Sterilization Machine Hot Stream Energy Recovery
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Solution Overview
Problem
Sterilization machines require significant energy to heat water to high temperatures for steam generation, leading to inefficiencies and waste, and existing systems face challenges with energy management, including downtime, lime scale accumulation, and costly drainage systems due to the discharge of hot streams at high temperatures.
Innovation Solution
An apparatus comprising a heat exchange chamber and a water collection chamber, connected via a heat exchanger, which cools hot streams from the sterilization machine using cold water, reducing the temperature of the streams and reusing the heat to pre-heat de-mineralized water for the steam generator, while also managing vacuum operations to prevent lime scale buildup and optimize energy use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cold de-mineralized water is heated to generate steam at 134°C, then sterilization can be performed, but a large amount of energy is required
Solution Approach 1:
The system pre-heats cold de-mineralized water using heat exchangers that recover thermal energy from hot streams generated during sterilization cycles. This preliminary heating action reduces the energy required by the steam generator to reach sterilization temperatures, directly addressing the energy consumption issue while maintaining sterilization effectiveness
Solution Approach 2:
The system converts the previously wasted thermal energy in hot streams (which were discharged to the floor) into a useful resource by routing them through heat exchangers to pre-heat incoming cold water. This transforms harmful energy waste into a beneficial pre-heating function, reducing overall energy consumption
2Ease of operation
If the sterilization chamber is kept at temperature between cycles, then readiness is maintained, but energy is continuously consumed
Solution Approach 1:
The system uses the hot streams generated during sterilization cycles to automatically maintain the chamber temperature through heat exchange. The thermal energy from the process itself serves to keep the chamber ready, eliminating the need for separate continuous heating systems and reducing energy consumption
3Productivity
If hot streams are discharged to the floor, then steam is removed, but enthalpy content is wasted and special drains are required
Solution Approach 1:
The system converts the previously wasted hot streams into a valuable thermal resource by routing them through heat exchangers to pre-heat incoming cold de-mineralized water. This eliminates the enthalpy loss by capturing and reusing the thermal energy, while still achieving effective steam removal from the chamber
Solution Approach 2:
Instead of discarding the hot streams to the floor, the system recovers their thermal energy through heat exchangers. The recovered heat is used to pre-heat incoming water, transforming a waste stream into a useful thermal resource that reduces overall energy consumption
4Extent of automation
If cold water is used for vacuum pump operations, then vacuum is created, but lime scale accumulation occurs
Solution Approach 1:
The system changes the temperature parameter of the water used in vacuum pump operations by pre-heating it through heat exchangers. This parameter change prevents lime scale accumulation by ensuring the water is warm enough to avoid rapid cooling and condensation that causes scaling, thereby extending device lifespan while maintaining vacuum functionality
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 effectively recovers energy from hot streams, reduces the temperature of discharged water, extends the life of suction devices, and prevents operational issues like lime scale accumulation, while ensuring efficient energy management and cost savings by pre-heating de-mineralized water and maintaining sterilization chamber readiness.
Implementation Method 1
a heat exchanger, wherein the heat exchanger is configured to be connected at entrance to a cooling water inlet pipe and to a vacuum extraction branch of a mixed hot stream connected to the sterilization chamber
Implementation Method 2
by means of condensation dischargers, is transformed into condensation, which is discharged as a stream of hot water to the floor
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Apparatus to manage the energy of hot streams of a sterilization machine (50), comprising a heat exchange chamber (12), a heat exchanger (14) and a water collection chamber (16).