Multilayer Fibrous Separation System for Solid and Liquid Removal
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Solution Overview
Problem
Current filtration systems are ineffective in simultaneously removing solid particles and fine liquid droplets from a continuous phase, leading to reduced efficiency and shortened lifespan due to the interference between solid particles and droplets, which causes clogging and alters surface properties, especially in systems with high stability emulsions.
Innovation Solution
A multilayer fibrous separation system with a filtration-coalescing element comprising a depth non-woven structure, including a filtration layer with nanometric fibers for initial retention and coalescence, a coalescing layer with variable porosity and surface properties, and a dripping layer, along with a hydrophobic separation element and drainage gap for effective droplet separation and extended filter operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a filtration system uses a porous filtration structure to remove solid particles, then solid particle removal efficiency is improved, but liquid droplets deposit on the separation surface and cause clogging and alter surface properties
Solution Approach 1:
The filtration system is divided into two distinct functional stages: a coalescing element for droplet removal and a filtration element for solid particle removal. This segmentation prevents droplets from reaching the filtration surface, eliminating clogging and surface property alteration while maintaining effective solid particle removal.
Solution Approach 2:
The coalescing element performs preliminary action by removing liquid droplets from the filtered medium before the flow reaches the filtration element. This preliminary droplet removal prevents subsequent clogging and surface property changes on the filtration element, ensuring stable and reliable operation.
2Productivity
If the system uses a coalescing structure to join droplets, then droplet coalescence efficiency is improved, but residence time of fluid in filter area is reduced and solid particle deposition efficiency decreases
Solution Approach 1:
The system segments the removal process into two sequential elements: the coalescing element optimized for droplet joining with higher flow velocity, and the filtration element optimized for solid particle deposition with lower flow velocity. This segmentation allows each element to operate at optimal conditions without compromising the other.
Solution Approach 2:
The coalescing element acts as an intermediary between the incoming filtered medium and the filtration element. It pre-processes the flow by coalescing droplets and reducing flow velocity, thereby creating favorable conditions for solid particle deposition in the subsequent filtration element.
3Manufacturing precision
If solid particles are removed by filtration, then solid particle capture efficiency is improved, but droplet deposition on fibres increases and filter lifetime is shortened
Solution Approach 1:
The filtration system is segmented into a coalescing element that handles droplet removal and a filtration element that handles solid particle capture. This segmentation protects the filtration element from droplet deposition, preventing clogging and extending filter operational lifetime while maintaining high solid particle capture efficiency.
Solution Approach 2:
The coalescing element performs preliminary action by removing droplets before the flow reaches the filtration element. This preliminary removal prevents droplets from depositing on filtration fibres, thereby extending filter lifetime without compromising solid particle capture efficiency.
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 achieves high efficiency in capturing submicron solid particles and fine droplets, minimizing droplet deposition on the filtration structure, reducing pressure drop, and extending the filter's operational lifetime by using superphobic and hydrophobic properties, and self-cleaning mechanisms.
Implementation Method 1
fibres composing the layer have extensively phobic properties, and preferably superphobic properties, of their surface relative to droplets of said dispersed phase
Implementation Method 2
filtration layer being an initial depth filtration layer comprising polymer fibres of nanometric sizes
Implementation Method 3
coalescing layer composed of polymer fibres and, adjacently following it, is arranged a dripping layer composed of polymer fibres
Implementation Method 4
a porosity gradient across the entire coalescing structure changes in the opposed direction with respect to said porosity gradient in the filtration layer
Implementation Method 5
separating element, which is a barrier layer for droplets of said dispersed phase, said element is formed of fibres with phobic properties, especially hydrophobic, relative to droplets of the dispersed phase
Implementation Method 6
large droplets that are retained flow down then into a lower or upper receiver
Implementation Method 7
drainage gap, disposed there between and separating said elements from each other, which gap being a free space for dripping of droplets of said dispersed phase, under influence of gravity
Data Source
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AI summary
The invention relates to a separation system for simultaneous removal of a solid phase particles and a dispersed phase droplets from a medium being a continuous phase to be purified by filtration, wherein said separation system comprises: a filtration-coalescing element (1) in a form of a fibrous structure, a separating element (2), which is a barrier layer for droplets of said dispersed phase and a drainage gap (3), disposed there between and separating said elements (1) and (2) from each other. Said filtration- coalescing element (1) is a non-woven fibrous structure in the form of a depth non-woven structure composed of fibers packed in a form of a cartridge and it comprises: a filtration layer (1a) being an initial depth filtration layer comprising polymer fibres of nanometric sizes, wherein said fibres composing the layer (la) have extensively phobic surface properties and having across its thickness a porosity gradient, a coalescing layer (1b) and adjacently following it a dripping layer (1c), both composed of polymer fibres and jointly forming a coalescing structure (1b, c) packaged in the form of a depth gradient structure of fibres, and wherein a porosity gradient across the entire coalescing structure (1b, c) changes in the opposed direction with respect to said porosity gradient in said filtration layer (1a).