Patent Description:
Particularly, the present disclosure relates to the use of ultrahigh pressure fluidic shear where the operating pressure is greater than <NUM> × <NUM><NUM> Pa (<NUM>,<NUM> psi) and where the fluid will benefit from extreme fluid shear and heating achieved during ultrahigh pressure discharge. More particularly, the disclosure relates to a method and system for the high shear processing of products utilizing a modular approach where the initial generation of the processing pressure is accomplished by a fluid independent of the product being processed. Specifically, the disclosure relates to a novel technique for allowing a high pressure source fluid to transfer pressure to a product in isolators and discharged through valves at pressure in excess of <NUM> × <NUM><NUM> Pa (<NUM>,<NUM> psi) while allowing easy cleaning of the equipment, long component life and suitability for thick or viscous products.

Pressure discharge based high shear processing is a common processing method for foods and other substances where size reduction, emulsification, and mixing are required. Homogenized milk for example is typically processed at <NUM> × <NUM><NUM> Pa (<NUM>,<NUM> psi). This is typically accomplished by use of a positive displacement pump and a discharge nozzle, sometimes called homogenizing valve. A pump is used to force the product through a nozzle under pressure. At the nozzle, the fluid experiences high shear stress as the pressure energy is converted to velocity. Homogenization happens at this point due to high fluid shear stresses, cavitation, and subsequent fluid impingement. Higher pressures typically produce a greater homogenization effect.

Ongoing research suggests that homogenization at ultrahigh pressure (for example from <NUM> × <NUM><NUM> Pa to <NUM> × <NUM><NUM> Pa (<NUM>,<NUM> psi to <NUM>,<NUM> psi)) may result in significant advantages. These advantages are related to the generation of extreme fluid shear stresses, which can rupture cellular materials, and achieve instantaneous heating of significant magnitude. For example, the discharge of <NUM> water from <NUM> × <NUM><NUM> Pa (<NUM>,<NUM> psi) will instantly increase the temperature of that water to <NUM> due to the conversion of potential pressure energy to kinetic energy, and then to thermal energy. The supersonic fluid flow at the homogenizer valve generates extremely high shear stress. These effects may lead to desirable thermal effects as well as greater size reduction effects. The thermal effects may be used to achieve rapid thermal processing. The shear effects may be used to achieve the creation of nanoparticle suspensions.

The current approaches employed to build direct displacement pump type homogenizers are difficult at ultrahigh pressures due to the high stresses on the mechanical pump components. Every cylinder in the pump would alternate between no pressure and extreme pressure during every cycle. Thus, for a pump operating at <NUM> rpm, every hour of operation would result in <NUM>,<NUM> pressure cycles. Doing this at <NUM> × <NUM><NUM> Pa (<NUM>,<NUM> psi) is a high technical challenge.

Large reciprocating pistons working at ultrahigh pressure require tremendous forces on the pistons and connected components. For example, at <NUM> × <NUM><NUM> Pa (<NUM>,<NUM> psi), a <NUM> (<NUM>") diameter homogenizer piston will require a force of <NUM> × <NUM><NUM> kg (<NUM>,<NUM> lbs. The best approach to engineer a high pressure pump is to reduce the forces by reducing the diameter of the piston. In order to compensate for the reduced volumetric flow of a smaller piston, a higher pump rotational speed would be used. However, high rotational speed and smaller diameter would be incompatible with viscous products. Furthermore, smaller size pump components would make equipment cleaning more difficult due smaller passageways.

High pressure pumps, however, have been developed for other industrial uses, such as water jet cutting and cleaning. These pumps work with clean water so valves are not subjected to viscous fluids. Processing products such as food through these pumps will not be possible. Cleaning these pumps from complex organic materials will also be difficult due to small internal passages.

<CIT> relates to processes for the forming and use of small diameter coherent abrasive suspension jets of high pressure (up to <NUM> × <NUM><NUM> Pa (<NUM>,<NUM> psi)) fluid with entrained abrasive particles directed to cutting of materials. <FIG> and <FIG> of <CIT> show systems within which a coherent abrasive suspension jet fluid may be created. <CIT> discloses an ultra high pressure pump for use in waterjet cutting apparatus. <CIT> relates to a method and apparatus for desalinating sea water or brine by reverse osmosis, and to methods and apparatuses for ultrafiltration of a liquid such as water.

There is a need to perform ultrahigh pressure fluid shear processing without the need to build massive conventional homogenizer pumps.

A first aspect of the disclosure is directed to a high fluid shear processing system. The system includes an ultrahigh pressure pump capable of advancing a first fluid at a pressure of at least <NUM> × <NUM><NUM> Pa (<NUM>,<NUM> psi), and at least one isolator for selectively containing and discharging (or dispensing) a second fluid. Each isolator includes an isolator wall defining a chamber and a separator positioned in the chamber and movable between a first end of the chamber and a second end of the chamber. The separator engages the isolator wall to further divide the chamber into a first sub-chamber and a second sub-chamber that are in pressure communication with each other but are not in fluid communication with each other. A first sub-chamber inlet valve is in fluid communication with the ultrahigh pressure pump and the first sub-chamber. A first sub-chamber outlet valve is in fluid communication with the first sub-chamber. A first check valve is in fluid communication with the second sub-chamber to allow fluid to enter the second sub-chamber. A second check valve is in fluid communication with the second sub-chamber to exhaust fluid from the second sub-chamber. A processing unit is in fluid communication with the second check valve, wherein the processing unit is a homogenizing valve. The system further includes a collection zone for collecting the second fluid after the second fluid has passed through the processing unit.

In some embodiments, there are at least two isolators, and the isolators are configured so that while a first one of the isolators is filling, a second one of the isolators is discharging.

In some embodiments, a first proximity sensor detects the proximity of the separator to the first end of the chamber, and a second proximity sensor detects the proximity of the separator to the second end of the chamber.

