Low-Temperature Distillation System Using Inert Gas
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Solution Overview
Problem
Conventional distilleries face issues with high energy consumption, production of unwanted volatile organic compounds, and quality degradation due to high temperatures, which lead to inefficient energy use and adverse effects on the quality of consumable spirits.
Innovation Solution
A low-temperature distillation system operating at 120° F to 155° F, using waste heat resources and minimizing oxygen exposure to produce high-quality spirits, incorporating a heat exchanger, carrier gas recycling, and a condenser system to maintain atmospheric pressure and reduce fusel oil production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional high temperature distillation (190°F-205°F) is used, then distillation efficiency is improved, but unwanted volatile organic compounds are produced and spirit quality deteriorates
Solution Approach 1:
The patent fundamentally changes the operating temperature parameter from conventional high temperature (190°F-205°F) to low temperature (120°F-155°F). This parameter change enables efficient distillation while avoiding the formation of unwanted volatile organic compounds that occur at higher temperatures, thus resolving the contradiction between productivity and harmful factor generation.
Solution Approach 2:
The patent introduces an inert nitrogen atmosphere to replace oxygen in the distillation environment. This prevents oxidation reactions that occur at high temperatures and generate harmful compounds. The inert environment allows efficient distillation to proceed without producing unwanted volatile organic compounds, addressing the contradiction between productivity and harmful factor generation.
2Productivity
If high temperature heat input (approx. 250°F) is used for vaporization, then distillation process is accelerated, but energy waste increases and fuel resources are depleted
Solution Approach 1:
The patent changes the heat input temperature parameter from high temperature (approx. 250°F) to low temperature (120°F-155°F). This parameter change maintains acceptable distillation rates while dramatically reducing energy consumption and avoiding the waste of fuel resources, thus resolving the contradiction between productivity and energy loss.
Solution Approach 2:
The patent converts the previously harmful effect of low-grade waste heat (120°F-155°F) into a beneficial resource. By designing the distillation process to operate at these temperatures, the patent enables the utilization of waste heat from industrial processes, solar thermal systems, and geothermal sources, transforming energy waste into useful distillation energy and resolving the contradiction between productivity and energy loss.
3Manufacturing precision
If multiple distillations with smaller cuts are performed to remove unwanted materials, then spirit quality is improved, but energy consumption increases
Solution Approach 1:
The patent changes the temperature parameter to low temperature (120°F-155°F), which fundamentally alters the distillation dynamics. This single parameter change achieves high manufacturing precision (spirit quality) in a single pass by preventing the formation of unwanted compounds in the first place, eliminating the need for multiple distillations and associated energy consumption.
Solution Approach 2:
The patent performs preliminary action by creating an inert nitrogen atmosphere and maintaining low temperature conditions before distillation begins. This preliminary setup prevents the formation of unwanted volatile organic compounds and oxidation products from the outset, ensuring high spirit quality without requiring subsequent multiple distillations to remove contaminants, thus resolving the contradiction between manufacturing precision and energy consumption.
4Object-affected harmful factors
If oxygen is present in the distillation environment, then combustion risk increases, but oxygen reacts with alcohol to produce off-taste and toxic compounds
Solution Approach 1:
The patent applies the inert atmosphere principle by introducing nitrogen gas to displace oxygen from the distillation environment. This simultaneously eliminates combustion risk (object-affected harmful factor) and prevents oxygen reactions that produce off-taste and toxic compounds (object-generated harmful factors). The inert nitrogen atmosphere resolves both harmful effects without compromising distillation 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
The system reduces energy costs, minimizes unwanted compound production, and produces high-quality spirits with reduced hangover symptoms, allowing for efficient production of consumable spirits using sustainable energy sources.
Implementation Method 1
a feed tank containing a heat exchanger for producing a heated fermentation product
Implementation Method 2
an evaporator tank receiving the heated fermentation product and vaporizing alcohol therefrom
Implementation Method 3
a condenser for condensing alcohol containing vapor
Data Source
AI summary
The system and methods described are directed to a distillation system and method having an evaporator tank with a wall surrounding an interior evaporator tank area. A non-oxidizing gas line is disposed at least partially outside the evaporator tank in communication with the interior evaporator tank area, wherein the non-oxidizing gas line introduces a non-oxidizing gas into the interior evaporator tank; the interior evaporator tank area is generally at or above an ambient atmospheric pressure.