cryogen flow rate adjustment. By maintaining a constant valve opening and controlling flow rate through electronic means, the system achieves faster response times and better adaptability to rapid temperature changes in the chilling process.
2Productivity
If cryogen flow is rapidly adjusted to achieve rapid chilling, then cooling speed increases, but temperature control precision deteriorates
Solution Approach 1:
The patent implements a feedback control system using temperature sensors that continuously monitor the chilling process and provide real-time data to the controller. This feedback mechanism enables the system to rapidly adjust cryogen flow rate while maintaining precise temperature control, resolving the contradiction between cooling speed and temperature precision.
Solution Approach 2:
The patent employs dynamic control of cryogen flow rate that adapts to changing process conditions. The system transitions from static valve positioning to dynamic electronic flow rate adjustment, enabling rapid response to temperature changes while maintaining control precision throughout the chilling process.
3Adaptability or versatility
If a modulating control valve is used in the cryogen pipeline, then flow adjustment is possible, but physical and mechanical limitations prevent effective rapid chilling control
Solution Approach 1:
The patent extracts the modulation function from the mechanical valve and transfers it to an electronic control system. By removing the modulating control valve and its associated mechanical complexity, the system achieves flow adjustment capability through simpler electronic means, reducing device complexity while maintaining adaptability.
Solution Approach 2:
The patent introduces an electronic controller as an intermediary between the constant-opening valve and the cryogen flow. This electronic mediator provides flow adjustment capability without the physical and mechanical limitations of traditional modulating valves, simplifying the overall control system while maintaining versatility.
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 approach enables faster and more efficient chilling of liquid products, improving temperature consistency, reducing waste, and enhancing productivity, while allowing for greater flexibility in processing high-heat load products and more effective cryogen use.
Implementation Method 1
injecting cryogen directly into the fluid to be cooled while the fluid flows through a pipeline
Implementation Method 2
first measuring a temperature of the flowing fluid in the pipeline with a first temperature sensor after the injecting the cryogen, second measuring the temperature of the flowing fluid with a second temperature sensor
Implementation Method 3
adjusting a flow rate of the fluid through the pipeline responsive to a difference between temperature measurements of the first and second temperature sensors
Data Source
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AI summary
In order to overcome the limitations and problems that earlier methods and apparatus / systems have experienced, a method for, in particular rapid, cooling of at least one fluid (15) is proposed, comprising - providing a source (12) of the fluid (15) to be cooled; - flowing the fluid (15) to be cooled through a pipeline (20); - injecting (26) cryogen into the fluid (15); - first measuring a temperature of the flowing fluid (15) in the pipeline (20) with a first temperature sensor (40) after the injecting (26) the cryogen; - second measuring the temperature of the flowing fluid (15) with a second temperature sensor (56) after the first measuring; and - adjusting a flow rate of the fluid (15) through the pipeline (20) responsive to a difference between temperature measurements of the first temperature sensor (40) and the second temperature sensor (56) while maintaining a rate of the injecting (26) of the cryogen and maintaining a temperature difference between the first temperature sensor (40) and the second temperature sensor (56). A corresponding apparatus (10) for, in particular rapid, cooling of at least one fluid (15) is also proposed.