Steam-Ultrasonic Cleaning of Porous Metallic Filters

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Solution Overview

Problem

Porous metallic filters used in refining technologies become plugged and undergo physical/chemical transformations, leading to high pressure drops and premature failure, making conventional cleaning methods ineffective and costly, as they often damage the filters or require harsh chemicals.

Innovation Solution

A combined steam-ultrasonic method involving steam cleaning and ultrasonic treatment of filters to dislodge particles without damaging the filter material, using steam to clear pores and ultrasound to further remove contaminants, thereby reducing pressure drops and extending filter life.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional cleaning methods (harsh chemicals) are used to remove solid particles, then pressure drop is reduced, but filter material is corroded or damaged

Engineering Contradiction:

Improvepressure drop reductionVSAvoidfilter structural integrity

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent replaces chemical cleaning methods with a physical steam-ultrasonic cleaning system. Steam provides thermal energy to loosen particles and ultrasonic waves provide mechanical vibration to dislodge contaminants without chemical corrosion. This substitution eliminates the need for harsh chemicals while maintaining effective particle removal.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the cleaning parameters from chemical concentration and temperature to steam temperature and ultrasonic frequency. By controlling steam temperature (typically 100-200°C) and ultrasonic frequency (20-100 kHz), the system achieves effective cleaning through physical mechanisms rather than chemical reactions, preserving filter material integrity.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If harsh chemicals are used to clean filters, then particle removal is improved, but filter life is reduced due to corrosion

Engineering Contradiction:

Improveparticle removal efficiencyVSAvoidfilter service life

Core Design Contradiction:

ProductivityVSDuration of action of stationary object

Solution Approach 1:

The patent substitutes chemical corrosion-based cleaning with physical steam and ultrasonic mechanisms. Steam condenses to provide mechanical impact and ultrasonic waves create cavitation and vibration that physically dislodge particles. This mechanical approach removes particles effectively without the corrosive damage that shortens filter life.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent converts the harmful effect of condensing steam into a beneficial cleaning mechanism. The phase change from vapor to liquid releases latent heat and creates condensation water that helps loosen and flush particles from the filter medium, turning a potentially damaging thermal shock into a gentle cleaning action.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Reliability

If filter replacement is performed instead of cleaning, then filter performance is restored, but maintenance cost increases

Engineering Contradiction:

Improvefilter performanceVSAvoidmaintenance cost

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

Instead of discarding plugged filters and replacing them with new ones, the patent recovers and cleans existing filters using steam-ultrasonic treatment. This recovery process restores filter performance to near-original levels, allowing the same filter medium to be reused multiple times, thereby reducing maintenance costs and waste.

Inventive Principle:

Principle #34Discarding and recovering

Solution Approach 2:

The steam-ultrasonic cleaning system enables filters to be cleaned in-place or easily removed and cleaned without complex disassembly. The automated steam generation and ultrasonic treatment processes make the cleaning operation simple and cost-effective, encouraging frequent cleaning rather than replacement.

Inventive Principle:

Principle #25Self-service

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 method effectively restores up to 90% of the filter's original activity without using harsh chemicals, reducing maintenance costs and preventing premature filter failure, while maintaining the structural integrity of the filters.

Implementation Method 1

steaming a filter element for a first period of time

Methodology Applied

Scientific EffectSteam condensation and expansion: Phase Change

Implementation Method 2

exposing the first solution to ultrasound waves for a second period of time

Methodology Applied

Scientific EffectUltrasonic vibration: Ultrasonic Vibration

Data Source

PatentUS9789520B2Method for cleaning porous metallic filters using a steam-ultrasonic technique

Publication Date: 2017.10.17 PHILLIPS 66 CO

AI summary

A method of cleaning plugged or dirty porous metallic filter elements to regain filter activity, comprising the steps of: steaming a filter element for a first period of time; submerging the filter element in a first solution; and exposing the first solution to ultrasound waves for a second period of time.