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 imparted on food products due to non-instantaneous pressure changes, significant shear damage, and limited ability to achieve high shear conditions for mixing and cooking, especially when dealing with varying flow rates and steam pressures.
Innovation Solution
A system that decouples steam pressure from temperature using a steam modulator to control the shear imparted on food products by varying the steam orifices and utilizing a pressure control valve with PID control, allowing for precise regulation of steam pressure and orifice size to achieve repeatable shear and temperature control.
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 steam pressure supplies change
Solution Approach 1:
The system changes multiple parameters simultaneously - steam pressure, orifice size, and steam flow rate - to maintain constant temperature. When steam supply pressure changes, the system adjusts the orifice size and steam flow rate to compensate, ensuring temperature remains stable despite pressure fluctuations
Solution Approach 2:
The system uses temperature feedback from the product flow to dynamically adjust steam injection parameters. Temperature sensors monitor the product flow temperature and feed this information back to the control system, which then modulates the orifice size and steam pressure to maintain the desired temperature setpoint
2Force
If steam pressure is increased to achieve high shear conditions, then shear mixing and emulsification improve, but temperature control becomes difficult and product damage occurs
Solution Approach 1:
The system segments the steam injection process into multiple controllable parameters - steam pressure, orifice size, and steam flow rate - rather than relying on a single high-pressure injection. This allows the system to achieve necessary shear forces through optimized combinations of parameters while maintaining temperature control and preventing product damage
Solution Approach 2:
The system dynamically adjusts steam injection parameters based on real-time process conditions. The orifice size and steam flow rate are continuously modulated to maintain optimal shear conditions without exceeding temperature thresholds that would damage the product
3Temperature
If orifice size is increased to introduce more steam for greater temperature change, then temperature control improves, but shear imparted on fluid becomes significant and damaging
Solution Approach 1:
The system changes multiple parameters in coordination - when orifice size is increased to allow more steam flow for greater temperature change, the steam pressure is simultaneously adjusted to maintain optimal shear conditions. This multi-parameter control allows temperature change without excessive shear damage
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 consistent temperature control with a ±0.55°C (±1°F) rise at both low and high shear conditions, enabling effective mixing and cooking of food products while preventing product damage and maintaining aseptic conditions.
Implementation Method 1
The present disclosure provides a system, as defined in claim 1, and a method, as defined in claim 13, to decouple steam pressure from temperature of food using direct steam injection
Implementation Method 2
The supply of steam is passed through a pressure control valve, which modulates the steam pressure to the plurality of steam injection heaters/cookers
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
Implementation Method 4
These technologies control the shear imparted on the product flow by varying the size of the steam orifices
Data Source
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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.