Membrane Valve Filter Cleaning Reduces Energy Loss
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Solution Overview
Problem
Existing filter cleaning systems face high energy consumption due to high pressure generation and throttling losses in valves and nozzles, which are inefficient and costly.
Innovation Solution
A system utilizing a membrane valve that operates in the subcritical range to control the flow of cleaning gas, reducing throttling losses and energy expenditure by maintaining a lower pressure in the pressure vessel, with a controller adjusting the compressor power based on filter contamination levels and a 3-2-way valve for rapid valve operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high pressure is generated and throttling is used in valves and nozzles for filter cleaning, then effective cleaning is achieved, but energy consumption increases significantly
Solution Approach 1:
The invention changes the pressure parameter from high pressure (6 bar) to low pressure (2-3.5 bar) operation. The membrane valve maintains subcritical flow conditions by keeping the pressure ratio below the critical value, thereby reducing throttling losses and energy consumption while still achieving effective filter cleaning through optimized flow control
Solution Approach 2:
The membrane valve provides dynamic control of the cleaning gas flow by adjusting the valve opening degree to maintain subcritical flow conditions. The valve responds dynamically to pressure changes and adjusts the flow cross-section to prevent throttling losses, optimizing the balance between cleaning effectiveness and energy efficiency
2Stress or pressure
If the valve opening is reduced to control pressure flow, then pressure control is improved, but throttling losses increase due to small flow cross-sections
Solution Approach 1:
The invention changes the flow regime parameter from supercritical to subcritical by maintaining the pressure ratio below the critical value. This allows the valve to control pressure without creating excessive throttling losses, as the flow remains subcritical even when the valve opening is adjusted
Solution Approach 2:
The membrane valve acts as an intermediary between the pressure vessel and the cleaning pipe, mediating the pressure control function. It maintains subcritical flow conditions by adjusting the flow cross-section dynamically, thereby controlling pressure while minimizing throttling losses through optimized valve design and operation
3Stress or pressure
If the compressor operates at high pressure continuously, then sufficient cleaning pressure is available, but energy expenditure increases
Solution Approach 1:
The compressor operates periodically rather than continuously, filling the pressure vessel to the required pressure (2-3.5 bar) and then allowing the membrane valve to control the flow during cleaning cycles. This periodic operation reduces energy expenditure by avoiding continuous high-pressure compression while ensuring sufficient pressure availability when needed
Solution Approach 2:
The invention changes the operating pressure parameter from high pressure (6 bar) to low pressure (2-3.5 bar), significantly reducing the energy expenditure of the compressor. The membrane valve compensates for the lower pressure by maintaining subcritical flow conditions and optimizing the flow control to achieve effective cleaning at reduced pressure
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 significant reduction in energy consumption by maintaining lower pressures and optimizing the flow of cleaning gas, allowing for efficient and responsive filter cleaning with minimal energy loss.
Implementation Method 1
throttling losses due to flow cross-sections that are too small or pressure differences that are too great can be avoided. The membrane valve therefore works mainly in the sub-critical range and the flow cross-sections are dimensioned in such a way that only low throttling losses occur
Implementation Method 2
a compressor, via which a cleaning gas can be compressed to a cleaning pressure and can be fed into a pressure vessel
Implementation Method 3
the propulsion jet emerging from a nozzle at almost the speed of sound entrains secondary air from its surroundings
Data Source
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AI summary
The installation has a compressor (14) through which a cleaning gas with compressible pressure can be passed to pressure vessel (13). The pressure vessel is connected to cleaning pipe (9), such that the cleaning gas is injected into a filter (5) through nozzle orifices (10), and the pressure vessel connected to cleaning pipe is closed with respect to cleaning product. A diaphragm valve (20) is provided in compressor operating in sub-critical range. An independent claim is included for a method of operating a system for cleaning of filters.