Integrated Column Condenser for Temperature-Sensitive Distillation
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Solution Overview
Problem
Distillation of temperature-sensitive liquids like acrylic acid is costly and inefficient due to high pressure drops and equipment expenses, especially when using external condensers under vacuum conditions, which can lead to polymerization and thermal degradation.
Innovation Solution
Integrating multiple plate heat exchangers within the distillation column allows vapors to flow cocurrently with condensed liquids, reducing pressure drop and eliminating the need for external condensate collection and pumping, while using a dual coolant system for efficient condensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an external condenser is used for distillation under vacuum, then condensation efficiency is improved, but pressure drop increases and equipment costs rise
Solution Approach 1:
The condenser is integrated directly into the distillation column structure, merging two previously separate units (column and external condenser) into one. This eliminates the need for large-diameter external vapor lines and complex support structures, thereby reducing equipment costs while maintaining condensation efficiency.
Solution Approach 2:
The condensation function is extracted from the external system and placed inside the column at the vapor outlet. This removes the need for expensive external condensation equipment and large vacuum lines, solving the cost issue while preserving the condensation capability.
2Speed
If vapor lines are made large in diameter for vacuum operation, then gas velocity is reduced, but pressure drop increases and structural costs rise
Solution Approach 1:
The condensation function is extracted from the external system and placed inside the column at the vapor outlet. This removes the need for expensive external condensation equipment and large vacuum lines, solving the cost issue while preserving the condensation capability.
Solution Approach 2:
The condenser is integrated directly into the distillation column structure, merging two previously separate units (column and external condenser) into one. This eliminates the need for large-diameter external vapor lines and complex support structures, thereby reducing equipment costs while maintaining condensation efficiency.
3Reliability
If condenser is placed outside the column, then condensation can occur, but residence time increases causing polymerization
Solution Approach 1:
The condenser is integrated directly into the distillation column structure, merging two previously separate units (column and external condenser) into one. This eliminates the need for large-diameter external vapor lines and complex support structures, thereby reducing equipment costs while maintaining condensation efficiency.
4Manufacturing precision
If multiple condensers are arranged outside the column, then product purity is improved, but pressure drop and costs increase
Solution Approach 1:
Multiple condensation stages are nested within the column structure at different heights, with each condenser handling specific fractions of the vapor stream. This nested arrangement achieves high product purity through staged condensation while minimizing pressure drop by keeping all condensers within the column's pressure environment.
Solution Approach 2:
The condenser is integrated directly into the distillation column structure, merging two previously separate units (column and external condenser) into one. This eliminates the need for large-diameter external vapor lines and complex support structures, thereby reducing equipment costs while maintaining condensation efficiency.
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 reduces equipment costs, minimizes polymerization risks, and enhances energy efficiency by lowering the boiling point of the bottom product, resulting in improved product quality and reduced thermal stress.
Implementation Method 1
several plate heat exchangers, preferably plate condensers, are installed in the distillation column above the column internals
Implementation Method 2
the vapor is at least partially condensed in a condenser provided within the column
Implementation Method 3
the starting mixture is brought to the boil. The resulting vapor
Implementation Method 4
the resulting vapor is condensed in a condenser and then the liquid condensate is collected
Implementation Method 5
Distillation is a thermal separation process that is used to separate a mixture of different substances that are soluble in one another
Implementation Method 6
the condensed liquid is at least partially withdrawn from the column
Data Source
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AI summary
The aim of the invention is the distillation of temperature-sensitive liquids, in particular acrylic acid and the esters thereof. This is achieved in that the liquid is heated in a column and at least partially vaporized. The vapor is conducted through a condenser that is provided within the column, said vapor being at least partially condensed in the condenser. The condensed liquid is at least partially drawn off from the column. The distillation is characterized in that the vapor that is not yet condensed is conducted through the condenser concurrently with the condensed liquid.