Hybrid Filter Element with Depth Media for Full Stream Filtration
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Solution Overview
Problem
Current filtration systems for gas and liquid streams require multiple filter housings and are inefficient in handling full process streams due to limitations with granular activated carbon, which leads to reduced performance and increased maintenance costs.
Innovation Solution
A filter element comprising a carbon block filter media surrounded by a protective porous depth filtration media, such as PEACH®, which enhances filtration efficiency by removing solids and liquids effectively, eliminating the need for multiple housings and allowing full stream filtration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If granular activated carbon (GAC) is used in a cartridge canister or fixed bed, then non-solid contaminants are effectively removed, but the flow rate is limited and the filter must be very large to accommodate total solvent flow
Solution Approach 1:
The filter element is segmented into distinct functional zones: an outer protective depth filter media layer that handles solids removal and a central carbon block filter media that handles non-solid contaminant adsorption. This segmentation allows each zone to optimize its function while working together, enabling higher flow rates through the carbon block compared to traditional GAC systems.
Solution Approach 2:
The invention uses a composite filter element combining depth filter media (such as PEACH®) with carbon block filter media. This composite structure integrates the advantages of both filtration types - the depth filter provides mechanical filtration and protects the carbon, while the carbon block provides adsorption capacity, achieving both high flow rate and effective contaminant removal.
2Volume of stationary object
If a slip stream is used to reduce carbon vessel size, then the carbon vessel size is reduced, but the solvent is treated less effectively
Solution Approach 1:
The hybrid filter element performs multiple functions within a single component: it provides depth filtration of solids, protects the carbon block from clogging, and enables effective adsorption of non-solid contaminants. This multi-functionality allows the system to treat full solvent flow effectively without requiring a slip stream, as the integrated design handles both filtration and adsorption simultaneously.
3Reliability
If GAC is used in the solvent stream, then non-solid contaminants are removed, but carbon fines are released into the process stream requiring another solids filter downstream
Solution Approach 1:
The outer protective depth filter media performs preliminary filtration of solids from the solvent stream before the solvent contacts the carbon block filter media. This preliminary action prevents solids from reaching and clogging the carbon block, eliminating the need for a separate downstream solids filter and simplifying the overall system while maintaining effective non-solid contaminant removal.
4Reliability
If multiple filter housings are used to remove all necessary contaminants, then filtration completeness is achieved, but system complexity and maintenance costs increase
Solution Approach 1:
The invention merges the functions of multiple separate filter housings into a single integrated filter element. The outer protective depth filter media and central carbon block filter media are combined in one element, allowing the system to achieve filtration completeness that previously required multiple housings while reducing device complexity and maintenance requirements.
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 hybrid filtration system significantly increases filtration capacity, reduces maintenance frequency, and lowers operational costs by using a single housing, while maintaining high adsorption efficiency and preventing carbon fines from entering the process stream.
Implementation Method 1
Activated carbon has proven very effective in removing these non-solid contaminants
Implementation Method 2
The protective depth filter media can comprise various depth filtration media known in the relevant industries
Data Source
Figure 1~3
AI summary
The present invention relates to an apparatus for filtering a gas or liquid stream of impurities and to filter elements used in such an apparatus. The apparatus includes a closed vessel having a longitudinally extending length, an initially open interior, an input port at one extent and an output port at an opposite extent thereof. A partition located within the vessel interior divides the vessel interior into a first stage and a second stage. At least one opening is provided in the partition. A filter element is disposed within the vessel to extend from within the first stage. The filter element is made up of a carbon block filter media surrounded by a protective porous depth filter media.