Waste Fat Purification via Thermal Softening of Plastic Particles
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Solution Overview
Problem
Current methods for cleaning waste fats and oils containing plastic particles, such as animal fats, are inefficient in reducing plastic content, require large amounts of filter aids, and face challenges with reproducibility and high operational costs, especially when dealing with small plastic particles that cause filter cake blockages.
Innovation Solution
Heating the waste fats/oils above the softening temperature of plastic particles, followed by cooling and separation, with optional addition of filter aids to facilitate the removal of plastic particles, using significantly smaller amounts of filter aid and incorporating a 3-phase decantation process to achieve effective separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If filtration with filter aids is used to remove plastic particles from animal fats, then plastic particle content is reduced, but large quantities of filter aids are required and precoat filtration leads to high investment and operating costs
Solution Approach 1:
The patent applies parameter changes by heating the animal fat to temperatures above the softening point of plastic particles (typically above 100°C, preferably above 120°C). This temperature parameter change causes the plastic particles to soften and become more separable, enabling effective removal with significantly reduced filter aid quantities (0.1-5 wt%, preferably 0.1-2 wt%). The process may also involve adjusting pH values and using centrifugal separation parameters to enhance plastic particle removal efficiency while minimizing filter aid consumption.
Solution Approach 2:
The patent exploits phase transitions of plastic particles by heating animal fat above the softening temperature of embedded plastics. This causes the plastic particles to transition from a hard, embedded state to a softened, more separable state. The phase change enables plastic particles to be more easily detached and removed during filtration or centrifugation, achieving effective purification with reduced filter aid quantities compared to conventional methods.
2Manufacturing precision
If precoat filtration is used to separate plastic particles, then separation is achieved, but investment and operating costs increase significantly
Solution Approach 1:
The patent replaces expensive precoat filtration with a simplified process using parameter changes. By heating animal fat above the softening point of plastic particles and adjusting other process parameters (pH, centrifugal force), the method achieves effective plastic particle separation without requiring complex precoat filtration equipment. This reduces both investment costs for equipment and operating costs for filter aid consumption while maintaining high separation efficiency.
Solution Approach 2:
The patent extracts the essential separation function from complex precoat filtration systems and implements it through a simpler process combining temperature-induced softening with basic filtration or centrifugation. This extraction of the core separation mechanism eliminates the need for expensive precoat equipment while achieving comparable or superior plastic particle removal efficiency.
3Manufacturing precision
If filtration is used to remove plastic particles, then some particles are removed, but small particles quickly lead to clogging of the filter cake
Solution Approach 1:
The patent applies preliminary action by heating animal fat above the softening temperature of plastic particles before filtration or centrifugation. This pre-treatment softens the plastic particles, making them more separable and less likely to cause rapid filter cake clogging. The preliminary thermal treatment enhances the effectiveness of subsequent separation steps and extends filter cake operational life by reducing the clogging effect of small plastic particles.
Solution Approach 2:
The patent uses parameter changes, particularly temperature elevation above the plastic softening point, to modify the physical state of plastic particles before separation. This parameter change reduces the clogging tendency of small plastic particles by softening them, allowing for more sustained filtration operation and reduced frequency of filter cake changes, thereby improving overall productivity.
4Manufacturing precision
If organic solvents are used to dissolve fat and separate plastic particles, then separation is achieved, but energy-intensive distillation is required to remove the solvent
Solution Approach 1:
The patent extracts the separation function from solvent-based processes and implements it through direct thermal treatment of the animal fat. By heating the fat above the plastic softening point and using physical separation methods (filtration, centrifugation), the process achieves effective plastic particle removal without introducing organic solvents. This eliminates the need for energy-intensive distillation steps required for solvent recovery, significantly reducing energy consumption while maintaining high separation 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
This method effectively reduces plastic particle content in waste fats/oils, even for small particles, without the need for large filter aid quantities, and enhances the removal of substances causing phase separation issues, thereby improving the suitability of the materials for biodiesel and soap production.
Implementation Method 1
Heating the waste fats and/or oils containing plastic particles to a temperature above the softening temperature of the plastic of the plastic particles
Implementation Method 2
cooling the waste fats and/or oils to a temperature below the softening temperature of the plastic of the plastic particles
Implementation Method 3
separating the plastic particles from the liquid waste fats and/or oils
Data Source
Figure 1
AI summary
A process for purifying waste fats and/or oils containing plastic particles comprises the steps of heating the waste fats and/or oils containing the plastic particles to a temperature above the softening temperature of the plastic particles, cooling the waste fats and/or oils to a temperature below the softening temperature, and separating the plastic particles from the liquid waste fats and/or oils. This process enables the separation of small plastic particles from animal fats and used cooking oils intended for further use, for example, in biodiesel production.