Grease Separator Skimming Control Using Sensor Feedback
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Solution Overview
Problem
Existing grease removal systems face inefficiencies due to reliance on fixed timers, leading to unnecessary energy consumption and potential odor issues from incomplete grease removal, particularly in facilities with irregular schedules or varying grease production.
Innovation Solution
A separator assembly equipped with thermocouples and a communications module that senses the presence of grease and solid waste, using cellular or WiFi signals to remotely control the skimming process, ensuring efficient grease removal and minimizing energy waste by adjusting operations based on actual grease levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a fixed timer controls the skimming operation, then the separator operates at regular intervals, but energy is wasted when no grease needs removal and skimming may be incomplete when grease accumulation varies
Solution Approach 1:
The patent employs sensors (optical, thermal, or capacitive) that continuously monitor grease layer thickness and provide feedback signals to the control system. The skimming operation is activated only when the sensor detects that grease accumulation exceeds a predetermined threshold, creating a closed-loop feedback control system that adapts to actual grease production rates rather than operating on fixed schedules
Solution Approach 2:
The system transitions from static, predetermined timer-based operation to dynamic, condition-based operation. The control system continuously adjusts skimming activation based on real-time grease layer measurements, allowing the operational parameters to adapt dynamically to varying grease production conditions, seasonal changes, and facility usage patterns
2Reliability
If the separator removes all grease from the effluent, then F.O.G. removal is maximized, but exposed water surface allows food solids to decompose and generate foul odors
Solution Approach 1:
The patent applies different quality requirements to different locations in the effluent stream. Rather than uniformly removing all grease throughout the container, the system maintains a controlled thin grease mat (approximately 0.5-2 mm thickness) on the water surface while removing thicker grease accumulations. This localized differentiation allows the grease mat to function as an odor barrier while still achieving effective F.O.G. removal from the bulk effluent
Solution Approach 2:
The system deliberately employs partial action by intentionally leaving a thin residue layer of grease on the water surface after skimming. This controlled incomplete removal serves the dual purpose of maintaining odor containment while still achieving sufficient F.O.G. separation, recognizing that complete removal is not always desirable
3Loss of energy
If the separator operates on irregular schedules to match facility needs, then energy waste is reduced, but traditional timer-based systems cannot adapt to schedule variations
Solution Approach 1:
The sensor-based monitoring system provides continuous feedback on grease layer development, enabling the control system to automatically adjust skimming schedules based on actual grease accumulation rates. This feedback mechanism allows the system to adapt to irregular facility operating schedules, seasonal variations, and changes in grease production without requiring manual reconfiguration of timer settings
Solution Approach 2:
The system performs self-adjustment by using its own sensor measurements to determine when skimming is needed, eliminating the need for external scheduling inputs or manual intervention. The control system autonomously adapts to varying operational conditions by responding to real-time grease layer measurements, making the system self-regulating and inherently flexible to schedule variations
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 optimizes grease removal by only operating when necessary, reducing energy consumption and maintaining a thin grease layer to contain odors, thereby improving the efficiency and effectiveness of grease removal processes.
Implementation Method 1
A separator assembly equipped with thermocouples and a communications module that senses the presence of grease and solid waste
Data Source
AI summary
A separator assembly for separating fat, oil, and grease from effluent includes a container for receiving and holding effluent water containing oil, grease and solid waste to be removed from the effluent water and a communications module having a processor, memory and transmitter at the facility site to communicate over cellular or WiFi signals with a remote station. The separator may include a skimmer to skim F.O.G. from the effluent water held in the container or be of a grease trap mode collecting F.O.G. for subsequent removal.