Dairy Filtration Pump Power Control via Feed Pressure
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Solution Overview
Problem
Conventional membrane filtration systems for dairy products operate pumps at higher power than necessary, leading to energy wastage and increased cooling requirements due to inefficient pump control based on delta pressure.
Innovation Solution
A method for filtering dairy products where the operation of circulation pumps is controlled based on feed pressure thresholds, adjusting power usage between 25% and 85% of maximum rated power depending on whether the feed pressure is below or above a predefined threshold.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If pumps are operated at high power to maintain sufficient filtering output, then productivity is improved, but energy consumption increases
Solution Approach 1:
The pump power is made dynamically adjustable based on feed pressure conditions. The system transitions between different operational modes (first mode at lower power 20-40%, second mode at higher power 60-80%, third mode at maximum power) according to real-time feed pressure measurements, allowing the pump to operate at optimal power levels rather than continuously at high power
Solution Approach 2:
The system changes the operating parameters of the pump based on feed pressure thresholds. When feed pressure is below a first threshold, the pump operates at 20-40% power; when between first and second thresholds, it operates at 60-80% power; when above the second threshold, it operates at maximum power. This parameter adaptation resolves the contradiction by matching pump power to actual system needs
2Productivity
If pumps are operated at high speeds to increase flow rate, then productivity is improved, but energy waste increases
Solution Approach 1:
The system incorporates feedback control by continuously monitoring feed pressure and adjusting pump power accordingly. The control unit receives feed pressure signals and automatically adjusts the pump operational mode, creating a closed-loop system that prevents energy waste by only increasing pump power when actually needed to maintain sufficient flow rate
Solution Approach 2:
The pump speed and power are made dynamic rather than fixed, allowing the system to adjust flow rate to match actual filtering needs. The pump operates at variable speeds corresponding to different operational modes, eliminating the energy waste associated with consistently high-speed operation while maintaining productivity when required
3Productivity
If pump power is increased to maintain filtering output, then productivity is preserved, but cooling requirements increase
Solution Approach 1:
The system changes the operational parameters of pumps based on feed pressure conditions, operating at reduced power levels (20-40% or 60-80%) during normal conditions and only using maximum power when feed pressure exceeds the second threshold. This parameter adaptation reduces unnecessary heat generation from pump operation, thereby reducing cooling requirements while maintaining filtering output when needed
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 operating pumps at lower efficiencies, decreases cooling fluid usage, and maintains consistent filtering output, with additional benefits of reduced chemical oxygen demand in permeate products in reverse osmosis applications.
Implementation Method 1
at least one pump loop (5) having a pump (6, 20) and a filter (7, 22), with the pump (6, 20) being arranged to feed a feed product (2) to the filter (7, 22)
Implementation Method 2
In membrane filtration, the use of a pressure difference across the membrane is the driving force for separation of the feed product that is supplied to the filter
Implementation Method 3
In reverse osmosis, membrane separation may be used for dehydration of milk, whey, ultrafiltration permeate, and condensate
Implementation Method 4
In nanofiltration, membrane separation may be used for partial desalination of milk, whey, ultrafiltration permeate or retentate
Data Source
AI summary
A method for filtering a dairy product is used in a filter system that includes at least one pump loop having a pump and a filter, with the pump being arranged to feed a feed product to the filter for filtering the feed product and outputting a permeate product and a retentate product. The method includes supplying the feed product to the pump at a feed pressure, during a first operational mode in which the feed pressure is below a first predefined threshold, controlling the pump to operate at a first power that is within a first percentage range of a maximum rated power of the pump, and during a second operational mode in which the feed pressure is above the first predefined threshold, controlling the pump to operate within a second percentage range of the maximum rated power which is higher than the first percentage range.