Ethanol Drying Apparatus with Sorbent and Catalyst Bed
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Solution Overview
Problem
Current methods for removing water from ethanol, such as distillation and existing adsorption processes, are inefficient and costly, limiting the production of anhydrous ethanol needed for fuel applications due to energy requirements and the formation of azeotropes, as well as high switch losses in pressure swing adsorption systems.
Innovation Solution
An apparatus and process utilizing a particulate bed with sorbent and catalyst particles in a reaction chamber, where sorbent particles adsorb water from wet ethanol and catalysts promote chemical reactions to generate heat for regenerating the sorbent, allowing for effective water removal and sorbent regeneration, with a layered particle size configuration to optimize adsorption and heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If distillation is used to remove water from ethanol, then ethanol concentration can be increased, but energy consumption increases and complete water removal is prevented due to azeotrope formation
Solution Approach 1:
The patent changes the separation mechanism from thermal distillation to adsorption by molecular sieves. The molecular sieves operate at lower temperatures and can achieve complete dehydration by adsorbing water molecules selectively, breaking the azeotrope limitation through a different physical mechanism rather than relying on vapor-liquid equilibrium
Solution Approach 2:
The patent utilizes the phase transition properties of water in the form of hydrates. Molecular sieves form hydrate structures that selectively incorporate water molecules into their crystal lattice, effectively removing water from ethanol through a solid-state phase transition mechanism rather than vaporization
2Use of energy by moving object
If pressure swing adsorption is used to remove water from ethanol, then energy consumption can be reduced, but switch losses increase and productivity decreases
Solution Approach 1:
The patent employs a multi-column pressure swing adsorption system with periodic operation cycles. Multiple columns operate in sequence, with some columns adsorbing water while others are being regenerated or cooled. This periodic switching maintains continuous ethanol production while reducing energy consumption compared to continuous distillation
Solution Approach 2:
The multi-column configuration ensures continuous useful action by maintaining at least one column in the adsorption phase at all times. While one column is being regenerated or cooled, another column continues to dehydrate ethanol, eliminating production interruptions and reducing switch losses
3Quantity of substance
If molecular sieves are used to adsorb water from ethanol, then water removal efficiency increases, but sorbent regeneration becomes necessary and adds operational complexity
Solution Approach 1:
The multi-column system allows continuous operation by maintaining at least one column in the adsorption phase while others undergo regeneration or cooling. This continuous configuration ensures uninterrupted ethanol dehydration despite the cyclic nature of sorbent regeneration
Solution Approach 2:
The patent uses an intermediary cooling step where the regenerated molecular sieves are cooled before being reintroduced to the adsorption column. This cooling intermediary prepares the sorbent for effective water adsorption, as lower temperatures enhance the adsorption capacity of molecular sieves
4Quantity of substance
If smaller sorbent particles are used to increase adsorption surface area, then water adsorption capacity increases, but pressure drop across the bed increases and heat transfer becomes less efficient
Solution Approach 1:
The patent optimizes the particle size parameter of molecular sieves to balance adsorption capacity with pressure drop and heat transfer efficiency. Rather than using the smallest possible particles, a specific size range is selected that provides sufficient surface area for effective water removal while maintaining acceptable pressure characteristics and thermal performance
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 approach enables efficient and cost-effective drying of ethanol to near-anhydrous levels, reducing energy consumption and operational complexities, while maintaining sorbent effectiveness and productivity.
Implementation Method 1
sorbent particles operate to adsorb water from the wet ethanol
Implementation Method 2
The catalyst particles promote a chemical reaction of the fuel resulting in generation of heat
Implementation Method 3
The thermal energy generated by the reaction heats the hydrated-sorbent particles, causing removal of adsorbed water and thereby regenerating the sorbent particles
Data Source
AI summary
An apparatus and method for drying ethanol includes a first reaction chamber for carrying out the removal of water from wet ethanol, a feed inlet for introducing the wet ethanol into the reaction chamber, a product outlet for removing dry ethanol from the reaction chamber, an optional fuel inlet for introducing a fuel into the reaction chamber, and a particulate bed, including sorbent particles, that is disposed within the reaction chamber. In a preferred embodiment, the bed is divided into first and second zones each provided with different size sorbent particles. In another preferred embodiment, the bed contains a mixture of sorbent particles and catalyst particles. The sorbent particles operate to remove water from the wet ethanol and form hydrated-sorbent particles. The catalyst particles operate to promote chemical reaction of the fuel, generating heat that causes removal of water from the hydrated-sorbent particles and regenerating the sorbent particles.