Method and apparatus for optimizing operation of a filter system

• US 5,589,076 A
• Filed: 01/11/1996
• Issued: 12/31/1996
• Est. Priority Date: 05/10/1994
• Status: Expired due to Fees

• Current Assignee: Womack International Incorporated
• Original Assignee: Womack International Incorporated
• Inventors: Womack, Thomas H.
• Primary Examiner(s): Drodge, Joseph W.
• Application Number:
  US08/585,144
• Time in Patent Office: 355 Days
• Field of Search: 72/41, 72/43-45, 210/86, 210/87, 210/93, 210/101, 210/103, 210/104, 210/110, 210/137, 210/143, 210/168, 210/193, 210/198.1, 210/257.1, 210/258, 210/739, 210/744, 210/767, 210/808, 210/94 , 210/96.1, 210/97, 210/387, 210/400, 210/416.1, 210/416.5, 55/270, 55/274
• US Class Current: 210/739
• CPC Class Codes: B01D 37/02 Precoating the filter medium; Addition of filter aids to the liquid being filtered devices for feeding reagents C02F1/685 and sub-groups; filter aids
• CPC Class Codes: B01D 37/041 by clearness or turbidity measuring
• CPC Class Codes: B01D 37/045 by level measuring

Abstract

A method and apparatus for optimizing operation of a filter system supplying filtered fluid to a process system characterized by varying demands for filtered fluid, a pump being operable at a varying flow rate for supplying inlet fluid to the filter system and developing a supply of outlet filtered fluid for the process system, a selected parameter of the process system indicative of its demands for filtered fluid being sensed in order to generate representative feedback data and regulating operation of the filter system pump to supply inlet fluid to the filter system at a rate determined by the feedback data whereby the filter system operates at a variable rate in proportion to the varying demands of the process system. Operation of the filter system pump is preferably regulated by adjusting either its operating speed or volumetric stroke. Parameters for the processing system include either the fluid level in a holding tank between the filtering system and the processing system or another condition of the process system. The introduction by bodyfeed systems of one or more filter aids to a filter element in the filter system is also regulated according to different variable conditions for optimizing filter system operation.

Claims

1. A method for optimizing operation of a pressure filter system comprising at least one readily replacable porous membrane or filter media supplying filtered fluid to a process system characterized by varying demands for filtered fluid, the method comprising the steps of:

controlling the filter system by a supply means for supplying filtered fluid to the process system at a flow rate generally proportional to the varying demands for filtered fluid from the process system;

constantly sensing a selected operating parameter of the process system indicative of its varying demands for filtered fluid and generating feedback data representative of the varying demands for filtered fluid by the process system; and

regulating operation of the filter system supply means by a device operable to vary supply of inlet fluid to the filter system at a flow rate determined by the feedback data provided by the selected operating parameter, whereby the filter system operates at a variable flow rate for supplying filtered fluid generally in proportion to the varying demands for filtered fluid by the process system to optimize operation of the filter system.

2. The method of claim 1 wherein the feedback data is selected and generated for operating the filter system supply means in proportional relation to the selected operating parameter of the process system.

3. The method of claim 1 wherein the filter system supply means is a pump regulated by adjusting at least its operating speed or volumetric stroke.

4. The method of claim 1 wherein the selected operating parameter is the rate of flow of filtered fluid demanded by the process system.

5. The method of claim 4 further comprising the steps of supplying filtered fluid from the filter system to a holding means and regulating a flow rate of filtered fluid from the holding means to the process system, the selected operating parameter being the flow rate of filtered fluid from the holding means to the process system.

6. The method of claim 5 wherein the flow rate of filtered fluid from the holding means to the process system is regulated by a process system pumping means responsive to the varying demands of the process system for filtered fluid and further comprising the step of monitoring a characteristic of the process system and generating the feedback data in proportion thereto.

7. The method of claim 5 further comprising the step of monitoring a level of fluid in the holding means as an indication of varying demands of the process system for filtered fluid and generating the feedback data in proportion thereto.

8. The method of claim 5 wherein operation of the filter system pumping means is regulated by adjusting at least its operating speed or volumetric stroke.

9. The method of claim 1 wherein the flow rate of filtered fluid from the holding means to the process system is regulated by a process system pumping means responsive to the varying demands of the process system for filtered fluid and further comprising the step of monitoring a condition of the process system and generating the feedback data in proportion thereto.

10. The method of claim 1 wherein the filter system supply means is an electrically operated pump, said pump regulated by a variable frequency device, said device regulated by the feedback data determined by sensing of the selected operating parameter.

