Cryogenic Powder Cooling With Vibrating Support Feedback Control
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Solution Overview
Problem
Existing cryogenic treatment systems for fine powders face challenges in achieving precise temperature control, particularly for powders with high fat content, due to limitations in pumping capacity, sanitation issues, and inefficient energy use, which can lead to incomplete crystallization, clustering, or excessive cooling, affecting the final product quality.
Innovation Solution
A vibrating support system with two independently controllable cryogenic liquid inlets, one for pre-cooling the support and another for projecting cryogenic liquid onto the powders, coupled with real-time thermal mass determination and synchronized control of cryogenic liquid injection, ensures precise temperature control and efficient cooling by adjusting the cryogenic liquid flow rates and pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a pump is used to circulate cryogenic liquid in a closed circuit, then the cooling capacity is improved, but the system complexity and energy consumption increase significantly
Solution Approach 1:
The patent removes the pump from the closed circuit system, extracting the sensitive element that causes complexity and energy consumption issues. The cryogenic liquid circulates without mechanical pumping, eliminating the need for compressed air and reducing system complexity while maintaining cooling capacity through natural circulation and phase change mechanisms.
Solution Approach 2:
The system enables self-service circulation of cryogenic liquid through natural convection and phase change processes. The liquid nitrogen circulates automatically without external mechanical assistance, using its own physical properties (density differences, evaporation) to maintain flow and cooling function.
2Productivity
If the product flow rate is increased to improve productivity, then the output increases, but the pump's pumping capacity becomes a limiting factor
Solution Approach 1:
By removing the pump from the system, the patent eliminates the pumping capacity bottleneck that limited product flow rate increases. The system can now accommodate higher productivity levels without being constrained by mechanical pumping capabilities.
3Loss of energy
If a film of cryogenic liquid is used for cooling, then the cooling efficiency is improved, but the treatment time becomes too long for fine powders
Solution Approach 1:
The patent segments the cooling process into two distinct phases: pre-cooling the support surface with cryogenic liquid, then introducing powder that is rapidly cooled during vibration. This segmentation allows efficient heat transfer without requiring prolonged exposure, reducing treatment time while maintaining cooling effectiveness.
Solution Approach 2:
The system uses mechanical vibration of the support surface to enhance heat transfer between the cryogenic liquid and powder particles. The vibration increases contact frequency and efficiency, enabling rapid cooling in reduced time compared to static film cooling methods.
4Stability of the object's composition
If the powder is cooled to very low temperatures to ensure complete crystallization, then the crystallization is improved, but the risk of clustering and sintering increases
Solution Approach 1:
The patent employs dynamic vibration of the support surface during the cooling process. This continuous motion prevents powder particles from settling and adhering to each other, maintaining particle separation even at low temperatures where crystallization is occurring, thus preventing clustering and sintering while ensuring complete crystallization.
5Speed
If the cryogenic liquid flow rate is increased to improve cooling speed, then the cooling rate increases, but the risk of overcooling and water vapor condensation increases
Solution Approach 1:
The system incorporates feedback control mechanisms that monitor the cooling process and adjust cryogenic liquid flow rates in real-time. This prevents overcooling by detecting temperature trends and reducing liquid flow accordingly, avoiding the formation of water vapor condensation while maintaining efficient cooling speeds.
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 precise control of the cooling process, preventing adhesion, ensuring complete crystallization, reducing energy consumption, and maintaining product quality by quickly responding to variations in thermal mass and flow rates, thus optimizing the cooling process for fine powders.
Implementation Method 1
the product thus treated floats on the surface of the film of gas liquefied by a phenomenon of calefaction
Implementation Method 2
a large quantity of liquid nitrogen is injected into the tank
Implementation Method 3
so-called 'vibrating support' cooling tunnels can represent an interesting solution to the technical problems listed above
Implementation Method 4
the product is brought into contact with a cooling surface, which results from the use of a vibrating support and of a liquefied gas
Data Source
AI summary
The cryogenic cooling of food or detergent fine powders in a tunnel (14) with a vibrating support (1), in which a controllable cryogenic liquid is introduced on the support. The powders are deposited on the support and another cryogenic liquid is introduced on the powders using an injector. Thermal mass of the powders is synchronized with powder supply as a function of time by controlling the cryogenic liquid in the tunnel. The synchronized information is transmitted to an acquisition unit and a data processor. The cryogenic cooling of food or detergent fine powders in a tunnel (14) with a vibrating support (1), in which a controllable cryogenic liquid is introduced on the support. The powders are deposited on the support and another cryogenic liquid is introduced on the powders using an injector. Thermal mass of the powders is synchronized with powder supply as a function of time by controlling the cryogenic liquid in the tunnel. The synchronized information is transmitted to an acquisition unit and a data processor. The content of the synchronized information, the acquisition unit and the data processors are retroacted on the supply of cryogenic liquid to ensure temperature of the powder at an exit of the tunnel. The cryogenic liquid is supplied through the valves and controlled through the acquisition unit and data processor by retroaction with respect to cryogenic liquid pressure reigning between the valve and the injector. The thermal mass of the powder is measured by determination of mass of product entering per unit time and by determination the temperature of the product in combination with determination of the powder mass throughput.