Liquid Ring Vacuum Pump Continuous Filtration
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Solution Overview
Problem
Existing liquid ring vacuum pumps for degassing plastic melts face interruptions and inefficiencies due to clogged filters, requiring frequent shutdowns for filter changes and the use of inadequate pre-condensation systems, leading to operational and environmental challenges.
Innovation Solution
A closed compression liquid circuit with a continuously operating ultra-fine filter that automatically switches to a new or cleaned filter surface, eliminating the need for multiple filters and pre-condensation systems, and incorporating a liquid separator for efficient gas separation and a cooling device for heat management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a replaceable filter insert (candle filter) is used in the compression liquid circuit, then coarse impurities are filtered from the compression liquid, but the circuit must be interrupted to change the clogged filter
Solution Approach 1:
The filter system is divided into multiple filter elements (first filter element and second filter element) that can be operated in parallel. When one filter becomes clogged, the system can switch to the other filter, allowing continuous operation without interrupting the compression liquid circuit. This segmentation enables maintenance of one filter while the other remains in service.
Solution Approach 2:
The system allows the compression liquid to be diverted to a storage tank when filters need maintenance. The filters can then be cleaned or replaced while the liquid is stored, and the circuit can be quickly reconnected without prolonged interruption. This recovers operational time by separating the maintenance process from the active filtration process.
2Reliability
If pre-condensation systems are used to filter fine impurities, then toxic components are removed from gases, but large cooling capacity is required and the system works unsatisfactorily
Solution Approach 1:
An ultra-fine filter is introduced as an intermediary component between the compression liquid pump and the filter system. This ultra-fine filter specifically targets and removes fine impurities and toxic components from the compression liquid without requiring extensive cooling capacity. The ultra-fine filter acts as a mediator that handles the fine filtration task more efficiently than pre-condensation systems.
Solution Approach 2:
The patent replaces the thermal-based pre-condensation system with a mechanical filtration approach using an ultra-fine filter. Instead of relying on cooling and condensation to remove fine impurities, the system uses physical filtration through specially designed filter media that can capture fine particles and toxic substances directly from the compression liquid at operating temperatures.
3Reliability
If two filter units are provided to separate coarse and fine particles, then both types of impurities are filtered, but the compression liquid circuit must be interrupted to clean or change filter inserts
Solution Approach 1:
The patent combines coarse filtration and fine filtration into a single integrated filter unit that contains both a filter element for coarse particles and an ultra-fine filter element for fine impurities. This merged design provides comprehensive filtration coverage while simplifying the system architecture and reducing the number of separate filter units that would need to be maintained.
Solution Approach 2:
The filter unit is designed with multi-functionality, handling both coarse and fine particle removal in a single component assembly. The ultra-fine filter element works in conjunction with the regular filter element to provide universal filtration coverage for all types of impurities in the compression liquid, eliminating the need for separate specialized filter units.
4Productivity
If polyester melts are degassed using liquid ring vacuum pump, then gases are removed from melts, but large amounts of water are absorbed into compression liquid requiring discharge
Solution Approach 1:
The ultra-fine filter is designed to capture water particles and other contaminants from the compression liquid through enhanced filtration parameters. By using specially designed filter media with appropriate pore sizes and surface properties, the system can remove absorbed water from the compression liquid, allowing the liquid to be reused without discharge and reducing substance loss.
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
Enables uninterrupted operation, reduces environmental impact, and optimizes fluid cleaning by filtering both coarse and fine impurities, including dissolved pollutants, while minimizing energy consumption and waste disposal costs.
Implementation Method 1
the compression liquid circuit has only one fine and/or ultra-fine filter (5)
Implementation Method 2
incorporating a liquid separator for efficient gas separation
Implementation Method 3
incorporating a liquid separator for efficient gas separation and a cooling device for heat management
Data Source
Figure 1
AI summary
A liquid ring vacuum pump (1) for degassing plastic melts, having a pump inlet (2) where gases are taken in, and a pump outlet (3) via which gases are blown out, and having a cycle (4) for the compression liquid, wherein a replaceable filter insert is provided for filtering coarse contaminants out of the compression liquid, and wherein a precondensation system is optionally provided upstream of the pump inlet for filtering fine contaminants out of the compression liquid, is to be further developed such that the pump is able to proceed continuous operation even during a filter change and that the compression liquid cycle does not have to be interrupted, wherein permanent stable process conditions are to be established, and wherein the management of the filter system is to be designed in a simple and energy-efficient and environmentally sound manner. The invention thus proposes for the compression liquid cycle (4) to be constantly closed and to have only one continuously operating fine and/or micro filter (5), replacing both the replaceable filter insert and the precondensation system.