Aqueous Solution Concentration via Membrane and Freeze Segmentation
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Solution Overview
Problem
Existing methods for highly concentrating aqueous solutions containing thermally sensitive organic constituents, such as proteins and enzymes, are limited by high viscosity issues in freeze concentration, leading to reduced separation efficiency and increased production costs due to the need for extensive drying processes.
Innovation Solution
A method involving pre-concentration through membrane filtration followed by targeted freeze concentration, where the ice crystallate and mother solution are returned to the membrane filtration stage, allowing for increased viscosity up to 0.001 m2/s (1000 cSt) and enabling higher concentration without organic substance loss, while maintaining pumping capability and controlling temperature sensitivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If freeze concentration is used to highly concentrate aqueous solutions, then water content is reduced and concentration is increased, but viscosity increases significantly reducing separation efficiency
Solution Approach 1:
The concentration process is divided into multiple freeze concentration stages, each operating at different temperatures and achieving progressive concentration. This segmentation allows the system to handle increasing viscosity by resetting conditions in each stage, maintaining separation efficiency while achieving high overall concentration.
Solution Approach 2:
The patent changes operating parameters (temperature, pressure, residence time) between stages to optimize performance at different concentration levels. By adjusting these parameters, the system adapts to changing viscosity conditions and maintains effective separation throughout the concentration process.
2Quantity of substance
If freeze concentration is used to achieve high concentration, then water removal is improved, but plant complexity and production costs increase
Solution Approach 1:
Multiple freeze concentration stages are combined into an integrated system with shared components (pumps, heat exchangers, separators). The stages are arranged in series with optimized material and energy flow, reducing overall plant complexity compared to separate independent concentration units.
Solution Approach 2:
The patent designs the system so that certain components serve multiple functions across different stages. For example, the separated water from one stage becomes feed for the next stage, and heat exchangers are configured to serve both cooling and heating functions in different operational contexts, reducing the total number of components needed.
3Quantity of substance
If freeze concentration is used for high concentration, then water removal is improved, but organic substance loss increases due to reduced separation efficiency
Solution Approach 1:
The system incorporates feedback mechanisms where the concentrate from each stage is monitored and adjusted before entering the next stage. This feedback control ensures optimal operating conditions are maintained, maximizing separation efficiency and minimizing organic substance loss throughout the concentration process.
Solution Approach 2:
The patent performs preliminary concentration and preparation in earlier stages to optimize the feed conditions for subsequent stages. By pre-conditioning the material (adjusting temperature, partial concentration), the system prepares it for more efficient separation in later stages, reducing organic substance loss.
4Ease of manufacture
If evaporation is used to concentrate aqueous solutions, then the process is simple, but thermally sensitive organic constituents are damaged
Solution Approach 1:
The patent uses freeze concentration which exploits the phase transition of water from liquid to solid (freezing) for separation, rather than evaporation which uses liquid to gas transition. This phase change occurs at low temperatures, preserving thermally sensitive organic constituents while still achieving effective water removal and concentration.
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 achieves a higher concentration of organic constituents with reduced water content, minimizing organic substance loss and thermal stress, resulting in a more efficient and cost-effective process with improved yield and product quality.
Implementation Method 1
a) a major portion of the water is extracted by means of membrane filtration from the solution for pre-concentration
Implementation Method 2
b) the solution which is pre-concentrated in this way is then subjected to a freeze concentration procedure, in which, in the form of separated ice crystallisate, further water is extracted from the solution
Implementation Method 3
the separated ice crystallisate from the freeze concentration with the adherent mother solution as a suspension is returned to the membrane filtration upstream of membrane filtration or after melting of the ice crystallisate
Data Source
AI summary
A method for highly concentrating aqueous solutions containing thermally sensitive organic constituents and with or without mineral constituents, wherein firstly, a major portion of the water is extracted by membrane filtration from the solution for pre-concentration and is discharged from the process and the solution which is pre-concentrated is then subjected to a freeze concentration procedure, in which, in the form of separated ice crystallisate, further water is extracted from the solution. To promote results, that concentration may be effected in the freeze concentration procedure until a viscosity of the mother solution of at least 0.0002 m2/s is achieved, and in that the separated ice crystallisate from the freeze concentration with the mother solution adhering thereto as a suspension is returned to the membrane filtration upstream of the membrane filtration or after melting of the ice crystallisate.