Multi-Solvent Liquid Extraction for Low-Energy Solid Drying
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Solution Overview
Problem
Conventional methods for removing water from solids, such as those encountered in ethanol manufacturing, require significant thermal energy and often result in residual contaminants, making the process inefficient and undesirable for many applications.
Innovation Solution
A process utilizing multiple solvents, either sequentially or concurrently, to step-wise replace and separate water from solids, reducing the energy required for drying and allowing for the recovery of pure ethanol and reusable water streams.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If thermal drying is used to remove water from solids, then water removal is achieved, but large amounts of thermal energy are required
Solution Approach 1:
The patent changes the physical-chemical parameters of the drying medium from pure thermal energy to a solvent system with specific vapor pressure and solubility characteristics. The solvent is selected to have a vapor pressure higher than water at operating temperatures, enabling selective evaporation and energy-efficient water removal.
Solution Approach 2:
The patent introduces an intermediary substance (solvent) that mediates between the water to be removed and the solid material. The solvent displaces water from the solid matrix through competitive sorption, then enables water removal through selective evaporation, reducing direct thermal energy requirements.
2Manufacturing precision
If conventional drying methods are used, then water is removed from solids, but residual contaminants remain and pure product streams are not obtained
Solution Approach 1:
The patent segments the drying process into distinct stages: (1) solvent displacement of water from solids, (2) selective evaporation of solvent, and (3) separation of water and solvent streams. This segmentation enables high purity product streams while managing process complexity through systematic stage division.
Solution Approach 2:
The patent utilizes parameter changes in solvent selection (vapor pressure, solubility, boiling point) to achieve selective separation. By choosing solvents with specific parameter ranges, the process achieves high product purity without requiring complex multi-component separation systems.
3Productivity
If single solvent extraction is used, then water removal is simplified, but complete water displacement and drying are not achieved
Solution Approach 1:
The patent merges multiple solvent functions into a coordinated system where the primary solvent handles water displacement and a secondary solvent assists in complete water removal and drying. This combination achieves superior drying efficiency while managing complexity through functional integration rather than separate operations.
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 reduces energy consumption by at least 20% compared to conventional forced air drying, enabling the production of dry solids and the separation of solvents, while also facilitating the recovery of pure ethanol and water, thus addressing the inefficiencies and contamination issues of traditional methods.
Implementation Method 1
The process uses a liquid-solid extraction process to remove the water from the solid feed stream
Implementation Method 2
The hexane is used to displace the water from the solids
Implementation Method 3
The hexane remaining with the solids is then evaporated from the solids with thermal energy
Implementation Method 4
The multiple solvents are separated from each other by liquid-liquid extraction or distillation processes
Data Source
AI summary
A process for removing water from solid material using liquid-solid extraction and liquid-liquid extraction. In most embodiments, multiple solvents are used to remove the water from the solids and obtain dry solids. Multiple solvents facilitate the removal of the water from the solids, by replacing the water with a solvent, replacing that solvent with a different solvent, and then eventually removing the second solvent from the solids. The process utilizes a lesser amount of thermal energy to dry the solids and separate the solvents than conventionally used in drying processes. The first solvent selected has a lower heat of vaporization, enthalphy of vaporization, boiling point, or other such physical property, than water. Each additional solvent can have a still lower heat of vaporization, enthalphy of vaporization, boiling point, or other such physical property.