Simulation of heat transfer for solidliquid food mixtures in cans

and model validation under pasteurization conditions

Selin Kzltas, Ferruh Erdogdu
*
, T. Koray Palazoglu
Department of Food Engineering (Gda Mhendisligi Blm), University of Mersin, 33343 iftlikky-Mersin, Turkey
a r t i c l e i n f o
Article history:
Received 10 March 2009
Received in revised form 28 October 2009
Accepted 29 October 2009
Available online 4 November 2009
Keywords:
Canning
Solidliquid food mixtures
CFD
Heat transfer
Natural convection
a b s t r a c t
During processing of canned mixtures of solidliquid foods, conduction and convection occur simulta-
neously. The literature lacks in a complete simulation study where a large number of solids are dispersed
in the liquid phase, e.g. canned peas. Therefore, the objectives of this study were to determine tempera-
ture changes inside a can containing solidliquid food mixtures. For this purpose, dispersed stationary
solids (canned peas in water) in a 2D (axi-symmetrical) conguration were applied. Ansys V11 (Ansys
Inc., Canonsburg, PA) was used to solve continuity, energy and momentum equations. For experiments,
canned pea samples were prepared in 500 g cans, and heating process was conducted in a retort under
pasteurization conditions at 98 C. Temperature changes were measured using needle type thermocou-
ples, and simulation results were validated against experimental data. This study is expected to be a sig-
nicant contribution to the literature for further optimization studies and to form basis of an industrial
project to improve canning process of solidliquid mixtures.
2009 Elsevier Ltd. All rights reserved.
1. Introduction
Heat transfer studies in foods are of greater importance since
thermal processing is the most common technique used for preser-
vation of foods. Thermal processing is the critical control point to
ensure safety and a critical unit operation to maximize process ef-
ciency (Weng, 2005). Aseptic processing and canning are used in
food processing for this purpose. Although aseptic processing gains
importance with recent developments, canning still provides a uni-
versal and economic method (Weng, 2005). Process efciency is
determined using analytical and numerical solutions of partial dif-
ferential equations governing the process, and there has been an
increasing interest in using new process modeling and calculation
methods in canning industry (Weng, 2005). Heat transfer modes in
a canned food are conduction for solid foods, natural convection
especially for low viscosity liquid foods, convection plus conduc-
tion for liquid foods with solid particles and convection followed
by conduction for liquid foods containing starch or high viscosity
modiers (Chen and Ramaswamy, 2007).
To determine process efciency for conduction heating, solution
of energy equation is required while energy, momentum and con-
tinuity equations should be solved for convection. Datta and Teixe-
ira (1988) were rst to develop numerical predictions of transient
temperature and velocity proles of a can lled with water. Then,
simulations of viscous liquid foods in cans were done by Kumar
et al. (1990) and Kumar and Bhattacharta (1991). Upon introduc-
tion of computational uid dynamics (CFD) programs and faster
computing abilities, simulation studies for natural convection
heating have been conducted for different processing conditions
(Abdul Ghani et al., 1999, 2002; Farid and Abdul Ghani, 2004; Chen
et al., 2005; Sriwattanayotin et al., 2006; Varma and Kannan,
2006). Besides solid and liquid products, mixtures of solidliquid
foods are also processed in cans. Processing time for these cases
can be determined assuming solidliquid mixture heats up by con-
duction ignoring natural convection effects. This leads to heating
times much longer than required with over-processed products.
For the case of agitation, spatial variation of liquid temperature
can be ignored assuming a lumped parameter model (Lenz and
Lund, 1978; Datta and Teixeira, 1988). For process simulation of
solidliquid mixtures, Lenz and Lund (1978) applied heat transfer
coefcient between liquid and particles to determine the transient
temperature change of the particles where it was assumed that the
liquid temperature change could be described with the lumped
model. Heat transfer coefcient approach was later justied by
Ramaswamy et al. (1982). Lekwauva and Hayakawa (1986) devel-
oped a model for temperature prediction of particleliquid
mixtures solving overall heat balance equations for spherical,
cylindrical and oblate spheroidal-shaped particles. Agarwal
(1988) proposed a model, based on a boundary-layer formulation
for individual particles in a sphere assemble, to provide a relation
between heat transfer characteristics and hydrodynamics of multi-
particle systems. Chinesta et al. (2002) used a homogenized
