Pre-loaded Filter Media for Process Vessel Filtration
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Solution Overview
Problem
Traditional filter media in process vessels have reduced trapping efficiency at start-of-run and result in early contaminant deposition in downstream layers due to reduced capacity utilization.
Innovation Solution
Treated filter media with a conditioner, such as iron sulfide, coke, bio-char, charcoal, carbon black, or phosphate salts, embedded within the internal void space to enhance filtration efficiency, allowing for improved contaminant capture and extended vessel cycle time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional filter media is used without conditioner, then the filter media structure remains simple and easy to manufacture, but the trapping efficiency is reduced at start-of-run and contaminant deposition occurs early in downstream layers
Solution Approach 1:
The filter media is pre-loaded with conditioner particles (such as iron sulfide, coke, bio-char, charcoal, carbon black, or phosphate salts) in the void spaces before being installed in the process vessel. This preliminary action ensures that the filter media is ready to capture contaminants immediately at start-of-run, eliminating the period of reduced trapping efficiency that occurs with traditional clean filter media.
Solution Approach 2:
The conditioner particles are specifically placed in the void spaces of the filter media structure, creating localized regions of enhanced contaminant capture capability. This local quality enhancement allows the filter media to have different functional zones: the conditioner-containing void spaces for immediate contaminant trapping and the filter media structure for structural support and fluid flow.
2Duration of action of stationary object
If filter media capacity is not fully utilized, then the operational cycle is extended, but contaminant deposition occurs early in downstream layers reducing overall system efficiency
Solution Approach 1:
By pre-loading the filter media with conditioner particles, the system ensures that contaminant capture begins immediately at the inlet, preventing early deposition in downstream layers. This maintains high filtration efficiency throughout the operational cycle, fully utilizing the filter media capacity and extending the vessel cycle time.
Solution Approach 2:
The conditioner particles act as an intermediary substance that facilitates contaminant capture. These particles are specifically selected to have affinity for the contaminants in the fluid stream, serving as a mediator between the contaminant-laden fluid and the filter media structure, thereby enhancing overall filtration efficiency.
3Reliability
If conditioner particles are added to fill void spaces, then contaminant capture efficiency is enhanced, but the void space available for fluid flow is reduced
Solution Approach 1:
The conditioner particles are placed specifically in the void spaces of the filter media, creating localized regions of enhanced contaminant capture. This local placement ensures that the conditioner particles are positioned where they can most effectively intercept contaminants while maintaining the overall porosity and fluid flow characteristics of the filter media.
Solution Approach 2:
The filter media maintains its porous structure with void spaces that are partially filled with conditioner particles. This porous configuration allows fluid to flow through while the conditioner particles in the void spaces provide contaminant capture functionality, balancing flow requirements with filtration efficiency.
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 treated filter media significantly increases filtration efficiency and extends the operational cycle of process vessels by effectively capturing contaminants, reducing premature deposition and enhancing the utilization of filter media capacity.
Implementation Method 1
a conditioner can be embedded within the internal void space prior to installing the treated filter media into the process vessel such that the internal void space is filled with the conditioner
Data Source
AI summary
A method of filtration in a process vessel using a treated filter media which has been treated with a conditioner for improved filtration of contaminants is provided. The treated filter media can be used in process vessels for refining, petrochemical, and chemical plants to treat process streams. The conditioner can be the same material as what is expected to be captured during the fouling process. In other words, the conditioner that is added to the treated filter media can be the same material as the contaminant in the fluid stream to be treated. This allows for chemical compatibility with an existing process fluid stream. This also allows for the natural continuation of the filtration process.