Diester Production Reflux System with Flash Drum
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Solution Overview
Problem
Existing diester-based material production processes face limitations in improving reflux efficiency, productivity, and energy usage due to the batch process nature and limitations in gas-liquid separation and heat recovery.
Innovation Solution
A diester-based material production unit with an improved reflux system that includes a flash drum for gas-liquid separation, a heat exchanger for heat recovery, and strategic connections for reflux lines to maintain high alcohol temperature and reduce coolant usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a batch process is used for diester-based material production, then the process simplicity is maintained, but the productivity is very low and there is a limit to improving the amount of reflux or the volume of steam
Solution Approach 1:
The patent implements a continuous process instead of batch processing, allowing the reactor to operate continuously with constant feed and product removal. This enables uninterrupted production, significantly improving productivity while maintaining process control through continuous monitoring and adjustment of operating parameters.
Solution Approach 2:
The patent divides the production system into multiple functional units including a reactor, flash drum, condenser, and fractionation column, each performing a specific function. This segmentation allows for optimized operation of each component and flexible adjustment of process parameters to improve overall productivity.
2Manufacturing precision
If reflux is increased to improve separation efficiency, then the amount of steam required increases, but this leads to higher energy consumption
Solution Approach 1:
The patent utilizes phase transitions of the alcohol component through controlled heating and cooling processes. The flash drum creates a liquid-vapor mixture through partial vaporization, and the condenser condenses the vapor back to liquid, enabling efficient separation and reflux without requiring excessive steam input.
Solution Approach 2:
The patent optimizes operating parameters including temperature, pressure, and flow rates to achieve efficient separation. By adjusting these parameters, the system maintains high separation efficiency while minimizing energy consumption, avoiding the need for excessive steam input.
3Temperature
If coolant usage is increased to maintain temperature control, then the energy loss increases, but this is necessary for temperature management in the reflux system
Solution Approach 1:
The system uses the hot vapor from the reaction zone to pre-heat the incoming feed and to generate the reflux liquid through controlled condensation. This self-service approach reduces the need for external coolant input, minimizing energy loss while maintaining effective temperature control through internal heat exchange.
Solution Approach 2:
The flash drum performs preliminary separation of the vapor-liquid mixture before the condenser, allowing the liquid phase to be removed early in the process. This preliminary action reduces the cooling load on the condenser and minimizes overall energy consumption while maintaining temperature control.
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 improved reflux system effectively addresses rheological issues, reduces coolant usage, and minimizes energy loss by maintaining high alcohol temperatures and optimizing reflux operations, thereby enhancing productivity and efficiency.
Implementation Method 1
a flash drum having a flash drum main body in which separation of a liquid phase and a gas phase is performed in the mixture stream including the primary alcohol and the water
Implementation Method 2
a condenser installed on the flash drum upper line to liquefy the mixture of the gas-phase primary alcohol and the water in the line
Implementation Method 3
a heat exchanger installed on the gas phase line of the column to remove heat of the gas phase line
Implementation Method 4
a column including a column main body in which the gas-liquid separation of the primary alcohol and the water introduced from the gas phase discharge line is performed
Data Source
AI summary
The present disclosure relates to a diester-based material production unit including a reaction device in which an esterification reaction of dicarboxylic acid and a primary alcohol is performed, a column in which the gas-liquid separation of the primary alcohol and the water introduced is performed, a heat exchanger installed on a gas phase line of the column to remove heat of the gas phase line, a flash drum in which separation of a liquid phase and a gas phase is performed in the mixture stream including the primary alcohol and the water, a condenser installed on the flash drum upper line, and a layer separator in which the layer separation of a mixture of a liquefied primary alcohol and water into an organic layer and an aqueous layer is performed, wherein one or more lines through which recirculated primary alcohol from the flash drum and the layer separator flows are connected to an upper portion of the column. According to the present invention, a coolant usage amount can be reduced and a rheological problem can be eliminated since a liquid phase and a gas phase coexist in a pipe.