Retort System Product Holding Structure Heat Distribution
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Solution Overview
Problem
Existing commercial sterilization processes, such as retort systems, require substantial energy and heat transfer fluid due to the need for full vessel heating and water immersion, which is inefficient and energy-intensive.
Innovation Solution
A retort system with a heat exchange liquid circulation path and a distribution feed system that fills product holding structures with heat exchange liquid to a target processing level, allowing for efficient heat transfer and energy management by pumping the liquid through the structures and back into the vessel, while monitoring and controlling the liquid levels and temperatures to optimize energy use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If full vessel heating and water immersion is used for commercial sterilization, then effective heat distribution and penetration into products is achieved, but energy consumption and heat transfer fluid requirements increase substantially
Solution Approach 1:
The system divides the retort vessel into multiple zones with independent heating and circulation capabilities. Each zone can be controlled separately, allowing heat to be applied only where needed rather than heating the entire vessel volume, thus reducing overall energy consumption while maintaining effective heat distribution to products.
Solution Approach 2:
The patent implements localized heating elements and circulation pumps in specific regions of the retort vessel. This allows the system to concentrate thermal energy and fluid flow precisely at product locations requiring sterilization, rather than uniformly heating the entire vessel, thereby improving heat distribution effectiveness while reducing total energy usage.
2Reliability
If the entire retort vessel chamber is filled with heated water under pressure, then complete product immersion and even heat distribution is achieved, but the amount of heat transfer fluid and energy required increases substantially
Solution Approach 1:
The circulation system is divided into multiple independent loops, each serving specific product zones. This segmentation allows the system to use smaller volumes of heat transfer fluid in each loop while collectively achieving complete product immersion and uniform heat distribution across the entire retort vessel.
Solution Approach 2:
The system uses just enough heat transfer fluid to achieve the required product immersion and heat distribution, rather than filling the entire vessel chamber. The circulation pumps deliver fluid at controlled rates and volumes tailored to product requirements, avoiding excessive fluid usage while maintaining effective sterilization conditions.
3Reliability
If multiple distribution headers with spray nozzles are used to distribute water throughout the product load, then homogeneous heat transfer is achieved, but device complexity increases
Solution Approach 1:
The patent combines multiple distribution functions into integrated manifold assemblies that distribute heat transfer fluid through a single coordinated system. Instead of separate spray nozzles and distribution headers, the merged manifold design achieves homogeneous fluid distribution to all product zones while reducing the number of individual components and simplifying system architecture.
Solution Approach 2:
The distribution manifold is designed to perform multiple functions simultaneously: it distributes heat transfer fluid to various zones, collects return fluid, and provides flow regulation all through a single integrated structure. This multi-functionality reduces the overall number of components needed compared to separate spray nozzle and distribution header systems.
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 by optimizing heat transfer and liquid levels within the retort system, achieving faster and more uniform heating of packaged products with reduced water usage, leading to efficient and cost-effective commercial sterilization.
Implementation Method 1
heat transfer from a process liquid in a controlled manner
Implementation Method 2
heated water is circulated via a pump circulation loop that draws the water from a sump or reservoir in the bottom of the retort and pumps the water through a distribution header
Implementation Method 3
heated water is circulated via a pump circulation loop that draws the water from a sump or reservoir in the bottom of the retort and pumps the water through a distribution header
Implementation Method 4
pumps the water through a distribution header fitted with spray nozzles at the top and or sides of the retort
Implementation Method 5
The header includes openings that allow water to flow down into a metal pan that runs the length of the retort above the product. The metal pan typically fills with water to a depth of about 12 mm to 20 mm, and has openings that allow the water to trickle or cascade from the pan (under the head pressure of the water depth in the pan), down to and through the product load.
Data Source
AI summary
A retort system includes a vessel defining an interior volume, and a product holding structure received within the interior volume. The product holding structure includes: one or more inlet openings that together define a first flow area for receiving heat exchange liquid and one or more outlet openings that together define a second flow area for outflow of heat exchange liquid, the second flow area being smaller than the first flow area for limiting flow of heat exchange liquid out of the product holding structure. A heat exchange liquid flow system that is configured to direct heat exchange liquid into the product holding structure causing the product holding structure to fill with heat exchange liquid to at least a submersion level above products within the product holding structure while a level of heat exchange liquid outside the product holding structure and within the interior volume remains below the submersion level.