In some embodiments, there is more than one high pressure pump to produce a continuous flow state of the first fluid to the isolators.

In some embodiments, there is a low pressure transfer pump in fluid communication with the first check valve, and configured to advance a second fluid to the first check valve.

In some embodiments, a manifold pressure sensor is in fluid communication with a manifold that is in fluid communication with the second check valve.

In some embodiments, a pump pressure sensor is in fluid communication with the ultrahigh pressure pump.

In some embodiments, a temperature controlled zone is downstream of the processing unit.

In some embodiments, a controllable pressure discharge valve is in fluid communication with the second outlet of each isolator, and is downstream of the processing unit.

In some embodiments, a vent is in fluid communication with the second sub-chamber of the at least one isolator, and is configured to allow clean in place operation of the system.

In some embodiments, the system includes a processor, at least one discharge pressure sensor in communication with the processor for measuring the discharge pressure, and a controller in communication with the processor. The controller is configured to throttle the pressure discharge valve to reduce flow during the switchover process between isolators, thereby maintaining a more constant discharge pressure (or a constant discharge pressure).

In some embodiments, the pumps are crank shaft driven positive displacement water pumps capable of at least <NUM> × <NUM><NUM> Pa (<NUM>,<NUM> psi).

In some embodiments, the pumps are hydraulic intensifier pumps capable of constant pressure operation of at least <NUM> × <NUM><NUM> Pa (<NUM>,<NUM> psi).

In some embodiments, the isolators, manifold, and pressure discharge valve can be maintained at a preselected temperature by insulation and/or secondary heating.

In some embodiments, the final product can be filled into containers at the collection zone in an aseptic manner.

In some embodiments, the first fluid is clean water.

In some embodiments, each isolator is positioned in a clean room environment.

In some embodiments, the isolator and the pump are separate modules that can be reconfigured.

Also disclosed is a high pressure isolator. The isolator has an isolator wall defining a chamber. The isolator has a separator positioned in the chamber and movable between a first end of the chamber and a second end of the chamber. The separator engages the isolator wall to further divide the chamber into a first sub-chamber and a second sub-chamber that are in pressure communication with each other but are not in fluid communication with each other.

In some embodiments, the first sub-chamber has a first inlet port and a first outlet port, and the first inlet port and the first outlet port are positioned vertically one above the other, and at an outer edge of the chamber. The second sub-chamber has a second inlet port and a second outlet port. The second inlet port and the second outlet port are positioned vertically one above the other, and at an outer edge of the chamber.

In some embodiments, the isolator is contained in an insulating jacket and/or provided with heating and/or provided with cooling to provide temperature control.

In some embodiments, the isolator contains a structure for agitating the product so as to keep multiphase mixtures in suspension prior to exiting the isolator.

In a second aspect of the present disclosure, a method is provided for high pressure, high shear processing of a fluid. The method comprises the step of providing at least one isolator for selectively containing and dispensing a second fluid. Each isolator has an isolator wall defining a chamber and a separator positioned in the chamber and movable between a first end of the chamber and a second end of the chamber. The separator engages the isolator wall to further divide the chamber into a first sub-chamber and a second sub-chamber that are in pressure communication with each other but are not in fluid communication with each other. The at least one isolator also includes a first sub-chamber inlet valve in fluid communication with an ultrahigh pressure pump and the first sub-chamber; a first sub-chamber outlet valve in fluid communication with the first sub-chamber; a first check valve in fluid communication with the second sub-chamber, wherein the first check valve is configured to allow the second fluid to enter the second sub-chamber; and a second check valve in fluid communication with the second sub-chamber, wherein the second check valve is configured to exhaust fluid from the second sub-chamber. The method further comprises the steps of providing a processing unit in fluid communication with the second check-valve of the at least one isolator; alternately directing a first fluid at a pressure of at least <NUM> × <NUM><NUM> Pa (<NUM>,<NUM> psi) into the first sub-chamber and directing the second fluid into the second sub-chamber, wherein the directing of the first fluid into the first sub-chamber causes the second fluid to be discharged from the second sub-chamber, through the second check valve, and through the processing valve; and collecting the second fluid after it has passed through the processing unit.

In some embodiments, the processing unit is a homogenizing valve.

In some embodiments, the temperature of the second fluid is controlled when it is in a manifold that is in fluid communication with the second check valve.

In some embodiments, there are at least two isolators.

In some embodiments, two isolators discharge the second fluid out of phase to provide a continuous flow of the second fluid through the manifold.

In some embodiments, the position of the separator is detected with respect to the first end of the chamber and the second end of the chamber for each respective isolator, and the isolators are controlled to be out of phase.

In some embodiments, a discharge valve is provided downstream of the processing unit, and the discharge valve is controlled.

In some embodiments, the second fluid is cooled after it has passed through a pressure discharge valve.

The present disclosure relates generally to high shear processing of multiphase fluids for the purpose of mixing, size reduction, emulsification, instant heating, or the like through the use of ultrahigh pressurized fluidic discharge. Specifically, embodiments of the present disclosure are described below with reference to an isolator that allows a first fluid under high pressure to cause a second fluid to be processed in a homogenizing (or other processing) system without having the first fluid directly contact the second fluid.

The method and system of the present disclosure are also useful for processing food and biological products based on emulsions, suspensions, and where cellular destruction and particle size reduction is desired.

One or more pressure-source-independent isolators is used to transfer pressure from a high pressure fluid, such as pressurized clean water obtained from high performance industrial pump(s), to the product to be homogenized (or otherwise processed). An isolator is a constant internal diameter cylinder separated by a movable piston (separator). A typical isolator diameter would be between <NUM> and <NUM> (<NUM>" and <NUM>") but larger or smaller diameter may be possible. Pressure on one side of the isolator is transferred to the other side of the isolator by the movement of the floating piston. Since the pressures on both sides of the isolator piston are almost the same, there is little friction during piston movement and the seal on the isolator piston is not subject to high wear.

