Contour-Adaptive Pig Composition for Contamination-Free Tube Cleaning
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Solution Overview
Problem
Existing methods for cleaning tubular cavities, such as ice pigs, often result in contamination of the product when the ice melts, especially in non-water-soluble products, and are not adaptable to varying pipeline geometries or unable to be removed after passage.
Innovation Solution
A passive, contour-adaptive pig composed of a solid suspension with a high solid phase mass fraction (>60%) that forms a dense packing with a propellant medium, featuring varying particle sizes for different sections to prevent contamination and effectively push out precursor products without forming mixed phases, using food-grade substances like sugar and cocoa butter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an ice pig is used to clean the tubular cavity, then the cleaning effect is improved, but the product is contaminated when the ice melts
Solution Approach 1:
The patent changes the physical and chemical parameters of the pig material from ice (water-based) to a fat-based solid suspension that remains stable at processing temperatures. The solid phase consists of particles with specific size distributions (fine particles ≤100-200 μm for sealing, coarse particles >200 μm for abrasion) suspended in a liquid phase (oil or cocoa butter), creating a material that maintains its cleaning function without melting and contaminating the product
Solution Approach 2:
The patent employs a composite material structure where solid particles (sugar, salt, or other edibles) are suspended in a liquid phase (oil, cocoa butter, or heated chocolate). This composite formulation provides both the mechanical cleaning action through particle abrasion and the sealing function through fine particle packing, while the fat-based composition prevents product contamination unlike water-based ice pigs
2Adaptability or versatility
If a traditional pig is used, then the pipeline geometry is fixed, but the pig cannot adapt to varying cross-sections or bends
Solution Approach 1:
The patent creates a flexible pig structure through the solid suspension formulation that can deform and adapt to varying pipeline geometries including bends and cross-section changes. The suspension of solid particles in a liquid phase allows the pig to conform to the pipe wall while maintaining its cleaning function, unlike rigid traditional pigs that cannot adapt to geometry variations
Solution Approach 2:
The patent implements a dynamic pig structure where the solid suspension can change its form and density in response to flow conditions and pipeline geometry. The propellant medium compacts the suspension into a dense packing that advances through the cavity, allowing the pig to dynamically adapt to different sections of the pipeline while maintaining cleaning effectiveness
3Productivity
If the pig is forced into dense packing by propellant medium, then the ejection of precursor product is improved, but the pig structure becomes complex
Solution Approach 1:
The patent employs a self-organizing solid suspension that automatically forms a dense packing structure when subjected to propellant medium pressure. The solid particles self-arrange into compact configurations without requiring external structuring mechanisms, allowing the pig to achieve high ejection efficiency while maintaining relatively simple overall device structure
Solution Approach 2:
The patent applies different particle size qualities to different sections of the pig to optimize local functions. The front third contains fine particles for sealing and tightness, the central section contains coarse crystals for abrasive cleaning, and the rear third contains fine particles for final cleaning and propellant sealing. This local differentiation improves ejection efficiency without requiring complex mechanical structures
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 solution effectively removes up to 99% of precursor products from tubular cavities without contaminating the product, maintaining effectiveness over long pipeline stretches and adapting to complex geometries, providing a robust and contamination-free cleaning method suitable for non-water-soluble products.
Implementation Method 1
the pig consists of a solid suspension and, if not already pre-compacted, is forced into a dense packing by a subsequent propellant medium and advanced within the tubular cavity
Implementation Method 2
the ejection of the precursor product is not impaired. The solid suspension consists of a solid phase with a mass fraction of at least 60%, which is only sparingly or insoluble in the liquid phase
Implementation Method 3
a subsequent propellant medium and advanced within the tubular cavity
Data Source
Figure 1
AI summary
Method and apparatus for cleaning a tubular cavity using a passive, contour-adaptive pig. The pig (1) consists of a solid suspension (2, 4, 6) with a high solids content compared to the suspension (14) typically used in the cavity (10) and is forced into a dense packing by a subsequent propellant medium (12) or by prior compaction. The dense packing of the solid suspension (2, 4, 6) exhibits such density and stability that the precursor product is ejected without the formation of mixed phases between the solid suspension (2, 4, 6), the precursor product, and the propellant medium (12). The solid suspension consists mainly of particles that are not soluble in the liquid phase or are so soluble that the ejection of the precursor product is not impaired.