Extractive Distillation Column with Nested Indirect Heat Exchangers

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Solution Overview

Problem

Existing extractive distillation methods require multiple stages and increased column height for efficient energy integration, leading to higher energy consumption and operational costs.

Innovation Solution

A method that uses an extraction medium with higher affinity to one component of the mixture, where the feed stream is processed through a series of indirect heat exchangers to optimize energy utilization, allowing for partial evaporation and recycling of the extraction medium, thereby reducing the need for additional column height and energy expenditure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If multiple evaporators are mounted laterally on the column for multistage heating, then energy integration is improved, but the column height increases significantly

Engineering Contradiction:

Improvethermal energy recoveryVSAvoidcolumn height

Core Design Contradiction:

Loss of energyVSLength of stationary object

Solution Approach 1:

The patent transitions from lateral mounting of evaporators (horizontal dimension) to stacking evaporators one above another (vertical arrangement within compact footprint). This dimensional reorganization allows multiple heating stages to be achieved without proportionally increasing the overall column height, as the evaporators utilize the internal volume more efficiently rather than extending the external dimensions.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The patent implements a nested configuration where evaporators are arranged within the column structure in a compact, space-efficient manner. The evaporators are positioned to utilize the internal volume of the column, with each evaporator nested within the available space, allowing multiple heating stages to be incorporated without linearly increasing the column height.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Loss of energy

If compartments are added to the column for evaporator mounting, then energy integration is improved, but device complexity increases

Engineering Contradiction:

Improvethermal energy recoveryVSAvoidcolumn structure complexity

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The patent designs the column structure to serve multiple functions simultaneously. The same column body houses both the separation functionality and the heating functionality through integrated evaporator mounting. The collecting trays and structural elements serve dual purposes: supporting the separation process and providing mounting surfaces for the evaporators, thereby reducing the need for additional specialized components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent combines the heating function and separation function within a single integrated column structure. The evaporators are mounted directly on the column walls, merging the thermal processing and mass separation operations into one unified device. This consolidation eliminates the need for separate heating chambers or additional structural compartments, simplifying the overall device architecture.

Inventive Principle:

Principle #5Merging (Combining)

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 energy integration and separation of mixtures with reduced column height, optimizing thermal energy use and minimizing energy costs while maintaining effective separation efficiency.

Implementation Method 1

the vapors are brought into contact with an extraction medium that selectively decreases the volatility of one of the components of the mixture that is to be separated

Methodology Applied

Scientific EffectSelective absorption: Absorption (physical)

Implementation Method 2

the liquid fraction is collected on a collecting tray and heated and partially evaporated in a first indirect heat exchanger

Methodology Applied

Scientific EffectHeat conduction: Conduction (thermal)

Implementation Method 3

the liquid fraction is collected on a collecting tray and heated and partially evaporated in a first indirect heat exchanger, the resultant vapor is released into the column

Methodology Applied

Scientific EffectEvaporation: Evaporation

Data Source

PatentUS10793494B2Method for separating materials by means of an extractive distillation process

Publication Date: 2020.10.06 BASF SE

AI summary

A method for separating a mixture of materials A and B by extractive distillation, using an extraction medium having a higher affinity to B than to A, collecting a liquid fraction on a collecting tray and heated and partially evaporated in a first indirect heat exchanger, collecting the resultant vapor is released into the column and a non-evaporated proportion of the liquid fraction in the sump of the column, and a series of heating, separation and cooling where partially cooled extraction medium fraction is used as heating medium for a heat exchanger.