Open-Loop Feedstock Delivery and Refrigeration Integration
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Solution Overview
Problem
Existing chemical manufacturing processes, such as propylene ammoxidation, suffer from inefficiencies and sensitivity to upsets due to complex closed-loop refrigeration systems, which are costly and require significant equipment, leading to heat loss and increased power consumption.
Innovation Solution
An open-loop system integrates feedstock delivery and refrigeration by using propylene or propane as both a feedstock and coolant, eliminating the need for separate refrigerants and reducing equipment requirements through an open refrigerant loop that includes a feedstock accumulator, heat exchangers, and a compressor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a closed-loop refrigeration system is used to cool feedstocks, then refrigeration is provided, but the system becomes complex and sensitive to upsets
Solution Approach 1:
The patent extracts the refrigeration function from a separate closed-loop system and integrates it directly into the feedstock delivery system. The feedstock itself serves as the refrigerant, eliminating the need for separate refrigerant loops and reducing system complexity while maintaining effective cooling capability.
Solution Approach 2:
The feedstock serves dual purposes: it is both the material to be delivered to the reactor and the refrigerant for cooling other feedstocks and process streams. This multi-functionality eliminates the need for dedicated refrigeration systems and reduces overall system complexity.
2Temperature
If separate refrigerant loops are used, then refrigeration is achieved, but equipment requirements increase and heat loss occurs
Solution Approach 1:
The patent merges the feedstock delivery system with the refrigeration system into a single integrated open loop. The same equipment (heat exchangers, accumulators, compressors) serves both to deliver feedstock to the reactor and to provide refrigeration, thereby reducing the total quantity of equipment required.
Solution Approach 2:
Feedstock is used for dual purposes: as the process material and as the refrigerant. This eliminates the need for separate refrigerant loops and associated equipment, reducing overall equipment quantity while maintaining effective refrigeration capability.
3Temperature
If closed-loop refrigeration is implemented, then cooling is provided, but power consumption increases
Solution Approach 1:
The patent converts the typically harmful effect of heat loss into a beneficial cooling effect. By allowing controlled heat exchange between the feedstock and other process streams through heat exchangers, the system recovers cooling capacity that would otherwise be lost, reducing the need for additional power-intensive refrigeration.
Solution Approach 2:
The feedstock serves its own cooling needs and those of other process streams through the open loop system. The refrigeration capability is generated internally by the feedstock itself rather than requiring external power-intensive refrigeration systems, thereby reducing overall power consumption.
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 stabilizes the manufacturing process, reduces equipment needs, minimizes heat loss, and decreases power consumption by utilizing propylene or propane as a dual-purpose refrigerant, enhancing efficiency and reliability.
Implementation Method 1
conveying a hydrocarbon feedstock in a liquid phase from a feedstock accumulator to a shell side of at least one heat exchanger... vaporizing the hydrocarbon feedstock in the shell side of the at least one heat exchanger
Implementation Method 2
compressing and condensing a first portion of the feedstock in the vapor phase from the economizer in a compressor
Implementation Method 3
compressing and condensing a first portion of the feedstock in the vapor phase from the economizer in a compressor
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
A chemical manufacturing process may include an open loop that provides both feedstock delivery and refrigeration. For example, the process may include conveying a hydrocarbon feedstock (e.g., propane or propylene) in a liquid phase from a feedstock accumulator to a shell side of a heat exchanger and vaporizing the feedstock in the heat exchanger. Then, the method may include collecting the feedstock in a vapor phase from the heat exchanger in an economizer; compressing and condensing a first portion of the feedstock in the vapor phase from the economizer in a compressor; and recycling the feedstock in the liquid phase from the compressor to the feedstock accumulator, which closes the refrigeration loop. As the open part of the loop to provide feedstock to the reactor, the method may further include conveying a second portion of the feedstock in the vapor phase from the economizer to a reactor.