This system combines the use of commercial ultrahigh pressures pumps, isolators, and valves to enable the homogenization of products at ultrahigh operating pressure of <NUM> × <NUM><NUM> Pa to <NUM> × <NUM><NUM> Pa (<NUM>,<NUM> psi to <NUM>,<NUM> psi).

The isolator prevents the mixing of the source water and the product, but allows pressure to be transferred to the product. In other embodiments, the isolator can be designed as compressible bellows or bladder without a moving piston. In all cases, one side of the isolator is in fluid communication with the pump which provides a source of high pressure water while the other side of the isolator is in fluid communication with the product and an external homogenization valve. The two sides of the isolator are in pressure communication with each other. The valve is adjustable to control the flow rate from the isolator such that a defined differential pressure is maintained during discharge. The valve will self-regulate by opening or closing to maintain a constant pressure at different flow rates.

The system works as follows: Product is transferred into an isolator by way of a low pressure transfer pump, for example, a diaphragm pump. The product flows into the isolator through a check valve. Once the isolator is filled, pressurized water (or another fluid) from a high pressure pump is admitted through a valve to the other side of the isolator. Pressure is transferred to the product by the movement of the isolator piston within the isolator. The pressurized product exits the first isolator via a second check valve and is discharged though a controlled discharge valve. Product is then collected. When the first isolator is nearly empty, a proximity sensor stops the flow of high pressure water into the first isolator and admits water flow into a second isolator. Product from the second isolator then flows to the controlled discharge valve. Concurrent with the discharge of one isolator, the other isolators is being refilled. Refilling is performed by the opening of a discharge valve on the water side of the isolator, allowing the water side to drain and new product to enter the product side.

Referring now to the drawings, and more particularly to <FIG>, there is generally indicated at <NUM> a system for high pressure, high shear processing of fluids according to an embodiment of the disclosure. As shown, the system <NUM> includes two isolators <NUM>, <NUM>. Isolator <NUM> has an isolator wall <NUM> that defines a chamber <NUM>. Chamber <NUM> is subdivided by a separator (isolator piston) <NUM> into two sub-chambers <NUM>, <NUM>. Due to movement of the separator <NUM> within the chamber <NUM>, the respective volumes of the sub-chambers <NUM>, <NUM> are variable and are inversely proportional to one another. Isolator <NUM> has an isolator wall <NUM> that defines a chamber <NUM>. Chamber <NUM> is subdivided by a separator (isolator piston) <NUM> into two sub-chambers <NUM>, <NUM>. Due to movement of the separator <NUM> within the chamber <NUM>, the respective volumes of the sub-chambers <NUM>, <NUM> are variable and are inversely proportional to one another.

The isolators <NUM>, <NUM> are configured to operate out of phase, so that when one isolator (e.g., isolator <NUM>) is filling with a second fluid, the other isolator (e.g., isolator <NUM>) is discharging (or dispensing) the second fluid. The operation of the isolators is described in more detail below.

The components of the system <NUM> include, in part, one or more positive displacement pump(s) <NUM> in fluid communication with two (or more) isolators <NUM>, <NUM>. As shown in <FIG>, the positive displacement pump <NUM> is capable of advancing a first fluid at a pressure of at least <NUM> × <NUM><NUM> Pa (<NUM>,<NUM> psi). In some embodiments, the positive displacement pump <NUM> is capable of advancing the first fluid at a pressure of <NUM> × <NUM><NUM> Pa (<NUM>,<NUM> psi). In still other embodiments, the positive displacement pump <NUM> is capable of pumping the first fluid at a pressure in the range of <NUM> × <NUM><NUM> Pa to <NUM> × <NUM><NUM> Pa (<NUM>,<NUM> psi to <NUM>,<NUM> psi), including the endpoints of the range. The pump <NUM> can be located in a separate room to keep the production area clean and noise free. As discussed, additional positive displacement pumps <NUM> can be provided depending on the configuration of the system <NUM>.

The fluid pressure generated by the pump <NUM> is monitored by a pressure sensor <NUM>. A high pressure shut off valve <NUM> is located between the pump <NUM> and the water side of the isolator <NUM>. A vent valve <NUM> is located on the same side of the isolator <NUM>. A high pressure shut off valve <NUM> is located between the pump <NUM> and the water side of the isolator <NUM>. A vent valve <NUM> is located on the same side of the isolator <NUM>.

In operation, the pump <NUM> is selectively in fluid communication with one of the two isolators <NUM>, <NUM> by selective opening and closing the respective shut off valves <NUM>, <NUM>. The pump <NUM> provides pressurized water at <NUM> × <NUM><NUM> Pa (<NUM>,<NUM> psi) alternately to each of the isolators <NUM>, <NUM>. When the pressurized water is provided to the isolator <NUM>, movement of the isolator piston <NUM> pressurizes the product contained in the sub-chamber <NUM> to the same pressure as the pressure in the sub-chamber <NUM>. When the pressurized water is provided to the isolator <NUM>, movement of the isolator piston <NUM> pressurizes the product contained in sub-chamber <NUM> to the same pressure as in the sub-chamber <NUM>. At all times, the water (or other first fluid) and the product (or the other second fluid) are in pressure communication, but not fluid communication with each other. Pressure communication means that the isolator piston freely moves within the isolator in response to a change in relative pressures of the sub-chambers of the isolator.

Product flows out of the isolator <NUM> via a check valve <NUM> into a common manifold <NUM>. Product flows out of the isolator <NUM> via a check valve <NUM> into the common manifold <NUM>. The pressure in the manifold <NUM> is measured by a pressure sensor <NUM> and is used to control a homogenizing valve <NUM>. The discharged product flows from the manifold <NUM> to a discharge valve <NUM> and then to the downstream section.