0260-8774/$ - see front matter 2009 Elsevier Ltd. All rights reserved.
doi:10.1016/j.jfoodeng.2009.10.042
* Corresponding author. Tel.: +90 324 361 0001x7199; fax: +90 324 361 0032.
E-mail addresses: ferruherdogdu@yahoo.com, ferruherdogdu@mersin.edu.tr (F.
Erdogdu).
Journal of Food Engineering 97 (2010) 449456
Contents lists available at ScienceDirect
Journal of Food Engineering
j our nal homepage: www. el sevi er. com/ l ocat e/ j f oodeng
thermal conduction model for particulate foods assessing the ef-
fects of particles spatial distribution and differences in thermal
conductivities. Abdul Ghani and Farid (2006) veried the effect of
natural convection on heating process of solidliquid food mix-
tures (pine-apple slices in a model liquid) indicating that natural
convection effects in the liquid played a signicant role in the evo-
lution of temperature. Abdul Ghani and Farid (2007) simulated
temperature distribution within beef fat and water mixture during
high pressure compression. Rabiey et al. (2007) simulated tran-
sient temperature and uid ow during natural convection heating
of a cylindrical can containing nine large spherical particles in a
model liquid. The latter two studies used CFD approaches for calcu-
lations and concluded that solid particles inuenced the buoyancy
which drove the ow.
The literature still lacks in a complete simulation study for pre-
dicting temperature changes of solidliquid mixtures where solids
are randomly dispersed in the liquid phase, e.g. canned peas.
Therefore, the objective of this study is to determine temperature
changes inside a can containing solidliquid food mixtures during
thermal processing and verify simulation results with experiments.
2. Materials and methods
To accomplish the stated objectives, canned pea samples were
used. Simulations were accomplished using Ansys V11 (Ansys
Inc., Canonsburg, PA), and simulations results were compared with
the experimental results for validation.
2.1. Experimental methodology
Canned peas, representing the solidliquid mixtures, were used
for experimental measurement of temperature changes. For this
purpose, canned peas were purchased from a local store. These
cans were opened, and weights of liquid (water) and solid (peas)
portions were determined. The objective to use water for lling li-
quid was to apply temperature variable thermo-physical proper-
ties in the simulations. However, to demonstrate the effect of
this assumption, experiments were also carried out where the ll-
ing was done directly with the liquid obtained from the purchased
cans. The dry matter of the lling material was 3.5%, and the heat-
ing rates were similar compared the cases where the water as the
lling liquid was used. Diameters of peas were also measured
(7.3 mm), and they were lled back in empty cans (500 g; #1;
73 mm in diameter 110 mm in length). Needle type thermocou-
ples were located on the side of the cans using ring gaskets and
locking-receptacles. One thermocouple was inserted in a peas cen-
ter located at the cans geometrical center while another one was
off-center to measure water temperature change (82 mm from
bottom and 12 mm from central line). Then, the cans were tightly
seamed (MAC-230, Umar Makina Sanayii,
_
Istanbul, TR) after lling.
Due to tightly-packed conguration of the cans constituents, pos-
sible thermocouple conduction errors were assumed to be negligi-
ble. For each thermocouple, different cans were used to minimize
thermocouple heating effects on velocity proles of water and
therefore on temperature changes due to natural convection. As re-
ported by Kannan and Sandaka (2008), disturbed temperature
velocity elds might result in difculties in accurate measurement
of temperature, and these effects might not be quantied either
experimentally or analytically. Ten experiments were conducted,
and average values of temperature change with standard devia-
tions were reported. Heating experiments were carried out in boil-
ing water (98 C) in a vertical retort (OMS Lab 20, Osmanl
Makina, Balkesir, TR), and temperature changes were recorded
using a Keithley 2700 DMM (coupled with Keithley 7700.20CH
multiplexer, Keithley Instruments, Cleveland, OH, USA) data acqui-
sition system. After each experiment was conducted, cans were
opened and checked to assure that the thermocouple inside the
pea was not disturbed. For the cases when the thermocouple was
disturbed, the data was discarded.
2.2. Simulations
As stated in Section 1; continuity, energy and momentum equa-
tions (NavierStokes equations) need to be solved when natural
convection heating was involved. Eqs. (1)(4) show the Navier
Stokes equations in cylindrical coordinates. The angular direction
equations were not involved since an axi-symmetric approach
was applied in this study.
Continuity equation:
1
r

