Flash Pasteurizer Heat Recovery for Hot-Filling
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Solution Overview
Problem
Existing methods for hot-filling liquid products, such as juices, are inefficient in heating the products to pasteurization temperature, as they require separate heat pumps and higher demands on heaters and pipelines, leading to increased costs and complexity.
Innovation Solution
A method and device utilizing a flash pasteurizer with a first and second heat exchanger, a filling station, and a cooling tunnel, where thermal energy from the cooling tunnel is transferred to the product through the first heat exchanger and further heated by a heat pump using a heat transfer medium, with an additional heater between the heat pump and second heat exchanger to achieve the target temperature, allowing for serial or parallel configuration of heat exchangers to enhance efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a separate heat pump is used to heat the liquid product to pasteurization temperature, then the heating function is achieved, but the device complexity and costs increase
Solution Approach 1:
The patent combines the heating function with the existing cooling tunnel system by using the coolant from the cooling tunnel as the heating medium. The cooling tunnel's coolant circuit is integrated to serve dual purposes: cooling during the cooling phase and heating during the heating phase, eliminating the need for a separate heat pump and reducing device complexity.
Solution Approach 2:
The coolant circuit of the cooling tunnel is designed to perform multiple functions: it serves as both a cooling medium during the cooling phase and a heating medium during the heating phase. This multi-functionality allows the same system components to achieve both cooling and heating objectives without requiring additional dedicated equipment.
2Temperature
If a separate heat pump is used for heating, then the heating requirement is met, but the costs increase
Solution Approach 1:
The patent merges the heating function into the existing cooling tunnel coolant circuit, eliminating the need for a separate heat pump. This integration reduces equipment costs, installation costs, and maintenance costs while achieving the required heating to pasteurization temperature.
Solution Approach 2:
The cooling tunnel's coolant system serves itself by using its own coolant to provide heating functionality. The system recovers thermal energy from the coolant during cooling operations and utilizes it for heating the liquid product, making the system self-sufficient and eliminating external heating equipment costs.
3Use of energy by moving object
If thermal energy is transferred from cooling tunnel to product, then heating efficiency is improved, but the heat transfer medium requires additional heating
Solution Approach 1:
The patent segments the heating process into two stages: first, thermal energy is transferred from the cooling tunnel coolant to the liquid product; second, the heat transfer medium is heated by a heater. This segmentation allows efficient heat recovery while managing the additional heating requirement through a simple, integrated heater component.
Solution Approach 2:
The patent introduces a heat transfer medium as an intermediary substance that circulates between the cooling tunnel and the liquid product. This intermediary enables efficient thermal energy transfer from the coolant to the product, with the medium being heated by a heater to maintain effective heat transfer throughout the process.
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 effective and economic heating of liquid products to pasteurization temperature, improving the coefficient of performance of the heat pump and reducing costs by utilizing thermal energy recovery and minimizing direct contact with the product, thus achieving efficient and cost-effective hot-filling processes.
Implementation Method 1
at least a part of the coolant is conducted from the cooling tunnel to and through a first heat exchanger, so that at least a part of the thermal energy of the coolant can be transferred to the product by means of the first heat exchanger
Implementation Method 2
the product is then conducted from the first to the second heat exchanger, where at least a further part of the thermal energy is transferable to the second heat exchanger by means of the heat pump using a heat transfer medium
Implementation Method 3
The heat transfer medium which circulates through the second heat exchanger and the heat pump is additionally heated by a heater arranged between the heat pump and the second heat exchanger in the direction of circulation
Implementation Method 4
a cooling tunnel comprising a plurality of cooling cells for cooling the filled containers by means of a coolant
Data Source
AI summary
A method and a device for hot-filling a liquid product with a flash pasteurizer comprising a first and a second heat exchanger, a filling station, a cooling tunnel for cooling filled containers, and a heat pump. Prior to the filling process, the product is heated to a target temperature in the flash pasteurizer. Coolant is conducted from the cooling tunnel to the second heat exchanger, so that at least a part of the thermal energy of the coolant can be transferred to the product. The product is then conducted from the first to the second heat exchanger, wherein a further part of the thermal energy can be transferred to the second heat exchanger by the heat pump using a heat transfer medium to heat the product to the target temperature. The heat transfer medium is additionally heated by a heater arranged between the heat pump and the second heat exchanger.