GB2468406A

GB2468406A - A fluid reconditioning system

Info

Publication number: GB2468406A
Application number: GB201003572A
Authority: GB
Inventors: Kevin Neal Davies; Albert Neal Davies
Original assignee: IND POWER UNITS Ltd
Current assignee: IND POWER UNITS Ltd
Priority date: 2009-03-05
Filing date: 2010-03-03
Publication date: 2010-09-08
Anticipated expiration: 2030-03-03
Also published as: GB2468406B; WO2010100420A3; CN102438720B; CN102438720A; WO2010100420A2; GB0903766D0; GB201003572D0

Abstract

An evaporation head 410 for a fluid reconditioning system 400, comprising a heat diffuser 415 and a cover 420 together defining an evaporation chamber 480, and a heating element 421 for heating the heat diffuser. The heating element 421 is carried on or by the diffuser 415 such that the heating element is encased by the diffuser 415. The diffuser may have a frusto-conical shape. The diffuser 415 and cover 420 are separate, individual parts with a heat and oil resistant gasket forming a seal. The fluid reconditioning system further comprises a holding canister 450 which contains a filter canister 440 containing cotton. In use, oil enters the system via inlet 475 and is filtered through filter canister 440. The filter oil then passes into the evaporation chamber via passageway 460 and flows in a thin film over heated surfaces 465. Contaminants are vapourised and leave the system via vent 470 while the purified oil leaves via outlet 471.

Description

FLUID RECONDITIONING SYSTEM

The present invention relates to a fluid reclamation device for reconditioning fluids, typically lubricants, used in machinery such as vehicle engines or hydraulic systems.

Oil reclamation devices are already known which treat a bypass flow of oil and may work in tandem with a conventional full flow oil filter. Such devices for use in engines, motors, hydraulics, transmissions and the like are gaining in popularity because they can dramatically increase the time between oil changes.

The present invention relates in part to an oil reclamation device that has enhanced efficiency compared to conventional devices.

According to a first aspect of the present invention there is provided an evaporation head for a fluid reconditioning system, comprising a heat diffuser plate and a cover together defining an evaporation chamber, and a heating element for heating the heat diffuser plate, in which the heating element is carried on or by the diffuser plate and in which the plate and cover are split and the plate is insulated from the cover.

According to a second aspect of the present invention there is provided a fluid reconditioning system comprising an evaporation head as described herein.

An oil cleaning system is provided for use on a wide variety of lubricating oils including synthetic and semi-synthetic. The system effectively removes harmful contaminants and thus significantly extends oil service life. The system will remove solid contaminants down to one micron in size and also has the ability to remove liquid and gas contaminants S..

: through an evaporation effect: as a result the build up of acidic contaminant is prevented, If has been shown that the use of the system will reduce oil consumption by 75% on engine applications and by greater than 90% on hydraulic applications, there is also a commensurate reduction in the consumption of full flow (standard) filters.

Although filtration is an important part of any cleaning system, removal of solid particles is not sufficient. Evaporation is required to remove liquid and gaseous contaminants.

The system of the present invention works to two basic principles: -Filtration and Evaporation. It has become evident that while the filtration aspect is relatively well proven the evaporation capability required significant improvement and development; accordingly it is to this area that the patent application is directed. Specifically: the evaporation head removes liquid and gas contamination through allowing a thin film of oil to flow over a heated (evaporation) surface area.. In effect the system ensures a comparatively small volume of oil flows over a (comparatively) large surface area thereby engendering the thin film evaporation effectt' which ensures rapid release of liquid and gas contaminants to atmosphere.

The filter typically comprises unbleached cotton. Not only does this provide a good physical particulate filter, but it also includes a protein which is easily attacked by acids, which helps with the chemical filtration.

The system may form part of a bypass system, a full flow system, or a combination of the two.

The current condition of the conditioned fluid can be monitored. For example, a sensor can be used to measure the dielectric constant (or relative permittivity) of oil.

There is a close correlation between the oil dielectric constant and the oil quality (or deterioration). This information can be transmitted locally or communicated, for example electronically, to allow remote monitoring. * *

The heat diffuser plate may be generally frusto-conical. The cover plate may be * generally frusto-conical.

I * ** * I *

The plate may be insulated from the cover by a heat and oil resistant gasket.

ISS

I

The heating element may be an electric heating element.

The heating element may be encased in the diffuser plate.

The plate may be adapted to receive fluid from underneath in use, with fluid then flowing out over the heated evaporation surface.

The plate may include an annulus of orifices through which fluid can enter the evaporation chamber.

The cover may include a vent for releasing contaminants.

