Cross-Flow Filtration Cleaning Method Using Variable Flow Rates
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Solution Overview
Problem
Existing cleaning-in-place (CIP) processes for processing systems, particularly those using cross-flow filtration, are energy-intensive and costly, as they require constant high fluid flow rates, leading to increased energy consumption and environmental impact.
Innovation Solution
A method that adjusts fluid flow rates during the CIP process, applying a first fluid flow rate for a first time interval and a second fluid flow rate, different from the first, for a second time interval, thereby reducing energy consumption without extending the CIP duration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If constant high fluid flow rate is applied during CIP process, then sufficient membrane cleaning is achieved, but energy consumption increases
Solution Approach 1:
The patent applies dynamic flow rate adjustment during the CIP process, transitioning from a constant high flow rate to a variable flow rate profile. The system dynamically reduces the flow rate after an initial high-flow phase, optimizing the balance between cleaning effectiveness and energy consumption. This is achieved through controlled adjustment of pump operation parameters during different stages of the cleaning cycle.
Solution Approach 2:
The patent implements periodic action by dividing the CIP process into distinct phases: an initial high-flow rate period for primary cleaning, followed by a reduced flow rate period for maintenance cleaning. This periodic variation in flow rate allows the system to achieve sufficient cleaning during the high-flow phase while reducing energy consumption during subsequent phases, thereby resolving the contradiction between cleaning effectiveness and energy usage.
2Reliability
If high fluid flow rate is maintained throughout CIP process, then cleaning quality is ensured, but operational costs increase
Solution Approach 1:
The system dynamically adjusts flow rate based on process stage, using high flow rate only when necessary for effective cleaning, then reducing to lower flow rates for the remainder of the CIP cycle. This dynamic operation reduces water and chemical consumption, thereby lowering operational costs while maintaining cleaning quality through the initial intensive cleaning phase.
Solution Approach 2:
The patent changes the flow rate parameter during the CIP process, transitioning from a constant high value to a variable profile with at least two distinct levels. This parameter change optimizes the cleaning process by applying high flow rate only during the critical initial phase, then reducing to lower flow rates that maintain cleaning effectiveness at reduced operational cost.
3Reliability
If constant high flow rate is used for membrane cleaning, then cleaning thoroughness is achieved, but environmental impact increases
Solution Approach 1:
The patent applies periodic action by structuring the CIP process with an initial high-flow rate phase followed by a reduced flow rate phase. This periodic variation ensures thorough cleaning during the high-flow period while minimizing water and chemical discharge during the reduced-flow period, thereby reducing environmental impact while maintaining cleaning thoroughness.
Solution Approach 2:
The system changes the flow rate parameter during the CIP process, using high flow rate only during the initial cleaning phase and then reducing to lower flow rates. This parameter change reduces the overall volume of water and cleaning chemicals required, thereby reducing environmental impact while achieving sufficient cleaning thoroughness during the high-flow phase.
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 reduces energy consumption by optimizing pump operation, allowing for sufficient membrane cleaning without increasing the overall duration of the CIP process, thus lowering costs and environmental impact.
Implementation Method 1
A CIP process typically comprises a number of steps, such as interchangeably applying specific various cleaning agents or chemicals to the entire processing system or a part thereof and applying water to rinse the system
Data Source
AI summary
Disclosed is a method for use in cleaning a cross-flow processing system. The processing system comprising a feed pump for feeding a fluid to a baseline of the processing system, and at least one filtration unit. The at least one filtration unit comprising a filtration membrane and a retentate outlet fluidly connected to the baseline for guiding retentate of the at least one filtration unit to the baseline. The processing system further comprising a loop pump for feeding the fluid in a predetermined flow direction to the at least one filtration unit. The loop pump being fluidly connected to the baseline and the at least one filtration unit so that a loop is formed comprising the loop pump, the at least one filtration unit, and the retentate outlet.