In-line cryogenic method and system for cooling liquid products
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Solution Overview
Problem
Conventional methods using modulating control valves and PID control loops are insufficient for rapid temperature control during cryogenic chilling of liquid food products, as they are not responsive enough to achieve the required cooling rates and are hindered by physical and mechanical limitations, as well as variability in cryogen quality.
Innovation Solution
A system that injects cryogen at a substantially constant rate into the fluid, using multiple temperature sensors to adjust the flow rate of the fluid through a pipeline, allowing for real-time control of temperature differences to maintain steady state conditions without the need for modulating control valves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a modulating control valve with PID control loop is used to control cryogen flow, then temperature control is achieved under steady state conditions, but the response speed is too slow for rapid chilling applications
Solution Approach 1:
The patent removes the modulating control valve from the cryogen injection system entirely. Instead of using a valve to modulate cryogen flow, the system uses a fixed orifice or constant flow injector that delivers cryogen at a predetermined rate, eliminating the mechanical components that limited response speed while maintaining temperature control through process design rather than active valve modulation.
Solution Approach 2:
The system pre-determines the optimal cryogen injection rate based on the desired cooling performance and product specifications. By establishing the cryogen flow rate in advance through fixed geometry or pre-calibrated injection mechanisms, the system eliminates real-time valve adjustment delays and achieves rapid response to temperature changes while maintaining reliable control through the predetermined parameters.
2Productivity
If cryogen flow is rapidly increased to achieve fast cooling rates, then cooling speed improves, but temperature control precision deteriorates
Solution Approach 1:
The system pre-calculates and pre-configures the optimal cryogen injection rate required to achieve the desired cooling curve from pasteurization temperature to final storage temperature. This preliminary determination of injection parameters allows the system to achieve both rapid cooling and precise temperature control by maintaining the predetermined injection rate throughout the process, eliminating the need for real-time modulation that would compromise either speed or precision.
Solution Approach 2:
The system incorporates temperature sensors that provide feedback to a control system, which monitors the cooling progress and ensures the predetermined cryogen injection rate is maintained. This feedback mechanism allows the system to achieve rapid cooling through high initial cryogen flow while maintaining temperature control precision by verifying that the process follows the predetermined cooling profile and making minor adjustments if deviations occur.
3Adaptability or versatility
If a modulating control valve is used to adjust cryogen flow, then adaptability to varying process conditions is achieved, but device complexity and mechanical limitations increase
Solution Approach 1:
The patent eliminates the modulating control valve and its associated complex control system from the cryogen injection mechanism. By using a fixed orifice, constant flow injector, or pre-calibrated injection system, the design achieves adaptability to varying process conditions through the inherent characteristics of the injection device and process design rather than through complex active control mechanisms, thereby reducing device complexity while maintaining versatility.
Solution Approach 2:
The system achieves adaptability to varying process conditions by changing the predetermined parameters of the cryogen injection system (such as orifice size, injection pressure, or flow rate) to match different product requirements. Rather than using a complex modulating valve system, the adaptable parameters are established beforehand for different application scenarios, simplifying the device while maintaining versatility across different chilling requirements.
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 method enables rapid and efficient cooling of liquid food products, improving temperature control, reducing bacterial growth, and enhancing production flexibility while maintaining product quality and effectively utilizing cryogen.
Implementation Method 1
injecting cryogen into the fluid to be cooled at a substantially constant rate... injecting cryogen into the fluid
Implementation Method 2
rapidly reduce the temperature of liquid products... rapid cooling of sauce products
Data Source
AI summary
Disclosed are an in-line direct cryogenic method and system for cooling heated fluid food products, such as sauces. The method includes injecting cryogen directly into the fluid to be cooled while the flow rate of the fluid to be cooled is adjusted in response to downstream temperature measurements and while maintaining the injection rate of the cryogen into the fluid. According to the method the flow of the sauce is adjusted during the flow of the cryogen to achieve process stability, product uniformity and efficient use of the cryogen.