Cross-flow filter for crystallized pellet liquid separation
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Solution Overview
Problem
Existing separation devices fail to effectively reduce fines in the liquid discharge stream and increase the dryness of the solids discharge stream while maintaining pressure equal to or greater than the vapor pressure of the liquid, leading to equipment fouling and high water content in discharged particles.
Innovation Solution
A separation device with a cross-flow filter and a decoupling device that maintains a pressurized environment above the vapor pressure of the liquid, featuring a porous filter with a terminal point above the liquid outlet to prevent liquid recirculation and enhance solid particle separation, allowing for continuous discharge of solids with reduced water content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional separation device with cylindrical wire mesh is used to separate particles from liquid, then the particles can be discharged through a gate means, but the fines build up in the closed loop process and foul equipment
Solution Approach 1:
The separation device is segmented into distinct functional zones: an inner annulus for particle flow, an outer annulus for liquid collection, and a cross-flow filter barrier between them. This segmentation allows particles and liquid to be separated into different discharge streams, preventing fines from contaminating the liquid recycle stream and reducing equipment fouling.
Solution Approach 2:
The harmful fines are extracted from the liquid stream by directing them into the inner annulus for separate discharge through the solids outlet. The cross-flow filter extracts and removes fines from the circulation loop, preventing their accumulation in the closed loop process and subsequent equipment fouling.
2Stability of the object's composition
If the particles are discharged through a gate means maintaining pressure above vapor pressure, then the liquid remains in liquid state, but the discharged particles have high water content proportional to water entrained in the gate means
Solution Approach 1:
The cross-flow filter acts as an intermediary barrier between the particle bed and the liquid discharge. It allows liquid to pass into the outer annulus for separate discharge while blocking particles and fines from entering the liquid stream. This intermediary structure enables pressure maintenance for liquid stability while significantly reducing water content in the discharged particles.
Solution Approach 2:
The discharge system is segmented into separate liquid and solids outlets. The liquid outlet discharges only liquid through the cross-flow filter, while the solids outlet discharges particles through the decoupling device. This segmentation prevents water entrainment in the particle discharge, reducing water content in the solids stream.
3Object-generated harmful factors
If a cross-flow filter with porous structure is introduced to separate liquid from particles, then fines in liquid discharge can be reduced, but the device complexity increases
Solution Approach 1:
A cross-flow filter with porous structure is introduced as the separation barrier between the inner and outer annuli. The porous structure allows liquid to pass through while blocking particles and fines, effectively reducing fines content in the liquid discharge stream.
Solution Approach 2:
The cross-flow filter performs multiple functions simultaneously: it separates liquid from particles, prevents fines from entering the liquid discharge, maintains pressure differential across the filter, and enables the decoupling device to function effectively. This multi-functionality reduces the need for additional separate components.
4Reliability
If the porous filter terminal point is located above the liquid outlet, then liquid recirculation is prevented and solid particle separation is enhanced, but the device complexity increases
Solution Approach 1:
The filter terminal point is positioned at a different vertical dimension above the liquid outlet, creating a height differential that prevents liquid recirculation. This dimensional arrangement uses gravity and pressure differential to direct liquid flow downward to the outlet while allowing particles to be discharged separately, enhancing separation effectiveness.
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
The solution effectively reduces fines in the liquid discharge and increases the dryness of the solids discharge stream without the need for rotation or heat application, maintaining a pressurized environment to prevent equipment fouling and minimize water content in the solids.
Implementation Method 1
a cross-flow filter, having pores, disposed within the separation device to form an outer annulus defined as a space between the wall of the separation device and the cross-flow filter to receive liquid
Implementation Method 2
maintaining the pressure on the particles prior to decoupling at or above the vapor pressure of the liquid within the separation zone
Data Source
AI summary
A process and apparatus which reduces the fines in a liquid discharge stream and/or increases the dryness of a solids discharge stream while under a pressure equal to or greater than the vapor pressure of the liquid. There is provided a process for separating particles such as polyethylene terephthalate or polyethylene naphthalate from a liquid in a slurry comprising feeding a slurry comprising solid particles and a liquid into a separation zone maintained at a pressure equal to or greater than the vapor pressure of the liquid; contacting the slurry in the separation zone with a porous filter; and separating liquid from the particles, wherein the liquid flows through the filter into an outer annulus defined as a space between a wall of the separation device and the filter, said porous filter having a terminal point beyond which the separated liquid does not pass from the outer annulus back through the filter; accumulating no liquid in the outer annulus or accumulating liquid in the outer annulus at a level below the terminal point, and continuously discharging the separated liquid form the outer annulus through a liquid outlet; and decoupling the particles from the separation zone through an outlet at a low pressure below the vapor pressure of the liquid at the liquid temperature within the separation zone, while maintaining a pressure on the particles prior to decoupling at or above the vapor pressure of the liquid within the separation zone.