Vacuum Vessel Design For Fry Drying.

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VACUUM VESSEL DESIGN FOR FRY DRYING

NOR AZIMAH BINTI MOHAMAD

FACULTY OF MECHANICAL ENGINEERING

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

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‘ I / We* confess that have been read this outstanding piece of works and at my / us * this piece of work is acceptable from the scope and the quality for the awarded

Bachelor of Mechanical Engineering ( Design and Innovation )’

Signature:……….. Supervisor Name: Prof. Madya Ir. Mustafa Ab. Kadir Date:………..

Signature:……….. Supervisor Name: Mr. Rizal Al Kahari

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VACUUM VESSEL DESIGN FOR FRY DRYING

NOR AZIMAH BINTI MOHAMAD

This report is submitted

in partial fulfillment for Bachelor of Mechanical Engineering (Design and Innovation)

Faculty of Mechanical Engineering Universiti Teknikal Malaysia Melaka

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“I declare that all part of this report are the results of my own work except for a few section which extracted and quoted from other resources that as been mentioned”

Signature : ….……… Author : Nor Azimah Mohamad Date : …...………

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To my beloved mum and dad, brother and sister, Prof. Madya Ir. Mustafar Abdul Kadir, lectures, friends and those supportive people. Your kindness is heartily

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ACKNOWLEDGEMENT

I would like to thank Allah S.W.T for His goodness and grace that sustained me throughout this crucial time in completing this major task in Project Sarjana

Muda entitled VACUUM VESSEL DESIGN FOR FRY DRYING.

I would like to take this opportunity deliver my special thanks to my supervisor, Prof. Ir. Mustafa Ab. Kadir and Mr Rizal Alkahari for their support and advises throughout this semester. The opportunity and exposure extended to me through this project will develop the skills and the self esteem in me as the preparation in the working environment.

My special thank to all of my friends that share the idea in developing this project especially for Raihanah Abdullah and Muhammad Lutfi Abd. Latif that shared the same project’s field. Their comments and suggestions are very helpful. Besides that, thanks to all of the lectures that have helped me in this project.

To my beloved father and mother, blesses from both of you is everything for me. Not forgotten to all the people who’s directly or indirectly involve in my project. Thank you very much. To all of my friends, thank you for being part of my life. As we crossed the path during this critical time, the joy and laughter that we share, the crazy stuff that we did and hope let it be a life lesson that we will cherish for a long time

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ABSTRAK

Projek ini adalah bertujuan untuk manghasilkan benjana vakum yang boleh digunakan dalam proses penggorengan kering dengan mengaplikasikan sistem vakum disamping tenaga haba dan memenuhi kehendak rekabentuk di awal proses rekabentuk. Rekabentuk seharusnya mencapai matlamat iaitu untuk mereka dan menghasilkan benjana vakum yang boleh dikurangkan sehingga 2mbar tekanannya serta mengenal pasti bentuk optima untuk benjana tersebut. Proses rekabentuk berdasarkan proses asas rekabentuk bermula dari analisis pasaran, penghasilan spesifikasi produk, rekabentuk asas dan seterusnya rekabentuk menyeluruh. Dalam menyiapkan projek ini, maklulmat-maklumat dikumpulkan dari buku-buku, jurnal dan dari produk-produk yang sedia ada dipasaran dan juga paten. Di Akhir projek ini, rekabentuk yang dihasilkan sepatutnya mencapai tujuannya dan untuk rekabentuk benjana vakum untuk penggorengan kering ini, rekabentuk menyeluruhnya memenuhi objektif utamanya iaitu untuk menghasilkan bentuk optima bagi banjana yang boleh dikurangkan dan dikenakan vakum sahingga 2mbar.

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ABSTRACT

The main idea of this particular project is to design a vacuum vessel which will be use in fry dry process by implementing the vacuum approach in spite of heat energy and fulfills the basic requirements which stated at the first stage of the design. The design should meet the objective of the project which is to develop and create a vacuum vessel that can be evacuated up to 2mbar and determining the optimum shape of the vacuum vessel. This design process is following the basic design process flow starting from the customer needs in market analysis, specification development, conceptual design and finally the detail design. In the process of completing this project, the information is gathered through the books, journals and existing products and patents. At the end of the project, the design should achieve its target or objective and as for this vacuum vessel design for fry dry project, the detail design should meet the main objective which is designing an optimum shape for the vessel and it manage to be evacuated up to 2mbar.

