Retort Vessel Liquid Column Heating for Lower Energy Use
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing retorting processes require large volumes of processing fluid and energy due to the need to immerse the entire retort vessel chamber, leading to inefficient heat transfer and prolonged heating times.
Innovation Solution
A closed loop system where packaged products are held in structures with controlled liquid flow, forming closed columns within the retort vessel, allowing precise heat transfer and reducing the volume of processing fluid required.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the entire retort vessel chamber is filled with heated water to completely immerse the product, then effective heat distribution and penetration into the product is achieved, but a large amount of energy is required to heat the entire volume of liquid
Solution Approach 1:
The retort vessel is segmented into multiple zones: a liquid-filled zone containing the product, and a vapor zone above it. This segmentation allows heat treatment to occur in the liquid zone while the vapor zone provides additional heating without requiring the entire vessel volume to be filled with liquid, thereby reducing energy consumption while maintaining effective heat distribution.
Solution Approach 2:
The invention introduces a vertical dimension to heat transfer by allowing vapor to rise and condense on the upper surfaces of products and container closures. This adds a top-down heat transfer pathway that complements the traditional side-to-side liquid immersion heating, enabling effective heat treatment with less liquid volume.
2Stress or pressure
If compressed air is used to develop overpressure in the retort to offset pressure differential inside product containers, then container integrity is maintained, but the energy required to heat and cool the large volume of liquid increases
Solution Approach 1:
The retort vessel is divided into a pressurized liquid zone and a vapor zone. Compressed air is applied selectively to maintain overpressure in the liquid zone where products are immersed, while the vapor zone operates at different pressure conditions. This segmented pressurization reduces the total volume requiring compressed air maintenance, lowering energy consumption.
3Temperature
If the entire retort vessel chamber is filled with heated water, then homogeneous heat transfer to all products is achieved, but the heatsink effect of the vessel shell and large liquid volume prolongs heating time
Solution Approach 1:
By segmenting the vessel into liquid immersion zones and vapor exposure zones, the system achieves homogeneous heat transfer through multiple pathways: liquid conduction to submerged surfaces and vapor condensation to exposed surfaces. This multi-zone approach reduces the total liquid volume required, minimizing the heatsink effect and shortening heating time while maintaining heat uniformity.
Solution Approach 2:
The invention utilizes phase transition of water from liquid to vapor and back to liquid (condensation) as a heat transfer mechanism. Vapor generated in the liquid zone rises, condenses on cooler product surfaces and vessel walls, releasing latent heat directly to products without requiring additional liquid volume, thereby reducing heatsink effects and heating time.
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
This approach reduces energy consumption and shortens heating times by using less process liquid and minimizing the heatsink effect, while maintaining effective heat transfer to the products.
Implementation Method 1
a circulation pump operable to transport heat exchange liquid from the suction side to the discharge side
Implementation Method 2
circulating heat exchange liquid through each product holding structure to treat the packaged products
Implementation Method 3
heated processing liquid can be pressurized to completely immerse the food product within the baskets
Implementation Method 4
each of the one or more removable baskets comprises at least one flow control orifice that is proximate the bottom of the basket and configured to slow drainage of heat exchange liquid out of the basket
Implementation Method 5
a distribution plenum for supplying heat exchange liquid into each of the one or more removable baskets, the distribution plenum in fluid connection with the discharge side of the heat exchange liquid circulation loop
Data Source
AI summary
A retort system includes a vessel and a plurality of product holding structures for holding one or more products to be treated, the product holding structures configured to be received within the interior volume of the vessel. A heat exchange system, includes a liquid circulation path having a discharge side, a suction side and a pump operable to move a heat exchange liquid from the suction side to the discharge side. The suction side is fluidly connectable to a lower region of the interior volume. The discharge side is fluidly connectable to deliver heat exchange liquid into the product holding structures via pump operation causing the product holding structures to fill with heat exchange liquid to a product submersion level while a level of heat exchange liquid outside the product holding structures and within the interior volume remains below the product submersion level.