11. The method of claim 1 wherein the filter system supply means includes a variable frequency device for establishing volumetric flow to the filter system, the variable frequency device being regulated by the feedback data determined by sensing of the selected operating parameter.

12. The method of claim 1 further comprising the step of averaging the feedback data over a selected time period to achieve uniform operation of the filter system supply means.

13. The method of claim 1 further comprising reducing operation of the filter system supply means to a minimum level in the absence of substantial demand for filtered fluid from the process system in order to further optimize operation of the process system.

14. The method of claim 1 further adapted for optimizing operation of the filter system, the filter system being of a type having a first bodyfed filter aid supplied from a first bodyfeed source to a filter element in the filter system, and further comprising the steps of:

constantly monitoring at least one first variable condition selected from the group consisting of (a) a condition of inlet fluid for the filter system, (b) a condition of outlet filtered fluid supplied to the process system, and (c) a condition of the filter element; and

regulating operation of the first bodyfeed source in response to the monitored condition in order to supply the first bodyfed filter aid to the filter element in an amount and at times indicated by the monitored condition of the outlet filtered fluid.

15. The method of claim 1 wherein the filtered fluid is a filtered coolant/lubricant.

16. The method of claim 15 wherein the process system comprises a mill for rolling various types of metals.

17. A method for optimizing operation of a filter system supplying outlet filtered fluid to a processing system, comprising the steps of:

supplying first and second bodyfed filter aids from first and second bodyfeed sources to a filter element in the filter system;

monitoring at least a first variable condition selected from the group consisting of (a) a condition of inlet fluid for the filter system, (b) a condition of the outlet filtered fluid supplied to the process system, and (c) a condition of the filter element;

regulating operation of the first bodyfeed source in response to the first monitored condition in order to supply the first bodyfed filter aid to the filter system in an mount and at times indicated by the first monitored condition of the filtered fluid;

monitoring at least a second variable condition selected from the group consisting of (a) a condition of inlet fluid for the filter system, (b) a condition of the outlet filtered fluid supplied to the process system, and (c) a condition of the filter element; and

regulating operation of the second bodyfeed source in response to the second monitored condition in order to supply the second bodyfed filter aid to the filter system in an amount and at times indicated by the second monitored condition.

18. The method of claim 17 wherein the first condition is turbidity of the filter inlet fluid as an indication of relatively larger particles capable of removal in the filter system by the first bodyfed filter aid and the second condition is color of the filter outlet fluid as an indication of relatively smaller particles or polar "color bodies" capable of removal by the second bodyfed filter aid supplied to the filter system, the first bodyfed filter aid being porous and/or depth filtering type filter aid material and the second bodyfed filter aid being a polar or charged clay particle type.

19. The method of claim 18 wherein the second bodyfed filter aid is always supplied to the filter system in combination with porous/depth type filter aid material in order to prevent or minimize blinding of the filter system.

20. The method of claim 17 further comprising the step of regulating operation of the filter system and supplying filtered fluid to the process system at a rate responsive to varying demands of the process system for filtered fluid.

21. Apparatus constructed and arranged for optimizing operation of a pressure filter system receiving fluid to be filtered from a supply means and supplying filtered fluid to a process system characterized by varying demands for filtered fluid, the apparatus comprising at least one readily replaceable porous membrane or filter media:

control means for variably controlling operation of the supply means and for supplying outlet filtered fluid to the process system at a flow rate generally proportional to the varying demands for filtered fluid by the process system;

means for sensing a selected parameter of the process system indicative of its varying demands for filtered fluid; and

means responsive to the sensing means for generating feedback data representative of the selected parameter, the control means being responsive to the generated feedback data for operating the filter system supply means in proportional relation to the selected operating parameter of the process system for supplying inlet fluid to the filter system and to produce filtered outlet fluid at a flow rate determined by the feedback data, whereby the filter system is caused to operate at a variable flow rate for supplying filtered fluid to the process system generally in proportion to the varying demands for filtered fluid by the process system to optimize operation of the filter system.

22. The apparatus of claim 21 wherein the control means for controlling operation of the supply means is responsive to the feedback data for operating the filter system supply means in proportional relation to the selected parameter of the process system.

23. The apparatus of claim 21 wherein the filter system supply means is a pump and the control means regulates operation of the pump by adjusting at least its operating speed or volumetric stroke.

24. The apparatus of claim 21 wherein the sensing means senses the rate of filtered fluid demanded by the process system.

25. The apparatus of claim 21 further comprising a holding means for receiving outlet filtered fluid from the filter system and for delivering filtered fluid to the process system on demand, the further sensing means further sensing a flow rate of filtered fluid from the holding means to the process system.

