Nanogas Shear Processing for Low-Residual-Oil Slurry Separation
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Solution Overview
Problem
Current methods for removing oil from particulate matter, such as sand, glass, and hazardous railway ballast, result in residual oil contamination levels that are difficult to manage and hazardous, especially when using centrifuges, hydrocyclones, or Denver Attrition cells, which require high energy and cause equipment damage.
Innovation Solution
A process involving the use of a nanogas solution, a homogeneous mixture of nanobubbles and water, is injected into a pipe carrying a slurry of particulate matter at controlled angles and pressures to shear and mix with the slurry, effectively separating oil from the particulates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If centrifuges are used to separate oil from particulate matter, then oil and water phase separation is achieved, but residual oil levels remain high (up to 15 wt. %) and the process becomes complex
Solution Approach 1:
The patent extracts the oil separation function from complex multi-stage processes (centrifuges, hydrocyclones, chemical treatment) and implements it through a single integrated device combining injection nozzles, mixing chamber, and separation section. This extraction simplifies the overall process while maintaining effective oil removal capabilities.
Solution Approach 2:
The injection device performs multiple functions simultaneously: it injects separation fluid, creates turbulence for oil detachment, provides mixing chamber for emulsion formation, and enables phase separation in the separation section. This multi-functionality replaces multiple separate equipment pieces, reducing process complexity.
2Manufacturing precision
If Denver Attrition cells are used to reduce residual oil contamination below 5 wt. %, then oil removal efficiency improves, but energy consumption increases significantly and equipment attrition rates increase
Solution Approach 1:
The patent replaces the high-energy mechanical impeller system with a fluid-dynamics-based separation mechanism. The injection nozzles create fluid turbulence and the mixing chamber generates emulsification without requiring high-speed rotating mechanical components, thereby reducing energy consumption while achieving comparable or better oil removal.
Solution Approach 2:
The patent changes the operational parameters from high-speed mechanical agitation to controlled fluid injection parameters (pressure, flow rate, nozzle geometry). This parameter transformation allows oil removal through fluid dynamics rather than mechanical force, reducing energy requirements while maintaining separation effectiveness.
3Manufacturing precision
If high-speed impellers are used in Denver Attrition cells to achieve low residual oil levels, then oil removal improves, but equipment damage increases due to high attrition rates
Solution Approach 1:
The patent extracts the oil detachment function from high-speed mechanical impellers and relocates it to the fluid injection and turbulence generation system. This eliminates the need for high-speed rotating mechanical components that cause equipment wear, while maintaining effective oil removal through fluid dynamics.
Solution Approach 2:
The patent introduces a separation fluid as an intermediary medium that facilitates oil removal without direct mechanical contact with the particulate matter. This intermediary fluid creates turbulence and emulsification, achieving oil detachment without the high mechanical stresses that cause equipment attrition.
4Manufacturing precision
If re-circulating hydrocyclones are used to achieve residual oil levels below 3 wt. %, then separation efficiency improves, but the process becomes batch-oriented with solids recirculation requiring multiple cycles
Solution Approach 1:
The patent implements continuous oil removal in a single pass through the device, eliminating the batch recirculation process. The continuous injection of separation fluid and continuous mixing/separation action allows oil removal to proceed without interruption, reducing processing time while achieving low residual oil levels.
Solution Approach 2:
The patent performs preliminary oil detachment through the injection and mixing sections before the separation section, preparing the mixture for efficient phase separation. This preliminary action ensures that oil is already detached and emulsified before entering the separation zone, enabling complete removal in a single continuous pass rather than requiring multiple recirculation cycles.
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 process achieves residual oil contamination levels below 200 ppm, significantly reducing hazardous waste and energy consumption compared to existing methods.
Implementation Method 1
shearing and/or admixing the slurry with the nanogas solution thereby forming an admixture
Implementation Method 2
injecting a nanogas solution into the pipe via the spray nozzles; and shearing and/or admixing the slurry with the nanogas solution
Data Source
AI summary
A process for separation of a slurry by radially injecting a stream of a nanogas solution at a shear-focus volume within a pipe; passing an aqueous slurry through the pipe along a direction of flow and through the shear-focus volume; and shearing and/or admixing the slurry with the nanogas solution within the shear-focus volume.