Higher Silane Synthesis Recycling With Staged Nitrogen Cooling
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Solution Overview
Problem
Conventional disilane production processes face inefficiencies due to low reactor efficiency, high energy costs from refrigerant systems, uneven temperature distribution, and safety and environmental risks associated with filter maintenance, leading to suboptimal recycling and increased synthesis costs.
Innovation Solution
A high-efficiency synthesis and purification recycling system for higher silane, incorporating a reaction system with a mono-silane drum, reactor, compressor, and liquid nitrogen cooling, along with a purification system using multiple distillation columns and a recycling system with helium-assisted fractional purification, and a liquid nitrogen cooling system to optimize disilane recovery and reduce energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional purification distillation column is used, then disilane can be purified, but the low-pressure high-concentration disilane discharged from the top cannot be effectively recycled resulting in low recycle rate
Solution Approach 1:
The patent recovers disilane that would otherwise be discarded from the top of the distillation column by introducing it into the reaction zone through a dedicated injection port, achieving comprehensive recycling and eliminating substance loss
Solution Approach 2:
The patent uses a disilane injection port as an intermediary device to transfer disilane from the distillation column top back to the reaction zone, enabling efficient recycling without direct compression or complex handling systems
2Manufacturing precision
If conventional purification distillation process is used, then disilane can be purified, but cooling system and refrigerant systems are required increasing the cost
Solution Approach 1:
The patent uses nitrogen gas as an inert atmosphere to replace complex refrigerant cooling systems, achieving safe and effective temperature control during distillation without requiring extensive cooling infrastructure
Solution Approach 2:
The patent employs disposable or easily replaceable heating elements and insulation materials in the distillation system, reducing the need for expensive, complex cooling systems while maintaining purification effectiveness
3Quantity of substance
If large diameter and volume reactor is used, then reaction capacity is increased, but uneven temperature inside the reactor causes poor reaction efficiency
Solution Approach 1:
The patent segments the reaction zone into multiple heating zones with independent temperature control, ensuring uniform temperature distribution throughout the large-volume reactor and preventing hot or cold spots that would reduce efficiency
Solution Approach 2:
The patent designs the reactor to serve multiple functions including reaction, heating, and temperature distribution through integrated heating elements and fluid circulation systems, maintaining temperature uniformity while accommodating large reaction capacity
4Productivity
If filter set is used to remove microsilica, then reaction efficiency is improved, but cleaning and maintenance cause safety and environmental problems
Solution Approach 1:
The patent maintains an inert nitrogen atmosphere during filter set cleaning and maintenance operations, preventing fire hazards from microsilica exposure to oxygen while enabling safe and efficient filter replacement without environmental pollution risks
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 achieves a high-yield, high-purity, and energy-saving disilane production with a 99% recycling rate, reducing operational costs and improving reaction efficiency while minimizing environmental risks.
Implementation Method 1
a liquid nitrogen cooling system to optimize disilane recovery and reduce energy consumption
Implementation Method 2
a purification system using multiple distillation columns and a recycling system with helium-assisted fractional purification
Implementation Method 3
a reaction system with a mono-silane drum, reactor, compressor
Implementation Method 4
a mono-silane preheater, a reactor... to heat mono-silane before entering into the reactor
Data Source
AI summary
The high-efficiency synthesis and purification recycling system of higher silane has a liquid nitrogen cooling system. The liquid nitrogen cooling system has a liquid nitrogen storage tank for being configured to distribute −196° C. liquid nitrogen via a first cooling tube to the hydrogen column and the mono-silane column for a first cooling process; a second cooling tube is configured to distribute −160° C. nitrogen after the first cooling process into the first distillation column, the second distillation column, the third distillation column and the recycling drum for a second cooling process, a third cooling tube is configured to distribute −30° C. nitrogen after the second cooling process into the disilane drum for a third cooling process, and a fourth cooling tube is configured to distribute 25° C. nitrogen after the third cooling process into the silicon particle disposal system for a blowback regeneration process and to generate an anaerobic environment.