Liquid-cryogen injection cooling devices and methods for using same
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Solution Overview
Problem
Existing direct-cryogen injection cooling devices face inefficiencies in heat extraction from heated food products and struggle to completely separate the gaseous cryogen phase from the cooled product without forming stable foams, which affects energy efficiency and product quality.
Innovation Solution
A heat exchange device comprising a double-helical pipe for phase-mixing-cooling and a helical pipe for phase-separation-cooling, with an intermediate pipe containing a backpressure valve, enhances mixing and separation of the cryogen and food product phases, maximizing heat extraction while preventing foam formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a traditional direct-cryogen injection cooling device is used, then cooling of the food product is achieved, but heat extraction is not maximized and complete separation of gaseous cryogen phase from cooled product is not achieved
Solution Approach 1:
The cooling device is segmented into two distinct functional sections: a double-helical coil section for phase mixing and heat extraction, and a helical coil section for phase separation. This segmentation allows each section to optimize its specific function, maximizing heat extraction in the first section and achieving complete separation in the second section.
Solution Approach 2:
The patent transitions from a single linear cooling path to a two-dimensional flow path with distinct mixing and separation zones. The double-helical and helical coil configurations create different flow patterns and residence times, adding dimensional complexity to the cooling process to achieve both maximum heat extraction and complete phase separation.
2Speed
If liquid cryogen is directly injected into heated food product, then rapid cooling is achieved, but stable foam formation occurs preventing complete phase separation
Solution Approach 1:
The device separates the cooling process into distinct phases: rapid cooling occurs in the double-helical coil section, while foam breakdown and phase separation occur in the helical coil section. This segmentation allows rapid cooling to proceed without immediate foam interference, followed by dedicated foam destruction in the separation section.
Solution Approach 2:
The patent converts the harmful effect of foam formation into a beneficial process by designing the helical coil section to specifically target and break down the foam structure. The foam, initially a problem preventing separation, becomes an intermediate state that is systematically destroyed to achieve complete phase separation and improve product quality.
3Device complexity
If single coil configuration is used, then device simplicity is maintained, but both maximum heat extraction and complete phase separation cannot be achieved simultaneously
Solution Approach 1:
The cooling system is divided into two distinct coil configurations: a double-helical coil for optimized heat extraction through enhanced mixing, and a helical coil for optimized phase separation. This segmentation justifies the increased device complexity by delivering superior performance in both heat extraction and separation functions that a single coil cannot achieve.
Solution Approach 2:
While the device uses two coil sections, each coil is designed to perform its specific function universally and efficiently. The double-helical coil universally handles mixing and heat extraction, while the helical coil universally handles phase separation, creating a multi-functional system that achieves both objectives simultaneously.
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 device achieves maximum heat extraction and complete separation of the gaseous cryogen phase from the cooled food product, improving energy efficiency and product quality by leveraging the Dean Flow effects in the coil geometry to enhance mixing and separation.
Implementation Method 1
The double-helical pipe is configured to force the heated product and the liquid cryogen to mix to form a two-phase mixture and exchange a maximum amount of heat between the two phases
Implementation Method 2
leveraging the Dean Flow effects in the coil geometry to enhance mixing and separation
Implementation Method 3
The helical pipe is configured to induce a two-phase flow between the cooled product and the gaseous cryogen phase
Implementation Method 4
The intermediate pipe includes a backpressure valve thereon
Data Source
AI summary
Heat exchange devices (30) and methods of using same are provided. In a general embodiment, the present disclosure provides for heat exchange devices (30) that are cooling devices having a double helical coil (32) in a phase-mixing-cooling section, a helical coil (36) in a phase-separation-cooling section, and a back-pressure valve (34) intermediate the two coils (32,36). The cooling devices provide maximum extraction of the heat content from a heated food product using a direct-injected liquid cryogen, and complete separation of the gaseous cryogen phase from the cooled product, while avoiding the formation of a stable foam. Hybrid direct-indirect cooling devices are also provided, as well as methods for using same.