Liquid Concentrator with Direct Gas Injection and Cyclonic Separation
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Solution Overview
Problem
Conventional wastewater concentration methods, particularly those using indirect and direct heat transfer systems, face limitations due to fouling, high maintenance costs, and the need for expensive materials, especially when dealing with wide varieties of wastewater streams and achieving low residual-to-feed volume ratios.
Innovation Solution
A liquid concentrator system that combines an evaporator assembly with a cyclonic separator and a settling chamber, utilizing a compact design with direct gas-liquid contact to achieve high turbulence and efficient heat transfer, reducing the reliance on solid heat exchangers and minimizing the use of high-alloy metals, and leveraging waste heat sources for energy efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If indirect heat transfer systems with heat exchangers are used, then heat transfer can be achieved, but fouling and deposit buildup occur on heat exchanger surfaces requiring frequent cleaning
Solution Approach 1:
The patent removes the solid heat exchanger surfaces from the system by using a direct injection approach where heating gas is introduced directly into the liquid stream. This extraction of the fouling-prone heat exchanger component eliminates deposit buildup while maintaining heat transfer functionality through the gas-liquid contact zone.
Solution Approach 2:
The patent employs pneumatic principles by using compressed or heated gas directly injected into the liquid stream to transfer thermal energy. The gas phase serves as both the heating medium and the transfer mechanism, eliminating the need for solid heat exchanger surfaces that are susceptible to fouling.
2Productivity
If direct heat transfer devices with submerged combustion systems are used, then high concentration levels can be achieved, but expensive high-alloy metals are required and maintenance costs increase
Solution Approach 1:
The patent employs standard, readily available materials for the injection system components rather than requiring expensive high-alloy metals. The simplified direct injection design uses conventional materials that are easier to manufacture and replace, reducing both initial costs and maintenance expenses while maintaining effective concentration capability.
Solution Approach 2:
The patent extracts the complex submerged combustion system and its associated high-alloy metal requirements by using a simpler direct gas injection approach. This removal of the combustion chamber and high-temperature direct contact elements eliminates the need for expensive materials while achieving the same concentration function.
3Productivity
If conventional heat transfer systems are used, then wastewater concentration can be performed, but the systems are bulky and require large amounts of high-alloy metal
Solution Approach 1:
The patent merges the heating function and the mixing function into a single direct injection process step. The heated gas is injected directly into the wastewater stream, simultaneously transferring thermal energy and creating turbulence, thereby eliminating the need for separate heat exchangers and large metal structures.
Solution Approach 2:
The patent uses pneumatic injection of heated gas to achieve both heating and mixing functions, replacing bulky mechanical heat exchanger systems. The gas phase provides a lightweight heating medium that creates turbulence and enhances heat transfer without requiring heavy metal construction.
4Temperature
If indirect heat transfer systems are used, then heat can be transferred to the process fluid, but the systems become complicated requiring separate processes to transfer heat energy to the heating medium
Solution Approach 1:
The patent combines the heat source and the heat transfer medium into a single integrated system where heated gas is directly injected into the process fluid. This eliminates the need for separate heat exchangers, steam boilers, and hot oil heaters, thereby reducing overall system complexity while maintaining heat transfer capability.
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 achieves high levels of wastewater concentration with reduced maintenance and operational costs, is more compact and lightweight, and can handle wastewater with suspended solids without frequent cleaning, while being adaptable to various waste heat sources, enhancing energy efficiency and portability.
Implementation Method 1
an evaporator assembly arranged to mix wastewater with gas and evaporate liquids from the wastewater
Implementation Method 2
utilizing a compact design with direct gas-liquid contact to achieve high turbulence and efficient heat transfer
Implementation Method 3
a cyclonic separator arranged to receive the mixed wastewater and gas from the evaporator assembly and to separate the gas and the evaporated liquids from solids and the wastewater
Implementation Method 4
separate the gas and the evaporated liquids from solids and the wastewater
Implementation Method 5
a settling chamber arranged to receive the solids and wastewater from the sump
Data Source
AI summary
A liquid concentrator having an evaporator assembly and a cyclonic separator includes features designed to improve the performance of the liquid concentrator. A settling chamber is separated from a sump of the cyclonic separator. A liquid inlet opening into a mixing chamber of the evaporator injects wastewater at low pressures. Features to aid in the cleaning of the liquid concentrator include easy open doors and clean water injection ports for cleaning interior portions of the liquid concentrator.