Ion Exchange Membrane Steam Purification
Solution Overview
Problem
Current methods for producing high purity steam are inefficient and costly, often requiring multiple boiling/condensation cycles and additional separation processes to remove impurities, which can introduce unwanted contaminants and pose safety risks, especially in industrial applications like semiconductor manufacturing and pharmaceutical processes.
Innovation Solution
A method involving the use of a substantially gas-impermeable ion exchange membrane, such as a perfluorosulfonic acid/tetrafluoroethylene copolymer membrane, to purify steam by selectively allowing water vapor to pass through while rejecting impurities, with the membrane being operated at controlled temperatures and pressures to maximize steam purity and minimize impurity content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple boiling/condensation cycles are used to remove impurities, then steam purity is improved, but process complexity and cost increase
Solution Approach 1:
The patent extracts and removes impurities from steam by passing it through a bed of molecular sieves or activated alumina, which selectively adsorb contaminants while allowing pure steam to pass through. This single extraction step replaces multiple complex boiling/condensation cycles.
Solution Approach 2:
The patent introduces molecular sieves or activated alumina as an intermediary substance between the impure steam and the final pure steam product. This intermediary material selectively interacts with impurities, capturing them while permitting pure steam to continue through the system.
2Manufacturing precision
If additional separation processes are implemented to remove contaminants, then steam purity is improved, but the risk of introducing unwanted contaminants increases
Solution Approach 1:
The patent employs disposable or easily replaceable adsorbent materials (molecular sieves, activated alumina) that can be regenerated or replaced without introducing contaminants. These materials are specifically selected for their chemical inertness and ability to be processed without contamination risk.
3Manufacturing precision
If separation processes are added to remove impurities, then steam purity is improved, but production cost increases
Solution Approach 1:
The patent implements a single extraction step using adsorbent materials that can be regenerated and reused multiple times, eliminating the need for multiple sequential separation processes and reducing overall production costs while maintaining high steam purity.
4Productivity
If hydrogen and oxygen reaction is used to produce steam, then steam production efficiency is improved, but safety risks increase due to explosive limits
Solution Approach 1:
The patent converts the harmful explosive potential of hydrogen-oxygen mixtures into a beneficial process by carefully controlling the reaction conditions and using the exothermic reaction heat to generate steam directly, thereby eliminating the need for separate heating steps while maintaining safety through controlled chemistry.
5Manufacturing precision
If residual oxygen and hydrogen are removed from synthesized steam, then steam purity is improved, but additional separation processes are required
Solution Approach 1:
The patent uses molecular sieves or activated alumina as intermediary materials that selectively adsorb residual oxygen and hydrogen from synthesized steam, allowing pure steam to pass through while removing trace contaminants in a single integrated step.
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 effectively achieves ultrapure steam with a purity of at least 99.9999% by weight, significantly reducing contaminant levels to below 1 ppt, thereby enhancing the safety and efficiency of steam-based industrial processes while minimizing environmental impact.
Implementation Method 1
The method is based on the ability to generate a high rate of diffusion of water vapor through a nonporous ionic membrane
Implementation Method 2
passing a steam feed through at least one substantially gas-impermeable ion exchange membrane
Data Source
AI summary
Methods for the purification of steam, systems for purifying steam, methods for measuring and/or controlling steam flow rates, and uses for purified steam are provide. Also provided are substantially gas-impermeable membranes, such as perfluorinated ionomers (e.g., perfluoroethylene-sulfonic-acid/tetrafluoroethylene membranes), having a high ratio of water vapor permeation relative to gas permeation through the membrane. Also provided are methods of operation of such membranes at relatively high operating temperatures for the purification of steam and for operation of such membranes at relatively low temperature and sub-atmospheric pressures for the purification of steam. In a preferred embodiment, the system 400 for purifying steam comprises heater 404 for creating a source of a steam feed, and a purification device 416 for housing a substantially gas-impermeable membrane 424. In the operation of system 400, water, such as deionized water, is added to vessel 402 to provide a source of the steam feed.