Fluid Synthesis System Segregating Viscous Components for Slurry Filtration
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Solution Overview
Problem
Conventional abrasive slurry manufacturing processes face inefficiencies due to the inability to effectively filter out viscous components, leading to frequent filter replacements and reduced productivity, as these components clog filters and inhibit filtration, resulting in suboptimal product quality and increased costs.
Innovation Solution
A system and method that includes a segregation step to separate viscous components from abrasive particles before filtration, utilizing differences in physicochemical properties to remove filtration-inhibiting agents, thereby optimizing the filtration process and extending filter life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional filtration is used to remove particles from abrasive slurry, then particle removal is achieved, but filter clogging occurs due to viscous components
Solution Approach 1:
The patent applies preliminary action by introducing a segregation step before filtration to remove viscous components that would otherwise clog the filter. This pre-treatment prepares the slurry by separating out the problematic viscous material, allowing the subsequent filtration step to operate efficiently without clogging, thus maintaining both particle removal effectiveness and filter reliability
Solution Approach 2:
The patent segments the filtration process into two distinct stages: first, a segregation step that separates viscous components from abrasive particles, and second, a filtration step that removes particles from the clarified slurry. This segmentation allows each stage to handle specific tasks optimally, preventing filter clogging while maintaining high particle removal rates
2Manufacturing precision
If filtration is performed on unsegregated slurry, then particle separation is achieved, but filter replacement frequency increases
Solution Approach 1:
The segregation step serves as a preliminary action that removes viscous components before filtration, preventing filter clogging and extending filter life. This reduces the frequency of filter replacements while maintaining high slurry quality, thereby improving overall productivity
Solution Approach 2:
The patent introduces an intermediary segregation process between the slurry preparation and filtration steps. This intermediary step acts as a mediator that removes the harmful viscous components, allowing the filtration system to operate continuously with fewer interruptions for filter replacement
3Productivity
If viscous components remain in slurry, then filtration process becomes inhibited, but removing them requires additional processing steps
Solution Approach 1:
The patent segments the overall processing into two functional portions: a segregation portion that removes viscous components and a filtration portion that removes particles. While this adds a step, each portion is relatively simple and can be implemented using standard equipment, balancing the added complexity against the significant improvement in filtration efficiency
Solution Approach 2:
The patent converts the harmful effect of viscous components (which inhibit filtration) into a beneficial separation process. By utilizing the physicochemical differences between viscous components and abrasive particles, the segregation step transforms a filtration obstacle into a means of improving overall process efficiency and product quality
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 segregation step enhances the efficiency of the filtration process, maintaining a 99.9% particle removal rate for particles above 500 nm, reducing filter replacements, and ensuring the quality of the final product while lowering manufacturing costs.
Implementation Method 1
in a segregating portion of the system, segregating viscous components contained in the first suspension from the first suspension to form a second suspension of the abrasive solid particles in the fluid medium
Data Source
AI summary
Fluid synthesis system and corresponding method for synthesis of slurry containing abrasive particles. The system and method are configured to substantially segregate the abrasive particles passing through the filter, used at the filtering step of the process, from the sticky components that clog such filter prior to the filtering step of the synthesis process to achieve a sustaining filtration of the slurry as a result of which the filter remains substantially unclogged for the whole predetermined duration of the filtering process.