Gas Separation Process Using Segmented Modules
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Solution Overview
Problem
Current gas separation units have difficulty in efficiently separating mixtures of non-polar and polar gases, particularly in removing high amounts of polar gases like CO2 and H2S from mixtures with non-polar gases like CH4, due to poor selectivity and permeance, leading to slow separation processes.
Innovation Solution
A process utilizing a gas separation unit with at least two gas-separation modules arranged in order of increasing selectivity for polar gases, where the feed gas contains between 35 mol% and 90 mol% polar gases, to effectively separate non-polar and polar gases into enriched and depleted gas mixtures, achieving both good selectivity and permeance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single gas-separation module with uniform selectivity is used, then the device complexity is low, but the separation efficiency and selectivity for polar gases are insufficient
Solution Approach 1:
The gas separation unit is divided into multiple gas-separation modules (first module, second module, third module) with progressively increasing selectivity for polar gases. Each module handles a specific stage of separation, allowing the system to achieve high overall separation efficiency by breaking down the complex separation task into manageable segments with specialized functions.
Solution Approach 2:
Each gas-separation module is designed with different selectivity characteristics tailored to its specific position and function in the separation sequence. The first module has lower selectivity for initial separation, while subsequent modules have progressively higher selectivity for refined separation, optimizing performance at each local stage rather than using uniform selectivity throughout.
2Manufacturing precision
If gas-separation modules with high selectivity for polar gases are used, then the selectivity improves, but the permeance and separation speed decrease
Solution Approach 1:
The separation process is segmented into multiple stages with modules of varying selectivity. Lower-selectivity modules with higher permeance handle the initial bulk separation quickly, while higher-selectivity modules perform refined separation on the remaining gas stream. This segmentation allows the system to achieve both high overall selectivity and maintained separation speed.
Solution Approach 2:
Rather than using one module with extremely high selectivity that would slow down the entire process, the system uses multiple modules with progressively increasing selectivity. Each module performs a partial separation task, and the cumulative effect achieves the desired high selectivity without requiring any single module to operate at excessively high selectivity levels that would reduce permeance.
3Manufacturing precision
If modules with higher selectivity are placed first in the series, then the initial separation is more effective, but the overall separation efficiency decreases
Solution Approach 1:
Instead of placing the highest-selectivity module first, the system inverts the conventional approach by arranging modules in order of increasing selectivity (lowest to highest). This inversion allows the lower-selectivity, higher-permeance modules to handle the initial high-volume separation, while the higher-selectivity modules refine the separation in subsequent stages, optimizing overall system efficiency.
Solution Approach 2:
The system dynamically adapts the separation approach by using progressively more selective modules as the gas stream composition changes through the separation process. The first module handles the bulk of polar gases when their concentration is highest, and subsequent modules with higher selectivity address the remaining polar gases at lower concentrations, optimizing performance at each stage.
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 rapid and selective separation of polar gases from non-polar gases, improving the efficiency of gas separation units by enhancing both non-polar gas/polar gas selectivity and polar gas permeance, thus addressing the limitations of existing technologies.
Implementation Method 1
Each gas-separation module comprises a gas-selective membrane which separates gas into a permeate which passes through the membrane and a retentate which does not pass through that membrane
Data Source
AI summary
A process for separating a feed gas comprising polar and non-polar gases into a gas mixture enriched in polar gas(es) and a gas mixture depleted in polar gas(es), the process comprising passing the feed gas through a gas separation unit comprising at least two gas-separation modules in order of increasing selectivity for the polar gas(es), wherein the feed gas entering the gas separation unit comprises more than 35 mol % and up to 90 mol % of polar gas(es).