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CONTENTS

CHAPTER ITEMS PAGES

DECLARATION i

DEDICATION iii

ACKNOWLEDGEMENT iv

ABSTRAK v

ABSTRACT vi

CONTENT vii

LIST OF TABLE xi

LIST OF FIGURE xii ABBREAVIATION

xiv

TRADEMARK

xiv

CHAPTER INTRODUCTION 1

1 1.1 Background 1

1.2 Problem statement 2

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1.4 Scope 3 1.5 Organization

CHAPTER LITERATURE REVIEW 4

2 2.1 Vacuum 4

2.1.1 Vacuum frying 7

2.1.2 Vacuum cooking 7

2.1.3 Vacuum impregnation 8

2.2 Fry dry 9

2.3 Vessel 10

2.3.1 Design of vessel 10

2.3.2 Operational condition 10

2.3.3 Failures in vessel 11

2.3.4 Analysis using COSMOSWorks 12 2.4 Pressure

2.4.1 Principle in vacuum pressure 19 2.4.2 Vacuum and pressure release 21

2.4.3 Vacuum inlet 23

2.5 Heating process 24

2.5.1 Gas 24

2.5.2 Electrical 26

2.5.3 Steam 27

2.5.4 Band Heater 28

2.6 Existing product 32

2.6.1 Vacuum frying machine by INDICITAGRO 32 2.6.2 Small sized high temperature vacuum cooker 33

CHAPTER METHODOLOGY 35

3 3.1 Research Method 35

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3.1.2 Information from web 40 3.1.3 The flow chart in vacuum cooker 43

3.2 Usage of software 46

3.3 Design process 48

3.3.1 Market analysis 48

3.3.2 Gather information 48

3.3.3 Develop specifications 48

3.3.4 Conceptual design 49

3.3.5 Detail design 49

CHAPTER CONCEPTUAL DESIGN 51

4 4.1 Product specification 51

4.2 Concept generation 56

4.2.1 Concept 1 58

4.2.2 Concept 2 59

4.2.3 Concept 3 60

4.2.4 Concept 4 61

4.2.5 Concept 5 62

4.3 Concept selection 63

4.4 Final sketch 65

4.4 Product safety 66

CHAPTER DETAIL DESIGN 67

5 5.1 Detail Drawing 68

5.1.1 Part Drawing 69

5.1.2 Assembly Drawing 69

5.1.3 Exploded Drawing 69

5.2 Theoretical Calculation 70

5.2.1 Volume 70

5.2.2 Force and pressure 71

5.2.3 Thickness suitability 72

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5.3 Material Selection 74 5.3.1 Material for the vacuum vessel 74

5.3.2 Material for the seal 76

5.3.3 Material for the other part 76

CHAPTER ANALYSIS, RESULTS AND SISCUSSION 78

6 6.1 Analysis 79

6.1.1 Constraint 80

6.1.2 Flow in analysis 80

6.2 Results 82

6.3 Discussion 88

CHAPTER CONCLUSION AND RECOMMENDATION 89

7 7.1 Conclusion 89

7.2 Recommendation 90

REFERENCES 91

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LIST OF TABLES

BIL. TAJUK MUKA

SURAT

2.1 The vacuum range 5

2.2 The pressure 6

2.3 The specification of the vacuum frying machine 33

2.4 The specification of the design 34

2.5 The features of design 34

4.1 The customer needs for the fry dry vacuum vessel and their

Importance 52

4.2 The list of metric for the fry dry vacuum vessel 54

4.3 The need-metric matrix 55

4.4 The morphology chart 57

4.5 The decision matrix 64

5.1 The summary of stainless steel 304 characteristic 75

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LIST OF FIGURES

NO. ITEMS PAGES

2.1 The drawing of the vacuum vessel 15

2.2 The sections in vacuum vessel 15

2.3 The stress distribution and displacement 16

2.4 The stresses distribution 17

2.5 The displacement distribution 17

2.6 The stress and displacement distributions 18

2.7 The buckling modes for the end cover 18

2.8 The types of pressure relief device 22

2.9 The vacuum cooker 23

2.10 The LPG gas 25

2.11 The example of band heater with the mineral insulated 29 2.12 The example of band heater with the mica insulated 30 2.13 The example of band heater with the ceramic insulated 31

2.14 The vacuum frying machine 32

2.15 The small sized high temperature vacuum cooker 33 3.1 The basic design of vacuum cooking apparatus 37 3.2 The patent review of the vacuum cooking apparatus 37 3.3 The patent review of vacuum cooking / warming appliance 38 3.4 Design 1 for the vacuum cooking / warming appliance 39 3.5 Design 2 for the vacuum cooking / warming appliance 39 3.6 The Vacuum frying machine from INDOCITAGRO 40

3.7 The vacuum cooker from GASTROVAC 41

3.8 The small sized high temperature vacuum cooker 42 3.9 The flow chart in vacuum cooking process 1 43 3.10 The flow chart in vacuum cooking process 2 44