When sub-chamber <NUM> of isolator <NUM> is nearly empty, as sensed by a proximity sensor <NUM>, the pump <NUM> is switched to fill sub-chamber <NUM> of the second isolator <NUM> by closing high pressure shut off valve <NUM> and opening high pressure shut off valve <NUM>. At that time, the sub-chamber <NUM> of the first isolator <NUM> refills with product. When sub-chamber <NUM> of isolator <NUM> is nearly empty, as sensed by a proximity sensor <NUM>, the pump <NUM> is switched to fill sub-chamber <NUM> of the first isolator <NUM> by closing high pressure shut off valve <NUM> and opening high pressure shut off valve <NUM>. At that time, the sub-chamber <NUM> of the second isolator <NUM> refills with product.

Refilling is provided by the use of a low pressure transfer pump <NUM>. The transfer pump <NUM> is in fluid communication with an inlet check valve <NUM> that only allows product to flow into the isolator <NUM>. By opening vent valve <NUM>, the water side (sub-chamber <NUM>) can be drained and product can enter sub-chamber <NUM> of the isolator <NUM>. Similarly, the transfer pump <NUM> is in fluid communication with an inlet check valve <NUM> that only allows product to flow into the isolator <NUM>. By opening vent valve <NUM>, the water side (sub-chamber <NUM>) can be drained and product can enter sub-chamber <NUM> of the isolator.

The discharged product would flow in the downstream section to a temperature controlled zone <NUM>. Typical temperatures within this zone would be sufficient to achieve a targeted thermal exposure. For example temperature near <NUM> would be used for the thermal destruction of bacterial spores within foods. This can be used to hold a high temperature or experience cooling at a cooling zone <NUM> to a low temperature prior to collection at the collection zone <NUM>. An optional discharge valve <NUM> can be used if a two-step decompression process is desired.

As described above, the exemplary embodiment of the system <NUM> of the present disclosure includes the high pressure pump <NUM> that serves as a source of a first fluid, and the low pressure pump <NUM> that serves as a source of a second fluid. In some embodiments, the high pressure pump <NUM> can be in fluid communication with a reservoir <NUM> that serves as a source of a first fluid. In other embodiments, the high pressure pump <NUM> can include a reservoir that serves as a source of the first fluid. The high pressure pump <NUM> advances the first fluid along fluid conduits in the direction of arrow A in <FIG> towards the isolators <NUM>, <NUM>.

In some embodiments, the low pressure pump <NUM> can be in fluid communication with a reservoir <NUM> that serves as a source of a second fluid. In other embodiments, the low pressure pump <NUM> can include a reservoir that serves as a source of the second fluid. The low pressure pump advances the second fluid along a conduit in the direction of arrow B in <FIG> towards the isolators <NUM>, <NUM>.

<FIG> and <FIG> show isolator <NUM> apart from isolator <NUM>. <FIG> and <FIG> show both of the isolators <NUM>, <NUM>. The exemplary embodiment includes two isolators <NUM>, <NUM> for selectively containing and dispensing a second fluid.

As mentioned above, isolator <NUM> has the isolator wall <NUM> defining the chamber <NUM>. This chamber <NUM> is further subdivided by a separator (isolator piston) <NUM> that is positioned in the chamber <NUM> and is movable between a first end <NUM> of the chamber <NUM> and a second end <NUM> of the chamber <NUM>. The separator <NUM> engages the isolator wall <NUM> to divide the chamber <NUM> into a first sub-chamber <NUM> and a second sub-chamber <NUM>, and to form a seal between the first sub-chamber <NUM> and the second sub-chamber <NUM>.

The first sub-chamber <NUM> is defined by the first end <NUM> of the chamber, the inner surface <NUM> of the isolator <NUM>, and a first surface <NUM> of the isolator piston <NUM>. The second sub-chamber <NUM> is defined by the second end <NUM> of the chamber, the inner surface <NUM> of the isolator <NUM> and a second surface <NUM> of the isolator piston <NUM>.

To sealingly engage the inner surface <NUM> of the isolator <NUM>, the separator <NUM> has an O-ring <NUM> seated on its outer periphery. Because of the seal provided by the isolator piston <NUM>, the first sub-chamber <NUM> and the second sub-chamber <NUM> are in pressure communication with each other but are not in fluid communication with each other. Thus, a working fluid, such as clean water, can be directed into the first sub-chamber (or water side of the isolator) <NUM>, while a flowable product to be can be directed into the second sub-chamber (or flowable product side of the isolator) <NUM>.

The first sub-chamber <NUM> has a first inlet port <NUM> and a first outlet port <NUM>. The second sub-chamber <NUM> has a second inlet port <NUM> and a second outlet port <NUM>.

Similarly, the isolator <NUM> has the isolator wall <NUM> defining the chamber <NUM>. This chamber <NUM> is further subdivided by a separator (isolator piston) <NUM> that is positioned in the chamber <NUM> and is movable between a first end <NUM> of the chamber and a second end <NUM> of the chamber <NUM>. The separator <NUM> engages the isolator wall <NUM> to divide the chamber <NUM> into a first sub-chamber <NUM> and a second sub-chamber <NUM>, and to form a seal between the first sub-chamber <NUM> and the second sub-chamber <NUM>.

The first sub-chamber <NUM> is defined by the first end <NUM> of the chamber, the inner surface <NUM> of the isolator <NUM>, and a first surface <NUM> of the isolator piston <NUM>. The second sub-chamber <NUM> is defined by the second end <NUM> of the chamber, the inner surface <NUM> of the isolator <NUM>, and a second surface <NUM> of the isolator piston <NUM>.

To sealingly engage the inner surface <NUM> of the isolator <NUM>, the separator <NUM> has an O-ring <NUM> seated on its outer periphery. Because of the seal provided by the isolator piston <NUM>, the first sub-chamber <NUM> and the second sub-chamber <NUM> are in pressure communication with each other but are not in fluid communication with each other, respectively. Thus, a working fluid, such as clean water, can be directed into the first sub-chamber (or water side of the isolator) <NUM>, while a flowable product to be can be directed into the second sub-chamber (or flowable product side of the isolator) <NUM>.

