Gas Separation Membrane Module Assembly with Internal Permeate Extraction
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Solution Overview
Problem
There is a need for gas separation membrane assemblies that are compact, safe, inexpensive to manufacture, and allow for easy replacement of modules, particularly in applications with large membrane area requirements, as existing solutions are complex, costly, and require extensive external piping and high-pressure-rated tubes.
Innovation Solution
A gas-separation membrane assembly comprising multiple tubes housed within a single pressure vessel, where the tubes are arranged in a longitudinal direction and supported by tube sheets, dividing the vessel into three gas-tight spaces, allowing for efficient gas flow and permeate collection, and enabling the use of standard, off-the-shelf piping for the tubes, with the pressure-withstanding function fulfilled by the outer vessel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple membrane modules are arranged within a single pressure vessel using conventional designs, then the membrane area can be increased, but the device complexity and manufacturing cost increase due to requiring high-pressure-rated tubes and extensive external piping
Solution Approach 1:
The patent merges multiple individual pressure vessels into a single integrated pressure vessel containing multiple membrane modules. The outer pressure vessel houses multiple inner tubes, each containing a membrane module, eliminating the need for separate high-pressure vessels and extensive external piping connections. This consolidation reduces device complexity while maintaining large membrane area capacity.
Solution Approach 2:
The outer pressure vessel serves multiple functions simultaneously: it provides the high-pressure containment environment, houses multiple membrane modules, and integrates the piping system. The manifold structure within the vessel distributes feed gas to multiple modules and collects permeate and retentate streams, making the single vessel a multi-functional component that replaces multiple separate systems.
2Quantity of substance
If conventional pressure vessels with multiple modules are used, then membrane area can be expanded, but capital costs and manufacturing complexity increase
Solution Approach 1:
By combining multiple membrane modules into a single pressure vessel with a shared piping system, the patent reduces the total number of high-pressure components that need to be manufactured and assembled. Instead of requiring multiple separate high-pressure vessels each with their own piping, a single vessel with internal manifolds suffices, reducing manufacturing complexity and capital costs.
Solution Approach 2:
The patent segments the membrane separation function into multiple independent modules within the single pressure vessel. Each module can be independently manufactured, tested, and replaced, while sharing the common high-pressure containment and piping infrastructure. This segmentation allows standardization of components and reduces overall manufacturing cost.
3Ease of repair
If complete modules are removed and replaced in the field, then membrane replacement can be performed, but plant downtime increases
Solution Approach 1:
The patent divides the membrane system into separable modules that can be independently removed and replaced. Each membrane module is contained within its own section of the pressure vessel, allowing targeted replacement of only the defective module rather than the entire system. This modular segmentation minimizes plant downtime by enabling quick swap-out of individual modules.
Solution Approach 2:
The patent designs the modules and their mounting arrangements to facilitate preliminary preparation for quick replacement. Modules can be pre-assembled and tested outside the vessel, then rapidly installed by simply removing the old module and inserting the new one. The standardized interfaces and mounting mechanisms enable this preliminary preparation, reducing on-site replacement time and plant downtime.
4Ease of manufacture
If standard off-the-shelf piping is used for tubes, then manufacturing cost decreases, but pressure-containing capability must be transferred to the outer vessel
Solution Approach 1:
The patent combines the pressure containment function of multiple individual tubes into a single outer pressure vessel. The inner tubes use standard off-the-shelf piping that does not need to be high-pressure rated, while the outer vessel provides the high-pressure containment environment. This merging of functions allows inexpensive standard piping to be used for the membrane modules while maintaining overall system pressure integrity.
Solution Approach 2:
The outer pressure vessel acts as an intermediary that provides the high-pressure environment for the standard off-the-shelf tubes. Instead of requiring the tubes themselves to withstand high pressure, the outer vessel mediates by containing the pressurized feed gas and transmitting the pressure environment to the modules, allowing the use of cheaper, non-pressure-rated tube materials.
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 arrangement reduces manufacturing complexity and capital costs, minimizes downtime for module replacement, and provides a more robust and compact containment system, significantly reducing the number of flanges, gaskets, and connections, while allowing for larger membrane areas to be accommodated in a smaller footprint.
Implementation Method 1
Gas flows and membrane performance are such that membrane area requirements may be very large
Implementation Method 2
Gas separation membranes have been in industrial use for close to 25 years
Data Source
AI summary
A gas-separation membrane module assembly and a gas-separation process using the assembly. The assembly includes a set of tubes, each containing gas-separation membranes, arranged within a housing. The housing contains tube sheets that divide the space within the housing into three separate, gas-tight spaces, with the tubes mounted in the central space. Within this space, each tube has an aperture or hole in its wall that enables gas that has been retained on the feed side of the membranes to flow out of the tubes and into the space. The assembly can be used in various ways to carry out gas separation processes.