Dynamic Membrane Soaking for Faster Separation Start-Up
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Solution Overview
Problem
Conventional methods for separating water and organic compounds, such as distillation and membrane technologies, face high energy consumption, low separation efficiency, and limited economic feasibility due to prolonged start-up times and inconsistent performance.
Innovation Solution
A membrane-based separation method with a rapid start-up procedure and optimized conditions, utilizing machine learning and artificial intelligence algorithms to adjust operating parameters, achieving increased flux and permeate purity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If conventional membrane-based separation methods are used, then separation of liquid mixtures can be achieved, but the start-up time is prolonged and steady state is attained slowly
Solution Approach 1:
The patent applies preliminary action by pre-soaking the membrane in the liquid mixture before actual separation operation. This pre-conditioning step allows the membrane to equilibrate with the feed solution, establishing favorable concentration gradients and reducing mass transfer resistance. The method specifically involves circulating the liquid mixture through the membrane at controlled flow rates during a predetermined soaking period, which prepares the membrane for rapid steady-state operation when production begins.
Solution Approach 2:
The patent implements dynamics by using variable flow rate operation during the start-up phase. Instead of maintaining constant flow rates, the system dynamically adjusts the circulating flow rate through the membrane module during the soaking period, then transitions to optimal separation flow rates. This dynamic operation allows the membrane to adapt to changing conditions and reach steady state more quickly, resolving the contradiction between fast start-up and consistent performance.
2Loss of energy
If distillation is used for separating water and organic compounds, then separation can be achieved, but energy consumption and steam consumption are high
Solution Approach 1:
The patent replaces the thermal field-based distillation process with a membrane-based separation system that operates on different physical principles. Instead of using heat and steam to achieve separation through vaporization and condensation, the system uses pressure-driven or concentration-gradient-driven membrane transport. This substitution eliminates the need for large amounts of steam and high energy consumption while maintaining effective separation of water and organic compounds, directly addressing the energy loss problem.
Solution Approach 2:
The patent changes the operating parameters from thermal conditions (temperature, steam pressure) used in distillation to mechanical/chemical parameters (transmembrane pressure, concentration gradients) used in membrane separation. By operating at moderate temperatures and using pressure differentials across the membrane, the system achieves separation without the high energy input required by distillation, thereby reducing energy consumption while maintaining productivity.
3Productivity
If multi-stage distillation with high reflux rate is employed, then separation efficiency improves, but capital expenditure and operational costs increase
Solution Approach 1:
The patent extracts the separation function from the complex multi-stage distillation system and implements it in a single membrane module. By taking out the core separation capability and placing it in a membrane-based system, the patent eliminates the need for multiple distillation columns, reflux systems, and associated complex infrastructure. This extraction approach maintains high separation efficiency while dramatically reducing device complexity and capital expenditure.
Solution Approach 2:
The patent uses thin film membranes as the separation medium, replacing the bulky, complex distillation column structures. The membrane's thin film structure provides large surface area for separation in a compact form factor, enabling high separation efficiency without requiring multiple large-scale columns. This approach reduces both capital expenditure on equipment and operational complexity, while maintaining or improving separation performance.
4Productivity
If large membrane area is used to compensate for limited flux, then separation capacity increases, but equipment cost and complexity increase
Solution Approach 1:
The patent uses preliminary soaking action to pre-condition the membrane, which increases the flux during the subsequent separation operation. By allowing the membrane to equilibrate with the feed solution during a controlled soaking period, the system develops optimal concentration gradients and reduces initial mass transfer resistance. This preliminary action enables the membrane to operate at higher flux rates, achieving the required separation capacity without needing excessively large membrane areas, thereby reducing equipment size and complexity.
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 method significantly reduces the time to attain steady state, enhances membrane lifetime, and improves separation efficiency by increasing flux and permeate purity, making it more economically viable.
Implementation Method 1
flowing the liquid mixture through the membrane module under conditions such that the liquid mixture is separated into a permeate and a retentate
Data Source
AI summary
Systems and methods for separating a liquid mixture are disclosed. A membrane is first soaked by the liquid mixture via dynamic soaking to reach steady state. During the soaking process, the flow rate of the liquid mixture is increased at a flow rate ramp, the temperature is increased at a temperature ramp, and the pressure drop is increased at a pressure drop ramp. After the soaking process, the liquid mixture is separated by the membrane under optimized conditions to produce a permeate and a retentate.