26. The apparatus of claim 25 further comprising a process system pumping means for transferring filtered fluid from the holding means to the process system in response to the varying demands for filtered fluid of the process system, the sensing means sensing operation of the process system pumping means.

27. The apparatus of claim 25 wherein the sensing means senses a level of fluid in the holding means as an indication of varying demands for filtered fluid of the process system.

28. The apparatus of claim 21 further comprising a holding means for receiving outlet filtered fluid from the filter system and for delivering the filtered fluid to the process system on demand, and a process system pumping means for transferring filtered fluid from the holding means to the process system in response to the varying demands for filtered fluid of the process system, the sensing means sensing a selected condition of the process system.

29. The apparatus of claim 21 wherein the supply means is an electrically operated pump and wherein the control means is a variable frequency device.

30. The apparatus of claim 21 wherein the control means comprises a variable stroke device for determining volumetric flow from the filter system supply means.

31. The apparatus of claim 21 further adapted for optimizing operation of the filter system, the filter system being of a type having a first bodyfed filter aid supplied from a first bodyfeed source to a filter element in the filter system, and further comprising:

first means for monitoring at least one first condition selected from the group consisting of (a) a condition of inlet fluid supplied to the filter system, (b) a condition of outlet filtered fluid supplied to the process system; and

(c) a condition of the filter element; and

first means for regulating operation of the first bodyfeed source in response to the first monitoring means in order to supply the first bodyfed filter aid to the filter system in an amount and at times indicated by the first monitored condition.

32. The apparatus of claim 21 wherein the generating means comprises means for averaging the feedback data over a selected time period to achieve uniform operation of the filter system supply means.

33. The apparatus of claim 21 further comprising means for reducing operation of the filter system supply means to a minimum level in the absence of substantial demand for filtered fluid from the process system in order to optimize operation of the process system.

34. Apparatus for optimizing operation of a filter system supplying filtered fluid to a process system, the apparatus comprising:

first and second bodyfeed sources for respectively supplying first and second bodyfeed filter aids to the filter system;

first means for monitoring at least one variable selected from the group consisting of (a) a condition of inlet fluid supplied to the filter system, (b) a condition of outlet filtered fluid supplied to the process system, and (c) a condition of a filter element of the filter system;

first means for regulating operation of the first bodyfeed source in response to the first monitoring means in order to supply the first bodyfed filter aid to the filter system in an amount and at times indicated by the first monitored condition;

second means for monitoring at least one variable selected from the group consisting of (a) a condition of inlet fluid supplied to the filter system, (b) a condition of the outlet filtered fluid supplied to the process system, and (c) a condition of the filter element; and

second means for regulating operation of the second bodyfeed source in response to the second monitoring means in order to supply the second bodyfed filter aid to the filter element in an amount and at times indicated by the second condition.

35. The apparatus of claim 34 wherein the first monitoring means monitors turbidity or particle count of the filter inlet fluid as an indication of relatively larger particles capable of removal in the filter system by the first bodyfed filter aid and the second monitoring means monitors color of the filter outlet fluid as an indication of relatively smaller particles or polar "color bodies" capable of removal by the second bodyfed filter aid, the second regulating means assuring supply of some porous and/or depth type filter aid material in combination with polar clay forming the second bodyfed filter aid.

36. The apparatus of claim 35 further comprising means for regulating operation of the filter system and supplying filtered fluid to the process system at a rate responsive to varying demands of the process system for filtered fluid.

37. An apparatus for optimizing operation of a filter system, the apparatus comprising:

a filter system comprising at least one readily replaceable porous membrane or filter media;

a process system coupled to the filter system, the process system having varying demands for filtered fluid from the filter system;

pump means adapted to vary the flow of fluid therethrough, the pump means supplying fluid to the filter system at varying flow rates depending upon the varying demands for filtered fluid of the process system for optimizing the operation of the filter system;

fluid holding means interposed between the process system and the filter system, the holding means receiving filtered fluid from the filter system for supplying the fluid to the process system;

monitor means for monitoring the level of filtered fluid in the holding means and for supplying feedback data indicative of the filtered fluid level; and

control means coupled to the pump means and to the monitor means, the control means constantly receiving the data from the monitor means for constantly regulating the operation of the pump means to vary the flow rate of fluid supplied to the filter system to optimize the operation of the filter system, such that the filter system supplies filtered fluid to the holding means at a rate generally proportional to the varying demands for filtered fluid of the process system, the control means further inhibiting the pump means from supplying an excessive amount or an insufficient amount of fluid to the filter system.

