Multi-point Fuel Tank Cleaning via Segmented Flow Paths
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Solution Overview
Problem
In mission-critical sites, rectangular base/belly fuel tanks for emergency generators experience high rates of microbial and fungal growth due to increased surface area and stagnant fuel, leading to fuel degradation, sludge formation, and potential filter clogging during power outages, which can disrupt critical electrical power supplies.
Innovation Solution
A multi-path cleaning system with a controller, fuel polisher, and controllable valves creates multiple fluid flow paths within the fuel tank, optimizing valve placement and operation to maximize fuel circulation and contamination removal, using Computational Fluid Dynamics to ensure comprehensive coverage of the tank bottom.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a rectangular base/belly tank is used to mount a generator on top, then the generator can be positioned on the tank, but the surface area of the fuel-water boundary increases, leading to higher rates of microbial and fungal growth
Solution Approach 1:
The patent divides the single large fuel tank into multiple compartments using internal baffles or walls. This segmentation reduces the surface area of the fuel-water boundary in each compartment while maintaining the overall rectangular external shape for generator mounting. The segmentation physically limits the spread of microbial colonies and reduces the effective area for contamination.
Solution Approach 2:
The patent introduces vertical dimensionality by installing multiple fuel entry and exit points at different heights and locations within the tank. This creates multi-level flow paths that reduce the horizontal surface area exposure while maintaining efficient fuel circulation. The multi-dimensional approach allows fuel to be drawn from and returned to various zones, preventing stagnant areas.
2Quantity of substance
If fuel is stored in large volumes for extended periods, then enough fuel is available for prolonged operation during power outages, but fuel turnover is very low and fuel degradation occurs
Solution Approach 1:
The patent implements a dynamic fuel circulation system with multiple controllable valves and entry/exit points that actively move fuel throughout the tank during storage. This dynamic approach prevents fuel from remaining stagnant in any single location, continuously mixing and circulating the fuel to maintain quality while preserving large fuel volumes for extended operation.
Solution Approach 2:
The system maintains continuous fuel circulation and polishing operations during storage periods. The fuel polisher operates continuously or periodically to remove contaminants, while the multi-point flow paths ensure continuous movement of fuel through different zones, preventing degradation and maintaining fuel reliability throughout extended storage periods.
3Device complexity
If a single fuel entry and exit point is used, then the system is simple, but localized pockets of water and sediment cannot be completely removed during fuel polishing
Solution Approach 1:
The patent segments the fuel flow path by installing multiple entry and exit points distributed throughout the tank at different locations and heights. This segmentation allows the fuel polisher to access and clean localized pockets of water and sediment that would be unreachable with a single entry/exit point, while the individual valve-controlled paths keep the control system relatively simple.
Solution Approach 2:
The patent applies local quality by positioning specific entry and exit points in areas prone to water and sediment accumulation, such as low points and corners of the tank. Each local flow path is optimized for its specific zone, allowing targeted removal of contaminants from problem areas while maintaining overall system simplicity through modular valve control.
4Object-affected harmful factors
If sulfur levels in fuel are reduced to below 15 PPM to reduce harmful sulfur oxides, then environmental compliance is improved, but microbial proliferation increases due to loss of sulfur's protective effect
Solution Approach 1:
The patent introduces a fuel polisher as an intermediary system that actively removes microbial contaminants and sludge from the low-sulfur fuel. Since low-sulfur fuel lacks the natural microbial inhibition provided by sulfur, the fuel polisher serves as a compensating mechanism that continuously cleans the fuel, preventing microbial proliferation while maintaining the environmental benefits of low sulfur content.
Solution Approach 2:
The system maintains continuous or periodic fuel polishing operations to continuously remove microbial contaminants from the low-sulfur fuel. This continuous action compensates for the lack of sulfur-based microbial protection, ensuring that despite reduced sulfur levels, microbial growth is prevented through active, ongoing contamination removal.
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 effectively removes contaminants and sediments from the entire fuel tank, preventing filter clogging and ensuring continuous clean fuel supply during outages, thereby maintaining reliable backup power systems.
Implementation Method 1
The pump, when operated, causes fuel to be drawn through the inlet and discharged at the outlet of the fuel polisher
Implementation Method 2
at least one filter/water separator coupled between the inlet and the outlet
Implementation Method 3
Water, being a higher specific gravity than fuel, tends to coalesce at the bottom of a fuel tank, underneath the fuel
Data Source
AI summary
A multi-path cleaning system is provided for a fuel tank. The multi-path cleaning system includes a controller, a fuel polisher, and a plurality of controllable valves. The plurality of controllable valves are operatively connected to the controller, and each valve fluidly coupled to at least one of the inlet and outlet of the fuel polisher on a first side and the interior of the fuel tank on a second other side. The pump, when operated, causes fuel to be drawn through the inlet and discharged at the outlet of the fuel polisher, and to pass through at least one filter/water separator. Selective operation of the plurality of valves by the controller selectively fluidly couples portions of the interior of the fuel tank to the inlet and the outlet of the fuel polisher, thereby creating a plurality of fluid flow paths through the interior of the fuel tank.