The present invention relates to a method and device for a liquid processing system. More particularly, the present invention relates to a method and a device for determining rheological properties of a liquid flowing through a liquid processing system.
In liquid processing, in particular liquid food processing, it is often desired to monitor the operation in order to obtain data being correlated to the actual treatment of the liquid. For example, liquid food is normally subjected to various processing steps such as heating, mixing, separation, etc. in order to provide treatment to the liquid food, which treatment is necessary to achieve the required properties for the final liquid product. By monitoring the operation of the process it is possible to accurately determine the status of the liquid processing system whereby faults may be detected and the quality of the final product may be ensured.
Especially in liquid food processing changes in raw material may occur rather frequently, which changes do not necessarily provide a significant impact on the operation on the processing equipment, however they may lead to undesired changes in the final product itself. One such example is when manufacturing tomato sauces or purees, wherein a change of raw material from one batch of tomatoes having a high amount of sugar to another batch with a less amount of sugar will cause the viscosity of the final product to change.
Traditionally viscometers or rheometers may be used to address this problem, whereby a sample is withdrawn from the liquid processing system and analyzed in the metering equipment for revealing any changes in the final product. Should such change in viscosity be detected, an operator may adjust the operating parameters of the liquid processing equipment accordingly, or even stop the processing equipment for replacing the raw material used. Such monitoring of the viscosity is very time consuming and requires the need for a skilled operator, not only for extracting samples but also for evaluating the results and making necessary decisions. A further drawback with this method is associated with the fact that for hygienic applications, an extracted sample must be discarded after testing leading to unwanted losses of the liquid to be processed.
It becomes even more complicated when the liquid to be processed is a non-Newtonian fluid, whereby the viscosity is in fact dependent on the shear rate or the shear rate history. Analyzing the rheological parameters alone will in those cases not be enough, since the rheological parameters may change depending on the shear rate caused by the processing equipment such as pumps, homogenizers, centrifugal separators, etc.
Hence, there is a need for an improved method and device for a liquid processing system, providing data which allows accurate in-line monitoring of the actual product.
It is, therefore, an object of the present invention to overcome or alleviate the above described problems.
The basic idea is to provide a method and device for a liquid processing system, in which the liquid being processed is represented by the power law model, and which method and device provides an in-line determination of the consistency (K) and the flow behaviour index (n) of the liquid being processed.
According to a first aspect of the invention a method for a liquid processing system is provided. The method comprises the steps of: providing a first flow of liquid through a predetermined geometry; determining the flow rate through said geometry and the pressure drop across said geometry for said first flow of liquid; providing a second flow of liquid through a predetermined geometry; determining the flow rate through said geometry and the pressure drop across said geometry for said second flow of liquid; and calculating the consistency and the flow behaviour index for said liquid using said geometries and the flow rate and pressure drop for said first and second flow of liquid.
Preferably, the liquid is a non-Newtonian fluid whereby the method provides continuous data of the consistency and the flow behaviour index representing the rheological parameters of the liquid for further improving process control for such liquids.
The geometry being associated with the first flow of liquid may be different from the geometry being associated with the second flow of liquid. Hence, the consistency and the flow behaviour index may be determined at a specific time thus reducing measurement errors caused by time variances in the process.
In other embodiments, the geometry being associated with the first flow of liquid is equal to the geometry being associated with the second flow of liquid, and the flow rate and/or the pressure drop being associated with the first flow of liquid is different from the flow rate and the pressure drop being associated with the second flow of liquid. This is advantageous in that although it is necessary to perform measurements for the same geometry but for different pressure drop and different flow rate, the device may be made much smaller with a reduced number of sensors.
Said geometries may be determined as their respective length and inner radius, wherein the flow behaviour index may be calculated as:
Further, the consistency may be calculated as:
where R, Q, L, and Δp are associated with one of said first or second flow of liquid.
The method may further comprise the step of comparing said calculated values of the consistency and the flow behaviour index with reference values being associated with the liquid flowing through said liquid processing system. It is thus possible to continuously perform quality checks for the liquid product for improving process control.
