Distillation Flooding Detection via Differential Pressure Phase Inversion
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Solution Overview
Problem
Distillation processes face challenges in detecting and controlling flooding conditions, which disrupt separation efficiency and can lead to product losses and system downtime, particularly in various distillation systems and processes.
Innovation Solution
A method and system that senses differential pressure signals along a distillation flow path, filters the signal based on frequency, and generates a flooding indicator to detect the onset of flooding, allowing for timely intervention to prevent runaway conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If vapor flow rate is increased to improve distillation throughput, then productivity increases, but flooding risk increases causing separation efficiency to deteriorate
Solution Approach 1:
The patent applies preliminary action by detecting early signs of flooding through differential pressure monitoring and phase inversion detection before actual flooding occurs. The system continuously monitors pressure differentials across the distillation column and detects phase inversion in the two-phase flow, providing advance warning that allows operators to adjust vapor flow rates before separation efficiency deteriorates and productivity is compromised
2Productivity
If heating rate is increased to improve distillation output, then productivity increases, but flooding occurs causing system stability to deteriorate
Solution Approach 1:
The patent implements feedback control by continuously monitoring differential pressure across the distillation column and using this information to detect flooding conditions. The system measures pressure differentials between multiple points in the column, processes these signals to detect phase inversion, and provides feedback that allows operators to adjust heating rates to maintain process stability while maximizing distillation output
3Stability of the object's composition
If vapor flow rate is increased to prevent runaway conditions, then system stability improves, but separation efficiency deteriorates due to axial mixing
Solution Approach 1:
The patent applies preliminary action by detecting early signs of flooding through differential pressure monitoring and phase inversion detection before actual flooding occurs. The system continuously monitors pressure differentials across the distillation column and detects phase inversion in the two-phase flow, providing advance warning that allows operators to adjust vapor flow rates before separation efficiency deteriorates and productivity is compromised
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
Effectively detects the onset of flooding, enabling proactive control measures to maintain separation efficiency and prevent system disruptions, adaptable to different distillation systems and processes.
Implementation Method 1
sensing a differential pressure signal along a distillation flow path
Implementation Method 2
filtering the signal as a function of frequency
Implementation Method 3
The filtered differential pressure signal is responsive to a phase inversion along the flow path
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
A method comprises sensing a differential pressure signal [64, 74], filtering the differential pressure signal [66, 76], generating a flooding indicator as a function of the filtered differential pressure signal, and indicating the onset of flooding [70, 80]. The differential pressure signal is sensed along a distillation flow path [16]. The filtered differential pressure signal is responsive to a phase inversion along the flow path, and the flooding indicator is responsive to an onset of a flooding condition, based on the phase inversion. The onset of the flooding condition is indicated based on a change in the flooding indicator.