Molecular Sieve Depressurization Using Low Pressure Eductor Condenser
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Solution Overview
Problem
Current ethanol production methods using molecular sieves for dehydration result in reduced plant capacity and increased energy consumption due to reverse flow systems during regeneration, and lead to negative effects such as fusel release in ethanol discharge.
Innovation Solution
A system and method utilizing a low-pressure eductor type vapor condenser to depressurize and recharge the molecular sieve, integrating a mixing condenser that combines vapor and liquid streams to increase the temperature of the recharge flow, thereby reducing energy demands and improving operational consistency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If reverse flow system is used to depressurize molecular sieve, then molecular sieve can be regenerated, but plant capacity is reduced and energy consumption increases
Solution Approach 1:
Instead of using reverse flow (from discharge end to feed end) to depressurize the molecular sieve, the patent applies forward flow (from feed end to discharge end) to maintain continuous production during regeneration, thereby avoiding plant capacity reduction while achieving sieve regeneration
2Reliability
If reverse flow system is used to depressurize molecular sieve, then molecular sieve can be regenerated, but energy consumption increases
Solution Approach 1:
The patent inverts the depressurization flow direction from reverse to forward, allowing the system to utilize existing pressure gradients and eliminate the need for additional pumping energy, thereby reducing overall energy consumption during molecular sieve regeneration
Solution Approach 2:
The forward flow depressurization system allows the molecular sieve to regenerate itself using the natural flow of ethanol vapor from the feed end through the sieve to the discharge end, eliminating the need for external energy input required by reverse flow systems
3Reliability
If reverse flow system is used, then molecular sieve regeneration is achieved, but fusel release into ethanol discharge increases
Solution Approach 1:
By inverting the flow direction from reverse to forward during depressurization, the patent ensures that ethanol vapor flows in the same direction as during normal operation, preventing fusel oil from being carried backward into the discharge stream while still achieving effective molecular sieve regeneration
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 enhances ethanol production efficiency by reducing energy consumption, minimizing fusel release, and extending equipment life, with estimated annual savings of $75,000 to $100,000 and improved product quality.
Implementation Method 1
a low pressure eductor type vapor condenser (26) that utilizes a liquid stream to create a vacuum to draw vapor from the molecular sieve
Implementation Method 2
the low pressure eductor type vapor condenser (26) that utilizes a liquid stream to create a vacuum to draw vapor from the molecular sieve and condense the vapor
Implementation Method 3
integrating a mixing condenser that combines vapor and liquid streams to increase the temperature of the recharge flow
Data Source
AI summary
A method and system of depressurizing a molecular sieve used in ethanol production is shown and described. The method and system utilizes a vapor mixing condenser that receives a vapor sieve feed from the molecular sieve during the depressurization cycle. The vapor from the molecular sieve during the pressurization cycle is used to heat the 190-proof product flow. The heated product flow is diverted directly to the 190-proof product vaporizer, which increases the input product flow temperature to the vaporizer, thereby reducing the amount of heat needed to vaporize the 190-proof product flow. The reduction in heat needed reduces energy costs and increases equipment life.