Chemical-Free Foam Control via Serial Fluid Spray Displacement
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Solution Overview
Problem
Current methods for controlling foam in industrial processes, such as in paper and pulp or food processing, rely heavily on chemical additives, which are costly and pose safety concerns, especially in food processing where chemical residues must be minimized. Existing non-chemical solutions like water sprays, optical systems, and centrifugal separators are either ineffective or too expensive for broad industrial implementation.
Innovation Solution
A chemical-free foam control system using a set of fluid-spray sources arranged to displace foam along a predetermined path, where each spray source is oriented to have a vertical component for subsiding and a horizontal component for moving the foam, reducing foam volume through mechanical means without chemical additives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If chemical de-foaming agents are added to control foam, then foam control effectiveness is improved, but safety and cost concerns worsen
Solution Approach 1:
The patent replaces chemical de-foaming agents with a mechanical foam control system consisting of spray nozzles that physically disrupt and collapse foam structures. This substitution eliminates harmful chemical substances from the process while maintaining effective foam control through mechanical means, directly resolving the contradiction between foam control effectiveness and safety concerns.
Solution Approach 2:
The system utilizes hydraulic spray nozzles to deliver water or process fluid onto foam surfaces, using fluid pressure and flow dynamics to mechanically collapse foam bubbles. This pneumatic-hydraulic approach provides effective foam control without introducing chemical additives, addressing both the effectiveness and safety requirements.
2Quantity of substance
If water spray systems are used to knock down foam, then localized foam volume is reduced, but foam is pushed into periphery where it continues to grow
Solution Approach 1:
The system divides the foam control function into multiple spray nozzles positioned at different locations and angles. Each nozzle targets specific foam regions with optimized spray patterns, preventing foam displacement to periphery while maintaining overall foam volume reduction. This segmented approach solves the problem of localized reduction causing peripheral foam accumulation.
Solution Approach 2:
Different spray nozzles are configured with varying spray angles, pressures, and fluid types to match the specific foam conditions in different process areas. This localized optimization ensures effective foam control throughout the entire process line without pushing foam to periphery regions, addressing both localized and overall foam management.
3Reliability
If optical laser systems are used to destroy foam, then foam control is achieved, but system cost becomes prohibitive
Solution Approach 1:
The system replaces expensive optical laser equipment with simple, inexpensive spray nozzles and fluid delivery components. These mechanical components are far more cost-effective to manufacture, install, and maintain while providing reliable foam control functionality, directly resolving the cost prohibition issue.
Solution Approach 2:
The patent employs conventional hydraulic spray systems instead of expensive optical systems. By utilizing readily available water or process fluid under pressure delivered through simple nozzles, the system achieves foam control at a fraction of the cost of laser-based solutions, making the technology economically viable for industrial deployment.
4Quantity of substance
If centrifugal gas/liquid separators are used, then foam separation is achieved, but system complexity and capital cost increase
Solution Approach 1:
The system extracts only the essential foam control function from complex centrifugal separation systems. By using simple spray nozzles that directly disrupt foam at its source, the patent eliminates the need for complex centrifugal mechanisms, vacuum systems, and multi-stage separation equipment, achieving foam control with minimal system complexity.
Solution Approach 2:
Instead of using complex centrifugal forces to separate foam from liquid as in conventional separators, the system inverts the approach by using direct spray impact to mechanically collapse foam in place. This inverted methodology achieves the same separation effect with dramatically simplified equipment, resolving the complexity issue.
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 effectively reduces foam volume by condensing and displacing foam along a defined path, minimizing the need for chemical additives and addressing the cost and safety concerns of existing methods, while being suitable for various industrial processes.
Implementation Method 1
Each of the spray sources is configured such that foam-subsiding fluid ejected therefrom is sprayed in a spray pattern
Implementation Method 2
a foam control system for subsiding, and moving in at least one predetermined direction, foam resulting from an industrial process
Implementation Method 3
Each spray source is oriented such that its associated spray vector has (i) a non-zero vertical component and (ii) a non-zero horizontal component in the foam-displacement direction
Data Source
AI summary
A method of subsiding foam resulting from an industrial process and moving it in a predetermined direction on the surface of an industrial-process liquid includes establishing a foam-displacement direction and a foam-displacement path. At least two fluid-spray sources from which a foam-subsiding fluid can be ejected are arranged serially above the industrial-process liquid and foam accumulating thereon. The fluid-spray sources are oriented and caused to eject foam-subsiding fluid such that foam impacted by foam-subsiding fluid ejected from the first fluid-spray source is wetted, partially subsided and displaced in the foam-displacement direction toward the spray being ejected from the second fluid-spray source by which the foam is further wetted, subsided and displaced in the foam displacement direction. In implementations including three or more fluid-spray sources, foam is moved sequentially through the sprays of the fluid-spray sources such that it is increasingly subsided as it moves through the foam-displacement path.