Cryogenic Collector Tray Assembly for Uniform Melt Bath Heating
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Solution Overview
Problem
Conventional melt tray assemblies in cryogenic distillation towers face challenges in maintaining uniform heat transfer and temperature stability, leading to inefficient separation of contaminants from hydrocarbons, which can result in increased contaminant content in hydrocarbon streams and operational disruptions.
Innovation Solution
The system incorporates a collector tray assembly with a deck featuring electrical heating elements and vapor risers with branching arms that direct vapor in a vertically upwards and then downwards direction through the liquid bath, promoting tumultuous flow and effective heat transfer across the available volume, thereby enhancing the melting of solids and maintaining a uniform temperature profile.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional melt tray assemblies are used in cryogenic distillation towers, then the structure is simple, but heat transfer efficiency is insufficient and temperature uniformity cannot be maintained
Solution Approach 1:
The melt tray assembly is segmented into multiple functional zones: a vapor distribution section with multiple nozzles arranged in a circular pattern, a liquid bath section, and a heating section with electrical heating elements. This segmentation allows each zone to perform its specific function optimally, contributing to overall temperature uniformity while managing device complexity through modular design
Solution Approach 2:
Different regions of the melt tray assembly are assigned different thermal characteristics. The vapor distribution section introduces warm vapor at specific locations, the liquid bath provides thermal mass and convection, and the heating section with electrical elements provides localized heating. This local differentiation of thermal properties enables maintenance of uniform temperature throughout the assembly
2Power
If vapor is passed through the liquid bath to improve heat transfer, then heat transfer efficiency increases, but lateral temperature differentials may increase
Solution Approach 1:
The vapor distribution section employs asymmetric nozzle arrangement with nozzles positioned at specific angles and heights in a circular pattern. This asymmetric configuration creates turbulent flow patterns that promote lateral mixing of the liquid bath, enhancing heat transfer efficiency while simultaneously reducing lateral temperature differentials through improved fluid circulation
Solution Approach 2:
The upward passage of vapor through the liquid bath creates natural turbulence and oscillating flow patterns. This mechanical disturbance of the liquid enhances convective heat transfer coefficients and promotes uniform temperature distribution laterally across the bath, resolving the contradiction between heat transfer efficiency and temperature uniformity
3Stability of the object's composition
If electrical heating elements are added to the melt tray assembly, then temperature stability improves, but device complexity and energy consumption increase
Solution Approach 1:
The melt tray assembly incorporates temperature sensing capability that provides feedback to control the electrical heating elements. The heating elements are activated only when temperature drops below a set point, and deactivated when the desired temperature is achieved. This feedback control maintains temperature stability while minimizing energy consumption by avoiding continuous heating
Solution Approach 2:
The liquid bath in the melt tray assembly serves a dual function: it acts as the process medium for contaminant removal and simultaneously provides thermal mass that resists temperature changes. This self-service capability of the liquid bath reduces the energy demand on the electrical heating elements, as the thermal inertia of the liquid helps maintain temperature stability without continuous external heating
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 configuration improves heat transfer efficiency, reduces lateral temperature differentials, and maintains a stable liquid bath temperature, leading to improved separation performance and reduced operational costs by ensuring consistent contaminant removal from hydrocarbon streams.
Implementation Method 1
The system incorporates a collector tray assembly with a deck featuring electrical heating elements
Implementation Method 2
vapor risers with branching arms that direct vapor in a vertically upwards and then downwards direction through the liquid bath
Implementation Method 3
promoting tumultuous flow and effective heat transfer across the available volume
Implementation Method 4
effective heat transfer across the available volume, thereby enhancing the melting of solids
Implementation Method 5
enhancing the melting of solids and maintaining a uniform temperature profile
Data Source
AI summary
The disclosure includes techniques associated with a collector tray assembly for a cryogenic distillation tower disposed below a slurry mix zone and above a lower distillation zone, wherein the collector tray assembly comprises a deck at a lower end of the slurry mix zone, and wherein the deck comprises at least one vapor riser configured to pass the vapor from the lower distillation zone into the slurry mix zone, wherein the vapor riser comprises a substantially vertical heat transfer section configured to pass the vapor substantially upwards through the slurry mix zone, and a vapor outlet section comprising at least one vapor outlet, wherein the vapor outlet section is below the heat transfer section.