Inverting Dispersion Direction for Rapid Phase Separation

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Solution Overview

Problem

Current methods for separating a phase with higher viscosity, such as ionic liquids, from a phase with lower viscosity, like hydrocarbons, in chemical processes are inefficient, requiring significant equipment and time due to the slow phase separation in the conventional 'low viscosity phase in higher viscosity phase' dispersion direction.

Innovation Solution

A process that recycles a stream containing excess of the lower viscosity phase to tilt the dispersion direction from 'low viscosity phase in higher viscosity phase' to 'higher viscosity phase in low viscosity phase', achieving rapid phase separation by adjusting the phase ratio and using a coalescing filter for further separation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Speed

If the dispersion direction is maintained as 'low viscosity phase in higher viscosity phase' for separating ionic liquids from hydrocarbons, then the separation process is simpler to implement, but the phase separation speed is slow and equipment requirements are significant

Engineering Contradiction:

Improvephase separation speedVSAvoidequipment requirements

Core Design Contradiction:

SpeedVSDevice complexity

Solution Approach 1:

The patent inverts the conventional dispersion direction from 'low viscosity phase in higher viscosity phase' to 'higher viscosity phase in low viscosity phase'. This inversion causes the dispersion to form a wedge structure in the separator, which accelerates phase separation by promoting coalescence of the dispersed phase droplets at the wedge interface, thereby reducing equipment size and improving separation speed

Inventive Principle:

Principle #13The other way round (Inversion)

2Manufacturing precision

If a coalescing filter is used to separate ionic liquid from hydrocarbon dispersion, then separation effectiveness is improved, but the filter becomes clogged and requires frequent maintenance

Engineering Contradiction:

Improveseparation effectivenessVSAvoidfilter maintenance

Core Design Contradiction:

Manufacturing precisionVSEase of repair

Solution Approach 1:

The patent performs preliminary phase separation by inverting the dispersion direction before the mixture reaches the coalescing filter. This preliminary action reduces the burden on the filter by pre-forming a wedge structure that promotes natural coalescence, allowing the filter to handle less loaded material and reducing clogging frequency

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The inverted dispersion wedge acts as an intermediary mechanism between the incoming dispersion and the coalescing filter. It mediates the separation process by pre-concentrating and coalescing dispersed phase droplets before they reach the filter, thereby protecting the filter from excessive loading and clogging

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If intensive mixing is applied to establish contact between ionic liquid and organic phase for catalysis, then reaction efficiency is improved, but the resulting dispersion is difficult to separate afterward

Engineering Contradiction:

Improvereaction efficiencyVSAvoidseparation time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent inverts the dispersion direction after intensive mixing to create a wedge structure in the separator. This inversion exploits the viscosity difference between phases to accelerate separation, counteracting the emulsification effect of intensive mixing and reducing the time required to separate the catalytic ionic liquid from the organic phase

Inventive Principle:

Principle #13The other way round (Inversion)

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 process enables quick and efficient separation of higher viscosity phases, reducing equipment requirements and improving the separation of ionic liquids from hydrocarbons, particularly in reactions like isomerization, by tilting the dispersion direction and utilizing a coalescing filter for enhanced separation.

Implementation Method 1

The coalescing filter separates the ionic liquid from the hydrocarbons

Methodology Applied

Scientific EffectCoalescence: Coagulation

Implementation Method 2

The coalescing filter material must be such that it has a stronger affinity for the ionic liquid over the hydrocarbons

Methodology Applied

Scientific EffectAffinity: Adsorption

Implementation Method 3

separating the stream (S3) in the phase separation unit into a stream (S5) containing at least 70% by weight of phase (B), and in a stream (S4) containing at least 70% by weight of phase (A)

Methodology Applied

Scientific EffectGravitational separation: Gravitation

Data Source

PatentEP2872469B1Phase separation method by inverting the direction of dispersion

Publication Date: 2018.04.04 BASF SE

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AI summary

The invention relates to a method for separating a phase (A) from a phase (B), phase (A) being more viscous than phase (B). In said method, the direction of dispersion, in which phase (B) is dispersed in phase (A), is inversed so that phase (A) is dispersed in phase (B), the inversion being created by recirculating a stream containing an excess of phase (B).