Heat Pump Thermal Management for Potassium Sulfate Crystallization

Solution Overview

Problem

Conventional processes for producing potassium sulfate from schoenite face challenges in maintaining specific reaction temperatures during conversion and crystallization steps, requiring effective heat management to regulate temperatures within narrow ranges.

Innovation Solution

The implementation of a heat pump system that collects heat generated in the conversion unit and provides it to the crystallization unit to maintain and regulate the temperature of the potassium sulfate product stream and crystallizer mother liquor stream, ensuring optimal operating conditions between 45° C. and 60° C.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If heat is removed from the conversion system to maintain temperature between 10°C and 40°C, then the conversion reaction can proceed efficiently, but additional cooling equipment and energy consumption are required

Engineering Contradiction:

Improveconversion reaction efficiencyVSAvoidcooling system complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent combines the cooling function for the conversion reactor with the heating function for the crystallization reactor into a single heat exchange system. The hot crystallization broth serves as the heating medium for the conversion reactor, while the cool conversion broth serves as the cooling medium for the crystallization reactor, eliminating the need for separate cooling and heating equipment.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The system uses its own process streams to provide the necessary thermal management. The conversion reaction broth, which needs cooling, is used to cool the crystallization reaction broth, and vice versa. This self-service approach eliminates external utility requirements and reduces equipment complexity.

Inventive Principle:

Principle #25Self-service

2Productivity

If heat is added to the crystallization system to maintain temperature between 45°C and 60°C, then the crystallization reaction can proceed efficiently, but additional heating equipment and energy consumption are required

Engineering Contradiction:

Improvecrystallization reaction efficiencyVSAvoidheating system complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent combines the cooling function for the conversion reactor with the heating function for the crystallization reactor into a single heat exchange system. The hot crystallization broth serves as the heating medium for the conversion reactor, while the cool conversion broth serves as the cooling medium for the crystallization reactor, eliminating the need for separate cooling and heating equipment.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The system uses its own process streams to provide the necessary thermal management. The conversion reaction broth, which needs cooling, is used to cool the crystallization reaction broth, and vice versa. This self-service approach eliminates external utility requirements and reduces equipment complexity.

Inventive Principle:

Principle #25Self-service

3Temperature

If external cooling is used for the conversion reaction, then temperature control is achieved, but energy is wasted and process efficiency decreases

Engineering Contradiction:

Improveconversion reaction temperature controlVSAvoidenergy waste

Core Design Contradiction:

TemperatureVSLoss of energy

Solution Approach 1:

The patent converts the waste heat from the exothermic conversion reaction into a useful resource by using it to heat the crystallization reactor. Similarly, the cooling requirement of the conversion reactor is used to cool the crystallization reactor. This transforms what would be energy waste into a beneficial heat exchange relationship.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent combines the cooling function for the conversion reactor with the heating function for the crystallization reactor into a single heat exchange system. The hot crystallization broth serves as the heating medium for the conversion reactor, while the cool conversion broth serves as the cooling medium for the crystallization reactor, eliminating the need for separate cooling and heating equipment.

Inventive Principle:

Principle #5Merging (Combining)

4Temperature

If external heating is used for the crystallization reaction, then temperature control is achieved, but energy consumption increases

Engineering Contradiction:

Improvecrystallization reaction temperature controlVSAvoidenergy consumption

Core Design Contradiction:

TemperatureVSLoss of energy

Solution Approach 1:

The patent converts the waste heat from the exothermic conversion reaction into a useful resource by using it to heat the crystallization reactor. Similarly, the cooling requirement of the conversion reactor is used to cool the crystallization reactor. This transforms what would be energy waste into a beneficial heat exchange relationship.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent combines the cooling function for the conversion reactor with the heating function for the crystallization reactor into a single heat exchange system. The hot crystallization broth serves as the heating medium for the conversion reactor, while the cool conversion broth serves as the cooling medium for the crystallization reactor, eliminating the need for separate cooling and heating equipment.

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 effectively controls reaction temperatures, enhancing the efficiency and recovery of potassium sulfate production by maintaining the desired temperature ranges, thereby improving the overall process recovery and product purity.

Implementation Method 1

collecting heat generated in the conversion unit by a heat pump; and providing at least a portion of the heat collected from the conversion unit to the crystallization unit to regulate a temperature

Methodology Applied

Scientific EffectHeat pump:

Implementation Method 2

The combined reactions occurring in conversion are exothermic, meaning that heat must be removed from the system to maintain a desired operating temperature

Methodology Applied

Scientific EffectExothermic reaction: Exothermic Reaction

Implementation Method 3

As the SOP crystallization reaction is endothermic, heat must be added to the system to maintain the operating temperature

Methodology Applied

Scientific EffectEndothermic reaction: Endothermic Reaction

Data Source

PatentUS10954133B2Systems and methods of producing potassium sulfate

Publication Date: 2021.03.23 NOVOPRO PROJECTS INC

AI summary

Systems and methods of producing potassium sulfate can involve converting a mixed salts feed stream into a conversion end slurry in a conversion unit, the mixed salts feed comprising at least one potassium-containing salt, at least one chloride-containing salt, at least one magnesium-containing salt and at least one sulfate-containing salt and the conversion end slurry comprising schoenite; separating conversion end slurry into a conversion end solids stream and a conversion brine; leaching the conversion end solids stream in a crystallization unit to produce a potassium sulfate product stream comprising potassium sulfate and a crystallizer mother liquor comprising magnesium sulfate and potassium sulfate; collecting heat generated in the conversion unit by a heat pump; and providing at least a portion of the heat collected to the crystallization unit to regulate a temperature of the potassium sulfate product stream and the crystallizer mother liquor stream contained in the crystallization unit.