Aseptic Steam Trap Annular Filtration Against Nozzle Clogging
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing condensate drains in beverage bottling plants are prone to clogging due to particles transported with condensate and steam, leading to frequent maintenance and cleaning requirements, which compromise the aseptic conditions and operational reliability.
Innovation Solution
A condensate drain with an integrated annular gap as a pre-filter upstream of the seat, which automatically cleans during the closing switching movement, preventing particles from entering the nozzle and ensuring reliable operation by maintaining an aseptic condition through efficient rinsing and sterilization cycles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If particles are discharged through the condensate drain, then the condensate can be effectively drained, but particles and foreign material clog the nozzle and seat, leading to frequent maintenance and cleaning requirements
Solution Approach 1:
The condensate drain is segmented into multiple functional zones: a pre-filter section with radial channels that intercepts particles before they reach the nozzle, and a main drainage section. This segmentation allows particles to be filtered out in the pre-filter zone while clean condensate flows through the nozzle, resolving the contradiction between drainage efficiency and operational reliability by preventing clogging without compromising drainage capability
Solution Approach 2:
A pre-filter structure serves as an intermediary element between the condensate inlet and the nozzle. This pre-filter intercepts particles and foreign material before they can clog the nozzle, acting as a mediator that protects the critical nozzle component while maintaining overall system functionality. The pre-filter is designed to be easily removable and cleanable, allowing maintenance without replacing the entire condensate drain
2Reliability
If the valve is cleaned and sterilized frequently, then aseptic conditions are maintained, but operational time is lost and maintenance costs increase
Solution Approach 1:
The valve is segmented into a removable pre-filter section and a fixed main body. The pre-filter can be independently removed and cleaned without disassembling the entire valve or losing operational time. This segmentation allows rapid maintenance of the contamination-prone pre-filter while keeping the sterilized main body in service, resolving the contradiction between maintaining aseptic conditions and minimizing maintenance time
Solution Approach 2:
The pre-filter is designed to be pre-assembled as a removable unit that can be quickly detached and replaced. This preliminary preparation of modular components allows maintenance personnel to perform cleaning and sterilization operations rapidly without complex disassembly procedures, reducing the time lost during maintenance while ensuring aseptic conditions are maintained
3Reliability
If a pre-filter is added upstream of the seat, then particles are prevented from clogging the nozzle, but the device complexity increases
Solution Approach 1:
The pre-filter is merged with the valve body as an integrated component rather than a separate external attachment. The pre-filter channels are formed directly within the valve housing, combining the filtering function with the existing valve structure. This merging approach prevents clogging and extends service life while minimizing the increase in device complexity by utilizing space already present in the valve design
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The annular gap effectively prevents nozzle clogging, ensuring a longer service life for the condensate drain and maintaining aseptic conditions, reducing maintenance needs and ensuring uninterrupted operation.
Implementation Method 1
the circumferential gap formed as a pre-filter upstream of the seat in the inlet, in particular an annular gap, with an approximately linear course and always the same effective length in the direction of flow, a geometrically determined passage as a pre-filter
Implementation Method 2
The leakage chamber of the double-seat valve is flushed with condensate in order to discharge the impurities and particles it contains via the condensate drain, and is then sterilized with steam in order to create an aseptic condition at least in the leakage chamber
Implementation Method 3
The leakage chamber of the double-seat valve is flushed with condensate in order to discharge the impurities and particles it contains via the condensate drain
Data Source
Figure 1~3
Figure 4~5
Figure 6
AI summary
In a condensate drain (A) with a housing (16) in which a seat (19) for a closing element (18) is provided between a steam and/or condensate inlet (12) and an outlet (13), which can be switched back and forth between a closed position in the seat (19) and a lifted open position, an annular gap (P) is formed upstream of the seat (19) in the final phase of the switching movement into the closed position and in the final position of the closed position, which serves at least to pre-filter condensate and prevents particles from being trapped in the seat (19) and a nozzle (D) from being blocked.