Horizontal Multi-Stage Tray Distillation System
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Solution Overview
Problem
Existing distillation systems, particularly vertical multi-stage columns, occupy large spaces, incur high capital and labor costs, and face operational inflexibility, along with issues like inter-stage backmixing of liquid and vapor, and difficulty in troubleshooting and maintenance.
Innovation Solution
A horizontal multi-stage tray distillation system is designed with interconnected vessels, vapour non-return valves, pumps, liquid recycle streams, and flow control valves to replicate reflux flow and prevent backmixing, offering automated or manual control over liquid overflow and reducing installation and maintenance costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If vertical multi-stage distillation columns are used, then separation of components with different volatilities is achieved, but large space occupation and high capital investment occur
Solution Approach 1:
The patent transforms the conventional vertical distillation column into a horizontal configuration, changing the spatial dimension of operation. This allows the distillation process to occur horizontally across multiple stages arranged in series, reducing the vertical footprint and overall space occupation while maintaining separation efficiency through controlled liquid-vapor contact in each horizontal stage.
Solution Approach 2:
The distillation system is divided into multiple discrete stages, each functioning as an independent separation unit. These stages are arranged horizontally and connected through liquid and vapor flow paths, allowing the separation process to be segmented into manageable sections that can be optimized individually while contributing to overall component separation.
2Reliability
If vertical multi-stage distillation columns are used, then separation process is achieved, but high labor cost for operation and troubleshooting occurs
Solution Approach 1:
By dividing the distillation column into discrete horizontal stages with separate access points and flow control mechanisms, the system enables easier troubleshooting and maintenance. Each stage can be independently accessed and serviced, reducing the need for complex operations and specialized labor compared to traditional vertical columns requiring high-altitude work.
Solution Approach 2:
The horizontal configuration introduces intermediate access points and flow control valves between stages, serving as mediators that facilitate easier monitoring and adjustment of liquid and vapor flows. These intermediate elements enable simpler operational control and troubleshooting without requiring direct access to high-altitude tray areas.
3Reliability
If vertical multi-stage distillation columns are used, then distillation separation is achieved, but inter-stage backmixing of liquid and vapour occurs
Solution Approach 1:
The patent extracts and eliminates the backmixing problem by designing flow paths that separate liquid and vapor streams into distinct channels between stages. Liquid flows downward through downcomers while vapor rises through separate pathways, preventing the mixing that would occur in traditional vertical columns where gravity-driven flow creates backmixing effects.
Solution Approach 2:
The system employs asymmetric flow arrangements where liquid and vapor streams are directed through different paths - liquid flows down through downcomer channels while vapor rises through tray openings and vapor spaces. This asymmetric separation of flow paths prevents the symmetric backmixing that occurs in conventional designs, maintaining stable compositions across stages.
4Reliability
If conventional distillation systems are used, then separation function is provided, but high installation and maintenance cost occurs
Solution Approach 1:
The horizontal multi-stage design segments the distillation function into discrete, modular units that can be manufactured separately and assembled horizontally. This segmentation reduces installation complexity and allows for easier maintenance access, lowering overall installation and maintenance costs compared to monolithic vertical columns requiring specialized installation equipment and high-altitude work.
Solution Approach 2:
By arranging stages horizontally rather than vertically, the patent changes the installation dimension from vertical stacking to horizontal sequencing. This dimensional change eliminates the need for complex vertical support structures, reduces installation height requirements, and provides easier access for maintenance activities, thereby reducing installation and maintenance costs.
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 high efficiency, operational flexibility, and reduced costs by minimizing space requirements and preventing inter-stage backmixing, while allowing for easier troubleshooting and maintenance, with improved control over liquid overflow.
Implementation Method 1
Vapours are generated in the reboiler vessel to increase its pressure. The condensation of vapour in the condenser vessel results in the generation of low pressure in the condenser vessel.
Implementation Method 2
The vapour travel from the reboiler vessel to the condenser vessel through various intermediate vessels because of the pressure differential between the reboiler vessel and the condenser vessel.
Implementation Method 3
A reflux flow of liquid under gravity in a vertical tray column is exactly replicated by putting pumps of suitably high rating between each pair of interconnected vessels and operating all the pumps in the sequence simultaneously to transfer liquid within the sequence of vessels from one vessel to the next interconnected vessel.
Implementation Method 4
A reflux flow of liquid under gravity in a vertical tray column is exactly replicated
Implementation Method 5
vapour bubble through the liquid present on the trays, attain vapour-liquid equilibrium with the liquid and enter the vessel vapour space of each of the vessels with some loss in pressure.
Implementation Method 6
enter the vessel vapour space of each of the vessels with some loss in pressure
Implementation Method 7
The flow control valves (FCV) are installed in the pump discharge lines to regulate liquid flow from the bottom of one vessel to the top downcomer area of the succeeding vessel.
Implementation Method 8
Liquid recycle streams recycles the excess liquid flow back from the pump discharges to the vessels on the suction side of the pumps maintaining the pump operations at the best efficiency point, reducing backflow load on the pumps.
Implementation Method 9
The vapour stream is connected to the vertical bottom of each of the vessels and fed into these trays from below. Similar to vertical distillation columns, vapour bubble through the liquid present on the trays
Data Source
AI summary
The present invention discloses a horizontal multi-stage distillation system. The system comprises a feed stream, a distillate stream, a residue stream, a group of vessels, a plurality of vapor non-return valves (NRVs), a plurality of plurality of pumps, a plurality of liquid recycle NRVs, a liquid stream, a vapor stream, a plurality of liquid recycle streams, a plurality of level transmitters, a plurality of flow control valves (FCVs) and a plurality of liquid non-return valves (NRVs). Each vessel is connected to the adjacent vessel. The group of vessels comprises a condenser vessel, a reboiler vessel, a feed vessel, at-least one rectification vessel and at-least one stripping vessel. The present invention provides a horizontal multi-stage distillation system with higher efficiency and operational flexibility compared with equivalent vertical distillation columns. The present invention also avoids the interstage backflow of the liquid and vapors.