Filter Cake Sonication for Faster Washing and Dewatering
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Solution Overview
Problem
Filtration processes for solid-liquid compositions face challenges with thixotropic filter cakes, leading to long wash times, high wash solution consumption, and high moisture content, which can overload downstream processes and increase energy consumption.
Innovation Solution
The use of sonication during filtration, washing, and dewatering steps to improve the filtration process, including methods such as sonicating the filter cake with various frequencies and powers, and combining sonication with washing and deliquoring using gases like air or nitrogen.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If chemical modifications are used to address thixotropic filter cake issues, then filtration efficiency may improve, but product quality deteriorates due to chemical residues in the final product
Solution Approach 1:
The patent replaces chemical modifications with physical sonication treatment. The sonication device applies ultrasonic waves to the filter cake, using mechanical vibration and cavitation effects to break up thixotropic structures and improve filtration performance, thereby avoiding chemical residues in the final product while maintaining filtration efficiency
Solution Approach 2:
The patent changes the physical state and structure of the filter cake through sonication treatment. By applying ultrasonic energy, the filter cake's thixotropic properties are modified, transforming it from a gel-like state to a more open structure that allows better liquid penetration and reduces wash time, without introducing chemicals
2Device complexity
If conventional filtration is used without sonication, then the process is simple, but wash time increases and wash solution consumption increases
Solution Approach 1:
The patent merges the sonication treatment with the existing filtration and washing steps. The sonication device is integrated into the filtration system, allowing simultaneous or sequential application of ultrasonic treatment during filtration and washing operations, thereby reducing wash time and solution consumption while maintaining process integration
Solution Approach 2:
The patent applies mechanical vibration through ultrasonic waves to the filter cake during washing. This vibration disrupts the thixotropic network structure, allowing wash liquid to penetrate more effectively and remove impurities faster, thereby reducing wash time and the amount of wash solution needed
3Device complexity
If conventional filtration is used without sonication, then the process is simple, but moisture content in filter cake increases
Solution Approach 1:
The patent uses ultrasonic vibration to create cavitation and mechanical disruption in the filter cake structure. This breaks up the thixotropic gel network that traps moisture, allowing water to be removed more effectively during filtration and dewatering steps, thereby reducing moisture content without adding complexity
Solution Approach 2:
The patent utilizes phase transition effects of water during sonication. The ultrasonic energy induces localized heating and phase changes in the bound water within the thixotropic filter cake, facilitating its removal during dewatering and reducing final moisture content
4Manufacturing precision
If high wash solution consumption is used, then washing effectiveness improves, but energy consumption in downstream processes increases
Solution Approach 1:
The patent applies ultrasonic vibration to enhance washing effectiveness with reduced wash solution consumption. The mechanical vibration disrupts the filter cake structure and improves liquid penetration, allowing better washing with less solution, thereby reducing the energy required for downstream drying and processing
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
Sonication reduces filtration cycle time, improves wash efficiency, and decreases moisture content in the filter cake, enhancing production rates and reducing energy consumption in downstream processes.
Implementation Method 1
sonicating the filter cake, the solid-liquid composition, or a combination thereof on the filter
Implementation Method 2
utilize sonication to mitigate thixotropic nature of a filter cake and improve washing of the filter cake
Data Source
AI summary
Described herein is a method for filtration of a solid-liquid composition. The method may include passing the solid-liquid composition through a filter to form a filter cake on the filter and sonicating the filter cake. A filtration system is also provided for filtering a solid-liquid composition. The filtration system includes a filtration device and a sonication device.