Dissolved Air Flotation for Cationic Metal Processing Fluids

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Solution Overview

Problem

Existing metal deformation processes face challenges with anionic and cationic chemistry emulsions, including metallic soap formation, emulsion stability issues, and inefficient removal of fine metal contaminants, which lead to costly and environmentally problematic filtration and fluid replacement.

Innovation Solution

The implementation of dissolved air flotation (DAF) technology to remove suspended foreign matter from cationic-based metal processing fluids without disrupting the emulsion environment, allowing for effective clarification and reuse of the fluid without the need for filtration or flocculants.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If DAF is applied to anionic metal processing fluid emulsions, then metal fines and debris are removed, but emulsion stability is disrupted and valuable chemical components are lost

Engineering Contradiction:

Improveremoval of metal fines and debrisVSAvoidemulsion stability

Core Design Contradiction:

Manufacturing precisionVSStability of the object's composition

Solution Approach 1:

The patent changes the chemical parameter of the metal processing fluid from anionic to cationic chemistry. This parameter change fundamentally alters the interaction between the fluid and air bubbles during DAF, preventing the disruptive electrostatic effects that occur with anionic fluids. The cationic chemistry maintains emulsion stability while enabling effective contaminant removal through DAF.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If filters are used to remove fine metal contaminants, then some contaminants are removed, but filtration efficiency is insufficient and filter disposal is costly

Engineering Contradiction:

Improveremoval of fine metal contaminantsVSAvoidfiltration efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent replaces the mechanical filtration system with a dissolved air flotation system. Instead of using physical filters that require frequent replacement and disposal, the invention uses DAF where air bubbles attach to and carry metal fines to the surface for removal. This substitution eliminates filter media consumption and significantly improves removal efficiency for fine particles.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent employs pneumatic principles by introducing dissolved air into the metal processing fluid. The air bubbles serve as the active medium to lift and remove contaminants through buoyancy forces, replacing the need for mechanical filter media. This pneumatic-hydraulic approach enables continuous operation without filter replacement.

Inventive Principle:

Principle #29Pneumatics and hydraulics

3Stability of the object's composition

If a portion of the emulsion system is removed and replaced with fresh rolling oil and water, then emulsion stability is restored, but operational costs increase

Engineering Contradiction:

Improveemulsion stabilityVSAvoidcost of fluid replacement

Core Design Contradiction:

Stability of the object's compositionVSLoss of substance

Solution Approach 1:

The patent implements a recovery system where contaminated metal processing fluid is continuously circulated through the DAF unit. The clarified fluid is recovered and returned to the metal deformation process, eliminating the need to discard and replace large volumes of fluid. Only the accumulated sludge at the surface needs periodic removal, significantly reducing material costs.

Inventive Principle:

Principle #34Discarding and recovering

Solution Approach 2:

The patent establishes a continuous circulation system where the metal processing fluid constantly flows through the DAF unit for clarification. This continuous operation maintains emulsion stability throughout the process without interruption or replacement, allowing the fluid to serve its lubrication and cooling functions indefinitely with minimal top-ups.

Inventive Principle:

Principle #20Continuity of useful action

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

DAF effectively removes metallic debris and fines from metal processing fluids, maintaining emulsion stability and chemical balance, thereby extending the life of the processing fluid and reducing operational costs and environmental impact.

Implementation Method 1

treating the metal processing fluid with dissolved air floatation

Methodology Applied

Scientific EffectDissolved air flotation: Bubble

Implementation Method 2

the bubbles adhere to and carry the suspended foreign matter from the contaminated metal processing fluid to the upper layer

Methodology Applied

Scientific EffectBuoyancy: Archimedes' Principle (Buoyancy)

Data Source

PatentUS11230476B2Dissolved air flotation use with cationic metal processing fluids

Publication Date: 2022.01.25 TOTALENERGIES ONETECH

AI summary

In an effort in solving the difficulties with cleaning cationic metal processing fluids and/or emulsions, processes for cleaning a metal processing fluid which is substantially free of fatty acids is provided herein and includes treating the metal processing fluid with dissolved air floatation. Also provided are processes for deforming metals and removing suspended foreign matter from a contaminated metal processing fluid and/or emulsions which are substantially free of fatty acids is provided and include the use of DAF technology. In one embodiment, the process is performed in the absence of a filter. In another embodiment, the process is performed in the absence of a filter which is capable of removing suspended foreign material in the contaminated metal processing fluid.