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3.11 The process design flow for vacuum vessel design 50

4.1 Concept 1 58

4.2 Concept 2 59

4.3 Concept 3 60

4.4 Concept 4 61

4.5 Concept 5 62

4.6 The final sketch of selected concept 65

6.1 The stress distribution in the vessel regarding the temperature

Effect 83

6.2 The displacement distribution in the vessel regarding the

temperature effect 83

6.3 The strain distribution in the vessel regarding the temperature

effect 84

6.4 The stress distribution in the vessel regarding the pressure

Effect 85

6.5 The displacement distribution in the vessel regarding the pressure

effect 85

6.6 The strain distribution in the vessel regarding the pressure

effect 85

6.7 The stress distribution in the vessel regarding the pressure and

temperature effect 87

6.8 The displacement distribution in the vessel regarding the

pressure and temperature effect 87

6.9 The strain distribution in the vessel regarding the pressure and

temperature effect 87

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ABBREVIATIONS

Terms Meaning

CAD Computer-Aided Design

FEA Finite Element Analysis

TRADEMARKS

Product

Owner

Solid Works Dassault Systemes

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CHAPTER 1

INTRODUCTION

This chapter consists of the background of the project and its problem statement which then followed by the objectives, scopes and its organization.

1.1 Background

In these days, the request for cooking equipment that can cook a desired food without losing the real taste or flavor, smell and color of the food has become the top priority in the food industries due to the demand from the customers are that looking forward for a quality foods. The quality of the food can be maintain by using several approach and one of it is fry drying process. Basically, with the fry drying process, the food will turn out to become crispy since the water inside the food has been absorbed or in other words dehydrated. The pre-fry drying process as well as the osmotic pre-treatment, increases the maximum stress and maximum strain of the food during frying [1].

One simple idea towards increasing the potential and efficiency of the fry drying process in maintaining the food’s quality is by implementing the vacuum approach into the design. This new concept of cooking is differed from the existing cooker which is more distressing in subjecting the high pressure towards the food to cook it, which in turns will affect the value or quality of the food.

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Basically, vacuum is defined as a space that is completely empty of all the substances, including air or other gases [2], but in this project, vacuum is reflected to the low pressure that applied to the system and merely a pressure below the atmosphere.

This project covered on the design of the vacuum vessel that can be use for the fry drying process where the main idea is to reduce the pressure up of up to 2mbar and allow the food to maintain its quality.

1.2 Problem statement

The existing cooking appliances in market nowadays are unable to maintain the quality of the food in terms of nutrient, colour, taste and looks. The quality of the food is ruin by the way of cooking it which need to be supply with high heat and temperature. In spite of that, the long period of time taken to cook them affected the quality of the food. It is a major issue in food industry to prioritize the quality of the food. The only way to control and maintain all aspects of the quality in food is by applying the vacuum approach in the cooking process.

The people that involve in food industry are looking forward for some machine or cooking appliance that can increase the quality in their foods. The demand towards this needs increased day by day and some concern inventor and alert company has come out with several equipment that can fulfill the requirements. But the number of them is too small comparing to the demands.

1.3 Objective

The objective of this project is to design a vacuum vessel that suitable for the fry drying process by implementing the vacuum and heat energy approach.

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1.4 Scope

This project covers the design of the vacuum vessel in order to fulfill the main requirement which is could be evacuated up to 2mbar (200pascal @ 1.98m atm). Besides that, it also covers on the optimum shape’s design for the vessel itself. Another part in this project is temperature and pressure analyses that reflect the performance of the vacuum vessel. Material that used in developing this project is also one of the scopes in this paper despite of the mathematical analysis or study. The part that not be emphasized on is the thermal analysis part and the prototype but the project is proposed for further fabrication.

1.5 Organization

The first part of the project is identification of the problem statement and development of the objective and scope of the design. Next, the review on the existing product which applies the same approach (vacuum system) with the project took place. Then, it is followed by the design flows which are the specification development and conceptual design. The detail design takes place after that with the mathematical study and material selection. Finally, the analysis of its performance is tested.

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CHAPTER 2

LITERATURE REVIEW

The related information on the vacuum and its related topics such as the vacuum frying, cooking and impregnation is gathered. The fry dry concept also being included together with the vacuum vessel’s information and pressure’s principles in spite of the heating elements in the heating process. The study on the existing product also covers in this chapter.

2.1 Vacuum

Even though the vacuum system is applied in many processes in the daily life nowadays, not only in the industrial field but also in the medical branch and not forgotten in the food technology; the researches and designers keep on developing and creating new idea on it in order to improve the capability and efficiency of the system.

