Thermally Inhibited Starch Processing with Gas-Flow Batch Heating
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Solution Overview
Problem
Stirred batch reactors face limitations in producing thermally inhibited starches efficiently at high loading capacities due to the need for longer reaction times and potential starch degradation, while fluidized bed reactors are more expensive and less common.
Innovation Solution
A method involving a stirred batch reactor with a gas inlet for introducing a flow of gas, preferably air, to thermally inhibit starch at temperatures above 140°C, maintaining a loading capacity of 40-95% and stirring the starch to achieve consistent thermal inhibition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a stirred batch reactor is used for thermal inhibition of starch, then the equipment cost is lower and the reactor is more commonly available, but the loading capacity is limited and reaction time increases
Solution Approach 1:
The patent introduces a gas flow system into the stirred batch reactor, using pneumatic principles to enhance heat and mass transfer. The gas flow (typically air or inert gas) circulates through the starch particles, improving thermal inhibition efficiency and allowing higher loading capacities without excessive reaction times, thus maintaining the cost advantage of stirred batch reactors while improving productivity
Solution Approach 2:
The patent modifies operational parameters of the stirred batch reactor, specifically introducing gas flow rate, temperature profiles, and stirring speed optimizations. These parameter changes enable the reactor to handle higher loading capacities (up to 95% volume occupancy) while maintaining effective thermal inhibition within acceptable time frames, resolving the contradiction between equipment simplicity and production efficiency
2Quantity of substance
If the loading capacity of the stirred batch reactor is increased, then the batch size and productivity improve, but the reaction time increases and starch degradation may occur
Solution Approach 1:
The gas flow system penetrates deep into the starch mass, ensuring uniform heat distribution and preventing localized overheating that could cause degradation. This allows higher batch sizes to be processed while maintaining starch quality through improved thermal management and mass transfer
Solution Approach 2:
The continuous gas flow throughout the reaction maintains consistent thermal inhibition conditions across the entire starch batch. This continuous action ensures uniform processing even at high loading capacities, preventing degradation by maintaining optimal conditions throughout the reaction volume rather than allowing stagnant zones to form
3Device complexity
If thermal inhibition is performed without gas flow, then the process is simpler, but thermal inhibition efficiency is reduced and consistent results are difficult to achieve
Solution Approach 1:
The gas flow system provides enhanced heat and mass transfer without requiring fundamental changes to the stirred batch reactor design. The gas circulation mechanism is relatively simple to implement and control, yet it dramatically improves thermal inhibition consistency by ensuring uniform heat distribution and preventing stagnant zones, thus achieving high manufacturing precision with minimal added complexity
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 method enables the production of thermally inhibited starch with improved efficiency and quality by increasing the loading capacity and preventing starch decomposition through gas flow, ensuring optimal viscosity profiles.
Implementation Method 1
introducing gas through said gas inlet to create a flow of gas and passing said flow of gas through the volume of dehydrated starch in the reactor while heating and stirring the starch to a temperature of at least 140° C.
Implementation Method 2
introducing gas through said gas inlet to create a flow of gas and passing said flow of gas through the volume of dehydrated starch
Data Source
AI summary
The present invention relates to a method for producing a thermally inhibited starch, the method comprising providing a volume of dehydrated starch having a pH value between 7.0 and 11 and having a moisture content of <2 wt. %, based on the weight of the starch, in a stirred batch reactor, said reactor being comprised with a gas inlet, and applying a flow of gas through the volume of dehydrated starch in the reactor while heating and stirring the starch to a temperature of at least 140° C. for a period of time sufficient to thermally inhibit the starch. In addition, the invention relates to a device for thermally inhibiting starch and use of a flow of gas in a stirred batch reactor during thermal inhibition of starch.