According to a second aspect, a device for a liquid processing system is provided. The device comprises a first measurement unit being configured to measure the flow rate through a predetermined geometry and the pressure drop across said geometry for a first flow of liquid, a second measurement unit being configured to measure the flow rate through a predetermined geometry and the pressure drop across said geometry for a second flow of liquid, and a control unit being configured to calculate the consistency and the flow behaviour index for said liquid using said geometries and the flow rate and pressure drop for said first and second flow of liquid.
The device may further comprise an open ended liquid channel being in fluid connection with said first and/or second measurement unit, which channel is configured to be arranged in fluid connection with a pipe of said liquid processing system. Hence, the device may be provided as a stand-alone unit which may be connected to the liquid processing system upon request from the system operator.
The device may be configured to form part of said liquid processing system such that said control unit is allowed to determine the consistency and the flow behaviour index in real time for liquid being processed by said liquid processing system. This is advantageous in that the device may always provide accurate values for the rheological properties of the liquid being process, thus allowing instant feedback if the liquid falls outside predetermined properties.
According to a third aspect a liquid processing system is provided, comprising a device according to the second aspect. Said liquid is preferably a food product.
The above, as well as additional objects, features, and advantages of the present invention, will be better understood through the following illustrative and non-limiting detailed description of preferred embodiments of the present invention, with reference to the appended drawings, wherein:
Starting with
In order to explain the basic setup of a liquid processing system 10 briefly, an inlet 12 provides a flow of liquid to be processed. The inlet 12 may be a connecting joint to upstream equipment, or a batch tank as indicated in
The processing equipment 18, 20, 22 may include components such as heaters, coolers, homogenizers, separators, holding cells, mixers, etc. The choice of processing equipment 18, 20, 22 may preferably be selected with respect to the particular liquid product and the desired treatment. For example, should the liquid product be sterilized it is probably necessary to provide some sterilizing equipment such as heaters, UV radiators, etc.
When the liquid is being transported through the liquid processing system 10 it is of high importance to receive input data relating to the actual treatment taking place. Especially in liquid food applications the final quality of the liquid food may vary greatly if one or several treatment processes is not operating as they should. In case of malfunction of a heater configured to pasteurize the liquid food, the final product may have an increased amount of microbiological substances thus leading to shortened storage time or in worst case causing diseases for the consumer.
Monitoring of the treatment steps may be performed by controlling one or several components of the liquid processing system 10. This may be done by providing particular parts of the liquid processing system 10 with specific outputs for transmitting data relating to the current operation of the specific component.
Monitoring may also be done by providing the liquid processing system 10 with one or several sensors, each sensor being configured to measure particular parameters during operation such as temperature, flow, pressure drop, etc. Such monitoring may preferably be done in-line, i.e. in real time without extracting samples of the liquid being process.
Hence, monitoring of the liquid treatment process may be made by in-line sensors for ensuring the desired operation of the liquid processing system, and thus also for ensuring the required quality level of the final liquid product. However, for certain liquids known monitoring principles have proven not to be sufficiently accurate. Such liquids, of which the rheological parameters are of crucial importance for the final product, include for example tooth paste, tomato sauces, custard, shampoo, and various starch suspensions. These liquids are generally denoted as non-Newtonian fluids for which the methods and devices described below are of particular importance.
Before describing specific embodiments of the method and device, some general comments on such non-Newtonian fluids will be given. Non-Newtonian fluids have a rheological behavior that may be represented theoretically by a number of models of which the power-law model is one.
According to the power-law model, the average velocity of a fluid flowing in a circular pipe may be expressed as:
where
Δp is the pressure drop across a circular pipe,
K is the consistency,
L is the length of the circular pipe,
n is the fluid behavior index,
Q is the volumetric flow rate,
R is the inner radius of the circular pipe,
v is the mean velocity over the cross sectional area of the circular pipe,
{dot over (γ)} is the shear rate,
μ is the dynamic viscosity, defined by μ=σ/{dot over (γ)}, and
σ is the shear stress, defined as σ=K{dot over (γ)}.