As shown in <FIG> and <FIG>, the isolators <NUM>, <NUM> are out of phase during operation of the system of the present disclosure. In particular, the two isolators <NUM>, <NUM> are preferably <NUM>° out of phase, so that a distance between the first surface <NUM> of the first isolator piston <NUM> and the first end <NUM> of the isolator <NUM> is equal to (or at least approximately equal to) a distance between the second surface <NUM> of the second isolator piston <NUM> and the second end <NUM> of the second isolator <NUM>.

Other embodiments may include more than two isolators. Where there are more than two isolators, the discharge of the second fluid from the respective isolators can be appropriately timed. For example, where there are three isolators, the isolators are <NUM>° out of phase, and where there are four isolators, the isolators are <NUM>° out of phase.

In the isolator <NUM>, a first sub-chamber inlet valve <NUM> selectively provides fluid communication between the pump <NUM> to the first inlet port <NUM>, and a first sub-chamber outlet valve (vent valve) <NUM> selectively provides fluid communication to the first outlet port <NUM>. In the isolator <NUM>, a first sub-chamber inlet valve <NUM> selectively provides fluid communication between the pump <NUM> to the first inlet port <NUM>, and a first sub-chamber outlet valve (vent valve) <NUM> selectively provides fluid communication to the first outlet port <NUM>.

The flow of the first fluid from the high pressure pump <NUM> to the isolator <NUM> is controlled by the inlet valve <NUM> of the isolator <NUM>. The flow of the first fluid from the high pressure pump <NUM> to the isolator <NUM> is controlled by the inlet valve <NUM> of the isolator <NUM>. When the inlet valve <NUM> of the isolator <NUM> is open, the inlet valve <NUM> of the isolator <NUM> is closed. Conversely, when the inlet valve <NUM> of the isolator <NUM> is open, the inlet valve <NUM> of the isolator <NUM> is closed.

The flow of the second fluid to the isolator <NUM> is controlled by the check valves in fluid communication with the isolator <NUM>. A first check valve <NUM> is in fluid communication with the second inlet port <NUM>, with the first check valve <NUM> being configured to allow the second fluid to enter, but not exit, the second sub-chamber <NUM> through the second inlet port <NUM>. A second check valve <NUM> is in fluid communication with the second outlet port <NUM>, and is configured to allow the second fluid to exit, but not enter the second sub-chamber <NUM> through the second outlet port <NUM>.

The low pressure transfer pump <NUM> is in fluid communication with the first check valve <NUM>, and is configured to advance a second fluid to the first check valve <NUM>.

Similarly, the flow of the second fluid is controlled by the check valves in fluid communication with the isolator <NUM>. A first check valve <NUM> is in fluid communication with the second inlet port <NUM>, with the first check valve <NUM> being configured to allow the second fluid to enter, but not exit, the second sub-chamber <NUM> through the second inlet port <NUM>. A second check valve <NUM> is in fluid communication with the second outlet port <NUM>, and is configured to allow the second fluid to exit, but not enter the second sub-chamber <NUM> through the second outlet port <NUM>.

The pressure in the low pressure pump <NUM> (typically <NUM> × <NUM><NUM> to <NUM> × <NUM><NUM> Pa (<NUM> to <NUM> psi)) is lower than the pressure in the high pressure pump <NUM>.

<FIG> shows isolator <NUM> in a discharge stroke, and isolator <NUM> in an intake stroke, with respect to the second fluid. In the intake stroke, the first fluid is vented out of the first sub-chamber <NUM> through the first outlet port <NUM> and the second fluid is pumped by the low pressure pump <NUM> into the second sub-chamber <NUM> through the second inlet port <NUM>. During the discharge stroke, the second fluid is pushed out of the second sub-chamber <NUM> as the isolator piston moves in response to the pressure of the first fluid provided by the high pressure pump <NUM>.

The second fluid flows out of the second outlet port <NUM> of the isolator <NUM> and is directed through conduits along arrow C1 into the manifold <NUM> that is in fluid communication with the second outlet port by the second check valve <NUM>. The second check valve allows the second fluid to flow from the second sub-chamber <NUM> to the manifold <NUM>.

The second fluid flows out of the second outlet port <NUM> of the isolator <NUM> and is directed through conduits along arrow C2 into the manifold <NUM> that is in fluid communication with the second outlet port by the second check valve <NUM>. The second check valve allows the second fluid to flow from the second sub-chamber <NUM> to the manifold <NUM>.

The combined second fluids flow through the manifold <NUM> along arrow D in <FIG>.

A homogenizing valve as processing unit <NUM> is positioned downstream of the isolators <NUM>, <NUM>, and is in fluid communication with the manifold <NUM>. The homogenizing valve <NUM> can be selected from homogenizing valves known in the art, and is useful for generating high fluid shear on the fluid as the fluid passes through the homogenizing valve.

In the exemplary embodiment, there are two isolators <NUM>, <NUM>. The two isolators <NUM>, <NUM> are configured so that while a first one of the isolators (e.g., isolator <NUM>) is filling, a second isolator (e.g., isolator <NUM>) is discharging.

Referring additionally to <FIG>, the operation of the high pressure shutoff valve <NUM> can be controlled by a controller <NUM> in response to position information about the isolator piston <NUM>. <FIG> shows how proximity sensors <NUM>, <NUM> can be provided in the ends of an isolator <NUM>. Sensors can be provided in one isolator or more than one isolator. When the isolator piston <NUM> of isolator <NUM> is adjacent the first end <NUM> of the chamber, the proximity sensor <NUM> sends a signal to the controller <NUM> that causes the controller to open the high pressure shutoff valve <NUM> to allow the high pressure pump <NUM> to move the first fluid into the first sub-chamber <NUM> through the first inlet port <NUM>. When the proximity sensor <NUM> senses that the isolator piston <NUM> is adjacent to the second end <NUM> of the second sub-chamber <NUM>, the proximity sensor <NUM> sends a signal to the controller <NUM> that causes the controller to close the high pressure shutoff valve <NUM> to prevent the first fluid from being advanced into the first sub-chamber <NUM> through the first inlet <NUM>.

