Ultra-High Pressure Cleaning System with De-ionization and Metal Scavenging
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Solution Overview
Problem
Ultra-high pressure water jet cleaning systems face challenges such as corrosion of metal surfaces due to residual minerals and salts, contamination of water with heavy metals, and environmental concerns from discharge of untreated water, which require effective filtration and treatment solutions.
Innovation Solution
The system employs reverse osmosis filtration to de-ionize water before use, followed by vacuum collection and membrane filtration to remove solids, and a metal scavenger unit using calcium polysulfide to precipitate out heavy metals, ensuring the water meets environmental discharge standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If ultra-high pressure water jet cleaning is used to clean metal surfaces, then cleaning effectiveness is improved, but corrosion of metal surfaces occurs due to residual minerals and salts
Solution Approach 1:
The system performs preliminary filtration of the water supply before it reaches the cleaning nozzle. A filter assembly is positioned in the water supply line to remove minerals, salts, and other contaminants from the water before the ultra-high pressure jet is generated, preventing corrosion-causing residues from being deposited on cleaned metal surfaces
Solution Approach 2:
The filter assembly acts as an intermediary between the water supply and the cleaning system. It intercepts and removes harmful minerals and salts from the water, allowing only purified water to proceed to the ultra-high pressure pump and nozzle, thereby protecting the cleaned surfaces from corrosion
2Productivity
If water is used for ultra-high pressure cleaning, then cleaning capability is improved, but water becomes contaminated with heavy metals and other pollutants
Solution Approach 1:
The system captures the contaminated water that would otherwise be discharged as waste and converts it into a treatable stream. The filter assembly captures heavy metals, minerals, and other contaminants, allowing the water to be either reused or discharged in a treated state, transforming a harmful waste problem into a manageable resource
Solution Approach 2:
The filter assembly separates and captures (discards) heavy metals, minerals, and other contaminants from the water stream. The filtered water can then be recovered for reuse in subsequent cleaning operations or discharged after treatment, reducing environmental impact and water consumption
3Device complexity
If traditional filtration methods are used, then system complexity is reduced, but insufficient removal of minerals and salts occurs
Solution Approach 1:
The filter assembly utilizes hydraulic pressure from the water supply system itself to drive the filtration process. The ultra-high pressure water flow passes through the filter media, using its own pressure to force contaminants through the filtration elements, eliminating the need for separate vacuum systems or complex mechanical filtration mechanisms
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 approach reduces corrosion risks, removes contaminants and heavy metals, and renders the water suitable for safe discharge into surface waterways, meeting federal regulations and extending the life of metal surfaces.
Implementation Method 1
The water is first filtered to remove substantially all dissolved mineral salts, organics, chlorides and other particles. The preferred primary filtration system is a reverse osmosis system.
Implementation Method 2
The vacuum source collects the dispensed water and debris removed from the surface.
Implementation Method 3
membrane filtration to remove solids
Implementation Method 4
a metal scavenger unit using calcium polysulfide to precipitate out heavy metals
Data Source
AI summary
A method of ultra-high pressure surface cleaning. Water is first preferably filtered and de-ionized. The de-ionized water is pressurized to about 25,000 to 60,000 psi. The ultra-high pressurized water is applied to a surface, typically using a robot. The robot includes a vacuum for collecting water and debris removed from the surface. The stream leaving the robot will be an aqueous mixture of everything removed from the surface. The mixture next passes through a vacuum filtration unit, where most solids will be removed. Next, the mixture passes through a membrane filtration unit for removal of most remaining suspended solids. If toxic heavy metals are present, the mixture will pass through a heavy metal scavenger. After the foregoing treatment steps, the mixture will have less than 29 ppm suspended solids and be substantially free of lead and other heavy metals, rendering the mixture safe for surface water discharge in most cases.