38. A method for optimizing operation of a pressure filter system supplying filtered fluid to a process system characterized by varying demands for filtered fluid, the method comprising the steps of:

controlling the filter system by a supply means for supplying filtered fluid to the process system at a rate of flow generally proportional to the varying demands for filtered fluid by the process system;

constantly sensing a selected operating parameter of the process system indicative of its varying demands for filtered fluid and generating feedback data representative of the varying demands for filtered fluid by the process system;

regulating operation of the filter system supply means to supply inlet fluid to the filter system at a rate of flow determined by the feedback data, whereby the filter system operates at a variable flow rate supplying filtered fluid generally in proportion to the varying demands for filtered fluid by the process system to optimize operation of the filter system;

supplying a first bodyfed filter aid to a filter element in the filter system by means of a first bodyfeed source;

constantly monitoring at least one first variable condition selected from the group consisting of (a) a condition of inlet fluid to the filter system, (b) a condition of outlet filtered fluid supplied to the process system, and (c) a condition of the filter element;

regulating operation of the first bodyfeed source in response to the monitored condition in order to supply the first bodyfed filter aid to the filter element in an amount and at times indicated by at least one first variable condition;

supplying a second bodyfed filter aid to the filter element by means of a second bodyfeed source;

monitoring a second variable condition indicating requirements for the second bodyfed filter aid; and

operating the first and second bodyfeed sources in response to the first and second monitored variable conditions for respectively supplying the first and second bodyfed filter aids to the filter element at times and in amounts determined by the first and second variable conditions.

39. The method of claim 38 wherein the first condition is turbidity of the filter inlet fluid as an indication of relatively larger particles capable of removal in the filter system by the first bodyfed filter aid and the second condition is color of the filter outlet fluid as an indication of relatively smaller particles or "color bodies" capable of removal by the second bodyfed filter aid supplied to the filter system.

40. Apparatus constructed and arranged for optimizing operation of a filter system receiving fluid to be filtered from a supply means and supplying filtered fluid to a process system characterized by varying demands for filtered fluid, the apparatus comprising:

control means for controlling operation of the supply means and for supplying outlet filtered fluid to the process system at a rate generally proportional to the varying demands for filtered fluid by the process system;

means for sensing a selected parameter of the process system indicative of its varying demands for filtered fluid;

means responsive to the sensing means for generating feedback data representative of the selected parameter, the control means responsive to the generated feedback data for causing the supply means to supply inlet fluid to the filter system and to produce filtered outlet fluid at a rate of flow determined by the feedback data, whereby the filter system is caused to operate at a variable flow rate for supplying filtered fluid to the process system generally in proportion to the varying demands for filtered fluid by the process system to optimize operation of the filter system;

a first bodyfed filter aid supplied from a first bodyfeed source to a filter element in the filter system;

first means for monitoring at least one first condition selected from the group consisting of (a) a condition of inlet fluid supplied to the filter system, (b) a condition of outlet filtered fluid supplied to the process system, and (c) a condition of the filter element;

first means for regulating operation of the first bodyfeed source in response to the first monitoring means in order to supply the first bodyfed filter aid to the filter system in an amount and at times indicated by the first monitored condition;

a second bodyfed filter aid supplied from a second bodyfeed source to a filter element in the filter system;

second means for monitoring at least one second condition selected from the group consisting of (a) a condition of the inlet fluid to the filter system, (b) a condition of the outlet filtered fluid supplied to the process system, and (c) a condition of the filter element; and

second means for regulating operation of the second bodyfeed source in response to the second monitored condition for regulating the supply of the second bodyfed filter aid to the filter element at times and in amounts determined by the second condition.

41. The apparatus of claim 40 wherein the first monitoring means monitors turbidity or contaminant particle count of the filter inlet fluid as an indication of relatively larger particles capable of removal in the filter system by a first bodyfeed and the second monitoring means monitors fluid color as an indication of relatively smaller particles or polar "color bodies" capable of removal by the second bodyfed filter aid supplied to the filter system, the first bodyfed filter aid being a porous/depth type filter aid material and the second bodyfed filter aid being a polar or charged clay.

42. The apparatus of claim 41 wherein the second regulating means is adapted for always supplying depth type filter aid material in combination with the polar or charged clay material.

