Partitioned Neutralization-Water Separation Tank for Ester Processing
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Solution Overview
Problem
Existing methods for preparing plasticizers face inefficiencies in both neutralization and water separation processes, leading to compromised overall efficiency and structural complexity due to the need for separate tanks and additional transfer pumps.
Innovation Solution
A combined neutralization/water separation tank design with separate neutralization and water separation parts, utilizing partition walls for efficient mixing and separation, and incorporating circulation and discharge pumps to manage the reaction and separation processes within a single unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate tanks are used for neutralization and water separation, then each process can be optimized independently, but device complexity and the need for additional transfer pumps increase
Solution Approach 1:
The patent combines the neutralization tank and water separation tank into a single integrated tank structure. The neutralization part and water separation part are divided by a partition wall, allowing both functions to be performed in one device, thereby reducing structural complexity and eliminating the need for additional transfer pumps while maintaining independent process optimization capabilities.
Solution Approach 2:
The integrated tank serves multiple functions simultaneously - it performs both neutralization and water separation operations. The partition wall creates separate zones within the same tank, enabling the device to handle multiple process steps without requiring separate dedicated tanks for each function.
2Productivity
If separate tanks are used for neutralization and water separation, then process efficiency can be maintained, but the need for additional transfer pumps increases cost and complexity
Solution Approach 1:
By merging the neutralization and water separation functions into a single tank, the patent eliminates the need for additional transfer pumps that would be required to move material between separate tanks. This reduces device complexity and cost while maintaining process efficiency through the partition wall design that enables both functions to operate simultaneously.
3Device complexity
If a single integrated tank is used for neutralization and water separation, then device complexity is reduced, but salt accumulation may occur
Solution Approach 1:
The patent divides the integrated tank into separate neutralization part and water separation part using a partition wall. This segmentation prevents salt accumulation by creating distinct zones where salt can be effectively removed in the water separation part while maintaining the structural simplicity of a single integrated tank.
4Productivity
If neutralization and water separation occur in the same tank, then process integration is improved, but mixing and separation effectiveness may be compromised
Solution Approach 1:
The partition wall divides the tank into separate neutralization and water separation zones, ensuring that mixing and separation processes remain effective in each zone while still allowing process integration at the system level. The segmentation maintains distinct functional zones without requiring complete physical separation into different tanks.
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 integrated design allows for improved efficiency in both neutralization and water separation, reduces structural complexity, prevents salt accumulation, and eliminates the need for additional transfer pumps, enhancing overall process efficiency.
Implementation Method 1
a neutralization part in which a crude product mixture containing alcohol and an ester compound, a neutralizing agent, and water are put to produce a neutralized mixture
Implementation Method 2
a water separation part which divides the neutralized mixture into a floating layer and an aqueous layer
Data Source
AI summary
A neutralization/water separation tank for an esterified product including: a neutralization part in which a crude product mixture containing alcohol and an ester compound, a neutralizing agent, and water are put to produce a neutralized mixture; a water separation part which divides the neutralized mixture into a floating layer and an aqueous layer; a first partition wall which extends upward from a bottom surface to provide an upper passage and by which the neutralization part and the water separation part are partitioned; and a second partition wall which extends downward from a ceiling to provide a lower passage, wherein the water separation part includes: a first water separation part into which the neutralized mixture is introduced from the neutralization part through the upper passage; and a second water separation part into which the neutralized mixture is introduced from the first water separation part through the lower passage, wherein the first water separation part and the second water separation part are partitioned by the second partition wall.