Integrated Condenser Separator Vertical Plate Heat Exchanger
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Solution Overview
Problem
Non-integrated solutions for producing condensable reaction products, such as methanol, require multiple separate process units and extensive piping, leading to high capital and operating expenses, pressure drops, heat losses, and increased energy input due to the need for multiple pressure jackets and pipe conduits.
Innovation Solution
An integrated apparatus with a pressure jacket housing two fluidically interconnected process units: a plate heat exchanger for condensing the reaction product and a gas-liquid separator for separating the condensed product from residual gas, arranged vertically to minimize the need for conveying means and reduce material stresses through a temperature gradient that allows gravity-driven flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple separate process units and pipe conduits are used, then process functions can be performed, but capital expenditure and operating expenditure increase
Solution Approach 1:
The patent combines multiple process units (condenser and separator) into a single integrated apparatus. The condenser and separator are merged into one device with a unified pressure jacket, eliminating the need for separate process units and reducing the number of pipe conduits required for connections between them.
Solution Approach 2:
The integrated apparatus performs multiple functions within a single device. The condenser section condenses the reaction product while the separator section separates the condensed product from residual gas, allowing one apparatus to fulfill what previously required multiple dedicated units.
2Loss of energy
If multiple separate process units and pipe conduits are used, then process functions can be performed, but pressure drops and heat losses increase
Solution Approach 1:
By merging the condenser and separator into a single integrated apparatus with continuous internal flow paths, the patent eliminates multiple external pipe conduits. This reduces the total surface area exposed to external environments, thereby minimizing heat losses and reducing pressure drops associated with multiple connection points.
3Volume of stationary object
If multiple separate process units are used, then process functions can be performed, but the total volume and surface area increase
Solution Approach 1:
The patent merges multiple process units into a single apparatus with one unified pressure jacket. This integration eliminates the need for multiple separate pressure jackets and reduces the total volume required, as the integrated design allows for more efficient space utilization compared to separate units arranged in series or parallel.
4Use of energy by moving object
If multiple conveying means are used, then process media can be transported between units, but energy input increases
Solution Approach 1:
The integrated apparatus eliminates the need for external conveying means between separate units by providing internal flow paths within the single pressure jacket. Process media flow continuously from the condenser section to the separator section through internal conduits, eliminating the need for additional pumps or conveying equipment and reducing energy input.
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 integrated apparatus reduces the number of required components and piping, minimizing capital expenditures, energy input, and thermal stresses while achieving efficient condensation and separation with reduced operational complexity.
Implementation Method 1
the first process unit is configured for condensing the reaction product from the process gas mixture
Implementation Method 2
the first process unit is in the form of a plate heat exchanger
Implementation Method 3
arranged vertically to minimize the need for conveying means and reduce material stresses through a temperature gradient that allows gravity-driven flow
Data Source
AI summary
The invention relates to an apparatus for separating a condensable reaction product from a process gas mixture. The apparatus includes a pressure jacket having an interior, wherein two process units are arranged one atop the other in the pressure jacket. The upper first process unit is configured for condensing the liquid reaction product from the process gas mixture and is thus in the form of a plate heat exchanger. The plate heat exchanger includes vertically arranged plates traversable by a cooling medium. The plates have plate interiors which are traversable by the cooling medium. Adjacent plates spaced apart from one another define plate interspaces which are traversable by the process gas mixture. The lower second process unit is configured for separating the reaction product condensed in the first process unit and is thus in the form of a gas-liquid separator.