Two-Step Centrifugal Phase Separation for High Viscosity
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Solution Overview
Problem
Efficient separation of two phases with relatively small density difference and high viscosity of the light phase is challenging, leading to leakage and low purification efficiency in conventional centrifugal separators.
Innovation Solution
A method involving a two-step separation process using a concentrator-type centrifugal separator followed by a hermetically closed purificator-type separator, with the first step employing centrifugal separators of either open or hermetic types to separate a heavy phase from a light phase, and the second step using a hermetically closed purificator-type separator to further purify the light phase, optimizing the interface location and applying sufficient pressure to manage high viscosity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional centrifugal separators with fixed paring discs are used, then the separation process is simple, but leakage occurs between the heavy and light phases resulting in low purification efficiency
Solution Approach 1:
The patent replaces fixed paring discs with rotating paring discs that rotate together with the separation bowl. This dynamic configuration allows the paring discs to move with the rotating system, eliminating leakage paths between stationary and rotating components while maintaining effective phase separation. The rotating paring discs create a dynamic seal that prevents mixing of heavy and light phases.
Solution Approach 2:
The patent introduces a centrifugal pump as an intermediary component between the separation bowl and the outlet. This pump actively manages the phase separation by creating controlled pressure differences and flow patterns, preventing direct leakage between phases while maintaining purification efficiency. The pump acts as a mediator that controls the interaction between the rotating bowl and stationary outlets.
2Productivity
If high rotation speed is used to increase centrifugal force, then separation efficiency improves, but energy consumption increases
Solution Approach 1:
The patent employs dynamic rotation of paring discs at variable speeds rather than fixed high-speed rotation. The rotating paring discs can operate at optimized speeds that balance separation efficiency with energy consumption. The system adapts the rotation speed to the specific separation requirements, avoiding excessive energy use while maintaining effective phase separation.
Solution Approach 2:
The patent utilizes centrifugal pumping action created by the rotating paring discs to manage phase discharge. This hydraulic action leverages the rotation to create pressure gradients that drive phase separation and discharge without requiring additional high-energy input mechanisms. The system converts rotational energy efficiently into separating and pumping action.
3Reliability
If the light phase has high viscosity, then the separated product has desired properties, but the phase is difficult to separate and prone to clogging
Solution Approach 1:
The rotating paring discs create dynamic flow patterns that prevent clogging of high-viscosity light phase. The rotation generates continuous motion and pressure variations that keep the viscous material flowing smoothly through the separation system. This dynamic action prevents the light phase from stagnating or clogging in the separation channels and outlets.
Solution Approach 2:
The centrifugal pumping action created by the rotating paring discs provides hydraulic force that drives the high-viscosity light phase through the separation system. The pump action generates sufficient pressure to overcome the high viscosity and prevent clogging, while maintaining continuous flow and reliable separation. The hydraulic force ensures smooth discharge of the viscous product.
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
This approach achieves high purification efficiency and reduces energy consumption by minimizing leakage and clogging, effectively separating phases with close densities and high viscosity, even when the light phase is highly viscous or solid.
Implementation Method 1
a separation bowl rotates, with typically at least 1000 revolutions per minute, such as at least 3000 rpm, more preferably at least 4500 rpm, preferably about 6000 rpm, and thereby creates a radially directed centrifugal force acting on the material contained within the bowl
Implementation Method 2
applying sufficient pressure to manage high viscosity
Data Source
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AI summary
The invention is characterised in the steps of a) performing a first separation of the mixture in a first centrifugal separator, resulting in a first heavy fraction comprised of the heavy phase with only small amounts of impurities in the form of the light phase and a first light fraction comprising of the light phase with impurities in form of the heavy phase; and b) performing a second separation of the first light fraction in a second hermetic centrifugal separator of purificator type, resulting in a second heavy fraction comprised of the heavy phase with impurities in the form of the light phase and a second light fraction comprised of the light phase with only small amounts of impurities in the form of the heavy phase. The invention also relates to a device.