Pasteurization Device Heat Pump Thermal Energy Recovery
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing pasteurization devices for liquid-filled containers are structurally large and energy-intensive due to the need for long residence times and limited heat transfer, requiring large volumes of liquid with high energy content, and existing energy recovery methods do not efficiently address these issues.
Innovation Solution
A pasteurization device with a heat pump connecting segments of the pasteurization and cooling zones for efficient thermal energy transfer, using a mixing device to regulate temperature and prevent overheating, and a method where the liquid from the heat exchanger is optimized to maintain a target temperature with minimal additional hot water input.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the residence time is increased to achieve adequate pasteurization, then the pasteurization effectiveness is improved, but the device size and structural complexity increase
Solution Approach 1:
The invention changes the temperature parameter profile by introducing a heat pump that actively heats the pasteurization zone, enabling higher temperatures to be maintained. This parameter change allows for shorter residence times while achieving the same pasteurization effectiveness, thereby reducing the required device size.
Solution Approach 2:
The heat pump acts as an intermediary device that transfers thermal energy from the cooling zone to the pasteurization zone. This mediator enables efficient heat recovery and reuse, allowing the system to maintain higher temperatures in the pasteurization zone without proportionally increasing energy input or device size.
2Productivity
If the temperature is increased to reduce residence time, then the productivity is improved, but the energy consumption increases
Solution Approach 1:
The heat pump utilizes phase transitions of the refrigerant (evaporation and condensation) to transfer thermal energy efficiently. This allows for effective heat recovery from the cooling zone and its application to the pasteurization zone, enabling higher processing temperatures with reduced net energy consumption.
Solution Approach 2:
The invention converts the waste heat from the cooling zone, which would otherwise be discarded, into a useful resource for heating the pasteurization zone. This transforms a harmful waste product into a beneficial energy source, reducing overall energy consumption while maintaining high productivity.
3Loss of energy
If heat recovery is implemented by circulating liquid between heating and cooling zones, then energy efficiency is improved, but the device complexity increases
Solution Approach 1:
The heat pump system serves multiple functions: it acts as a heater for the pasteurization zone, a cooler for the cooling zone, and a heat recovery device all simultaneously. This multi-functionality improves energy efficiency without requiring separate systems for each function, thereby limiting the increase in device complexity.
4Use of energy by stationary object
If the pasteurization zone is heated without energy input, then energy consumption is reduced, but the temperature control precision deteriorates
Solution Approach 1:
The system incorporates temperature sensors and control mechanisms that continuously monitor the temperature in the pasteurization zone and adjust the heat pump operation accordingly. This feedback control ensures precise temperature maintenance while optimizing energy consumption, preventing both overheating and energy waste.
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 solution reduces the size of the pasteurization device and maintains energy efficiency by enabling continuous heat pump operation with reduced hot water volume, achieving a lower outlet temperature without increasing energy costs.
Implementation Method 1
a heat pump, which is connected to a segment of the pasteurization zone and a segment of the cooling zone via lines and conveyor units in such a way that part of the thermal energy of the liquid volume of a segment of the cooling zone can be transferred to a segment of the pasteurization zone by means of this heat pump
Implementation Method 2
sprinkling devices being provided in the segments for heating, pasteurization and/or cooling
Implementation Method 3
the liquid-filled containers are conveyed through segments with increasing or decreasing temperature for gentle heating and cooling
Data Source
Figure 1
AI summary
The invention relates to a pasteurizing device for the thermal treatment of liquids present in closed containers, comprising a heating zone, a pasteurization zone, and a cooling zone, wherein each zone may be made of one or more segments, and the filled liquid containers may be guided from the inlet of the pasteurization device to the outlet thereof through all segments, and irrigation devices are provided for the heating, pasteurization and/or cooling in the segments, wherein the irrigation liquid of one of more segments is collected in a collecting vessel for the purpose of heat recovery, and these liquids are exchanged between individual segments for the purpose of heating or cooling in a suitable manner. The pasteurization device comprises a heat pump that is connected to a segment of the pasteurization zone and a segment of the cooling zone via lines and pumping units such that part of the thermal energy of the liquid volume of a segment of the cooling zone can be transferred into a segment of the pasteurization zone by means of this heat pump.