Thin-Film Evaporator Inner Device for Separating Capacity
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Thin-film evaporators have limited separating capacity and inefficiencies in energy usage, particularly in heating and cooling, which hampers the processing of temperature-sensitive substances and those with poor flow properties.
Innovation Solution
Incorporating an inner device with a circular cross-section as a mass transfer area, preferably a catalyst or heat-exchange surface, between the heating jacket and condenser, to enhance vapor action and preheat the medium, along with a rotary design that recirculates the medium for increased efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional thin-film evaporator is used, then the structure is simple, but the separating capacity is limited
Solution Approach 1:
The inner device is nested within the evaporator chamber, positioned between the heating jacket and condenser. This nested configuration allows the additional mass transfer functionality to be integrated into the existing evaporator structure without requiring a completely new system design, thereby increasing separating capacity while maintaining relatively simple overall structure.
Solution Approach 2:
The invention introduces a new spatial dimension by placing an inner device within the existing evaporator chamber volume. This utilizes the three-dimensional space more effectively, creating additional mass transfer area without significantly increasing the external footprint or structural complexity of the evaporator.
2Productivity
If the medium is heated to boiling point for evaporation, then evaporation occurs, but energy consumption is high
Solution Approach 1:
The inner device preheats the medium to be evaporated before it reaches the heating jacket, performing preliminary thermal processing. This preliminary action reduces the energy required in the main heating stage, thereby decreasing overall heating energy consumption while maintaining evaporation productivity.
Solution Approach 2:
The system recovers thermal energy by using the inner device to preheat incoming medium with heat from the evaporation process. This energy recovery mechanism reduces waste heat loss and decreases the total heating energy required to maintain evaporation productivity.
3Productivity
If a condenser is used to condense vapors, then condensation occurs, but cooling energy consumption is high
Solution Approach 1:
The inner device performs preliminary cooling of vapors before they reach the condenser, reducing the thermal load on the condensation process. This preliminary action decreases the cooling energy required by the condenser while maintaining condensation efficiency and productivity.
Solution Approach 2:
The system recovers cooling capacity by using the inner device to pre-cool vapors, reducing the energy demand on the condenser system. This energy recovery approach reduces overall cooling energy consumption while maintaining effective condensation.
4Productivity
If temperature-sensitive substances are evaporated, then evaporation occurs, but thermal degradation may occur
Solution Approach 1:
The inner device preheats the medium gradually before it contacts the main heating jacket, performing preliminary thermal conditioning. This gradual heating approach reduces thermal shock and prevents sudden temperature spikes that could cause degradation of temperature-sensitive substances, while still achieving the required evaporation rate.
Solution Approach 2:
The thin-film evaporation process skips the harmful prolonged high-temperature exposure by rapidly evaporating the liquid film. The inner device enhances this by providing controlled preheating that prepares the medium for quick evaporation, minimizing the time substances spend at high temperatures and reducing thermal degradation risk.
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 configuration significantly increases separating capacity, reduces energy consumption by 32%, and allows for chemical reactions by utilizing catalysts and mass transfer areas within the evaporation process.
Implementation Method 1
a heating jacket arranged on the periphery of the drum and forming vapours
Implementation Method 2
a heating jacket arranged on the periphery of the drum and forming vapours
Implementation Method 3
a condenser supplied with a coolant
Implementation Method 4
the inner device is designed as a heat-exchange surface and preferably is connected to a supply line for the medium to be evaporated in order to preheat the medium to be evaporated
Implementation Method 5
the inner device is suitably designed as a mass transfer area
Implementation Method 6
the inner device is designed as a catalyst, in particular as a heterogeneous catalyst
Data Source
AI summary
A thin-film evaporator with a vertical drum (1), a supply line (4) that is arranged in the upper region of the drum (1) and is used to supply a medium to be evaporated, a heating jacket (3) arranged on the periphery of the drum and forming vapors, a discharge line (20) for discharging the residue left in the lower end of the drum, and a condenser (11) supplied with a coolant, for increasing the separating capacity and optionally for performing chemical reactions, is characterized in that an inner device (24) influencing the action of the thin-film evaporator is provided in the path of the vapors from the heating jacket (3) to the condenser (11).