Grease Separator Remote Skimming Control Using Thermocouple Feedback
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Solution Overview
Problem
Existing grease removal systems lack precise control over skimming operations, leading to energy waste and odor issues due to irregular schedules and incomplete grease removal, and there is a need for improved control in grease removal assemblies.
Innovation Solution
A separator assembly with thermocouples and a communications module that uses cellular or WiFi signals to remotely monitor and control grease removal, determining the presence of grease through voltage changes and communicating with a remote station to optimize skimming operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a timer is used to control skimming operations at fixed intervals, then the separator operates automatically without manual intervention, but energy is wasted when no grease is present and odors are released when grease is completely removed
Solution Approach 1:
The patent implements a feedback control system using sensors (optical, capacitive, or resistive) that detect the presence and thickness of grease on the water surface. The sensor signals are fed back to the controller, which adjusts skimmer operation accordingly - activating the skimmer when grease is detected and deactivating it when the grease layer is insufficient, thereby eliminating energy waste from unnecessary operation.
Solution Approach 2:
The system performs self-monitoring and self-regulation of skimming operations. The sensors automatically detect grease conditions and the controller autonomously decides when to activate or deactivate the skimmer without requiring external intervention, enabling the system to serve itself in optimizing operational timing.
2Ease of operation
If a timer is used to control skimming operations at fixed intervals, then the separator operates on a simple schedule, but it runs even when there is no grease to be removed, causing energy waste
Solution Approach 1:
The feedback mechanism provides simple yet effective control by using sensor-derived signals to directly control skimmer operation. The controller activates the skimmer only when sensor readings indicate sufficient grease presence, and deactivates it when grease is absent or insufficient, optimizing skimming efficiency without complex control logic.
3Reliability
If all grease is removed from the effluent, then the F.O.G. removal objective is achieved, but exposed water allows food solids to decompose and release foul odors
Solution Approach 1:
The system applies partial action by intentionally leaving a thin layer of grease (approximately 0.25 to 2 inches thick) on the water surface instead of removing all grease. This controlled incomplete removal prevents odor release from exposed water while still achieving sufficient F.O.G. removal to meet regulatory objectives and prevent sewer clogging.
Solution Approach 2:
The sensor system provides feedback on grease layer thickness, enabling the controller to terminate skimming operations when the grease layer reaches the optimal thin residual thickness. This feedback control ensures that enough grease remains to cover odors while maintaining effective F.O.G. removal performance.
4Loss of energy
If the separator operates on irregular schedules to match facility needs, then energy waste is reduced, but precise control over skimming timing becomes difficult
Solution Approach 1:
The feedback control system automatically adjusts skimming timing based on real-time grease detection, eliminating the need for complex scheduling algorithms. The sensor-controller feedback loop inherently adapts to varying grease accumulation patterns, providing irregular but optimized operation schedules without increasing control system complexity.
Solution Approach 2:
The system self-regulates its operation schedule by autonomously responding to grease presence conditions. The controller independently decides when skimming is needed based on sensor input, enabling the system to adapt to irregular operational patterns without requiring external scheduling input or complex control logic.
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
Reduces energy waste and odor release by optimizing grease removal based on actual grease levels, ensuring efficient operation and timely maintenance, while allowing for centralized management and data analysis.
Implementation Method 1
a first thermocouple mounted at a first location within the container and a second thermocouple mounted at a second location within the container
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.