Emulsion Separation Using Non-Wettable Diatomite Granules
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Solution Overview
Problem
Existing methods for emulsion separation, such as filtering through a granular bed, face inefficiencies due to low regeneration efficiency, complex designs, high energy consumption, and significant downtime for bed replacement, leading to reduced filtration quality and capacity.
Innovation Solution
The method involves creating a granulated bed with at least 55% of its surface made non-wettable by impregnating it with a dispersion medium and using abrasive particles to prevent sticking, facilitating backwashing and improving regeneration efficiency, while using diatomite-based granules with specific size and shape characteristics to enhance filtration and backwashing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the granular bed is filtered through a layer of granules of oleophilic foamed plastic, then the emulsion can be cleaned from oil and oil products, but significant technological downtime is required for bed replacement since regeneration is not provided
Solution Approach 1:
The invention implements bed regeneration by discarding the accumulated oil contamination and recovering the filtering bed for reuse. The process involves washing the bed with water to remove accumulated oil, followed by heating to evaporate residual water and oil, thereby restoring the bed's filtering capacity without requiring replacement.
Solution Approach 2:
The invention applies preliminary action by performing regeneration operations (washing and heating) during scheduled maintenance periods before the bed becomes completely saturated. This prevents complete clogging and extends the operational life of the filtering bed, reducing unexpected downtime.
2Reliability
If double mechanical pressing with intermediate washing is used for bed regeneration, then the bed can be regenerated, but the emulsion separation efficiency is reduced due to low regeneration degree and duration of regeneration cycle
Solution Approach 1:
The invention replaces the complex mechanical pressing system with a simpler thermal field approach. Instead of using mechanical presses to compact and wash the bed, the method uses water washing followed by thermal heating to evaporate contaminants. This substitution eliminates the need for complex mechanical equipment while achieving more effective regeneration.
Solution Approach 2:
The invention changes the regeneration parameters from mechanical pressure-based processes to temperature-based processes. By controlling temperature during the heating phase, the method effectively removes oil and water contaminants through evaporation, achieving higher regeneration degrees without prolonged cycle times.
3Reliability
If double mechanical pressing and washing equipment is installed for bed regeneration, then the bed can be regenerated, but the unit's design complexity increases and additional energy consumption is required for mechanical pressing
Solution Approach 1:
The invention eliminates mechanical pressing equipment by substituting it with a thermal processing system. The regeneration process uses water washing followed by heating in a furnace or heater, completely removing the need for mechanical presses, hydraulic systems, and associated control mechanisms, thereby simplifying the overall unit design.
Solution Approach 2:
The invention extracts and removes the complex mechanical pressing subsystem from the regeneration process. By taking out the mechanical pressing component entirely and replacing it with simple thermal processing, the design complexity is significantly reduced while maintaining or improving regeneration effectiveness.
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 significantly enhances emulsion separation efficiency, simplifies the design, reduces energy consumption, and extends the filter cycle duration by preventing sticking and easy regeneration, resulting in improved performance and reduced downtime.
Implementation Method 1
at least part of the surface of granules of the bed (not less than 55%, optimally 70-95% of the total surface) is made nonwettable for the dispersed phase in conditions of filtration (temperature, filtration rate, pressure) due to its covering with a dispersion medium
Implementation Method 2
The open-porous granules impregnated with dispersion medium is used as a filtering bed since the granules' open pores possess a capillary effect in relation to the dispersion medium, ensuring retention of the dispersion medium on the surface of granule
Implementation Method 3
The abrasive material (silicon carbide, natural corundum, emery, diatomite, tripoli, etc.) has sharp edges, which makes it possible to clear clogged pores during the bed backwashing process, increasing its service life
Implementation Method 4
prior to filtering the bed is impregnated with the dispersion medium; and regeneration of the bed is carried out by backwashing
Data Source
AI summary
The proposed solution relates to the field of emulsions separation by filtering, in particular, to the field of cleaning liquids from oil and oil products, as well as from organic substances. It can be used in the oil producing, chemical, petrochemical, food-manufacturing, pharmaceutical, engineering and other sectors of industry, as well as in wastewater treatment systems. The device for emulsions separation contains a case, wherein the filtering bed is located. Granules formed from crushed particles of diatomite and burned at the temperature of 700-1,000 °C are used as the filtering bed, which ensure sintering of particles of diatomite to each other while retaining pores available between the particles. When cleaning water from oil, the filtering bed is pre-filled with clean water, which fills the pores of granules, creating zones nonwettable for oil (dispersed phase) at exit points of pores on a granule surface. Only then filtering of the water-oil emulsion through the layer of diatomite granules is started. Since the flow rate decreases sharply in the course of filtering in the pyramid-like cavities between granules, the dispersed phase begins to settle on protrusions of the surface of granules (primarily, in side cavities), gradually filling these cavities completely. When backwashing, the granules are shifted, spatial structure of cavities is destroyed, and dispersed phase accumulated in the pyramid-like cavities and on the surface of granules it is carried away by the washing liquid. The technical result of the proposed solution consists in the efficiency enhancement of the emulsions separation process.