Gas Separation System with Dynamic Flow Control for Methane Purity
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current gas separation systems face challenges in achieving high-purity and high-recovery rate methane production, especially when the methane content in the source gas is low, while also requiring significant energy consumption and being inefficient in handling changing gas compositions.
Innovation Solution
A gas separation system incorporating a pressurizing unit, multiple refining units using PSA and membrane separation methods, a buffer tank, flow rate control valves, and a detection sensor system to monitor and adjust gas compositions and pressures in real-time, ensuring optimal separation and recycling of gases to maintain high purity and recovery rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the absorption method is used to separate methane and carbon dioxide, then separation/refinement efficiency is improved, but energy consumption increases and maintenance cost rises
Solution Approach 1:
The gas separation process is divided into multiple stages: a first gas separation unit followed by a second gas separation unit. Each unit performs partial separation, and the outputs are combined to achieve high-purity methane separation. This segmented approach improves separation efficiency while reducing the energy consumption and maintenance costs associated with a single absorption-based system.
2Ease of manufacture
If the membrane separation method is used, then process simplicity is improved, but methane purity achievement becomes difficult
Solution Approach 1:
The patent combines two different separation methods: a first gas separation unit (using absorption or PSA) and a second gas separation unit (using membrane separation). By merging these units in sequence, the system achieves both high methane purity and maintains process simplicity, overcoming the limitation of using membrane separation alone.
3Device complexity
If a single refining unit is used, then device complexity is reduced, but ability to handle changing gas composition deteriorates
Solution Approach 1:
The patent implements a dynamic multi-unit system where the first and second gas separation units operate in sequence with adjustable parameters. The system can adapt to changing gas compositions by optimizing the operation of each unit independently, providing both complexity management and adaptability to varying feed gas conditions.
4Manufacturing precision
If multiple refining units are added to improve separation efficiency, then methane purity is improved, but system complexity increases
Solution Approach 1:
The system segments the gas separation process into two distinct units with different separation mechanisms. This segmentation achieves high methane purity while managing complexity through modular design, where each unit performs a specific function and can be optimized independently.
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
The system stabilizes high-purity methane production even with low initial methane content, reduces energy consumption, and improves methane recovery rates by dynamically controlling gas flow and refining unit operations based on real-time composition data.
Implementation Method 1
a PSA (Pressure Swing Adsorption) method of separating gas-phase substances by using a difference in their adsorption characteristics
Implementation Method 2
a membrane separation method using a difference in permeability of gas molecules
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A gas separation system, comprising a buffer tank (600) that stores therein a source gas and supplies the source gas; a pressurizing unit (400) configured to receive the source gas from the buffer tank (600) and pressurize the received source gas; a first refining unit (100) configured to produce a first refined gas by refining the source gas pressurized by the pressurizing unit (400), and discharge a first waste gas; a second refining unit (200) configured to produce a second refined gas by refining the first refined gas, and discharge a second waste gas; a third refining unit (300) configured to produce a third refined gas by refining the first waste gas; a first collection line (710) configured to guide the second waste gas to the buffer tank (600), and including a second flow rate control valve (932) for controlling a flow rate of the second waste gas; a second collection line (720) configured to guide the third refined gas to the buffer tank (600), and having a first flow rate control valve (931) for controlling a flow rate of the first waste gas; and a control unit (800) configured to control the first flow rate control valve (931) and the second flow rate control valve (932).