Steam Compression Frying for Waste Heat Recovery
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Solution Overview
Problem
Frying processes for snack foods, particularly potato chips, face challenges in reducing energy costs and waste heat generation while maintaining high product quality and consistency.
Innovation Solution
A method and apparatus that includes a fryer with an oil recirculating system, a heat exchanger, a steam compressor, and a gas-powered engine to compress and reuse steam, which is used to heat the oil and reduce waste heat, along with a hood to collect and pressurize steam, enhancing energy efficiency and reducing oil content in the final product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If steam is exhausted to atmosphere or thermal oxidizer, then waste heat is removed, but energy efficiency is reduced and waste heat generation increases
Solution Approach 1:
The patent converts the harmful waste steam and waste heat into beneficial resources by compressing the steam back into the fryer system. The steam compressor takes waste steam from the hood and recompresses it into the fryer, while the thermal oxidizer exhaust heat is recovered to preheat incoming air. This transforms energy losses into useful heating functions, directly resolving the contradiction between waste heat removal and energy efficiency.
Solution Approach 2:
The patent implements recovery of both steam and heat that would otherwise be discarded. The steam recovery system compresses and returns steam to the fryer, while the heat recovery system captures thermal energy from the thermal oxidizer exhaust. This dual recovery approach eliminates the need to discard these resources, improving energy efficiency while maintaining waste heat management.
2Productivity
If high production volumes are maintained, then productivity is high, but energy costs increase
Solution Approach 1:
The patent establishes continuous cycles of steam compression and heat recovery that operate throughout the frying process. The steam compressor continuously recycles steam back into the fryer, and the thermal oxidizer continuously preheats incoming air. These continuous actions ensure that energy is constantly being recovered and reused, maintaining high productivity while reducing energy costs through ongoing energy efficiency improvements.
3Reliability
If conventional frying process is used, then product quality is maintained, but oil content in final product is high
Solution Approach 1:
The patent changes the thermal parameters of the frying environment by introducing compressed steam and preheated air from the thermal oxidizer. These parameter changes create a more controlled moisture and heat environment during frying, which affects oil absorption by the potato chips. The modified thermal conditions reduce oil uptake while maintaining the frying effectiveness needed for product quality.
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 achieves significant energy and cost savings, reduces waste heat, and lowers the oil content in fried products without compromising taste or sensory qualities, resulting in a more efficient and nutritional snack food production process.
Implementation Method 1
a heat exchanger for heating the oil in the oil recirculating system
Implementation Method 2
a compressor for compressing the collected steam, the compressor having an input for inputting steam from the hood and an output for outputting compressed steam to the heat exchanger
Implementation Method 3
The apparatus may further comprise a gas-powered engine for driving the compressor
Implementation Method 4
the steam is passed into a thermal oxidiser for volatile destruction
Data Source
AI summary
A method for frying foodstuffs, the method comprising a fryer having inlet and outlet longitudinal ends, an oil recirculating system coupled to the fryer, a heat exchanger for heating the oil in the oil recirculating system, a hood above the fryer for collecting steam generated during the frying process, a conduit for conveying steam from the hood, and a compressor for compressing the steam, the compressor having an input connected to the conduit and an output for compressed steam connected to the heat exchanger.