Mini-Channel Membrane Device for Water-Hydrocarbon Separation
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Solution Overview
Problem
Current methods for separating water from water-hydrocarbon mixtures, such as ethanol-water, are energy-intensive and costly, especially at industrial scales, due to the formation of azeotropic mixtures and the fragility of ceramic membrane tubes, which limits the scalability of membrane separation processes.
Innovation Solution
A mini-channel separation device using thin H2O-selective molecular sieve membrane sheets stacked face-to-face to form mini-flow feed channels, supported by a durable backing structure with permeate channels, allowing for efficient water-hydrocarbon mixture separation with high packing density and reduced pressure drop.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If ceramic tube-supported zeolite membranes are used for membrane separation, then water/ethanol selectivity and flux are improved, but device complexity and manufacturing difficulty increase due to the large number of fragile tubes required
Solution Approach 1:
The invention divides the membrane separation function into stacked flat membrane sheets instead of using numerous tubular membranes. Each sheet contains multiple parallel flow channels that segment the feed stream, achieving high productivity without requiring a large number of fragile tube components
Solution Approach 2:
The invention transitions from one-dimensional tubular membrane geometry to two-dimensional flat sheet geometry with multi-channel configuration. This dimensional change allows for more efficient packing and reduced component count while maintaining or enhancing separation productivity
2Reliability
If ceramic tube-supported zeolite membranes are used, then separation selectivity is improved, but reliability decreases due to tube fragility
Solution Approach 1:
The invention uses thin flat membrane sheets supported by porous substrates instead of thick-walled ceramic tubes. This thin-film approach reduces material fragility while maintaining separation selectivity, and the flat geometry is inherently more resistant to mechanical stress and breakage
Solution Approach 2:
The invention employs composite structures combining thin zeolite membrane layers with porous support substrates. This composite approach provides the necessary mechanical strength and durability without requiring fragile solid ceramic tubes, achieving both reliability and separation performance
3Reliability
If distillation is used for bulk separation, then separation capability is improved, but energy consumption increases due to thermal energy requirements
Solution Approach 1:
The invention replaces the thermal field-based distillation process with a membrane-based separation process that operates isothermally or with minimal temperature change. This substitution eliminates the need for continuous heating and cooling cycles, dramatically reducing energy consumption while maintaining separation capability
Solution Approach 2:
The invention changes the separation mechanism from thermal-driven phase equilibrium (distillation) to concentration-driven permeation (membrane separation). This parameter change allows separation to occur at constant or near-constant temperature, avoiding the high thermal energy requirements of distillation
4Reliability
If adsorption is used for water removal, then separation effectiveness is improved for low water concentrations, but equipment size and regeneration energy increase for significant water concentrations
Solution Approach 1:
The invention uses porous zeolite membrane materials that provide high water selectivity through their pore structure. The membranes achieve effective water removal across a wide range of water concentrations without requiring large equipment volumes, as the separation occurs continuously through the membrane surface area rather than through bulk adsorption beds
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 mini-channel device achieves high water flux and selectivity, reducing energy consumption and capital costs by enabling efficient industrial-scale separation of water-hydrocarbon mixtures, including ethanol-water, with minimal pressure drop and increased membrane durability.
Implementation Method 1
thin H2O-selective molecular sieve membrane sheets
Implementation Method 2
transporting water molecules from the water-hydrocarbon mixture across the membrane sheet
Data Source
AI summary
A membrane device and separation process are presented to enable removal of water from water-containing mixtures at high throughput and high energy efficiency. The membrane device is made of thin H2O-selective molecular sieve membrane sheets with small feed channels and small permeate channels. The thin membrane sheet provides H2O-molecular specificity and allows H2O molecule to permeate through while blocking the other molecules. The membrane device provides large membrane area per unit volume and reduces mass transfer and flow resistance. Water is removed from the mixture by flowing the water-containing mixture through the feed channels of the device at a pressure above atmospheric pressure and removing the permeated water vapor from the permeate channels in the device under vacuum.