As vacuum is define as a low pressure that applied to the system and merely a pressure below the atmosphere, the vessel that designed should be able to lasting its ordinary shapes even with the high changes in the pressure that subjected to it.

Vacuum is a volume of space that is essentially empty of matter, such that its pressure is much less than standard atmospheric pressure. The root of the word

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vacuum is the Latin adjective vacuus which means "empty," but space can never be

perfectly empty. A perfect vacuum with a gas pressure of absolute zero is a philosophical concept that is never observed in practice because quantum theory predicts that no volume of space can be perfectly empty in this way. Physicists often use the term "vacuum" slightly differently and they discussed; ideal test results that would occur in a perfect vacuum, which they simply call "vacuum" or "free space" in this context, and use the term partial vacuum to refer to the imperfect vacuum realized in practice [13].

In quantum mechanics, the vacuum is defined as the state with the lowest energy and this is simply a state without particles, referring to its name. However, even an ideal vacuum; thought of as the complete absence of anything, will not in practice remain empty. One reason is that the walls of a vacuum chamber emit light in the form of black-body radiation; visible light if they are at a temperature of thousands of degrees, infrared light if they are cooler. Another reason that the perfect vacuum is impossible is the Heisenberg uncertainty principle which stated that no particle can ever have an exact position. Each atom exists as a probability function of space, which has a certain non-zero value everywhere in a given volume. Even the space between molecules is not a perfect vacuum [13].

Table 2.1 : The vacuum range

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Vacuum means the reduction of pressure in a close environment under atmospheric pressure or in simple word is any pressure lower than atmosphere pressure (1013mbar) at sea level [3]. This pressure reduction (evacuation by means of a vacuum pump) is achieved by removing air particles from an enclosed volume which cause the gas pressure and density to reduce. The resultant pressure is known as the end vacuum and defined in mbar as absolute pressure. An absolute pressure of 0 mbar means a perfect vacuum which in realistically unachievable [3].

Based on the JIS (Japanese Industrial Standard), vacuum is defined as the space that exists where the air pressure is less than the surrounding atmospheric pressure [8].

Table 2.2 : The pressure (Source : Seiko EPSON corporation)

1 atmospheric = 760mmHg (Mercury Liquid Metal) = 760 Torr = 101,325 pa = 105bar

1 pa = 1N/m2

1N = Force that need for 1kg object at 1m/s2

F = m.a = kg .m /s2 = N

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2.1.1 Vacuum frying

Vacuum frying; in theory, to fry any kind of food we need the cooking medium (in this case refer to the oil) to reach temperatures around 170-180° C. Those temperatures cause the oxidation of the oil and the loss of many nutrients of the foods. In low pressure conditions, however it is possible to fry at 90° C, which prolongs the useful life of the oil and most important guarantees that the retention of the aromas and nutrients of the product will be far greater [12].

The vacuum frying concept functions by creating an artificial low pressure, oxygen-free atmosphere which considerably reduces cooking and frying temperatures, maintaining the texture, colour and nutrients of the food. Moreover, it creates the “sponge effect” by means when the atmospheric pressure is restored; the food absorbed the liquid around it and allowed infinite combinations of foods and flavours. Since the food is prepared in a vessel or container that has most of their oxygen removed, it oxidized at much slower rates and the effects would be as a sliced of fruits or vegetables can last days without turning brown [12].

2.1.2 Vacuum cooking

Vacuum cooking by means when we cook food which is not packed at a pressure lower than atmospheric pressure we can make both the cooking liquid and the product constitution water boil at a temperature lower than 100° C and at this condition, the condition of the food in terms of the flavours and nutrient is preserve [12].

This type of cooking also makes it possible to enrich the product with the characteristics of the cooking liquid. Moreover, the absence of oxygen in the vacuum prevents the oxidation of the food, so that their original colouring is perfectly conserved [12].

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2.1.3 Vacuum impregnation

Normally most of the animal products and vegetable have a rather porous structure. That is why the vacuum produces the “sponge effect” during the cooking process and the air contained in the products expands and comes out when the atmospheric pressure is restored, the food immediately absorbs the liquid in which it is submerged [12].

The fundamental thing is for the texture of the product to be maintained without undergoing the softening caused by maceration, which usually causes dehydration with the consequent loss of firmness of the foods. Vacuum impregnation also serves to speed up the marinades or seasonings, since it helps the transfer of components (salt, sugar, water) towards the interior of the product. The equipment comes with two kinds of basket; one for frying, which prevents the food from being impregnated with oil by means of a system which lifts it and eliminates contact between liquids and solids; and another for cooking with subsequent impregnation, which uses the full capacity of the pot [12].

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