@
@r
r q
f
v
r

@
@r
q
f
v
z
0 1
Fig. 1. Arrangement of solids in the 2D axi-symmetric arrangement (left hand side
is center line).
450 S. Kzltas et al. / Journal of Food Engineering 97 (2010) 449456
Energy equation:
@T
@t
v
r

@T
@r
v
z

@T
@z

k
f
q
f
c
p
f
1
r

@
@r
r
@T
@r

@
2
T
@z
2
" #
2
Momentum equation in the radial direction:
q
f

@v
r
@t
v
r

@v
r
@r
v
z

@v
r
@z


@P
@r
l
@
@r
1
r

@
@r
r v
r

@
2
v
r
@z
2
" #
3
Momentum equation in the vertical direction:
q
f

@v
z
@t
v
r

@v
z
@r
v
z

@v
z
@z


@P
@z
l
1
r

@
@r
r
@v
z
@r

@
2
v
z
@z
2
" #
q
f
g 4
where T is temperature (K), P is pressure (Pa), t is heating time (s), g
is gravitational acceleration (9.81 m/s
2
), l is dynamic viscosity
(Pa s), k
f
, q
f
and c
pf
are the thermal conductivity (W/m K), density
(kg/m
3
) and specic heat (J/kg K) of the uid (water) and v
r
and
v
z
are the velocity components (m/s) in radial and vertical direc-
tions, respectively. Ansys V11 (Ansys Inc., Canonsburg, PA) was
used to solve the NavierStokes equations to simulate the heat
transfer in both liquid and solid phases. For this purpose, Ansys-
Flotran module was applied with the following parameters and
assumptions:
Fig. 2. Torus volume approach applied using the axi-symmetry.
Table 1
Temperature-variable thermo-physical properties of water applied in the simulations
(engel, 2007).
Temperature (K) Density
(kg/m
3
)
Viscosity
(Pa s)
Thermal
conductivity
(W/m K)
Specic heat
(J/kg K)
293.15 998 0.001002 0.598 4182
313.15 992.1 0.000653 0.631 4179
333.15 983.3 0.000467 0.654 4185
353.15 971.8 0.000355 0.670 4197
373.15 957.9 0.000282 0.679 4217
393.15 943.4 0.000232 0.683 4244
Fig. 3. (a) Mesh structure applied in the simulation (right hand side is can wall);
and (b) nodes at particle surfaces and between the particles.
S. Kzltas et al. / Journal of Food Engineering 97 (2010) 449456 451
Solid phase (peas) was assumed to be stationary, a perfect
sphere shape and uniformly distributed in the can.
To reduce the problem from 3D to 2D for a vertical can,
axi-symmetrical analysis has been applied. With this approach,
computation time was reduced considerably since there was
no need to dene the nodes in the angular direction. The dis-
tance between the spheres was 0.5 mm, and the circles on the
vertical center line were half in area since they will result in a
complete sphere when the 2D axi-symmetrical shape is com-
pleted to the 3D.
To locate the stationary solids in the water, the porosity value of
the can constituents (ratio of the water volume to the volume of
can; 35% 2.0%) was chosen to be target value. For this pur-
pose, required diameters of solids were estimated to be
7.5 mm. Based on different pre-trials, 65 solids, arranged as
shown in Fig. 1, resulted in the target porosity value with their
torus volumes when the 2D shape was completed to 3D
(Fig. 2; completed shape of the assumed axi-symmetrical
situation resulted in torus-shaped volumes uniformly distrib-
uted in the water).
0.5 mm distance between the particles was due to the problems
faced during meshing the uid phase. There were restrictions in
meshing abilities to let numerous particles touch each other
while meshing. Since meshing was not possible for that kind
of approach, a certain space (0.5 mm) between the particles
was assumed.
Including head space in the model would result in the require-
ment of the analysis of airwater interface problem with addi-
tional complexities in the problem. Erdogdu et al. (2009)
neglected the effect of air space for comparison of natural con-
vection and conduction heating processes in cans, and this
assumption was shown not to affect the simulation results.
In the 2D axi-symmetric congurations, number of nodes were
over 60,000.
In the Ansys-Flotran module, Collocated Galerkin advection
scheme was used to get a convergent solution in a straight for-
ward fashion for solution of momentum, pressure and tempera-
ture variable as reported in ANSYS help.
Modied inertial relaxation parameter was set to 1 to prevent
possible spurious oscillations in the uid phase and resulting
convergence difculties in the solutions.
Three dimensional matrix algorithm (TDMA) was used to solve
velocity and temperature changes while preconditioned conju-
gate gradient method (PCGM) was applied to solve pressure
changes.
Time step was progressively increased from 0.001 to 0.05 s in
the rst 120 s of heating; it was specied based on the results
of pre-runs. Then, it was again progressively increased to 0.1
(for 120240 s of heating) and 0.25 s (for 240360 s of heating)
during the run. It was important to note that a higher number of
iterations were required in the Ansys-Flotran module to
improve the accuracy due to lower viscosity of water. A similar
comment was also noted by Abdul Ghani et al. (1999). This was
especially signicant at the initial stages of heating to solve the
momentum equations for correct velocity proles.
Literature-reported values for thermo-physical properties (ther-
mal conductivity, k = 0.5 W/m K; specic heat, c
p
= 3057 J/kg K,
and density, q = 1062 kg/m
3
) of the solid phase (peas) were used
(Garrote et al., 2006, 2008) in the simulations. Since the heat
transfer in peas were in conduction mode, variation in thermal
diffusivity value a
k
qcp

