Polyurethane Foam Coalescing Medium for Oil-Water Separation
Solution Overview
Problem
Existing coalescing media used in oil-water separation systems are prone to leaking and deformation under constant flow conditions, leading to reduced oil recovery efficiency due to fluid breakthrough, and require fiber reinforcement to mitigate these issues.
Innovation Solution
A coalescing medium comprising particles of polyurethane foam with specific Indentation Force Deflection (IFD), Ball Rebound (BR), Support Factor (SF), and density characteristics, which can withstand pressure drops without deformation and leakage, eliminating the need for fiber reinforcement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional coalescing media are used in oil-water separation systems, then oil separation function is provided, but the media are prone to leaking and deformation under constant flow conditions, leading to reduced oil recovery efficiency
Solution Approach 1:
The patent applies parameter changes by specifying precise physical properties for the polyurethane foam particles: IFD number of 40 or higher, BR number of 35 or higher, SF number of 1.8 or higher, and density of 42 kg/m³ or higher. These parameter specifications ensure the coalescing medium maintains structural integrity and resists deformation under flow pressure, preventing leaking while maintaining separation efficiency
Solution Approach 2:
The patent uses polyurethane foam as a composite material that inherently provides both coalescing functionality and mechanical strength. The foam structure combines gas-filled cells within a polymeric matrix, creating a material that is both lightweight (density 42 kg/m³ or higher) and resistant to deformation, eliminating the need for fiber reinforcement while maintaining reliability under constant flow conditions
2Strength
If fiber reinforcement is added to coalescing media to prevent leaking and deformation, then structural strength is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent achieves the required structural strength (IFD ≥ 40, BR ≥ 35, SF ≥ 1.8) by optimizing the polyurethane foam's inherent properties through chemical composition and cellular structure control, rather than adding fiber reinforcement. This maintains the coalescing medium as a simple particulate material that can be freely流动 between particles, reducing device complexity while providing adequate pressure resistance
Solution Approach 2:
The patent employs inexpensive polyurethane foam particles that can be easily manufactured and replaced. The foam material provides sufficient strength for its intended service life without requiring complex reinforcement structures, aligning with a disposable approach where the coalescing medium is replaced rather than repaired when depleted
3Productivity
If coalescing media are used at high flow rates (up to 80 m/h or more), then productivity is improved, but pressure drop across the media increases and fluid breakthrough occurs
Solution Approach 1:
The patent optimizes the density parameter of the polyurethane foam to 42 kg/m³ or higher, which provides sufficient structural rigidity to withstand high flow rates (up to 80 m/h or more) without excessive deformation. This density threshold ensures the media can handle the associated pressure drops while maintaining integrity and preventing fluid breakthrough, enabling high productivity operation
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 polyurethane foam-based coalescing medium effectively separates non-aqueous phases from aqueous phases with improved resistance to fluid breakthrough, maintaining separation efficiency and reducing the risk of leakage, thereby enhancing oil recovery in oil-water separation systems.
Implementation Method 1
exploit various kinds of particulate type materials for adsorbing or coalescing a non-aqueous phase
Implementation Method 2
oil droplets are coalesced and an oil phase separates from the water passing through the coalescent bed
Data Source
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AI summary
A coalescing agent for facilitating the separation of a non-aqueous phase from an aqueous phase of an aqueous medium, said agent consisting of particles of a polymeric foam material having: an IFD no. of 40 or higher (i.e. at least 40); a BR no. of 35 or higher (at least 35); a SF no. of 1.8 or higher (i.e. at least 1.8) and a density of 42 kg/m3 or less.