Gas Purification Using High-Pressure Droplet Clouds
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Solution Overview
Problem
Existing gas purification systems, such as scrubbers and filters, are ineffective in removing particles smaller than a few microns, particularly mist containing hydrochloric acid and sulfuric acid aerosols, leading to temporary efficiency drops and non-compliance with emission standards due to the buildup of filter media.
Innovation Solution
A system creating a cloud of droplets with a large surface area using a high-pressure pump and sprinklers, increasing droplet concentration and reducing diameter, achieving a specific surface area of approximately 100 cm² per cm³ of gas, allowing for efficient removal of particles smaller than one micron without the need for filter media replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If filters with filter media are used to remove particles, then particle removal efficiency is improved, but filter media buildup increases resistance to gas flow requiring periodic maintenance
Solution Approach 1:
The patent uses a hydraulic spray system where liquid is pumped under pressure through nozzles to create a mist cloud within the gas stream. This hydraulic approach replaces the mechanical filter media with a fluid-based separation mechanism, allowing continuous operation without flow resistance buildup.
Solution Approach 2:
The patent changes the physical state and distribution parameters of the washing liquid by controlling nozzle pressure and spray patterns to optimize droplet size and cloud density, achieving effective particle removal while maintaining gas flow throughput.
2Reliability
If scrubbers with liquid spray are used to purify gas, then particle removal is achieved, but droplet size must be optimized for efficiency
Solution Approach 1:
The patent segments the liquid spray into numerous fine droplets through multiple nozzles positioned throughout the gas stream path. This segmentation increases the total surface area of liquid-gas contact, improving particle removal efficiency without requiring overly complex single-nozzle designs.
Solution Approach 2:
The patent transitions from traditional two-dimensional filter surfaces to a three-dimensional mist cloud that fills the gas stream volume. This volumetric approach provides numerous contact points for particle removal throughout the entire gas flow path.
3Reliability
If high pressure is applied to create fine droplets, then droplet surface area increases improving purification, but energy consumption increases
Solution Approach 1:
The patent applies high pressure only at the nozzle outlets where droplet formation occurs, rather than maintaining high pressure throughout the entire system. This localized pressure application achieves fine droplet formation with minimized overall energy consumption.
Solution Approach 2:
The patent uses dynamic spray patterns where nozzle pressure and droplet formation are continuously optimized based on gas flow conditions, allowing the system to maintain high purification efficiency while adapting energy consumption to actual operational needs.
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 provides continuous, efficient particle separation down to sub-micron sizes, reducing maintenance and investment costs, and maintaining high purification efficiency without temporary interruptions, suitable for various industrial and domestic applications.
Implementation Method 1
A high pressure pump (3) is connected to the nozzles (2). The washing liquid pressure is gradually increased. The number of droplets increases at the same time, on the one hand because of the increasing flow rate, on the other hand because of the reduction in the average size of the droplets under the influence of the pressure with which the liquid is forced to through the nozzle orifice.
Implementation Method 2
The specific surface area of the washing liquid represents a key value in the system. It determines the residence time necessary in the scrubber to carry out the purification
Data Source
Figure 1~2
AI summary
The apparatus has a cylindrical glass column (1) including an inlet (6) and an outlet (7) for a gas stream, and a hollow cone type nozzles (2) with orifices whose diameter ranges from 0.5 to 20 millimeters, where each nozzle is connected to a high pressure pump (3). The pump supplies washing liquid e.g. tap water, to the nozzle at a pressure ranges between 50 and 2000 bars to create a large surface area of washing liquid droplets such that products to be eliminated such as solid and liquid particles and micro-organism e.g. bacteria, are captured by the droplets and transferred to the liquid. The washing liquid is tap water combined with chemical products such as alkalis, acids, oxidizing or reducing products and organic or inorganic liquid. An independent claim is also included for a method of purifying gas stream.