Onsite Oxyfuel CO2 Generation for Reliable Poultry Stunning
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Solution Overview
Problem
The reliability of carbon dioxide supply for stunning systems in poultry processing is vulnerable to disruptions, leading to production halts and financial losses, as bulk CO2 delivery is subject to feed gas supplier outages and disruptions.
Innovation Solution
An on-site oxyfuel combustion process generates carbon dioxide and other gases using available oxygen and natural gas or propane, producing a flue gas mixture that can be processed and used as a stunning gas mixture, eliminating the need for bulk CO2 delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bulk CO2 delivery from external suppliers is used, then initial CO2 supply is established, but supply reliability deteriorates due to feed gas supplier outages and disruptions
Solution Approach 1:
The system generates its own CO2 supply through an on-site combustion process using natural gas or propane and oxygen, eliminating dependence on external bulk CO2 deliveries and feed gas suppliers. The combustion chamber continuously produces CO2 as needed for the stunning process.
Solution Approach 2:
A combustion chamber acts as an intermediary device that converts readily available natural gas or propane and oxygen into the required CO2 gas mixture. This intermediary process provides a reliable on-site source of CO2 without direct dependence on external CO2 suppliers.
2Quantity of substance
If bulk CO2 storage tanks are used, then CO2 storage capacity is increased, but vulnerability to supply disruptions increases due to contractual outages at feed gas suppliers
Solution Approach 1:
The combustion chamber operates continuously to generate CO2 as needed, ensuring an uninterrupted supply for the stunning process. This continuous generation eliminates the vulnerability associated with periodic bulk deliveries and contractual outages at external suppliers.
Solution Approach 2:
The system produces its own CO2 supply on-demand through the combustion process, eliminating the need for external bulk storage tanks and deliveries. The CO2 is generated continuously at the point of use, ensuring supply continuity regardless of external supplier status.
3Ease of operation
If scheduled deliveries from tanker trucks are used, then bulk CO2 supply is established, but production halt risk increases when deliveries are interrupted
Solution Approach 1:
The on-site combustion system provides continuous CO2 generation without interruption by scheduled deliveries. The process runs continuously, ensuring that stunning operations can proceed without production halts even when external delivery schedules are disrupted.
Solution Approach 2:
The combustion chamber serves as a local intermediary that converts readily available natural gas or propane and oxygen into CO2, eliminating dependence on external tanker truck deliveries and their associated scheduling vulnerabilities.
4Ease of manufacture
If external bulk CO2 supply is used, then initial gas supply is provided, but control over delivery continuity is lost due to supplier contracts
Solution Approach 1:
The system generates its own CO2 supply through the combustion process, providing complete control over delivery continuity. The facility can adjust production levels and maintain supply according to its own operational needs without being subject to external supplier contract terms.
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
Ensures a continuous and reliable supply of CO2 for stunning, reducing the risk of disruptions and enabling precise gas mixture adjustments to optimize meat quality and yield.
Implementation Method 1
combustion chamber located at the processing site for combusting a mixture of gases to provide therefrom an exhaust gas mixture comprising carbon dioxide
Data Source
AI summary
An apparatus for stunning an animal with an exhaust gas mixture includes a stunning chamber located at a processing site to contain therein as many an animal selected to be stunned; and a combustion chamber located at the processing site for combusting a mixture to provide therefrom an exhaust gas mixture which includes carbon dioxide for stunning the animal in the stunning chamber. A related method and exhaust gas mixture are also provided.