Flotation Tank and Filter System for Solid Separation
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Solution Overview
Problem
Existing filter systems for separating process liquids from solids, such as lubricants in machining processes, face issues with achieving the desired level of purity and efficiency due to limitations in filter cake build-up and high consumption of filter materials, leading to reduced filtration capacity and increased maintenance.
Innovation Solution
A treatment device incorporating a flotation tank with air bubbles to separate solids by flotation and sedimentation, reducing the load on the separating filter by concentrating solids in specific areas, allowing for a smaller filter system design with improved filter performance and reduced maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the filter area is increased to allow slow filter cake build-up, then filtration performance is improved, but the device size becomes excessively large
Solution Approach 1:
The filter belt is divided into multiple zones with different functions: a first zone for initial filtration and filter cake build-up, and a second zone for additional filtration capacity. This segmentation allows the system to achieve the equivalent of a larger filter area without proportionally increasing the overall device size, as the zones can be arranged compactly in sequence along the belt path.
Solution Approach 2:
The invention utilizes the temporal dimension by implementing continuous filtration with a moving belt that cycles through different zones. Instead of expanding filter area in a single spatial dimension, the system achieves increased effective filtration capacity by extending the filtration path through multiple zones along the belt's continuous motion, effectively using the time dimension to compensate for spatial constraints.
2Productivity
If the filter belt is moved quickly to maintain fluid level, then overload is prevented, but filter cake thickness is reduced and filtration performance deteriorates
Solution Approach 1:
The filter belt is divided into multiple zones with different functions: a first zone for initial filtration and filter cake build-up, and a second zone for additional filtration capacity. This segmentation allows the system to achieve the equivalent of a larger filter area without proportionally increasing the overall device size, as the zones can be arranged compactly in sequence along the belt path.
Solution Approach 2:
The invention implements continuous filtration with an endlessly moving filter belt that operates without interruption. The continuous motion of the belt through multiple zones ensures uninterrupted filtration while maintaining optimal filter cake thickness, as the system can process fluid continuously without the need for rapid belt movement that would thin the filter cake.
3Productivity
If a large filter area is used, then filtration capacity is improved, but the device complexity and size increase
Solution Approach 1:
The filter belt is divided into multiple zones with different functions: a first zone for initial filtration and filter cake build-up, and a second zone for additional filtration capacity. This segmentation allows the system to achieve the equivalent of a larger filter area without proportionally increasing the overall device size, as the zones can be arranged compactly in sequence along the belt path.
Solution Approach 2:
The single filter belt serves multiple functions by implementing different zones along its length: the first zone performs initial filtration and filter cake formation, while the second zone provides additional filtration capacity. This multi-functionality allows one component to replace what would traditionally require multiple separate filtration units, reducing overall system complexity.
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 enhances filter performance by allowing a thicker filter cake to build up, reducing the risk of blockages and backwater, while minimizing filter consumption and energy usage, and enabling the production of high-purity process liquids for reuse in machining processes.
Implementation Method 1
Air is supplied to the container from the outside. The supplied air forms air bubbles that adhere to the solids, causing them to rise to the surface and accumulate there.
Implementation Method 2
solid particles collect in the flotation tank by flotation in an upper region and by sedimentation in a lower bottom region of the flotation tank
Data Source
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AI summary
To improve the separation efficiency of a processing plant with a filter system and separator filter for filtering process liquid loaded with solids, the processing plant (1) is provided with a flotation tank (10) and a feed line (3) for supplying impure process liquid loaded with solids, wherein the feed line (3) is connected to the flotation tank (10) and solid particles collect in the flotation tank (10) by flotation in an upper area (14) and by sedimentation in a lower bottom area (15) of the flotation tank (10), that the processing plant (1) includes a filter system (20) with a separator filter (21) for filtering the solids from the process liquid, and that lines (11, 12) are provided in the processing plant (1).to supply the separator filter (21) from the upper area (14) of the flotation tank (10) and from the bottom area (15) of the flotation tank (10) with process fluid loaded with solids, and that a process fluid container (30) is provided in the treatment unit (1) for receiving process fluid filtered in the filter system (20).