Filter System Control Method for Energy-Optimized Cleaning
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Solution Overview
Problem
Filter systems require frequent cleaning and backwashing, which consumes additional energy and leads to stoppages, increasing operational costs and reducing efficiency in water filtration processes.
Innovation Solution
A control method that optimizes the timing of cleaning processes by continuously monitoring and analyzing energy consumption and permeate volume, shifting the start of physical cleaning to minimize energy costs and extending intervals between cleaning cycles based on relative energy consumption and system parameter stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cleaning and backwashing are performed frequently to maintain filtration quality, then the reliability and purity of the filtration system are improved, but energy consumption increases and productivity decreases due to stoppages
Solution Approach 1:
The patent implements dynamic adjustment of cleaning cycle frequency based on actual system conditions. Instead of fixed periodic cleaning, the system continuously monitors differential pressure, flow rate, and energy consumption to adaptively determine when cleaning is necessary, allowing extended operation between cleanings when conditions permit
Solution Approach 2:
The system changes operational parameters (pressure, flow rate, cleaning timing) based on real-time monitoring data. By tracking differential pressure trends and energy consumption patterns, the system optimizes cleaning parameters to balance filtration quality with productivity and energy efficiency
2Reliability
If cleaning and backwashing procedures are implemented regularly, then the reliability of the filter system is improved, but energy consumption increases
Solution Approach 1:
The system continuously monitors differential pressure, flow rate, and energy consumption, using this feedback to determine optimal cleaning timing. The control unit analyzes real-time data to predict when cleaning will be most efficient, avoiding both premature and delayed cleaning operations
Solution Approach 2:
The system performs preliminary monitoring and analysis of system parameters to predict the optimal cleaning moment before actual cleaning is needed. By tracking trends in differential pressure and energy consumption, the system prepares for cleaning at the most efficient time, minimizing energy waste
3Productivity
If the filtration cycle is extended to increase productivity, then energy consumption per unit time is reduced, but the filter element becomes more contaminated and requires more intensive cleaning
Solution Approach 1:
The system uses its own operational data (differential pressure, flow rate, energy consumption) to automatically determine when cleaning is needed. The control unit continuously evaluates system state and triggers cleaning procedures based on actual contamination levels rather than fixed schedules, allowing extended filtration cycles when the system can maintain quality standards
Data Source
AI summary
A control method is provided for a filter system, which includes at least one filter element (2). The method includes continuously recording a total energy consumption (EG) during a filtration cycle (22) of the filter system. The total energy consumption (EG) includes at least of the energy consumption (EB) for a physical cleaning (24) and the energy consumption (EP) for the subsequent production cycle (23) up to a predefined, in particular current point in time. The method further includes computing a relative energy consumption (Erel) by way of division of the recorded total energy consumption (EG) by a net permeate volume (QN) which has been produced during the filtration cycle (22) up to the predefined point in time and starting a physical cleaning (24) in dependence on the relative energy consumption or of a characteristic value derived from this.