Feed Stream Distribution in Controlled Freeze Zone Distillation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional distillation methods for separating hydrocarbons from contaminants, such as carbon dioxide, are inefficient and prone to solidification issues, leading to energy inefficiencies and potential adhesion of solids in distillation towers, which can interfere with the separation process.
Innovation Solution
A distillation tower with a controlled freeze zone section, incorporating a spray assembly and a melt tray assembly, and a feed stream distribution mechanism that optimally directs the feed stream based on its composition to form solids at specific temperatures and pressures, preventing unnecessary energy usage and solid accumulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional distillation methods are used to separate hydrocarbons from contaminants, then separation is achieved, but energy efficiency deteriorates and solidification issues occur
Solution Approach 1:
The distillation tower is divided into distinct sections: a controlled freeze zone section and a non-freeze zone section. This segmentation allows different separation mechanisms to operate in different zones, improving energy efficiency by preventing unwanted solidification in the non-freeze zone while maintaining reliable separation through the controlled freeze zone.
Solution Approach 2:
Different sections of the distillation tower are given different thermal characteristics. The controlled freeze zone is designed to allow solidification of contaminants at specific temperatures, while the non-freeze zone maintains temperatures above solidification points. This local differentiation of thermal properties enables energy-efficient operation by eliminating the need to cool the entire tower to prevent solidification.
2Productivity
If feed stream is not optimally directed based on composition, then tower sizing increases, but separation effectiveness deteriorates
Solution Approach 1:
The feed stream distribution mechanism performs preliminary action by analyzing feed stream composition and directing it to the appropriate section before the separation process begins. This preliminary classification ensures that streams requiring freeze-zone processing are sent there, while others go to the non-freeze zone, optimizing separation effectiveness and preventing unnecessary oversizing of the tower.
Solution Approach 2:
The feed stream distribution mechanism provides dynamic routing based on real-time feed composition. Rather than a fixed configuration, the system adapts its operation to match feed characteristics, enabling optimal utilization of tower capacity and improving separation effectiveness without requiring excessive tower size.
3Reliability
If solids are allowed to form in the distillation tower, then contaminant separation is improved, but solid adhesion occurs interfering with the separation process
Solution Approach 1:
The harmful effect of solid adhesion is eliminated by extracting the solidification process to a dedicated controlled freeze zone. Solids form only in this designated area where they can be properly managed, while the rest of the tower remains free of solidification issues. This separation of functions prevents solid adhesion from interfering with the overall separation process.
Solution Approach 2:
The controlled freeze zone acts as an intermediary that mediates between the need for contaminant separation and the problem of solid adhesion. By providing a controlled environment for solidification with appropriate heat transfer surfaces and flow patterns, it enables contaminant removal while preventing uncontrolled solid adhesion that would interfere with the separation process.
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 optimizes energy efficiency and tower sizing by ensuring the feed stream enters the distillation tower at the appropriate section based on its composition, preventing solid adhesion and enhancing the separation of hydrocarbons from contaminants.
Implementation Method 1
a feed stream distribution mechanism below the spray assembly and above the melt tray assembly. The feed stream distribution mechanism may be constructed and arranged to uniformly distribute the feed stream in the controlled freeze zone section
Implementation Method 2
a spray assembly in the controlled freeze zone upper section
Implementation Method 3
the controlled freeze zone section is constructed and arranged to form a solid from a feed stream
Implementation Method 4
a melt tray assembly in the controlled freeze zone lower section
Implementation Method 5
the controlled freeze zone section is constructed and arranged to form a solid from a feed stream
Implementation Method 6
the disclosure relates to the cryogenic separation of contaminants, such as acid gas, from a hydrocarbon
Implementation Method 7
The separation of contaminants from hydrocarbons is difficult and consequently significant work has been applied to the development of hydrocarbon/contaminant separation methods. These methods can be placed into three general classes: absorption by solvents (physical, chemical and hybrids), adsorption by solids, and distillation
Data Source
AI summary
The present disclosure provides a distillation tower for separating a feed stream. The distillation tower includes a controlled freeze zone section having a controlled freeze zone upper section and a controlled freeze zone lower section below the controlled freeze zone upper section. The controlled freeze zone section includes: (a) a spray assembly in the controlled freeze zone upper section; (b) a melt tray assembly in the controlled freeze zone lower section; (c) a feed stream distribution mechanism between the spray assembly and the melt tray assembly. The feed stream distribution mechanism is constructed and arranged to uniformly distribute the feed stream in the controlled freeze zone section.