Freeze-drying plant
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Solution Overview
Problem
Existing lyophilization plants face high energy consumption, particularly in heat extraction and supply phases, leading to increased operational costs and limiting the application of the process to a limited group of products.
Innovation Solution
A lyophilization plant with a closed-loop refrigeration system using a carrier fluid and a dual heat exchanger configuration, where one heat exchanger cools the containment volume and the other provides heat to the shelves, eliminating the need for external heat sources and optimizing energy use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a conventional refrigeration system with external heat sources is used, then the lyophilization process can be completed, but energy consumption becomes extremely high
Solution Approach 1:
The patent merges the refrigeration system and heating system into a single integrated closed-loop system. The refrigerant circulates through heat exchangers that perform both cooling (in the cold trap) and heating (in the drying chamber) functions, eliminating the need for separate external heat sources and significantly reducing energy consumption.
Solution Approach 2:
The refrigerant circulation system performs multiple functions: it cools the cold trap to condense vapor, heats the drying chamber to facilitate sublimation, and can be adjusted to provide different temperature profiles for primary and secondary drying phases. This multi-functional system replaces what would traditionally require separate refrigeration and heating systems.
2Use of energy by stationary object
If external heat sources are used for drying phases, then the required heat can be supplied, but operational costs increase significantly
Solution Approach 1:
The system uses its own refrigerant circulation system to provide both cooling and heating functions. The heat required for drying is obtained from the refrigerant itself as it circulates through the system, making the system self-sufficient and eliminating dependence on external heat sources, thereby reducing operational costs while maintaining reliability.
3Volume of stationary object
If a compact structure is maintained, then the plant size is reduced, but energy efficiency decreases
Solution Approach 1:
By combining the refrigeration and heating systems into a single integrated closed-loop structure with shared components (compressor, condenser, expansion device, and refrigerant circulation paths), the patent achieves compact plant size without compromising energy efficiency. The integrated design allows efficient heat transfer between chambers while minimizing the overall system footprint.
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
The system achieves reduced energy consumption, maintaining a compact structure and efficient operation, thereby lowering production costs and expanding the applicability of lyophilization.
Implementation Method 1
a first heat exchanger (202), arranged downstream of the expansion unit (201) and operatively inserted in the containment volume (V), configured to promote a thermal exchange between the carrier fluid and the containment volume (V) so as to determine at least one cooling of the containment volume (V)
Implementation Method 2
a compression unit (203, 204) of the carrier fluid, arranged downstream of the first heat exchanger (202)
Implementation Method 3
a second heat exchanger (210), connected to the one or more shelves (101) and configured such that the carrier fluid yields heat to the one or more shelves (101)
Implementation Method 4
The expansion unit (201) is configured to conduct a lamination on the carrier fluid
Implementation Method 5
The lyophilization tank comprises a vacuum pump (102) configured to maintain the containment volume (V) in a vacuum condition
Implementation Method 6
The sublimated or desorbed vapor is condensed in a cold trap, consisting of a cold surface inside the lyophilization tank
Implementation Method 7
the crystals of the frozen substance sublimate from solid to vapor
Data Source
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AI summary
Lyophilization plant configured to remove a substance from a product to be lyophilized, comprising a lyophilization tank and a closed-loop refrigeration system, coupled to the lyophilization tank and operated by a carrier fluid. The refrigeration system includes a carrier fluid expansion unit, a first heat exchanger, a carrier fluid compression unit, and a main flow regulating member of the carrier fluid. The main flow regulating member has an inlet opening in fluid communication with the compression unit, a first discharge opening connected to a first branch and a second discharge opening connected to a second branch, parallel to the first branch. The main flow regulating member is configured to regulate and determine respective amounts of carrier fluid conveyed in the first branch and in the second branch so as to obtain a plurality of operating configurations of the lyophilization plant.