The present invention will now be more particularly described, by way of example, with reference to the accompanying drawings, in which: Figure 1 is a perspective view of an evaporation head designated development P1; Figure 2 is a perspective view of a heat diffuser forming part of an evaporation head designated development P2; Figure 3 is a perspective view of the heat diffuser of Figure 2 shown with a cover, which together form the evaporation head; Figure 4 is a magnified view showing the underside of the cover of P2; Figure 5 is a perspective view of a cover (shown upturned for clarity) and a heat diffuser * S..

20 together forming an evaporation head designated P3;

S

* *. S.. * S

Figure 6 is a magnified view showing the underside of the cover of P3; S. ** * S S * * Figure 7 is a side view of an evaporation head designated development P4; Figure 8 is an underplan perspective view of P4; S..

Figure 9 is a section of a fluid reconditioning system including an evaporation head designated development P5; Figure 10 shows perspective view of the evaporation head, filter unit and holding canister which together make up the system of Figure 9; Figure 11 is a perspective view of the filter unit of Figure 10 shown fitted into the canister; Figure 12 is a perspective view of the filter unit of Figures 10 and 11; Figure 13 is a plan view of a cover unit forming part of the evaporation head of Figure 9; Figure 14 is a side perspective view of the evaporation head of Figure 9; Figure 15 is a perspective view of a heat diffuser forming part of the evaporation head of Figure 14; Figure 16 is a side view of the heat diffuser of Figure 15; Figure 17 is an underplan view of the heat diffuser of Figures 15 and 16; Figure 18 is an underplan view of the cover of Figure 13; and Figure 19 is a perspective view of a heat diffuser forming part of an evaporation head formed according to an alternative embodiment of development P5.

The evaporation head of the present invention has been developed to provide a significantly improved evaporation effect over existing systems. The Research and * .** S..... Development Programme resulting in various embodiments of the present invention is a.

* S detailed below. ** S.

An extensive test programme had been completed to achieve maximum evaporation *.* * effect. * .. * . . *** *

* Figure 1 illustrates an evaporation head 10 formed according to the original *,S embodiment-designated P1.

The head 10 comprises a heat diffuser part 15 and a cover part 20 which when fitted together form an evaporation chamber.

The cover 20 is provided with a cylindrical casing 21 which houses a heater.

The heat diffuser 15 is provided with a plurality of inlets 1 6 in two diametrically opposed arcuate evaporation blocks 17. The inlets 16 receive contaminated fluid so that it can flow over onto the outer surfaces of the blocks.

When the cover 20 is fitted onto the diffuser 15 the heater is positioned centrally between the blocks 17.

This embodiment is more efficient than known systems but ultimately inefficient in comparison to later developments due to minimal heat transfer from the heating element slots and a small evaporation surface area. On tests using 25 litres of hydraulic oil laboratory contaminated with 2% water (the speed of the systems ability of the to remove the water is efficiency of the evaporation effect) version P1 took greater than 48 hours to remove the water.

Figure 2 to 4 illustrate an evaporation head 110 formed as the next stage of development -P2.

In this embodiment the oil passes through slots 122 next to an electric heater 121 and then flows over a frusto-conical plate 118 centrally positioned on the diffuser 115 to provide the evaporation effect. This system removed the water contaminated as ** 20 detailed above in approximately 36 hours. * *

To improve on P2, an evaporation head 210 known as P3 was developed using a spiral ** S. * S * * oil flow channel pattern 223 around the heating element 221 (as illustrated in Figure 5 S..

and 6). This embodiment was designed to increase the temperature of the oil by * ..

:. . providing a larger surface area for the oil to flow through. However, there was no noticeable improvement in the system's ability to remove the water contamination (2% by volume in hydraulic oil as detailed above).

This led to the conclusion that the key to effective evaporation was the heated surface area of the conical plate -therefore P4 was developed as illustrated in Figures 7 and 8.

In this embodiment the evaporation head 310 is formed with a cover 320 and diffuser plate as an integral unit. An oil inlet 319 is formed in a flow cylinder depending from the centre of the diffuser plate 315.

With the tests conducted on this embodiment we were able to observe that the rate of evaporation did significantly improve -24 hours to remove the water. This further proved that the increased surface area for evaporation improved the evaporation effect.

however it was observed that the system lost significant amounts of heat from the integral top cover.

Accordingly P5 was developed as shown in Figures 9 to 18. The improved evaporation head 410 forms part of a reconditioning system 400 (as shown best in Figure 9) with a filter canister 440 and a casing 450.

The head 410 incorporates a split (in other words -formed separately) cover 420 and frusfo-conical heat diffuser plate 415. A heat and oil resistant gasket 455 is inserted between the two parts 415, 420 to insulate the plate from the cover.

Tests conducted on this unit proved that retaining the heat on the conical diffuser plate was highly effective -complete evaporation of the water in the test oil was achieved in less than 10 hours.

20 The evaporation head 410 has an electric hedting element 421 encased in aluminium which is shaped as a frusto-conical plate which in turns acts as the heated evaporation plate. S..