In order to describe the actual behavior of the fluid it is advantageous to express the functions for K and n, respectively. Hence, the equation above may be rewritten as:
By providing a two-point measurement, leaving the rheological properties K and n constant, it is possible to rewrite n as:
where index 1, 2 denotes the particular point of measurement.
From above it is evident that a two-point measurement is necessary for calculating K and n. In liquid processing, real time monitoring of K and n has proven to be a very efficient method for quality checks, system performance analysis, processing status checks, etc.
Now turning to
The tubular conduit 110 includes a first section 112 having a first inner diameter, and a second section 114 having a second diameter. The first and second diameters are different from each other, thus leading to different velocities when the liquid is transported through the tubular conduit 110. During operation, the liquid enters the first section 112 and exits the second section 114 after flowing through the tubular conduit 110.
The first section 112 is provided with one or more sensors 120, 122, 124 for measuring the flow rate and the pressure drop across the first section 112. As shown in
The second section 114 is provided with two additional sensors 126, 128 for measuring the pressure at the inlet end and the outlet end of the second section 114. The sensors 120, 122, 124, 126, 128 may be selected from various available sensors used within liquid processing systems. In a preferred embodiment the two sensors 122, 124 may be provided as a single sensor configured to measure the pressure drop across the first section 112, i.e. a single sensor measuring the difference between inlet pressure and outlet pressure. Similarly, the two sensors 126, 128 may be provided as a single sensor configured to measure the pressure drop across the second section 114, i.e. a single sensor measuring the difference between inlet pressure and outlet pressure.
A controller 130 is provided for collecting the data from the sensors 120, 122, 124, 126, 128. For this purpose the controller 130 includes a plurality of input channels of a calculating unit 134, wherein each input channel is associated with a specific sensor 120, 122, 124, 126, 128.
Hence, the calculating unit is connected with the first sensor 120 of the first section 112, whereby the calculating unit 134 receives data corresponding to the volumetric flow rate through the tubular conduit 110.
The calculating unit 134 is further connected with the second and third sensors 122, 124, whereby the calculating unit 134 receives data corresponding to the pressure drop across the first section 112. For this, the calculating unit 134 is configured to calculate the pressure drop from the data of the second and third sensors 122, 124. Optionally, if the pressure drop is measured by a single sensor in accordance with the embodiment described above, the calculating unit 134 is connected to only one sensor for receiving data corresponding to the pressure drop.
The calculating unit 134 is connected with the sensors 126, 128 of the second section 114 whereby the calculating unit 134 receives data corresponding to the pressure drop across the second section 114. For this, the calculating unit 134 is configured to calculate the pressure drop from the data of the sensors 126, 128. Optionally, if the pressure drop is measured by a single sensor in accordance with the embodiment described above, the calculating unit 134 is connected to only one sensor for receiving data corresponding to the pressure drop across the second section.
The calculating unit 134 receives the data values from each sensor 120, 122, 124, 126, 128. The calculating unit 134 further comprises a memory (not shown), either stored within the controller 130 or arranged remotely and accessed via wired or wireless data communication. The memory stores values corresponding to system constants, such as the radius of the tubular conduit 110 and the length of each section 112, 114. When the calculating unit 134 receives data from the sensors 120, 122, 124, 126, 128 the calculating unit 134 is programmed to fetch the system constants from the memory for calculating the consistency K and the fluid behavior index n according to the formulas given above. Hence, these values are transmitted to two separate outputs 136a, 136b for allowing other components of the liquid processing system 10 to access and analyze these values representing the rheological properties of the liquid being processed by the liquid processing system.
