Vacuum Cooling Pump Staging for Lower Energy Pressure Hold
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Solution Overview
Problem
Vacuum cooling systems for produce typically use undersized two-stage vacuum pumps, leading to higher energy consumption due to unnecessary operation of the high-pressure stage during pressure maintenance, resulting in inefficient energy use and limited simultaneous operation of multiple chambers.
Innovation Solution
The method employs separate single and two-stage vacuum pumps for distinct phases of pressure lowering and maintenance, optimizing each pump's operation within its range to reduce energy consumption and allow simultaneous operation of multiple chambers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a two-stage vacuum pump is used for both pressure lowering and maintaining steps, then the system structure is simplified, but energy consumption increases due to unnecessary operation of high-pressure stages
Solution Approach 1:
The vacuum pump system is segmented into two independent single-stage vacuum pumps: a first single-stage vacuum pump dedicated to the pressure lowering step and a second single-stage vacuum pump dedicated to the pressure maintaining step. This segmentation allows each pump to operate at optimal efficiency for its specific function, eliminating the energy waste of running high-pressure stages during pressure maintaining, while maintaining relatively simple system structure through the use of standard single-stage pump units.
2Adaptability or versatility
If a two-stage vacuum pump is used, then the pump can handle both pressure ranges, but the high-pressure stage operates at less than 10% capacity during pressure maintaining step
Solution Approach 1:
The versatility of handling both pressure lowering and maintaining is achieved through segmentation into two specialized single-stage pumps rather than one two-stage pump. The first single-stage pump handles pressure lowering with full capacity utilization, while the second single-stage pump handles pressure maintaining with optimal efficiency, eliminating the energy waste of operating high-pressure stages at less than 10% capacity.
Solution Approach 2:
Each single-stage vacuum pump is designed to be universally applicable to its specific function. The first single-stage pump is optimized for pressure lowering operations, and the second single-stage pump is optimized for pressure maintaining operations. This multi-functionality approach allows the system to adapt to different operational requirements without the energy inefficiency of using a two-stage pump for both functions.
3Use of energy by moving object
If separate single and two-stage vacuum pumps are used for distinct steps, then energy consumption is reduced, but the system complexity increases
Solution Approach 1:
The system uses two separate single-stage vacuum pumps instead of one two-stage pump. While this segmentation reduces power consumption by approximately 75% during pressure maintaining operations, it does increase system complexity by requiring coordination between two independent pumps. However, the complexity is manageable because each pump operates independently in its optimized range, and the system can be controlled through a programmable logic controller that manages the switching between pumps based on operational phase.
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 significantly reduces energy consumption by up to 75% during the pressure maintenance phase and enables efficient operation of multiple vacuum chambers, enhancing the overall efficiency and capacity of the cooling process.
Implementation Method 1
lowering the pressure inside the vacuum chamber to a predetermined pressure level and maintaining the vacuum chamber at this predetermined pressure level both by removing air through a vacuum pump system
Implementation Method 2
condensing water vapor inside the vacuum chamber through a refrigeration system
Implementation Method 3
heat transfer out of the produce to take place
Implementation Method 4
the method relies on latent heat of vaporization of water at low pressure in order to effect the cooling of the produce
Data Source
AI summary
Described is a method as well as an apparatus for vacuum cooling of food produce through moisture removal, which method comprising the steps of loading the food produce to be cooled into a vacuum chamber, lowering the pressure inside the vacuum chamber to a predetermined pressure level and maintaining the vacuum chamber at this predetermined pressure level both by removing air through a vacuum pump system for a sufficient of time to allow heat transfer out of the food produce to take place, and condensing water vapor inside the vacuum chamber through a refrigeration system. The method and apparatus is unique in that the step of lowering the pressure inside the vacuum chamber to the predetermined pressure level is carried out using a single stage vacuum pump and the step of maintaining the vacuum chamber at this predetermined pressure level is carried out using a two stage vacuum pump.