DAF Skimmings Separator Using Pressurized Nozzle and Heated Airstream
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Solution Overview
Problem
The meat processing industry faces challenges in cost-effectively handling dissolved air floatation (DAF) skimmings, which contain valuable nutrients, due to high energy and chemical costs in existing separation methods, leading to inefficient recovery of animal fat and protein nutrients and increased waste disposal.
Innovation Solution
A DAF skimmings separator system utilizing a heated airstream and pressurized nozzle to break down animal components, separating them from water, with a processor chamber and cyclone separator to achieve efficient separation and dewatering, reducing energy and chemical usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If heat process is applied to separate emulsions by evaporating water, then water removal is achieved, but energy cost increases significantly
Solution Approach 1:
The patent changes the physical parameters of the separation process by using centrifugal force (rotational speed parameter) instead of thermal energy to separate emulsion components. The centrifugal separator rotates at controlled speeds to differential settle fat, water, and solids based on density differences, achieving water removal without high energy thermal input.
Solution Approach 2:
The patent replaces the thermal/chemical separation system with a mechanical centrifugal separation system. The centrifugal separator uses rotational mechanics to create centrifugal force that separates emulsion components by density, substituting the high-energy heat process with a lower-energy mechanical process.
2Loss of substance
If chemical process with solvents is used to separate emulsions, then separation efficiency improves, but chemical cost and environmental hazard increase
Solution Approach 1:
The patent replaces the chemical solvent-based separation system with a mechanical centrifugal separation system. Instead of using chemicals to break emulsions, the centrifugal separator uses rotational force to physically separate components based on density differences, eliminating chemical hazards while maintaining separation efficiency.
Solution Approach 2:
The patent enables the emulsion to separate itself through centrifugal force without requiring external chemical agents. The natural density differences between fat, water, and solids components allow them to differential settle under centrifugal acceleration, making the system self-sufficient and free from chemical additives.
3Loss of substance
If belt press devices are used for dewatering DAF skimmings, then water removal is achieved, but product quality deteriorates due to pathogen growth and free fatty acid buildup
Solution Approach 1:
The patent changes the operational parameters by controlling residence time and separation speed in the centrifugal separator, preventing the conditions that lead to pathogen growth and free fatty acid buildup. The continuous separation process maintains product quality by avoiding the stagnation and heat exposure associated with belt pressing.
Solution Approach 2:
The patent replaces the belt press mechanical system with a centrifugal separation system that operates under different mechanical principles. The centrifugal force continuously moves material through the separation zone without compression or stagnation, preserving product quality while achieving effective dewatering.
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 system effectively reduces the water content of DAF skimmings from 85-90% to 50-60%, enhancing the recovery of valuable nutrients, minimizing waste, and enabling the safe return of clarified water to sanitary systems, while reducing handling and processing costs.
Implementation Method 1
the pressurized DAF skimmings ejected from the introductory pressure nozzle impacts upon the spatter surface with sufficient force to cause animal components within the DAF skimmings to break into smaller pieces
Implementation Method 2
The system effectively reduces the water content of DAF skimmings from 85-90% to 50-60%
Implementation Method 3
A DAF skimmings separator system utilizing a heated airstream
Implementation Method 4
a processor chamber and cyclone separator to achieve efficient separation and dewatering
Data Source
AI summary
A DAF skimmings separation system 10 that processes SPN/DAF skimmings 11 received from a meat processing facility to separate water and SPN-content solids includes a heating chamber coupled to a processor chamber having one or more pressurized discharge nozzles that expels DAF skimmings onto a spatter plate to cause SPN animal components within the DAF skimmings to break into smaller pieces denaturing the molecular structure and allowing the entrapped moisture to be evaporated within a heated airstream in the processing chamber, for separating nutritionally valuable SPN while reducing moisture content. A method of processing DAF skimmings to yield dryer SPN with reduced moisture content is disclosed.