Continuous Fat Fractionation with Periodic Crystallizer Heating
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Solution Overview
Problem
Continuous dry fractionation processes for edible oils and fats face challenges with encrustation on cooling elements, leading to reduced cooling capacity and necessitating process interruptions, which affects efficiency and consistency of fraction properties.
Innovation Solution
A continuous dry fractionation process using crystallizers with a temperature gradient and gentle agitation, where encrustations are managed by interrupting the cooling medium flow and partially melting deposits using electrical heating or steam, allowing continuous operation without interrupting the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If continuous dry fractionation is used to improve productivity and integration with refinery processes, then continuous operation is achieved, but encrustation on cooling elements occurs leading to reduced cooling capacity
Solution Approach 1:
The patent applies periodic action by implementing cyclic heating intervals during continuous operation. The system alternates between normal cooling operation and heating cycles that melt encrustations on cooling elements. This periodic heating maintains cooling capacity over time while preserving continuous fractionation operation, directly resolving the contradiction between continuous productivity and reliable cooling performance.
2Manufacturing precision
If cooling elements are used to achieve temperature gradient for crystallisation, then fractionation efficiency is improved, but encrustation reduces heat exchange effectiveness
Solution Approach 1:
The patent applies parameter changes by dynamically adjusting the temperature parameter of the heating medium during operation. The system monitors heat exchange effectiveness and adjusts heating temperature and duration to optimize encrustation removal while minimizing energy consumption. This maintains precise temperature control for crystallisation while compensating for encrustation-induced heat transfer degradation.
Solution Approach 2:
The patent implements feedback control by monitoring operational parameters such as cooling capacity and heat exchange effectiveness. Based on this feedback, the system automatically adjusts heating intervals and intensity to remove encrustations when they begin to significantly impact heat transfer, thereby maintaining energy efficiency while preserving temperature control precision.
3Productivity
If cooling medium flows continuously to maintain temperature gradient, then crystallisation efficiency is improved, but encrustation accumulates on cooling elements
Solution Approach 1:
The patent converts the harmful effect of continuous cooling (encrustation accumulation) into a beneficial periodic maintenance mechanism. By introducing controlled heating intervals, the system uses the same cooling medium flow continuity to enable efficient crystallisation while periodically eliminating encrustations. The continuous operation is maintained, and encrustation is transformed from a progressive problem into a periodically managed condition.
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 continuous operation with reduced energy requirements, improved fraction properties, and higher olein yield, while minimizing interruptions and maintaining consistent product quality.
Implementation Method 1
the fat is gradually cooled by using heat exchangers containing a cooling medium so that a crystal slurry is formed
Implementation Method 2
at least partially melting fat encrustations deposited on said heat exchangers
Implementation Method 3
at least partially melting fat encrustations deposited on said heat exchangers
Implementation Method 4
a crystal slurry is formed
Data Source
AI summary
A continuous process for the dry fractionation of edible oils and fats using one or more crystallisers in series, said process comprising the steps of: (a) providing a molten fat; (b) continuously feeding said molten oil or fat to the first of said one or more crystallisers in series in which the fat is gradually cooled by using heat exchangers containing a cooling medium so that a crystal slurry is formed, each of said one or more crystallisers exhibiting a temperature gradient, the temperature at the point where the molten or partially crystallised fat enters one of the crystallisers being higher than that at the point where the slurry leaves that crystalliser; (c) continuously withdrawing said slurry from the last of said one or more crystallisers; (d) separating said crystal slurry by filtration in a filter cake and a filtrate, wherein said process further comprises the step of at least partially melting fat encrustations deposited on said heat exchangers; and an oil fraction produced by therefrom.