Compact Cryogenic Cold Box Layout for Higher Throughput
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Solution Overview
Problem
Cryogenic plants face challenges in maximizing production capacity due to constraints on weight, length, and cross-sectional area of cold boxes, leading to inefficiencies in heat and mass transfer operations, which result in high refrigeration needs and power consumption.
Innovation Solution
The design of a cryogenic process apparatus featuring two direct phase separation devices with circular perimeters enclosed by a cold box perimeter, with ancillary equipment strategically placed to minimize cold box volume and construction costs, allowing for optimized sizing of heat exchangers and columns to fit within the cold box dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If process equipment is packaged in a cold box with standard dimensions, then transportation constraints are satisfied, but production capacity is limited
Solution Approach 1:
The patent places multiple process equipment items (heat exchangers, columns, phase separators) inside the cold box in a nested arrangement, maximizing the utilization of internal volume and achieving higher production capacity within constrained cross-sectional dimensions
Solution Approach 2:
The patent optimizes the vertical arrangement and spatial orientation of equipment within the cold box, transitioning from horizontal to vertical dimension utilization to increase throughput capacity without expanding the horizontal cross-section
2Weight of stationary object
If cold box dimensions are reduced to meet transportation constraints, then weight and shipping requirements are satisfied, but heat ingress mitigation becomes more difficult
Solution Approach 1:
The patent changes the dimensional parameters of the cold box, specifically reducing cross-sectional area while maintaining optimized internal volume utilization, which affects the surface-area-to-volume ratio and consequently the heat ingress characteristics
Solution Approach 2:
The patent employs composite insulation structures and advanced insulation materials in the cold box design to achieve effective heat ingress mitigation in a compact, weight-efficient manner that satisfies both transportation and thermal performance requirements
3Productivity
If equipment is arranged to maximize cold box throughput, then production capacity increases, but device complexity increases
Solution Approach 1:
The patent divides the cold box into distinct functional zones or modules, each containing specific equipment (heat exchangers, columns, separators), which allows for systematic arrangement that maximizes throughput while managing complexity through modular design
Solution Approach 2:
The patent designs equipment and arrangements that serve multiple functions simultaneously, reducing the total number of components needed and simplifying the overall system while maintaining high throughput capacity
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 maximizes cold box throughput for a given cross-sectional area, reducing the need for additional refrigeration and associated power consumption while maintaining high production capacity.
Implementation Method 1
direct phase separation device which serves to separate a combined gas and liquid stream
Implementation Method 2
A cold box is an insulated enclosure which encompasses sets of process equipment
Data Source
AI summary
A cryogenic plant having at least two direct phase separation devices such as distillation columns whose circular perimeters serve to define the perimeter of the cold box encompassing the direct phase separation devices and ancillary equipment for the process.