was assumed to be negligible even
though thermo-physical properties of the liquid phase were
applied ad as a function of temperature as explained below.
Temperature dependent thermo-physical properties of liquid
phase (water), as applied in the simulations, are reported in
Table 1. Water density, with all the other properties, were
assumed to be the function of temperature to account the natu-
ral convection.
Meshing was implemented with a very ne grid at the vicinity of
can walls, particle surfaces and between the particles to
accurately resolve velocities and temperatures near the surfaces.
Velocity and temperature gradients were expected to be rela-
tively higher especially at the can walls due to higher tempera-
ture difference at the initial steps of the analysis. While Fig. 3a
shows the mesh structure applied in the simulation, Fig. 3b
shows the nodes at particle surfaces and between the particles.
Initial temperature of the system was 27 1 C (based on the
experiments) while the medium temperature was boiling water
(98 C) with innite heat transfer coefcient assumption. Since
the cans were immersed in boiling water, a high heat transfer
coefcient with a very low thermal resistance of the can walls
Fig. 4. Movement of liquid phase adjacent to can wall due to buoyancy effects (right hand side is can side wall).
452 S. Kzltas et al. / Journal of Food Engineering 97 (2010) 449456
was assumed. Therefore, constant surface temperature as a
thermal boundary condition was applied in the simulations
assuming that surface temperature reaches medium tempera-
ture immediately and stayed constant. Validity of this assump-
tion was shown by Erdogdu et al. (2009).
No-slip condition was applied at the can walls and particle
(sphere) surfaces.
Liquid phase inside the can was assumed to be initially at rest
with the given uniform initial temperature.
Laminar ow mode was assumed to occur through the whole
heating process. This resulted in oscillations in the rst few sec-
onds of the simulations. Since the oscillations did not continue,
turbulent ow mode was not required to apply, and the oscilla-
tions that occurred were just neglected. Further information on
this issue was given by Erdogdu et al. (2009).
Calculations were carried out on an Intel Pentium QuadCore,
2.4 GHzwith8 GbyteRAMPCrunningonWindows XP64bit edition.
3. Results and discussion
When a uid is subjected to a rapid temperature increase adja-
cent to a solid wall, part of the uid in the wall vicinity expands
resulting in an increase in the local pressure with signicant effects
in heat transfer due to thermal buoyancy effects in a gravitational
force eld (Aktas and Farouk, 2003). In a similar way, during
Fig. 5. Velocity prole of the liquid phase at 30 s of the process at the vicinity of can wall and between the particles.
S. Kzltas et al. / Journal of Food Engineering 97 (2010) 449456 453
thermal processing of solidliquid mixtures in cans, water adjacent
to the can walls receives the heat resulting in expanding and get-
ting a lower density while the liquid away from the walls stay at
lower temperature. This leads to development of an upward buoy-
ancy force with a motion due to density differences. This move-
ment also carries the colder uid upward by viscous drag. The
uid owing upward is deected by top surface of the can and
starts moving in radial direction by getting heavier and starting
to move downwards. Fig. 4 shows this movement. As the liquid
descends, its temperature decreases upon mixing with colder lay-
ers, and a new cycle starts from bottom. These changes create a re-
circulating owincreasing the rate of heat transfer. When there are
solid impermeable particles distributed in the uid, velocity pro-
les change due to the heat exchange and surface deections while
the ow is slowly through the stack of solid particles. Fig. 5 shows
the evolved velocity proles on vicinity of can wall and between
the particles at 30 s of the process. Conned natural convection
is related to RayleighBenard problem where the hot uid expands
and produces an unstable density gradient in the uid layer at the
bottom (Vargas et al., 2002). The slowest heating zone, a critical
parameter in estimating process efciency, between geometric
center and bottom of the can with formation of Benard convective
cells is shown in Fig. 6a and b. When the effect of natural
convection heating is pronounced, thermal stratication is also ob-
served (Fig. 6a and b) based on the uid movement due to buoy-
ancy effects explained above.
Figs. 7 and 8 show the comparison of simulation results with
the experimental data obtained from cans heated in boiling water
under pasteurization conditions (at 98 C) for peas located at the
can geometric center and off-center water temperature (82 mm
from bottom and 12 mm from central line). As seen in these
gures, simulation results agreed well with the experimental data
Fig. 6. Temperature contours at 30 and 300 s of the process (left hand side is center line); (a) t = 30 s; and (b) t = 300 s.
454 S. Kzltas et al. / Journal of Food Engineering 97 (2010) 449456
validating the given 2D assumption to simplify the canned solid
liquid mixture. Based on these gures, however, center pea
temperature seemed to be over-estimated (the differences were
