Method and system to decouple steam pressure from temperature to control shear imparted on product flow
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Solution Overview
Problem
Current direct steam injection technologies face challenges in controlling temperature and shear in food processing, as pressure changes are not instantaneous, leading to temperature fluctuations, and low pressure differentials limit high shear conditions necessary for mixing and cooking.
Innovation Solution
A system that decouples steam pressure from temperature using a steam modulator and PID control to vary steam orifice sizes, allowing for precise control of shear and temperature, with a pressure control valve and backpressure valve to maintain consistent conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If steam pressure is modulated to control temperature, then temperature control is achieved, but temperature fluctuations occur when flow rates or plant steam pressure change
Solution Approach 1:
The patent segments the steam injection control into two independent parts: steam pressure control and steam orifice size control. This allows temperature and shear to be controlled separately, resolving the coupling problem where pressure changes affected both temperature and shear simultaneously.
Solution Approach 2:
The patent uses dynamic modulation of steam orifice size through a steam modulator that can rapidly adjust opening dimensions in response to flow rate changes or plant steam pressure variations. This dynamic adjustment compensates for pressure changes and maintains stable temperature control.
2Force
If steam pressure is increased to achieve high shear conditions, then shear effects are improved, but temperature control becomes difficult and product damage may occur
Solution Approach 1:
The patent separates shear control from temperature control by using steam orifice size modulation for shear control while maintaining independent pressure control. This allows high shear conditions to be achieved through increased steam velocity from larger orifices without necessarily increasing steam pressure, thus avoiding excessive temperature rise.
Solution Approach 2:
The patent changes the physical parameters of steam injection by independently adjusting pressure and orifice size. High shear is achieved by optimizing the combination of steam pressure and orifice dimensions, allowing shear force to be increased without proportionally increasing temperature that would cause product damage.
3Temperature
If low pressure differentials are used to avoid overheating, then temperature control is improved, but steam velocity and shear conditions are reduced
Solution Approach 1:
The patent changes multiple parameters simultaneously - using moderate pressure differentials combined with optimized orifice sizes to achieve both controlled temperature rise and high steam velocity. The steam modulator dynamically adjusts orifice dimensions to maintain high velocity even at lower pressure differentials, enabling both temperature control and high shear conditions.
Solution Approach 2:
The dynamic steam modulator allows the system to respond in real-time to maintain optimal steam velocity. When pressure differential is reduced to prevent overheating, the modulator adjusts orifice size to compensate and maintain sufficient steam velocity for high shear conditions, creating a dynamic balance between temperature control and shear generation.
4Temperature
If steam orifice size is increased to introduce more steam for greater temperature change, then temperature control range is improved, but shear imparted on fluid becomes significant and damaging
Solution Approach 1:
The patent segments the control functions so that temperature control range is achieved through coordinated adjustment of both steam pressure and orifice size, while shear force is controlled separately through the steam modulator's precise orifice modulation. This prevents the scenario where increased orifice size for temperature range automatically causes excessive shear.
Solution Approach 2:
The steam modulator provides dynamic control that allows the system to achieve greater temperature change ranges by modulating orifice size in coordination with pressure adjustments. The dynamic response ensures that shear force remains within acceptable limits even as temperature control range is expanded, by optimizing the timing and magnitude of orifice adjustments.
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
Enables repeatable control of shear and temperature, achieving a steady temperature rise and targeted shear levels, enhancing food processing capabilities and preventing product damage.
Implementation Method 1
vary the position of the steam modulator to control the amount of shear impacted on the product flow as the product flow passes through the steam injection cooker
Implementation Method 2
designed to cook a product flow as the product flow enters into a product supply pipeline and flows from a product input to a product output
Implementation Method 3
The supply of steam is passed through a pressure control valve, which modulates the steam pressure to the plurality of steam injection heaters/cookers through PID control using a pressure transmitter as feedback
Data Source
AI summary
A cooking system for cooking a product flow utilizing steam. A supply of steam is provided at a supply pressure that is regulated by a control unit to a regulated pressure. The supply of steam is provided to a plurality of steam injection cookers which are positioned within a product supply pipeline that receives a product flow. The product flow is cooked as the product flow passes through the product supply pipeline and the plurality of cookers. Each of the steam injection cookers includes a steam modulator that controls the amount of steam injected. By regulating the steam pressure and the steam modulator, the control unit can modify the amount of shear created within the product flow and control the temperature of the fluid. The cooking system further includes a clean-in-place system that can inject a cleaning solution into the steam supply pipeline and the plurality of steam injection cookers.