Modular Phase Separation Device for Emulsion Handling
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Solution Overview
Problem
Existing phase separation devices are inefficient in separating finely dispersed oil phases from emulsions, such as machining oils and hydraulic oils, as they struggle to effectively separate foreign oil from these complex fluid mixtures.
Innovation Solution
A phase separation device with a modular housing structure combining coalescence and gravity separators in a single device housing, featuring a coalescence element with an inlet for emulsions flowing from inside to outside, and a dedicated outlet for the lighter phase, allowing for efficient separation and compact design with reduced heat losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a combination of coalescence and gravity separator is used in a single device housing, then separation efficiency is improved and device compactness is improved, but device complexity increases
Solution Approach 1:
The patent combines a coalescence separator and a gravity separator into a single device housing, integrating two separation mechanisms that work sequentially. The coalescence element merges fine droplets into larger ones, which then separate by gravity in the gravity separation chamber, achieving high efficiency in a compact unit.
Solution Approach 2:
The device is divided into distinct functional chambers: a coalescence separation chamber with a coalescence element, and a gravity separation chamber. This segmentation allows each component to perform its specific function optimally while being part of an integrated system.
2Loss of energy
If a compact design with smaller bath volumes is used, then heat losses are reduced and energy efficiency is improved, but separation capacity may be limited
Solution Approach 1:
The patent changes the physical parameters of the separation process by using coalescence to transform fine dispersed droplets into larger droplets, which then separate more efficiently by gravity. This parameter change allows for smaller separation volumes while maintaining high separation performance.
3Reliability
If dedicated outlets for each separated phase are provided, then complete separation of components is achieved, but device complexity increases
Solution Approach 1:
The patent extracts each separated phase through dedicated outlets: a first outlet for the separated component and a second outlet for the further separated component that floats on top. This extraction of each phase through separate pathways ensures complete separation while the modular outlet design keeps the device manageable.
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
This configuration enables high-efficiency separation of emulsions with finely dispersed oil phases, allowing complete segregation of components, reduced bath volumes, and lower energy consumption due to compact design and minimized heat loss.
Implementation Method 1
a coalescence element (42), which has an inlet (40) for the supply of an emulsion which flows through the interior of the coalescence element (42) to separate it by means of coalescence into at least two of its components
Implementation Method 2
a combination of a coalescence and a gravity separator is located in the first device housing (2)
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A phase separating device having a device housing (2) which accommodates at least one coalescence element (42) and has an inlet (38) for feeding in an emulsion that flows through the coalescence element (42) so as to separate into at least two of its component parts, an outlet (46) for one separated component part and a further outlet (22, 64) for a further separated component part, which, having a lower density than the one component part, floats thereon.