HEAT TREATING A DAIRY PRODUCT USING A HEAT PUMP
A method for heating and cooling a consumable product disposed in a product container includes the steps of: (i) heating the consumable product to a first temperature by transferring heat from ambient air to refrigerant through a liquid-to-air heat exchanger; and (ii) heating the consumable product to a second temperature without transferring heat from the ambient air to the refrigerant through the liquid-to-air heat exchanger; wherein the second temperature is greater than the first temperature.
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This application claims priority to U.S. Provisional Appln. No. 61/251,091 filed Oct. 13, 2009, which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION1. Technical Field
This disclosure relates generally to a heating and refrigeration system and, more particularly, to a system for heating a dairy product using a heat pump.
2. Background Information
Dairy heating and cooling (“H&C”) systems are used to prepare (e.g., mix, pasteurize and cool), store in a chilled environment and/or dispense dairy products such as soft serve ice cream and milk shakes. A typical dairy H&C system includes a dairy product heat exchanger thermally coupled to a container (e.g., a hopper or a freezing cylinder), a compressor, a condenser, an expansion valve and a hot gas solenoid valve. In a cooling cycle, the dairy product heat exchanger (e.g., operating as an evaporator), the compressor, the condenser and the expansion valve form a cooling loop. In a heating cycle, the dairy product heat exchanger (e.g., operating as a condenser), the compressor and the hot gas solenoid valve form a heating loop.
During the cooling cycle, the compressor directs refrigerant through the condenser and the expansion valve, and into the dairy product heat exchanger in a typical fashion. The dairy product within the container is chilled as heat transfers from the dairy product to the refrigerant. During the heating cycle, the compressor directs the refrigerant through the hot gas solenoid valve and into the dairy product heat exchanger bypassing the condenser. The dairy product within the container is heated (e.g., up to 150° Fahrenheit (“F”) for pasteurization) as heat transfers from the refrigerant to the dairy product.
The efficiency for the dairy H&C system can be determined by dividing the heat energy transferred into or out of the dairy product (i.e., “transferred heat energy”) by the respective electrical energy used to heat or cool the dairy product (i.e., “work energy”); that is
Efficiency≈(Transferred Heat Energy)/(Work Energy).
In the aforesaid heating cycle, the transferred heat energy is typically less than the work energy used to heat the dairy product since approximately all the heat energy is generated via the compressor. Thus, disadvantageously the dairy H&C system obtains a maximum efficiency of one or below.
SUMMARY OF THE DISCLOSUREAccording to one aspect of the invention, a multi-phase heating system is provided that includes a product container, a product heat exchanger, a liquid-to-air heat exchanger, a compressor, and a system valve. The product heat exchanger selectively transfers heat into or out of the product container. The system valve selectively configures the system between a first heating loop and a second heating loop. The first heating loop extends through the product heat exchanger, the liquid-to-air heat exchanger and the compressor. The second heating loop extends through the product heat exchanger and the compressor, and bypasses the liquid-to-air heat exchanger.
According to another aspect of the invention, a heating and refrigeration system is provided that includes a product container, a product heat exchanger, an expansion valve, a liquid-to-air heat exchanger, a compressor, and a system valve. The product heat exchanger selectively transfers heat into or out of the product container. The system valve selectively configures the system between a cooling loop and heating loop. The cooling loop extends through the liquid-to-air heat exchanger, the expansion valve, the product heat exchanger and the compressor. The heating loop extends through the product heat exchanger, the expansion valve, the liquid-to-air heat exchanger and the compressor.
According to still another aspect of the invention, a method for heating and cooling a consumable product disposed in a product container is provided. The method includes the steps of: (i) heating the consumable product to a first temperature by transferring heat from ambient air to refrigerant through a liquid-to-air heat exchanger; and (ii) heating the consumable product to a second temperature without transferring heat from the ambient air to the refrigerant through the liquid-to-air heat exchanger; wherein the second temperature is greater than the first temperature.
The product containers 12, 14 are adapted to hold, mix and/or dispense the consumable products. Each product container 12, 14 has an outer surface and an inner volume. The inner volume may be enclosed (e.g., where the product container is a sealed canister), or may be accessible (e.g., where the product container includes an access/fill aperture). For example, as illustrated in
The product heat exchangers 16 are adapted to transfer heat into or out of the product containers 12, 14. Each product heat exchanger 16 has a heat exchange surface and a refrigerant flow path 29 extending between first and second inlet/outlet apertures 28, 30 (“I/O apertures”). An inlet/outlet aperture is defined as an aperture that is operable as both a fluid inlet and a fluid outlet.