43. Apparatus constructed and arranged for optimizing operation of a filter system receiving coolant/lubricant to be filtered from a supply means and supplying filtered coolant/lubricant to a process system, the apparatus comprising:

variable control means for controlling operation of the supply means and for supplying outlet filtered coolant/lubricant to the process system at a rate of flow generally proportional to the varying demands for filtered coolant/lubricant by the process system;

means for sensing a selected parameter of the process system indicative of its varying demands for filtered coolant/lubricant;

means responsive to the sensing means for generating feedback data representative of the selected parameter, the control means responsive to the generated feedback data for causing the supply means to supply inlet coolant/lubricant to the filter system and to produce filtered outlet coolant/lubricant at a rate of flow determined by the feedback data, whereby the filter system is caused to operate at a variable rate of flow for supplying filtered coolant/lubricant to the process system generally in proportion to the varying demands for filtered coolant/lubricant by the process system to optimize operation of the filter system;

means for supplying bodyfed filter aid material from bodyfeed means to a filter element in the filter system;

means for monitoring at least one variable condition selected from the group consisting of (a) turbidity of inlet coolant/lubricant supplied to the filter system, (b) color of outlet filtered coolant/lubricant supplied to the process system, and (c) a condition of the filter element; and

means for regulating operation of the bodyfeed means in response to the monitoring means in order to supply the bodyfed filter aid material to the filter system in an amount and at times indicated by the monitored condition.

44. The apparatus of claim 43 wherein the bodyfed filter aid material comprises a porous and/or depth filtering type filter aid material and the bodyfeed means comprises a bodyfeed source for supplying the filter aid material to the filter system in an amount and at times indicated by the monitored condition for removing relatively larger particles from the coolant/lubricant to supply the process system with filtered coolant/lubricant.

45. The apparatus of claim 43 wherein the bodyfed filter aid material comprises a polar or charged clay type filter aid material and the bodyfeed means comprises a bodyfeed source for supplying the filter aid material to the filter system in an amount and at times indicated by the monitored condition for removing relatively smaller particles or polar "color bodies" from the coolant/lubricant to supply the process system with filtered coolant/lubricant.

46. The apparatus of claim 43 wherein bodyfeed means comprises a first bodyfeed source for supplying a first bodyfed filter aid material that comprises a porous/depth filtering type filter aid material for removing relatively larger particles from the coolant/lubricant, the regulating means regulating operation of the first bodyfeed source in response to the monitoring means in order to supply the first bodyfed filter aid material to the filter system in an amount and at times indicated by a first one of the monitored conditions, and a second bodyfeed source for supplying a second filter aid material for removing relatively smaller particles or polar "color bodies" from the coolant/lubricant, the regulating means regulating operation of the second bodyfeed source in response to the monitoring means in order to supply the second bodyfed filter aid material to the filter system in an amount and at times indicated by a second one of the monitored conditions.

47. A method for optimizing operation of a filter system supplying outlet filtered fluid to a processing system, comprising the steps of:

supplying at least a first and a second bodyfed filter aid from at least a first and a second bodyfeed source respectively to the filter system;

monitoring at least a first variable condition selected from the group consisting of (a) a condition of the inlet fluid to the filter system, (b) a condition of outlet filtered fluid supplied to the process system, and (c) a condition of a filter element of the filter system;

regulating operation of the first bodyfeed source in response to the first monitored condition in order to supply the first bodyfed filter aid to the filter system in an amount and at times indicated by the first monitored condition of the filter fluid;

monitoring at least a second variable condition selected from the group consisting of (a) a condition of the inlet fluid to the filter system, (b) a condition of the outlet filtered fluid supplied to the process system, and (c) a condition of the filter element; and

regulating operation of the second bodyfeed source in response to the second monitored condition in order to supply the second bodyfed filter aid to the filter system in an amount and at times indicated by the second monitored condition.

48. Apparatus for optimizing operation of a filter system supplying filtered fluid to a processing system, the apparatus comprising:

first and second bodyfeed sources for respectively supplying either a first or a second bodyfed filter aid to the filter system;

first means for monitoring at least one variable selected from the group consisting of (a) a condition of the inlet fluid to the filter system, (b) a condition of outlet filtered fluid supplied to the process system, and (c) a condition of a filter element of the filter system;

first means for regulating operation of the first bodyfeed source in response to the first monitoring means in order to supply the first bodyfed filter aid to the filter system in an amount and at times indicated by the first monitored condition;

second means for monitoring at least one variable selected from the group consisting of (a) a condition of the inlet fluid to the filter system, (b) a condition of the outlet filtered fluid supplied to the process system, and (c) a condition of the filter element; and

second means for regulating operation of the second bodyfeed source in response to the second monitored condition in order to supply the second bodyfed filter aid to the filter system in an amount and at times indicated by the second monitored condition.