Separator Design for Low Discharge Applications
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Solution Overview
Problem
Existing liquid separation devices, particularly in the food industry, face issues with valve mechanisms sticking, leading to inefficiencies and contamination risks during the separation of oil and water, and require complex and expensive electromechanical assistance to prevent water from mixing with grease or oil.
Innovation Solution
A separator design that eliminates the need for valve mechanisms by controlling the flow of denser and less dense fluids using a variable height weir and a collection device that rises and falls with the water level, ensuring the less dense fluid is collected without the risk of water entering the oil container.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a floating ball valve mechanism is used to separate oil and water, then the less dense fluid can be collected, but the valve mechanism may stick leading to water entering the oil container and contamination
Solution Approach 1:
The patent removes the floating ball valve mechanism entirely from the system. Instead of using a mechanical valve to control fluid flow, the invention uses a simple outlet at the bottom of the separation chamber that allows the less dense fluid to exit naturally without any moving parts or complex control mechanisms.
Solution Approach 2:
The system uses the natural density difference between oil and water to achieve separation and controlled discharge. The less dense fluid automatically rises and exits through the outlet chamber while the denser water remains in the separation chamber, eliminating the need for external control mechanisms.
2Productivity
If a floating ball valve is used to control fluid flow, then separation can be maintained, but the valve requires maintenance and may fail due to sticking
Solution Approach 1:
The patent extracts the problematic floating ball valve from the system and replaces it with a passive outlet structure. This eliminates the need for maintenance while maintaining continuous operation, as the density-based separation mechanism requires no moving parts that can wear or stick.
Solution Approach 2:
The invention replaces the expensive, maintenance-prone valve mechanism with a simple, inexpensive outlet structure that has no moving parts. This simple structure is inherently more reliable and requires no maintenance, effectively being a permanent solution rather than a component needing replacement.
3Reliability
If electromechanical assistance is added to prevent water from mixing with grease, then contamination is prevented, but the device becomes more complex and expensive
Solution Approach 1:
The system uses the natural physical property of density difference to automatically prevent water from entering the oil collection container. The outlet chamber design allows only the less dense fluid to exit, while the denser water is naturally blocked by gravity and density, requiring no electromechanical control.
Solution Approach 2:
The patent removes all electromechanical control systems and replaces them with a passive physical separation mechanism based on density differences. This eliminates complexity while maintaining reliable prevention of fluid mixing through the natural behavior of immiscible liquids.
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 design prevents water from entering the oil container, reduces the risk of contamination, and simplifies maintenance by eliminating the need for complex valve mechanisms, while maintaining efficient separation of immiscible liquids.
Implementation Method 1
separates into a denser immiscible fluid and a less dense immiscible fluid in the separation chamber
Implementation Method 2
the lower density liquid (grease/oil) rises. The flow through the separation chamber 28 is set at a rate that allows the lower density liquid to separate from the water and float upwards to the surface
Implementation Method 3
the water in separation chamber 28 attempts to rise to approximately the same height. Since the top of the separation chamber 28 is below the top of weir plate 38, the hydrostatic pressure of the upward force of the water will push the separated grease/oil at the top of the separation chamber 28 through valve 34
Data Source
AI summary
A separator 252 for immiscible liquids comprises a tank having an inlet, a separation chamber and an outlet chamber 262, with the inlet 12 feeding effluent into the separation chamber 28 at or below a maximum acceptable flow rate. The effluent is separated into a more dense and less dense fractions in the separation chamber 28. The separation chamber 28 is in communication with the outlet chamber 262, where the more dense fraction exits. An outlet 260 for the less dense fraction is in communication with the separation chamber 28 and has a lowermost exit level at which the less dense fluid exits. The more dense fluid cannot rise to the level of the lowermost level, and the height of the less dense fluid is such that it will exit through the outlet as the more dense fluid passes over the weir.