The expansion valves 18 (e.g., electrically actuated thermostatic expansion valves) are adapted to meter and expand refrigerant flowing therethrough. In some embodiments, the expansion valves 18 are bi-directional expansion valves operable to meter and expand the refrigerant flowing in both directions therethrough.
The liquid-to-air heat exchanger 20 (e.g., a tube and fin radiator) has a heat exchange surface and a refrigerant flow path extending between first and second I/O apertures 32, 34. The liquid-to-air heat exchanger 20 is adapted to transfer heat between refrigerant traveling through the refrigerant flow path and ambient air traveling over the heat exchange surface. In some embodiments, the liquid-to-air heat exchanger 20 is configured with at least one fan 36 to direct the ambient air over the heat exchange surface; i.e., induce convection.
The compressor 22 (e.g., a variable speed electrical compressor) has an inlet 38 and an outlet 40 and is adapted to compress refrigerant flowing therethrough. Compressors are known in the art, and the present invention is not limited to any particular configuration thereof.
The system valve 24 (e.g., an electrically actuated valve) is adapted to selectively configure the multi-phase system 10 between a plurality of heating/cooling loops. The heating/cooling loops, which include a first heating loop 42 (see
In those embodiments that include a suction heat exchanger 26, the suction heat exchanger 26 (e.g., a liquid-to-liquid heat exchanger) has a heat exchange surface disposed between first and second refrigerant flow paths 74, 76 and is adapted to transfer heat between the first and the second refrigerant flow paths 74, 76. Each of the first and the second refrigerant flow paths 74, 76 extend between two I/O apertures. An example of a suction heat exchanger (e.g., a “sub cooler”) is disclosed in U.S. Pat. No. 6,735,967 to Bischel et al., which is herein incorporated in by reference in its entirety.
The product heater 31 (e.g., see
Referring to
Alternatively, as shown in
Alternatively, as shown in
Alternatively, as shown in
The various embodiments of the multi-phase system 10 illustrated in
In a first mode of operation, as illustrated in
As set forth above, the refrigerant is heated in the liquid-to-air heat exchanger 20 and the compressor 22. Notably, in the liquid-to-air heat exchanger 20, minimal electrical energy is used to facilitate the heating of the refrigerant via the fan 36; i.e., the heat energy transferred into the refrigerant is greater than the electrical energy used to power the fan 36. Heat energy transferred from the ambient air into the refrigerant increases the efficiency of the process by decreasing the amount of work energy that would otherwise be used to increase the temperature of the products in the product containers 12, 14. For example, where (i) the ambient air has a temperature of approximately 70° F., (ii) the refrigerant in a low side of the first heating loop 42 (i.e., between the second I/O aperture of the expansion valves 18 and the inlet 38 of the compressor 22) has a temperature of approximately 50° F. and a pressure of approximately 118 pounds per square inch absolute (“psia”), and (iii) the refrigerant in a high side of the first heating loop 42 (i.e., between the outlet 40 of the compressor 22 and the second I/O aperture of the product containers 12, 14) has a temperature of approximately 100° F. and a pressure of approximately 250 psia, the efficiency of the multi-phase system 10 can exceed one (e.g., ˜5.0 efficiency where enthalpy for heating equals approximately 61.65 BTU/lb and electrical enthalpy input into the system is approximately 12.39 BTU/lb).
In a second mode of operation, as illustrated in
In a third mode of operation, when the multi-phase system 10 includes the electrical heating elements 86, the heating elements 86 can be used to transfer heat energy to the consumable products through the product containers 12, 14.
In a fourth mode of operation, as illustrated in
During a heating and cooling cycle, the multi-phase system 10 can operate in a multiple modes of operation. For example, during pasteurization, the multi-phase system 10 can heat the consumable products to the first temperature using the first mode of operation. To heat the consumable products to the second temperature, the multi-phase system 10 can operate according to the second and/or the third modes of operation. During cooling (e.g., chilling or freezing the dairy product to form an ice cream product, etc.), the multi-phase system 10 can chill or freeze the consumable products using the fourth mode of operation.
