Multisection Solvent Extraction Settler for Coalescence and Safety
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Solution Overview
Problem
Conventional solvent extraction settlers face issues with slow coalescence due to small specific surface area, transverse flow patterns, difficulty in maintenance, limited capacity, flammability, and high damage potential from leakage, as they are large, square tanks with minimal wall effect and poor fire protection.
Innovation Solution
A solvent extraction settler with multiple parallel and separated plug flow channels, formed by elongated settler sections that enhance coalescence, prevent transverse flow, allow for partial isolation and maintenance, increase capacity, improve fire protection, and compartmentalize to limit damage from leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a large square settler tank is used, then the settler capacity is increased, but the specific surface area of wall surfaces becomes small resulting in slow coalescence
Solution Approach 1:
The settler is divided into multiple parallel flow channels separated by vertical partitions. This segmentation increases the wall surface area relative to the cross-sectional area, enhancing the wall effect and coalescence rate while maintaining large settler capacity. Each channel provides sufficient wall interaction for effective droplet coalescence.
2Quantity of substance
If a large square settler tank is used, then the settler capacity is increased, but transverse flow patterns develop slowing down coalescence
Solution Approach 1:
Vertical partitions divide the settler into multiple independent parallel flow channels. This segmentation prevents transverse flow patterns by constraining the flow to move predominantly in the longitudinal direction through each channel, ensuring stable plug flow conditions and effective gravity-driven phase separation.
3Quantity of substance
If a conventional large settler tank is used, then the settler capacity is sufficient, but maintenance requires shutting down the whole process and is difficult
Solution Approach 1:
The settler is divided into multiple parallel flow channels by vertical partitions that extend from the top to the bottom of the settler. This segmentation allows individual channels to be isolated and maintained while other channels continue to operate, enabling continuous process operation during maintenance activities.
Solution Approach 2:
The vertical partitions are designed to be removable or accessible from the outside of the settler. This allows maintenance personnel to access and remove partitions for cleaning accumulated crud or inspecting flow channels without shutting down the entire solvent extraction process.
4Quantity of substance
If a conventional large settler tank is used, then the settler capacity is sufficient, but the atmosphere above the liquid surface is flammable and fire protection is difficult
Solution Approach 1:
The settler is divided into multiple parallel flow channels by vertical partitions, creating separate fire compartments. This segmentation limits the spread of fire and allows targeted fire protection measures in each compartment, reducing the overall fire hazard despite large settler capacity.
Solution Approach 2:
The vertical partitions create enclosed flow channels that can be purged with inert gas or maintained at positive pressure to prevent the formation of flammable atmospheres above the liquid surface. This isolates the volatile organic compounds within the channels and prevents their accumulation in the settler headspace.
5Quantity of substance
If a conventional large settler tank is used, then the settler capacity is sufficient, but leakage causes large damages
Solution Approach 1:
The settler is divided into multiple parallel flow channels by vertical partitions that extend from top to bottom. This segmentation creates isolated compartments that limit the spread of leakage, containing damages to individual channels rather than affecting the entire settler.
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 multisection settler design increases coalescence efficiency, enables continuous maintenance, expands capacity, enhances fire safety, and minimizes damage from leaks by creating a large specific surface area and plug flow pattern, while compartmentalizing sections for easier fire extinguishing and containment.
Implementation Method 1
the dispersion moves towards the settler discharge end and, at the same time, the phases separate by gravity into two layers
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A solvent extraction method for hydrometallurgical liquid-liquid extraction processes, in which method solution phases are separated from a dispersion while the dispersion flows horizontally in a settler from a feed end to a discharge end. The mass flow of the dispersion and solution phases is divided into a plurality of parallel and mutually separated plug flows flowing in the settler from the feed end to the discharge end. The settler (1) comprises a plurality of elongated settler sections (4) which are mutually separated and side by side in parallel to each other, the settler sections (4) extending from the feed end (2) to the discharge end (3), forming a plurality of mutually separated parallel plug flow channels.