Similarly, the operation of the high pressure shutoff valve <NUM> can be controlled by a controller <NUM> in response to position information about the isolator piston <NUM>. <FIG> shows how proximity sensors <NUM>, <NUM> can be provided in the ends of an isolator <NUM>. Sensors can be provided in one isolator or more than one isolator. When the isolator piston <NUM> of isolator <NUM> is adjacent the first end <NUM> of the chamber, the proximity sensor <NUM> sends a signal to the controller <NUM> that causes the controller to open the high pressure shutoff valve <NUM> to allow the high pressure pump <NUM> to move the first fluid into the first sub-chamber <NUM> through the first inlet port <NUM>. When the proximity sensor <NUM> senses that the isolator piston <NUM> is adjacent to the second end <NUM> of the second sub-chamber <NUM>, the proximity sensor <NUM> sends a signal to the controller <NUM> that causes the controller to close the high pressure shutoff valve <NUM> to prevent the first fluid from being advanced into the first sub-chamber <NUM> through the first inlet <NUM>.

In some embodiments, the high pressure pump <NUM> can be a plurality of pumps used to produce a continuous flow state.

To measure the pressure of the second fluid flowing through the manifold <NUM>, some embodiments include a manifold pressure sensor <NUM> in fluid communication with the manifold.

In some embodiments, the system further includes a pump pressure sensor <NUM> in fluid communication with the ultrahigh pressure pump to monitor the pressure of the high pressure pump <NUM>.

In some embodiments, the system <NUM> further includes a temperature controlled zone <NUM> downstream of the homogenizing valve or other processing unit <NUM>.

In some embodiments, the system <NUM> further includes a controllable pressure discharge valve <NUM> in fluid communication with the second outlet of each isolator via the manifold <NUM>. The controllable pressure discharge valve <NUM> is downstream of the homogenizing valve <NUM> or other processing unit.

The system is capable of being cleaned in place. In some embodiments, there is a vent valve (cleaning port) <NUM> that is in fluid communication with the second outlet port <NUM> of the first isolator <NUM> via the outlet check valve <NUM>, with the second outlet port <NUM> of the second isolator <NUM>, and with the manifold <NUM>. This vent valve <NUM> allows the manifold <NUM> to be flushed through a clean in place operation of the system.

In some embodiments, the sensor <NUM> configured to measure discharge pressure is in fluid communication with the manifold <NUM>. The sensor <NUM> is in communication with a processor on a server <NUM>. The controller <NUM> is in communication with the processor, and is configured to throttle the discharge valve <NUM> to reduce flow during the switchover process between isolators <NUM>, <NUM>, thereby maintaining a more constant discharge pressure.

In some embodiments, each of the high pressure pump(s) <NUM> is a crank shaft driven positive displacement water pumps capable of at least <NUM> × <NUM><NUM> Pa (<NUM>,<NUM> psi).

In some embodiments, each of the high pressure pump(s) is a hydraulic intensifier pumps capable of constant pressure operation of at least <NUM> × <NUM><NUM> Pa (<NUM>,<NUM> psi).

In some embodiments, the isolator <NUM>, the isolator <NUM>, the manifold <NUM>, and the discharge valve <NUM> can be maintained at a preselected temperature by insulation and/or secondary heating.

In some embodiments, the second fluid can be processed by the system <NUM> into a final product that can be filled into containers at the collection zone <NUM> in an aseptic manner.

In some embodiments, each isolator <NUM>, <NUM> is positioned in a clean room environment. The high pressure pump <NUM> and the low pressure transfer pump <NUM> do not need to be positioned in the clean room environment in this case. For example, the isolators <NUM>, <NUM> could be positioned in a clean room environment, while the high pressure pump <NUM> and the low pressure transfer pump <NUM> could be positioned in another room.

The system of the present disclosure is configured to be easily cleaned. Within the isolator <NUM>, the first fluid is limited to the first side <NUM> of the isolator and the second fluid is limited to the second side <NUM> of the isolator, as discussed above. The first and second fluids do not come into direct contact. Thus, there is little concern of the first fluid contaminating the second fluid. However, it may be desirable to periodically clean the internal chamber of the isolator <NUM>.

To allow easy cleaning of the isolator, the inlet ports <NUM> and <NUM> and outlet ports <NUM> and <NUM> are located at the distant end of the inside diameter of the isolator <NUM> and positioned in the vertical plane on both ends of the isolator <NUM>.

Within the isolator <NUM>, the first fluid is limited to the first side <NUM> of the isolator and the second fluid is limited to the second side <NUM> of the isolator, as discussed above. The first and second fluids do not come into direct contact. Thus, there is little concern of the first fluid contaminating the second fluid. However, it may be desirable to periodically clean the internal chamber of the isolator <NUM>.

To allow easy cleaning of the isolator, the inlet ports <NUM>, <NUM> and outlet ports <NUM>, <NUM> are located at the distant end of the inside diameter of the isolator <NUM> and positioned in the vertical plane on both ends of the isolator <NUM>.