Now turning to
The device 200 includes a tubular conduit 210 having a constant diameter, i.e. the cross section of the tubular conduit 210 is constant over its length. The tubular conduit 210 is connected to a pipe 16 of the liquid processing system 10 by means of two branch pipes 16a, 16b. The diameter of the tubular conduit 210 is selected such that it is different from the diameter of the pipe 16 of the liquid processing system 10. In this embodiment, the tubular conduit 210 is equipped with three sensors 220, 222, 224 for measuring the flow rate and the pressure drop across the tubular conduit 210. Hence, the sensor arrangement of the tubular conduit 210 is equal to the sensor arrangement of the first section 112 of the tubular conduit 110 described with reference to
The piping 16 also includes three sensors 30, 32, 34 for measuring the flow rate and the pressure drop across the piping 16. Hence, the sensor arrangement of the piping 16 is equal to the sensor arrangement of the first section 112 of the tubular conduit 110 described with reference to
It should be noted that sensors 222, 224, i.e. the pressure sensors provided for measuring the inlet pressure and the outlet pressure of the tubular conduit 210 could be replaced by a single sensor configured to measure the pressure drop directly. The same applies to the sensors 32, 34 being provided for measuring the inlet pressure and the outlet pressure of the pipe 16.
Similarly to what has been described with reference to
Now turning to
The device 200 operates by measuring the pressure drop and the flow rate at a specific time, and at a second time again measuring the pressure drop and the flow rate across the tubular conduit 210. For these measurement points, the flow rate and thus also the pressure drop must have changed such that the values of the first and second input channels are different from the values of the third and fourth input channels. Hence, by measuring the pressure drop and the flow rate for two different flows of liquid it is possible to calculate the consistency K and the flow behavior index n for the fluid.
For all embodiments described so far, it is necessary to select the process parameters, i.e. the geometries, the pressure drops, and the volumetric flow rates such that the denominator in the formulas above does not equal zero. It is also preferred to design the process such that the numerator in the formulas above does not equal zero.
The device 100, 200 may preferably be used for a number of applications within liquid processing, and in particular for food processing. In order to perform a quality check of the process, the device 100, 200 may be operated to provide actual values of n and K. By comparing these values with reference values using an additional controller, such as a controller of the liquid processing system or a further module within the controller 130, 230, it may be possible to detect any undesired variances in the final product. This may e.g. be the case for ketchup manufacturing, wherein the rheological properties should be within strict intervals for the consumer to experience the expected product quality of the consumer. If the raw material is changed from a first batch of tomatoes to a second batch of tomatoes, wherein the amount of starch is different due to different degree of ripeness, the rheological parameters may change at an amount large enough to render the final product outside consumer expectations.
Since the rheological parameters n and K are dependent on heat treatment, i.e. the temperature and the time for which the product is exposed to such temperature, the device 100, 200 may also be used to verify heat treatment processes by comparing measured values with reference values. Hence, the device 100, 200 may be used for condition monitoring, i.e. for monitoring the actual condition of processing equipment in real time.
Now turning to
The method 300 may also comprise an optional step 312 in which the values for n and K are transmitted to a further controller which compares the measured values with reference values for evaluating and/or analysing the current process for the liquid.
The predetermined geometries may preferably represent the length and radius of tubular conduits or pipes having a circular cross section. However, the presented methods and devices may also be implemented for conduits and pipes having a non-circular cross section. For such embodiments the consistency and the flow behaviour index may be calculated by replacing the radius value R1,2 by a value corresponding to the hydraulic radius {hacek over (R)} which may be expressed as
Hence, for a circular tubular conduit the hydraulic radius equals the radius of the circular cross section.
Although the above description has been made mostly with reference to a liquid food processing system, it should be readily understood that the general principle of the method and device is applicable for various different liquid processing systems.
Further, the invention has mainly been described with reference to a few embodiments. However, as is readily understood by a person skilled in the art, other embodiments than the ones disclosed above are equally possible within the scope of the invention, as defined by the appended claims.
Number | Date | Country | Kind |
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1350984-9 | Aug 2013 | SE | national |
Filing Document | Filing Date | Country | Kind |
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PCT/EP2014/068187 | 8/27/2014 | WO | 00 |