Distillation Vessel Segmentation for Solvent Recycling
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Solution Overview
Problem
Existing solvent recycling systems for industrial processes are inefficient in terms of space, energy, and operator intervention, particularly in small operations, due to the need for large waste collection and distillation vessels, and frequent manual removal of sludge.
Innovation Solution
A distillation system with a separate waste collection zone and automatic operation, where the distillation zone is confined to the top of the vessel, allowing sludge to accumulate without impeding heating efficiency, and utilizing the change of solvent vapor state to cycle contaminated solvent without user intervention, reducing energy consumption and increasing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a large waste collection container and large distillation vessel are provided to accommodate sludge accumulation between removal operations, then the sludge capacity is sufficient, but the space requirements and cost increase
Solution Approach 1:
The distillation vessel is segmented into two distinct zones: a distillation zone for solvent processing and a waste collection zone for sludge accumulation. This segmentation allows the waste collection zone to be separately optimized for sludge capacity while the distillation zone maintains efficient processing volume, resolving the contradiction between accommodating accumulated sludge and maintaining processing efficiency.
2Productivity
If the distiller is run periodically to process contaminated solvent, then sufficient recycled solvent is produced for cleaning operations, but a large mass of contaminated solvent must be heated to boiling each time, increasing energy consumption
Solution Approach 1:
The system enables continuous operation by maintaining a constant supply of contaminated solvent to the distillation zone through the vacuum pumping action during the cooling phase. This continuous feed allows the distillation process to operate repeatedly without large periodic batches, reducing the total energy required to heat and process the solvent while maintaining sufficient recycled solvent production.
3Ease of operation
If manual operation is used to initiate and terminate batchwise operations, then operator control is maintained, but operator intervention is inevitably involved, reducing automation
Solution Approach 1:
The system performs automatic operation through the inherent cyclic behavior of the distillation-vacuum process. The heating phase generates vapor that condenses during the cooling phase, creating a vacuum that automatically draws more contaminated solvent into the vessel. This self-sustaining cycle eliminates the need for manual initiation and termination of batches, achieving automation while maintaining ease of operation through simple monitoring.
4Quantity of substance
If sludge is allowed to accumulate in the distillation zone, then waste collection capacity increases, but the efficiency of the heating medium is impeded
Solution Approach 1:
The distillation vessel is divided into separate distillation and waste collection zones, allowing sludge to accumulate in the waste collection zone without contacting or impeding the heating medium in the distillation zone. This spatial separation maintains heating efficiency while providing adequate waste collection capacity.
Solution Approach 2:
The waste collection function is extracted from the distillation zone and placed in a separate zone within the vessel. This extraction allows sludge to be collected and accumulated without interfering with the heating process, resolving the contradiction between waste collection capacity and heating efficiency.
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 solution reduces the frequency of manual waste removal, minimizes energy usage, and allows for continuous solvent recycling with a smaller distillation vessel, making it suitable for small operations and adaptable for larger ones, while maintaining efficient processing and solvent recovery.
Implementation Method 1
heating only the upper region of the vessel and providing a separate waste collection zone within the vessel. The sludge passes from the distillation zone to the waste collection zone
Implementation Method 2
heating only the upper region of the vessel
Implementation Method 3
During the cooling phase, solvent vapour re-condenses in the distillation vessel and this change of state creates a vacuum which sucks more contaminated solvent into the vessel
Implementation Method 4
this change of state creates a vacuum which sucks more contaminated solvent into the vessel
Data Source
AI summary
A contaminated solvent recycling system is disclosed and claimed. The system comprises a distillation vessel having an upper distillation zone and a separate, lower, waste collection zone. A heater heats contaminated solvent feed within the distillation zone to distill off the solvent. By separating the distillation zone from the waste collection zone, the distillation zone can process consecutive batches of contaminated solvent feed. The waste collection zone can accommodate waste accumulating from the distillation process for extended periods of time between waste removal operations.