The cross-sectional views of <FIG> show the outlet port <NUM> being vertically above the inlet port <NUM> and the inlet port <NUM> being vertically above the outlet port <NUM> for isolator <NUM>. The cross-sectional views of <FIG> show the outlet port <NUM> being vertically above the inlet port <NUM> and the inlet port <NUM> being vertically above the outlet port <NUM> for isolator <NUM>. Because of the relative positions of the inlet port <NUM> with respect to the outlet port <NUM>, the isolator is configured to allow cleaning fluid to be pushed through check valve <NUM> through second sub-chamber <NUM> of the internal space <NUM> of the isolator <NUM> and purged out of check valve <NUM>. Similarly, because of the relative positions of the inlet port <NUM> with respect to the outlet port <NUM>, the isolator <NUM> is configured to allow cleaning fluid to be pushed through check valve <NUM> through the second sub-chamber <NUM> of the internal space <NUM> of the isolator <NUM> and purged out of check valve <NUM>.

In some embodiments, to further clean the system, a source of cleaning fluid and a cleaning fluid pump are in fluid communication with the first check valve <NUM> and the first check valve <NUM>. The manifold cleaning port <NUM> can be opened and the cleaning fluid pump can be activated to allow a large volume of cleaning fluid to be flushed through the isolators. In addition, the isolator pistons can be moved back and forth by activating valves <NUM>, <NUM>, <NUM>, <NUM> to assist isolator cleaning.

<FIG> shows one embodiment of a system <NUM> according to the present disclosure where the proximity sensors <NUM>, <NUM> and pressure sensors <NUM>, <NUM> are connected to the controller <NUM> that is in communication with the high pressure shutoff valves <NUM>, <NUM>. The proximity sensors <NUM>, <NUM> and the pressure sensors <NUM>, <NUM> are connected to a server <NUM> through a network <NUM>, which can be either wired or wireless. The server <NUM> includes a processor and a memory component that are configured to receive data from the sensors and to process the data from the sensors. The server <NUM> is in communication with the controller <NUM> through the network <NUM>, and sends instructions to the controller <NUM> over the network <NUM>. The controller <NUM> is configured to receive the instructions and to send signals that actuate the high pressure shut off valves <NUM>, <NUM> either together (e.g., to entirely shut down the flow of the first fluid to the isolators) or individually in an alternating manner. A general purpose computer <NUM> is connected both to the server <NUM> and to the controller <NUM> through the network <NUM>, and allows a user to interface with the controller <NUM> and the server <NUM>. The controller <NUM> is also in communication with the discharge valve <NUM> to open/close it, and is communication with a heater or cooling unit <NUM>. Other embodiments are possible. It is also possible to connect the proximity sensors <NUM>, <NUM> of the second isolator <NUM> to the server.

In <FIG> the isolator <NUM> is shown alone.

In some embodiments, each isolator <NUM>, <NUM> is contained in an insulating jacket and/or provided with a heating device and/or provided with a cooling device to provide temperature control of the isolator.

In some embodiments, each isolator <NUM>, <NUM> contains an agitator to agitate the second fluid (the flowable product) where the second fluid is a multiphase mixture. The agitator keeps the multiphase mixture in suspension prior to exiting the isolator.

The isolator(s) <NUM>, <NUM> and the pump <NUM> are separate modules within the system <NUM>, and the system can be reconfigured with a different size isolator <NUM>, <NUM>, as well as a different size homogenizer valve (or other processing unit <NUM>) to accommodate a drastic change in sample properties or intended application. The modular approach is useful for an industrial environment that processes diverse products for customers (e.g. toll processors).

Another aspect of the present disclosure includes a method of high shear processing of a fluid. An exemplary embodiment of the method <NUM> is shown in <FIG>.

In block <NUM>, a user provides the system <NUM> as shown and described herein. Specifically, the user provides two isolators <NUM>, <NUM> for selectively containing and dispensing a second fluid in response to pressure applied to the isolator piston <NUM> by the first fluid. The first isolator is an embodiment of the isolator <NUM> disclosed herein, such as an embodiment described in further detail above. The user also provides the first check valve <NUM> in fluid communication with the second inlet port <NUM>. The first check valve <NUM> is configured to allow the second fluid to enter the second sub-chamber <NUM> through the second inlet port <NUM>. The user also provides the second check valve <NUM> in fluid communication with the second outlet port <NUM>. The second check valve <NUM> is configured to allow the second fluid to exit the second sub-chamber <NUM> (to exhaust from the second sub-chamber) through the second outlet port <NUM>. The user also provides the manifold <NUM> in fluid communication with the second outlet port <NUM> by the second check valve <NUM>. Additionally, the user provides a processing unit <NUM> in fluid communication with the manifold <NUM>.

In block <NUM>, the system is controlled to direct the first fluid at a pressure of at least <NUM> × <NUM><NUM> Pa (<NUM>,<NUM> psi) into the first sub-chamber <NUM> of the isolator <NUM> and to direct the second fluid into the second sub-chamber <NUM> of the isolator. Directing the first fluid into the first sub-chamber <NUM> causes the second fluid to be discharged from the second sub-chamber <NUM> through the second outlet port <NUM>, through the second check valve <NUM>, through the manifold <NUM> and through the processing unit <NUM>. These components may be connected as shown and described above in relation to <FIG>.

In block <NUM>, the method detects the position of the isolator piston <NUM> (separator) of the isolator <NUM> with respect to the first end of the chamber of the isolator and with respect to the second end of the chamber of the isolator. As with the system <NUM> described above, two proximity sensors <NUM>, <NUM> can be used, with the first sensor <NUM> being used to detect the position of the isolator piston with respect to the first end <NUM> of the isolator and the second sensor <NUM> being used to detect the position of the isolator piston with respect to the second end <NUM> of the isolator <NUM>. These sensors can be included in one or more of the isolators.

