Hydrocooler Thermal Storage for Peak Produce Cooling Loads
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Solution Overview
Problem
Conventional hydrocooler systems for cooling produce lack efficient thermal storage capabilities, which limits their ability to maintain optimal cooling conditions and extend the shelf life of produce effectively.
Innovation Solution
A modular hydrocooler system incorporating a thermal storage device that generates a thermal storage medium, such as ice, by using a refrigerant to cool a fluid in the hydrocooler tank, allowing for efficient heat removal and storage, enabling continuous operation and enhanced cooling capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional hydrocooler systems are used without thermal storage capabilities, then the system structure remains simple, but the ability to maintain optimal cooling conditions and extend produce shelf life is limited
Solution Approach 1:
The system is divided into separate functional modules: a hydrocooler tank for produce cooling, a thermal storage device for ice generation and storage, and a refrigeration system. This segmentation allows each component to perform its specific function efficiently while maintaining overall system reliability for extended produce shelf life.
Solution Approach 2:
The thermal storage device generates and stores ice in advance before produce needs cooling. This preliminary action ensures that cooling capacity is available when produce is loaded, maintaining optimal cooling conditions without requiring the refrigeration system to run continuously at full capacity.
2Productivity
If a thermal storage device is added to generate thermal storage medium, then heat removal and storage capacity is enhanced, but the system complexity increases
Solution Approach 1:
The thermal storage device is integrated within the hydrocooler tank structure, combining the cooling function and thermal storage function in a unified system. The evaporator coils are positioned to directly contact or be in thermal communication with the hydrocooler fluid, merging heat removal and storage capabilities while avoiding the need for completely separate systems.
Solution Approach 2:
The refrigeration system serves multiple functions: it cools the hydrocooler fluid directly through the evaporator, and it generates ice in the thermal storage device for later use. This multi-functionality increases cooling capacity without proportionally increasing system complexity, as one refrigeration cycle supports both cooling modes.
3Power
If refrigerant is supplied to thermal storage device to generate thermal storage medium, then heat removal efficiency is improved, but energy consumption increases
Solution Approach 1:
The refrigeration system operates in periodic cycles, alternating between cooling mode (refrigerant to evaporator) and ice generation mode (refrigerant to thermal storage device). During ice generation, the system builds up thermal storage capacity that will be used during subsequent cooling operations, allowing the high-power heat removal function to be used intermittently rather than continuously, thereby reducing overall energy consumption.
Solution Approach 2:
The system utilizes the phase transition of water to ice in the thermal storage device as a high-efficiency heat removal mechanism. When ice forms, it absorbs large amounts of latent heat, providing efficient heat removal during the ice generation phase. During produce cooling, the ice melts and absorbs heat from the hydrocooler fluid, maintaining efficient cooling without requiring continuous high-power refrigeration operation.
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 effectively extends the shelf life of produce by maintaining optimal cooling conditions through efficient heat removal and storage, improving thermal efficiency and handling sudden heat loads from freshly harvested produce.
Implementation Method 1
The thermal storage device is positioned in the hydrocooler tank and configured to receive a refrigerant. The thermal storage device is configured to generate a thermal storage medium from the fluid on the thermal storage device in response to the flow of refrigerant through the thermal storage device.
Implementation Method 2
an evaporator fluidly connected to the hydrocooler tank and configured to be in thermal communication with the fluid
Implementation Method 3
The refrigerant is operable to remove heat from the fluid during a first mode of operation and a second mode of operation.
Data Source
AI summary
A hydrocooler system for cooling produce. The hydrocooler system comprises a hydrocooler tank configured to contain a fluid used to saturate and cool the produce, and a thermal storage device positioned in the hydrocooler tank and configured to receive a refrigerant. The thermal storage device is configured to generate a thermal storage medium from the fluid on the thermal storage device in response to the flow of refrigerant through the thermal storage device.