Pasteurization Plant Heat Pump Zone Flexibility
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Solution Overview
Problem
Existing pasteurization systems face challenges in efficiently utilizing heat pumps across multiple zones due to complex design requirements and pressure losses, and open systems complicate setup and control behavior.
Innovation Solution
A pasteurization system with pressure-closed heating and cooling line systems, allowing for flexible positioning of heat exchangers and heat pumps, and incorporating bypasses to manage heat transfer efficiently without additional pressure losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the heat pump is integrated directly into the process water circuit of two zones, then the cooling/heating energy of the heat pump can be used in two zones, but switching between different zones is very complex in terms of construction and the heat pump is permanently connected to the same pair of zones
Solution Approach 1:
The system divides the process water circuit into multiple independent zones, each with its own heat exchanger unit. The heat pump can be connected to different zone combinations by switching between pre-defined segment groupings, reducing construction complexity while maintaining flexibility.
Solution Approach 2:
The heat pump system is designed with universal connectivity to multiple zones through a standardized interface. A single heat pump unit can serve different zone configurations (e.g., cooling zone A+B, heating zone C+D) without requiring custom construction for each pairing, achieving versatility without increasing construction complexity.
2Ease of manufacture
If the heat pump is permanently connected to the same pair of zones, then construction is simplified, but no advantage can be gained when heating or cooling energy is predominantly required in other zones
Solution Approach 1:
The system implements dynamic zone assignment where the heat pump can be operatively connected to different zone pairings based on real-time thermal demands. The connection topology changes dynamically through valve switching or pump routing, allowing the system to adapt to varying operational conditions while maintaining simple physical infrastructure.
3Duration of action of stationary object
If heat exchangers connected to the heat pump are always flowed through, then heat transfer is continuous, but additional pressure losses occur even when the heat pump is switched off
Solution Approach 1:
The system incorporates bypass lines with isolation valves positioned upstream of the heat exchangers. When the heat pump is switched off, these bypasses allow process water to flow through alternative routes, preventing unnecessary pressure losses through the heat exchanger circuits while maintaining system readiness for rapid reactivation.
4Ease of manufacture
If open tanks are used for water balance between pasteurizer tank and tanks, then installation is simpler, but tanks must be integrated into the pasteurizer or located at fixed geodetic height
Solution Approach 1:
The system employs a pressurized closed-loop water balance system using hydraulic principles. Pumps and pressure vessels enable water circulation between tanks located at different elevations without requiring open-top gravity-fed connections, allowing flexible spatial arrangement of tanks while maintaining controlled water balance.
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 flexible positioning of system elements for heating or cooling, reduces pressure losses, and simplifies setup by eliminating the need to consider geodetic height, thereby improving operational efficiency and control behavior.
Implementation Method 1
a heat pump (35), in that additional heat can be supplied to the process fluid in the heating line system by means of a condenser (37) of the heat pump (35) and in that the process fluid in the cooling line system can be additionally cooled by means of an evaporator (39) of the heat pump (35)
Implementation Method 2
additional heat can be supplied to the process fluid in the heating line system by means of a condenser (37) of the heat pump (35)
Implementation Method 3
the process fluid in the cooling line system can be additionally cooled by means of an evaporator (39) of the heat pump (35)
Data Source
Figure 1
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AI summary
The invention relates to a plant (1, 42, 53, 56) for pasteurizing foodstuffs/beverages in containers by way of a process liquid (13), having: at least one heating zone (6, 7), pasteurizing zone (8-10) and cooling zone (11, 12), wherein each of said zones is assigned a sprinkling device (14-20) for discharging the process liquid and a collecting region (23-29) for receiving the discharged process liquid, a first heat exchanger (31) which feeds heat from a heat source (32) to the process liquid from a collecting region of the at least one pasteurizing zone and which, for this purpose, has a line connection to said collecting region and to inlets to sprinkling devices of the at least one heating zone via a pressure-closed heating line system (95), a second heat exchanger (30) which is coupled to a cooling system in order to cool the process liquid from the collecting region of the at least one cooling zone and which, for this purpose, has a line connection to said collecting region and to inlets to sprinkling devices of the at least one cooling zone via a pressure-closed cooling line system (96), wherein the process liquid can additionally be fed heat in the heating line system by means of a condenser (37) of a heat pump (35), and the process liquid can additionally be cooled in the cooling line system by means of an evaporator (39).