While various embodiments of the present invention have been disclosed, it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible within the scope of the invention. Accordingly, the present invention is not to be restricted except in light of the attached claims and their equivalents.
Claims
1. A multi-phase heating system, comprising:
- a product container;
- a product heat exchanger that selectively transfers heat into or out of the product container;
- a liquid-to-air heat exchanger;
- a compressor; and
- a system valve that selectively configures the system between a first heating loop and a second heating loop, which first heating loop extends through the product heat exchanger, the liquid-to-air heat exchanger and the compressor, and which second heating loop extends through the product heat exchanger and the compressor, and bypasses the liquid-to-air heat exchanger.
2. The system of claim 1, wherein the system valve further selectively configures the system into a cooling loop that extends through the liquid-to-air heat exchanger, the product heat exchanger, and the compressor.
3. The system of claim 2, further comprising a bi-directional expansion valve coupled with the product heat exchanger.
4. The system of claim 2, wherein the system valve comprises a four-way valve, a first three-way valve, and a second three-way valve, which four-way valve couples the first and the second three-way valves to the compressor.
5. The system of claim 2, wherein the system valve comprises a four-way valve, a first two-way valve, a second two-way valve and a third two-way valve, which four-way valve couples the first, the second and the third two-way valves to the compressor.
6. The system of claim 2, further comprising a suction heat exchanger coupled between the product heat exchanger and the liquid-to-air heat exchanger, and between the product heat exchanger and the compressor in the cooling loop.
7. The system of claim 1, wherein the product container comprises at least one of a product storage canister and a hopper.
8. The system of claim 1, further comprising a product heater disposed with the product container.
9. A heating and refrigeration system, comprising:
- a product container;
- a product heat exchanger that selectively transfers heat into or out of the product container;
- an expansion valve;
- a liquid-to-air heat exchanger;
- a compressor; and
- a system valve that selectively configures the system between a cooling loop and heating loop, which cooling loop extends through the liquid-to-air heat exchanger, the expansion valve, the product heat exchanger and the compressor, and which heating loop extends through the product heat exchanger, the expansion valve, the liquid-to-air heat exchanger and the compressor.
10. The system of claim 8, wherein the expansion valve comprises a bi-directional expansion valve.
11. The system in claim 9, wherein the system valve further configures the system into a second heating loop that extends through the product heat exchanger, the expansion valve and the compressor, and bypasses the liquid-to-air heat exchanger.
12. The system of claim 9, further comprising a product heater disposed with the product container, which product heater transfers heat into the product container.
13. The system of claim 9, wherein the system valve comprises a four-way valve, a first three-way valve, and a second three-way valve, which four-way valve couples the compressor to the first and the second three-way valves.
14. A method for heating and cooling a consumable product disposed in a product container, comprising:
- heating the consumable product to a first temperature by transferring heat from ambient air to refrigerant through a liquid-to-air heat exchanger; and
- heating the consumable product to a second temperature without transferring heat from the ambient air to the refrigerant through the liquid-to-air heat exchanger;
- wherein the second temperature is greater than the first temperature.
15. The method of claim 14, wherein the consumable product is a diary product.
16. The method of claim 14, wherein the step of heating the consumable product to the second temperature comprises the step of heating the consumable product via a product heater.
17. The method of claim 16, wherein the product heater is an electrical heating element.
18. The method of claim 14, wherein the step of heating the consumable product to the second temperature comprises the step of compressing the refrigerant in a compressor.
19. The method of claim 14, further comprising the step of cooling the consumable product.
20. The method of claim 14, further comprising the steps of:
- configuring a multi-phase system into a first heating loop for heating the consumable product to the first temperature, which multi-phase system includes the liquid-to-air heat exchanger; and
- configuring the multi-phase system into a second heating loop for heating the consumable product to the second temperature, which second heating loop bypasses the liquid-to-air heat exchanger.
Type: Application
Filed: Oct 13, 2010
Publication Date: Apr 21, 2011
Applicant: CARRIER CORPORATION (Farmington, CT)
Inventors: Stephen M. Wadle (Beloit, WI), Robert K. Newton (Beloit, WI), Peter F. McNamee (Beloit, WI)
Application Number: 12/903,816
International Classification: F25B 29/00 (20060101); F25B 13/00 (20060101);