It is possible to provide two isolators <NUM>, <NUM> or more than two isolators. In block <NUM>, a user provides the second isolator <NUM> in addition to the isolator <NUM> discussed in relation to block <NUM> above. Specifically, the user provides at least one isolator <NUM> for selectively containing and dispensing a second fluid in response to pressure applied to the isolator piston <NUM> by the first fluid. The isolator <NUM> is an isolator embodiment, such one described in further detail above. The user also provides the first check valve <NUM> in fluid communication with the second inlet port <NUM>. The first check valve <NUM> is configured to allow the second fluid to enter the second sub-chamber <NUM> through the second inlet port <NUM>. The user also provides the second check valve <NUM> in fluid communication with the second outlet port <NUM>. The second check valve <NUM> is configured to allow the second fluid to exit the second sub-chamber <NUM> through the second outlet port <NUM>. The user also connects the manifold <NUM> to the second outlet port <NUM> via the second check valve <NUM>.

In addition to the operation of the first isolator <NUM>, in block <NUM>, the system is controlled to alternately direct the first fluid at a pressure of at least <NUM> × <NUM><NUM> Pa (<NUM>,<NUM> psi) into the first sub-chamber <NUM> of the isolator <NUM> and to direct the second fluid into the second sub-chamber <NUM> of the isolator. Directing the first fluid into the first sub-chamber <NUM> causes the second fluid to be discharged from the second sub-chamber <NUM> through the second outlet port <NUM>, through the second check valve <NUM>, through the manifold <NUM> and through the processing unit <NUM>. These components may be connected as shown and described above in relation to <FIG>. The alternating filling of the first fluid into the isolators <NUM>, <NUM> is performed in accordance with the out of phase description above in relation to <FIG> and <FIG>.

In block <NUM>, the method detects the position of the isolator piston <NUM> (separator) of the isolator <NUM> with respect to the first end of the chamber of the isolator and with respect to the second end of the chamber of the isolator. As with the system <NUM> described above, two proximity sensors <NUM>,<NUM> can be used, with the first sensor <NUM> being used to detect the position of the isolator piston with respect to the first end <NUM> of the isolator and the second sensor <NUM> being used to detect the position of the isolator piston with respect to the second end <NUM> of the isolator <NUM>. These sensors can be included in one or more of the isolators.

In block <NUM>, the two isolators <NUM>, <NUM> are controlled to be out of phase. That is, the first fluid is first pumped into the first isolator <NUM>, then the first shut off valve <NUM> is closed to prevent the first fluid from entering the first isolator <NUM> and the second shut off valve <NUM> is opened to allow the first fluid to be pumped into the second isolator <NUM>. The alternating closing and opening of the first and second shut off valves <NUM>, <NUM> causes the isolator pistons of the respective isolators to move out of phase. The out of phase movement of the isolator pistons <NUM>, <NUM> facilitates a continuous flow of the second fluid through the manifold <NUM>.

The steps in blocks <NUM>, <NUM>, and <NUM> may be performed simultaneously in some embodiments.

The method can include at least two isolators that are out of phase. The method can include additional isolators that are out of phase, as discussed above in relation to the system of the present disclosure.

In block <NUM>, the controller <NUM> controls the temperature of the second fluid when it is in the manifold, after it has exited the isolators by controlling the heater or the cooling unit <NUM>.

In block <NUM>, the pressure discharge valve <NUM> is provided downstream of the homogenizing valve or other processing unit <NUM>, and in block <NUM> the pressure discharge valve <NUM> is controlled by the controller <NUM> to reduce flow through the manifold <NUM> during the switchover process between isolators (when valves <NUM> and <NUM> are being throttled on and off) and to maintain a constant discharge pressure of the second fluid.

In block <NUM>, the second fluid is cooled after it has passed through the pressure discharge valve <NUM>.

In block <NUM>, the second fluid is collected after it has passed through the homogenizing valve or other processing unit <NUM>, and after the cooling step of block <NUM> has been performed. For example, the second fluid can be directed into individual containers, such as bottles, vials, etc. at the collection zone <NUM>.

In other embodiments of the method, only one isolator <NUM> is provided.

Embodiments are not limited in their application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings.

Claim 1:
A method of high pressure, high shear processing of a fluid, the method comprising the steps of:
providing at least one isolator (<NUM>, <NUM>) for selectively containing and discharging a second fluid, the at least one isolator further including
an isolator wall (<NUM>, <NUM>) defining a chamber (<NUM>, <NUM>),
a separator (<NUM>, <NUM>) positioned in the chamber and movable between a first end of the chamber and a second end of the chamber, the separator engaging the isolator wall (<NUM>, <NUM>) to further divide the chamber into a first sub-chamber (<NUM>, <NUM>) and a second sub-chamber (<NUM>, <NUM>) that are in pressure communication with each other but are not in fluid communication with each other,
a first sub-chamber inlet valve (<NUM>, <NUM>) in fluid communication with an ultrahigh pressure pump and the first sub-chamber (<NUM>, <NUM>),
a first sub-chamber outlet valve (<NUM>, <NUM>) in fluid communication with the first sub-chamber (<NUM>, <NUM>),
a first check valve (<NUM>, <NUM>) in fluid communication with the second sub-chamber (<NUM>, <NUM>) to allow fluid to enter the second sub-chamber (<NUM>, <NUM>), and
a second check valve (<NUM>, <NUM>) in fluid communication with the second sub-chamber (<NUM>, <NUM>) to exhaust fluid from the second sub-chamber (<NUM>, <NUM>);
providing a processing unit (<NUM>) in fluid communication with the second check valve (<NUM>, <NUM>) of the at least one isolator (<NUM>, <NUM>);
alternately directing a first fluid at a pressure of at least <NUM> × <NUM><NUM> Pa (<NUM>,<NUM> psi) into the first sub-chamber (<NUM>, <NUM>) and directing the second fluid into the second sub-chamber (<NUM>, <NUM>), wherein directing the first fluid into the first sub-chamber (<NUM>, <NUM>) causes the second fluid to be discharged from the second sub-chamber (<NUM>, <NUM>), through the second check valve (<NUM>, <NUM>), and through the processing unit (<NUM>); and
collecting the second fluid after it has passed through the processing unit (<NUM>).