less than 2 C in the worst case) and water temperature to be un-
der-estimated (the differences were less than 5 C in the worst case)
at the processing time of 3050 s. This possibly implies that natural
convection between particles and liquid phase was over-estimated
in the simulations. It is suspected that due the assumption of thin
lm water between the particles, natural convection effects might
be over-estimated as a result of faster liquid phase movement be-
tween the particles, and this might result in higher heat uxes be-
tween the solid and liquid phases leading to the higher estimated
temperature in the simulations. For the case of liquid temperature,
the thermocouple location was in the upper side of the cans as ex-
plained in the methods. Since, in the upper side of the cans, vorti-
ces, recirculation and the natural convection currents were denser
compared to the other regions, these kinds of differences were ex-
pected to be. In addition, thermocouple conduction errors should
also be noted.
As indicated, experimental validation of the simulation was car-
ried out in boiling water under pasteurization conditions (at
98 C). Hence, simulation results should be used with caution
while extending to the sterilization conditions.
For further development of the simulation model, use of 3D
geometry with a packing optimization algorithm which will lead
to locating homogeneous spherical particles inside a cylindrical
can might be used. Mueller (2005) described the details of a
numerical packing algorithm using a sequential technique to pack
spheres in cylinders. Using such an algorithm with a CFD program
is expected to improve the heat transfer model for soliduid mix-
tures used in this study. Due to the complexity of the requirement
for solutions of continuity, energy and momentumequations in the
solidliquid mixture systems, porous media approaches might
have been considered for the solution. Inuence of porosity on nat-
ural convective ow and heat transfer was reported to be signi-
cant in uid saturated porous media (Nithiarasu et al., 1998). For
this approach, the given system could be considered as a porous
media involving small pores where the uid ow becomes mostly
outside the solid (Datta, 2007). However, as stated by Datta (2007),
an exact manner should refer to the solution velocity distribution
of the uid in the void space of the soliduid mixture using the
NavierStokes equations even though higher number of calcula-
tions is required (Xu and Jiang, 2008). Xu and Jiang (2008) also pre-
sents considering limited number of identical particles as the
porous media for various arrangements to solve the NavierStokes
equations.
4. Conclusions and suggestions
In this study, simulation of heat transfer in canned solidliquid
mixtures was carried out applying a CFD methodology. The axi-
symmetric assumption, leading to the formation of torus volumes
of solid phase inside the liquid reduced the problem from 3D to 2D
without affecting the results signicantly, and the simulations
were validated by experiments. This part might be especially sig-
nicant for further optimization studies. So far in the literature,
optimization of heat transfer in solidliquid food products, where
heat transfer occurs by natural convection and conduction heating
simultaneously, has not been reported probably due to the require-
ment of extensive CPU usage, very dense computations for deter-
mining temperature distribution. Alvarez-Wazquez and Martinez
(1999) described the optimal control of natural convection in
canned foods from a mathematical point of view. The 2D assump-
tion might help in reducing the computational requirements and
developments of optimization models for canned solidliquid food
mixtures. Canned solidliquid mixtures are usually processed in
agitated retorts where heat transfer is easily inuenced by particle
to uid relative motion (Meng and Ramaswamy, 2007a). Excellent
experimental studies were reported in the literature (Meng and
Ramaswamy, 2007a,b, 2009). Simulation of thermal processing
for this case becomes an important task for process design and
control. Based on the results of this study, applying a CFD method-
ology for a heat transfer study in an agitated retort might also be
carried out including the particles movement in the lling liquid
where a 3D modeling should be done since the 2D assumption sce-
nario will not hold.
Acknowledgement
This research was supported by the Scientic and Technical Re-
search Council of Turkey, project no: 107O619 (TOVAG-Agricul-
ture, Forestry and Veterinary Research Grant Committee).
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0
20
40
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0 60 120 180 240 300 360
TIme (s)
C
e
n
t
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r

P
e
a

T
e
m
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r
a
t
u
r
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(

C
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Center Pea Temp.SD
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W
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a
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(

C
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