DAF Float Fractionation for Recovering Oil, Solids, and Nutrients
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Solution Overview
Problem
Existing methods for processing DAF float from food processing plants are inefficient and uneconomical, failing to effectively recover valuable components like oil, solids, and liquids, leading to disposal challenges due to the resinous and oily nature of the waste sludge.
Innovation Solution
A multi-stage process involving magnetic filtration, hydrothermal fractionation, centrifugation, thermal treatment, mechanical separation, and chemical processing to separate DAF float into bio-available components such as oil, solids, and liquid phases, utilizing equipment like centrifuges, heat tanks, and separators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If traditional DAF sludge disposal methods are used, then disposal problems are avoided, but valuable components like oil, protein, and nutrients are lost
Solution Approach 1:
The patent converts the harmful oily sludge waste product into valuable bio-available components through hydrothermal processing. The resinous and oily DAF waste sludge, which creates disposal problems, is transformed into usable oil, protein, carbohydrates, and other nutrients that can be applied to land or used as animal feed, thereby converting a waste disposal burden into an economic benefit.
Solution Approach 2:
The patent applies hydrothermal processing by heating the DAF float to specific temperatures (190°F to 210°F) for set periods of time to induce phase separation. This parameter change in temperature and time enables the separation of oil, solids, and liquid phases from the homogeneous sludge mixture, making the valuable components recoverable and usable.
2Productivity
If multi-stage separation process is implemented, then recovery efficiency of valuable components is improved, but process complexity increases
Solution Approach 1:
The patent segments the waste processing into distinct stages: magnetic filtration to remove metal solids, hydrothermal fractionation to separate phases, centrifugation or decanting to divide oil/solids/liquid, and further processing of each stream. This segmentation allows each stage to target specific components, improving overall recovery efficiency while making the complex process more manageable through modular treatment steps.
Solution Approach 2:
The patent introduces an intermediary hydrothermal processing step that acts as a mediator between the raw DAF float and the final separation products. This intermediate treatment modifies the sludge properties to enable effective phase separation, serving as a bridge that facilitates the transition from homogeneous waste to separated valuable components.
3Manufacturing precision
If hydrothermal fractionation is applied, then separation of oil, solids and liquid phases is improved, but energy consumption increases
Solution Approach 1:
The patent utilizes phase transitions during hydrothermal fractionation, where heating the DAF float to 190°F-210°F induces changes in the physical state of oil, water, and solid components. This phase transition enables natural separation of the three phases based on their different densities and solubilities at elevated temperatures, achieving high separation quality while using moderate energy input compared to more intensive thermal processing methods.
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 process efficiently recovers valuable components like oil, proteins, and nutrients, producing high-quality animal feed and nutrient-rich fertilizer, while reducing waste disposal issues and improving compliance with water discharge regulations.
Implementation Method 1
magnetically filtering the DAF float for removal of metal solids
Implementation Method 2
hydrothermally fractionating the DAF float within a heat tank
Implementation Method 3
heating the DAF float with at least one pick heater within a range of 190° F. and 210° F.
Implementation Method 4
separating oil phase, solids phase and liquid phase by centrifugation
Implementation Method 5
exposing the liquid phase to a thermal exchange
Implementation Method 6
binding proteins within the liquid with coagulant polymer
Implementation Method 7
pressing the liquid from suspended solids with a screw press
Data Source
AI summary
Method and system of processing DAF float and other waste streams containing oils, solids and liquid in order to remove them from the waste cycle to be put back into beneficial use.