Oil flows out of the filter 440 underneath the diffuser cone and exits into the evaporation S. chamber by an annulus of orifices 460 which give a controlled and measured flow of oil film over the heated surface 465. In this embodiment there are eighteen orifices each of which is 1.5mm in diameter.

Gases and liquids are released from the oil by evaporation -the oil is now at atmospheric pressure due to the pressure drop through the filter which means that the gas and liquid contaminants can be vented to atmosphere through the vent valve 470 mounted on top of the evaporation chamber cover 420.

The oil then exits the evaporation chamber via an outlet 471 and returns to the lubrication system by gravity.

Contaminated oil enters the unit through a restrictor 475 ensuring a slow, measured flow rate. The oil passes through the replaceable filter element 440; the filter medium, consisting of compressed, unprocessed, long strand cotton removes solid contaminants down to one micron.

Oil then passes into the heated evaporation chamber 480 where liquid contaminants (e.g. water and volatile organic and inorganic compounds of fuel) and gaseous contaminants (e.g. sulphur dioxide) are evaporated and immediately vented -i.e. acid precursors are removed before they react to form harmful acids in the oil.

H20 + S02 / SO3 H2S04: Water reacts with Sulphur Dioxide, Trioxide to form Sulphuric Acid.

The system removes H2S04 components -Proactive, Pre-reaction.

The oil then flows back to the engine sump or hydraulic system by gravity.

Filtration * *** * * *S*.

: 20 1. Particulate size of less than one micron will not have an abrasive effect in an engine or hydraulic oil. * S S * S

2. Most quality engine oils will keep solid contaminants (such as sludge) in suspension to a particle size of 3-4 microns. When the particle size agglomerates to greater than this the contaminant will fall out of suspension to be deposited in the sump or other areas of the engine, with resultant detrimental effect on the qualities of oil and engine performance.

Evaporation In terms of oil cleanliness equally important to the effect of filtration is that of evaporation.

Removal of Liquid and Gaseous contaminants.

For example (Engine Oil): -Water (H20) is present in oil due to condensation or as a by-product of combustion. Gas contaminants in the form of Sulphur Dioxide (S02) and Sulphur Trioxide (SO2) are also present due to the combustion process combined in the heat and pressure of the engine they form Sulphuric Acid (H2S04).

The system removes wafer and gas contaminants through the thin film evaporation effect present in the evaporation chamber acid formation is prevented -additives remain intact.

The system has similar benefits in hydraulic systems continuous evaporation of water.

A smaller version (known as PS mini version) has been developed for smaller engines and hydraulic systems. A diffuser plate 515 for this purpose is shown in Figure 19.

Unexpectedly this version has been found to be particularly efficient when used in combination with the same heater used for larger versions. In one embodiment the heater has the following characteristics: 24 volts; 150 watts; 6.25 Amps. This is used in *..a * * *S..

conjunction with a slower restrictor: 20 litres/hour. * * *. ** * S * * S

S *S.

S * 55 * 5 5 S.. S

S *e.

S

Claims

CLAIMS1. An evaporation head for a fluid reconditioning system, comprising a heat diffuser and a cover together defining an evaporation chamber, and a heating element for heating the heat diffuser, in which the heating element is carried on or by the diffuser, the diffuser and cover are split, and the diffuser is insulated from the cover.
2. An evaporation head as claimed in Claim 1, in which the heat diffuser is a generally frusto-conical plate.
3. An evaporation head as claimed in Claim 1 or Claim 2, in which the cover is a generally frusto-conical plate.
4. An evaporation head as claimed in any preceding claim, in which the plate is insulated from the cover by a heat and oil resistant gasket.
5. An evaporation head as claimed in any preceding claim, in which the heating element is an electric heating element.
6. An evaporation head as claimed in any preceding claim, in which the heating element is encased in the diffuser. * *
7. An evaporation head as claimed in any preceding claim, in which the diffuser is adapted to receive fluid from underneath in use. * I.S S.. *S S..
8. An evaporation head as claimed in any preceding claim, in which the diffuser includes an annulus of orifices through which fluid can enter the evaporation chamber.
9. An evaporation head as claimed in any preceding claim, in which the cover includes a vent for releasing contaminants.
10. An evaporation head substantially as hereinbefore described with reference to, and as shown in, the accompanying drawings.
11. A fluid reconditioning system comprising an evaporation head as claimed in any preceding claim.
12. A system as claimed in Claim 11, in which the system comprises a filter.
13. A system as claimed in Claim 12. in which the filter comprises unbleached cotton.
14. A system as claimed in any of Claims 11 to 13, in which the system comprises a holding canister.
15. A fluid reconditioning system substantially as hereinbefore described with **.reference to, and as shown in, the accompanying drawings. 9* .*
16. A vehicle provided with a fluid reconditioning system as claimed in any of S..Sclaims 11 to 15. * I. * * * Ill u a **.S