Modular Polymer Evaporation System with Vapor Recompression
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Solution Overview
Problem
Conventional solvent treatment systems face challenges in processing a broad range of effluent due to scaling, maintenance issues, high energy consumption, and material corrosion, particularly with non-neutral pH values, and are limited by membrane wetting and corrosion in industrial applications.
Innovation Solution
A modular evaporation and condensation system using polymer films driven by a mechanical vapor recompressor unit, where frames are detachably integrated and made of polymer materials like Polyvinylidene fluoride, allowing for easier maintenance and operation across a wide pH range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If membranes are used in vapor compression systems, then separation efficiency is improved, but the system becomes susceptible to wetting failures from oil, surfactants, and scaling
Solution Approach 1:
The patent changes the material parameter from organic polymer membranes to inorganic ceramic membranes, which fundamentally alters the chemical and thermal stability properties. Ceramic membranes resist wetting from oil and surfactants while maintaining separation efficiency, and can operate at higher temperatures without degradation.
Solution Approach 2:
The system uses composite construction combining ceramic membrane elements with stainless steel support structures and housing. This composite approach leverages the chemical inertness and thermal stability of ceramics for separation while using the mechanical strength of stainless steel for structural integrity and pressure containment.
2Reliability
If high-grade stainless steel or titanium is used to prevent corrosion, then material durability is improved, but system cost significantly increases
Solution Approach 1:
The patent changes the material parameter from exotic stainless steels or titanium to standard 304 or 316 stainless steel by controlling the operating temperature parameter. The system operates at temperatures below 200°C where standard stainless steel exhibits sufficient corrosion resistance, eliminating the need for expensive exotic materials while maintaining durability.
Solution Approach 2:
The patent employs cheaper standard stainless steel materials that can be easily replaced if needed, rather than investing in expensive exotic materials. The modular design allows individual components to be replaced independently, reducing overall system cost while maintaining reliability through ease of maintenance.
3Reliability
If vacuum or high pressure systems are designed to safely contain processes, then safety is improved, but additional turbo-machinery is required which significantly increases costs
Solution Approach 1:
The patent changes the operating pressure parameter from vacuum or high-pressure conditions to near-atmospheric pressure operation. The ceramic membranes provide sufficient structural integrity to contain the pressure differential without requiring additional turbo-machinery or complex safety containment systems, significantly reducing equipment costs while maintaining process safety.
4Productivity
If conventional evaporation systems are used to treat contaminated solvents, then evaporation capability is achieved, but energy consumption is excessively high
Solution Approach 1:
The patent utilizes the phase transition of water from liquid to vapor within the ceramic membrane pores during evaporation. The latent heat of vaporization is efficiently transferred through the membrane structure, and the condensed vapor on the other side releases heat that can be recovered, reducing overall energy consumption compared to conventional direct heating evaporation systems.
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 achieves efficient evaporation and condensation with reduced costs and maintenance efforts, overcoming scaling and corrosion issues, and is suitable for various industrial applications without the need for high-grade materials.
Implementation Method 1
a mechanical vapor recompressor mounted outside the at least one evaporation-condensation unit receiving the generated vapor from the at least one evaporation-condensation unit at a vapor outlet and feeding back the vapor with high pressure and temperature to the evaporation-condensation unit at an upper inlet
Implementation Method 2
The unit receives a feed at the lower inlet and a part of the feed partially evaporates at the evaporation frame and generates vapor
Implementation Method 3
each stack comprises an evaporation frame and a condensation frame separated by a polymer sheet
Implementation Method 4
passing the generated vapor at a vapor outlet to a mechanical vapor recompressor mounted outside the evaporation-condensation unit for compression and feeding back the compressed vapor with the high pressure and temperature at an upper inlet of the evaporation-condensation unit from the mechanical vapor recompressor
Data Source
AI summary
According to the present disclosure, a system and method for evaporation and condensation are disclosed. The system (1) comprises at least one evaporation-condensation unit (2) comprising a plurality of frames arranged in a series of stacks, each stack comprises an evaporation frame (9) and a condensation frame (5) separated by a polymer sheet (6). The unit (2) receives a feed (3) and a part of the feed (3) partially evaporates within the unit (2) and generates vapor (4). The system further comprises a mechanical vapor recompressor (8) mounted outside the unit (2) receiving the generated vapor from the unit (2) at a vapor outlet. Each frame is made of a polymer material and a plurality of frames are detachably integrated within the unit thereby forming a modular system. A multi-effect system for evaporation and condensation is formed by arranging at least two evaporation-condensation units in series with a recompressor (8).