Gas-Infused Additive Injection for Downstream Pump Protection

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Solution Overview

Problem

Existing gas-floatation systems in paint spray booths suffer from insufficient dissolved air, leading to inefficient particle separation and potential damage to system components due to cavitation corrosion from upstream gas addition.

Innovation Solution

A gas-infusion apparatus is used to infuse additives with gas downstream of system pumps, creating a gas-infused additive that is injected into the suspension via a single point, enhancing dissolved gas levels and protecting pumps from corrosion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If gas is added upstream of pumps to increase dissolved gas levels, then floatation efficiency is improved, but pump impeller damage occurs due to cavitation corrosion

Engineering Contradiction:

Improvefloatation efficiencyVSAvoidcavitation corrosion

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

Instead of adding gas upstream of the pump (conventional approach), the patent adds gas downstream of the pump. This reverses the sequence of operations to avoid exposing the pump impeller to gas bubbles that cause cavitation, while still achieving the desired dissolved gas concentration in the water for effective floatation.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The gas addition process is separated into distinct stages: first, gas is added to the additive solution in a separate chamber; then, the gas-infused additive is injected into the water stream downstream of the pump. This segmentation protects the pump from cavitation while ensuring proper gas dissolution.

Inventive Principle:

Principle #1Segmentation

2Device complexity

If a single in-line injection point is used for additive addition, then system simplicity is maintained, but options for adding dissolved gas are limited

Engineering Contradiction:

Improveinjection system complexityVSAvoidgas addition capability

Core Design Contradiction:

Device complexityVSAdaptability or versatility

Solution Approach 1:

The patent combines the gas addition function with the existing additive injection system. By infusing gas into the additive solution before injection, the system uses the single additive injection point to deliver both additive and dissolved gas, thereby maintaining system simplicity while enabling gas addition capability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The additive solution serves as an intermediary carrier for the gas. Instead of directly injecting gas into the water stream (which would require separate gas injection infrastructure), the gas is first dissolved in the additive solution, which then transports and releases the gas at the injection point.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If insufficient dissolved air is present in the consolidator, then system operation is simple, but particle floatation efficiency is reduced

Engineering Contradiction:

Improveparticle separation efficiencyVSAvoiddissolved gas concentration

Core Design Contradiction:

ProductivityVSQuantity of substance

Solution Approach 1:

The patent changes the physical-chemical parameters of the additive solution by infusing it with gas under pressure, increasing the dissolved gas concentration. This parameter change ensures that when the additive is injected into the consolidator, sufficient dissolved gas is present to enable effective particle floatation and separation.

Inventive Principle:

Principle #35Parameter changes

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 improves separation efficiency while safeguarding system components, allowing for effective particle separation without complex modifications to existing systems.

Implementation Method 1

a gas-infusion apparatus configured to infuse a gas into an additive to produce a gas-infused additive

Methodology Applied

Scientific EffectGas dissolution: Absorption (physical)

Implementation Method 2

gas-floatation systems and processes that utilize a gas-infused additive for separating solids or oils from liquids within a suspension

Methodology Applied

Scientific EffectGas-floatation: Bubble

Data Source

PatentUS12351481B2Systems and processes for injecting gas-infused additives

Publication Date: 2025.07.08 ECOLAB USA INC

AI summary

The present disclosure relates generally to systems, apparatuses, and processes for preparing a gas-infused additive that is useful within gas-floatation systems configured to separate solids and/or oils from a liquid within a suspension. The gas-infused additive can be injected into systems having a floatation consolidator to provide additional dissolved gas to the system. Advantageously, the processes and apparatuses disclosed herein are compatible with systems and processes having a single injection point for the addition of an additive or gas, without requiring substantial modification or reconfiguration of the system. The inventions described herein additionally teach that the gas-infused additive can be prepared and injected downstream of any pump present within the system, thereby protecting the pump from the damaging effects of cavitation corrosion and similar phenomena.