Pneumatic Spray Recirculation for Incomplete Reaction Conversion
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Solution Overview
Problem
Chemical reaction yield in liquid spray discharge systems is limited due to incomplete reactions, leading to low product yields and solvent wastage, as reactions do not go to completion and there is a constraint on the distance droplets can travel within the spray.
Innovation Solution
A recirculation system is implemented, where unreacted molecules and reaction products are collected and reused in the pneumatic sprayer, allowing for multiple cycles and increasing the yield of chemical reactions, with components like electrostatic precipitators, condensers, and mass spectrometers for analysis and solvent recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If spray techniques are used to generate reaction products, then reaction rates are accelerated, but reactions do not go to completion and product yield is low
Solution Approach 1:
The patent implements a recirculation system where unreacted molecules are continuously collected and resprayed, allowing the reaction to proceed over multiple cycles until completion. This continuous action resolves the contradiction by maintaining the accelerated reaction rate while ultimately achieving complete conversion and high product yield.
Solution Approach 2:
The system recovers unreacted molecules from the spray discharge and returns them to the reaction process through recirculation. This recovery principle allows the system to maintain high reaction rates while preventing loss of unreacted material, thereby achieving both speed and productivity.
2Productivity
If droplets are allowed to travel farther in the spray, then reaction extent increases, but there is a limit to how far droplets can travel
Solution Approach 1:
Instead of extending the spray path length (one dimension), the patent introduces a temporal dimension through recirculation. Unreacted molecules are collected and resprayed in subsequent cycles, effectively extending the reaction time without requiring longer droplet travel distance, thus resolving the contradiction between reaction extent and travel distance constraint.
Solution Approach 2:
The recirculation system provides continuous reaction opportunities for unreacted molecules through multiple spray cycles, achieving complete conversion without requiring droplets to travel beyond the physical limits of the spray system.
3Speed
If reactions are conducted in liquid spray discharge, then reaction rates are accelerated, but solvent is wasted when reactions do not go to completion
Solution Approach 1:
The patent recovers solvent containing unreacted molecules from the spray discharge and returns it to the reaction system through recirculation. This recovery approach maintains the benefits of accelerated reaction rates while preventing solvent waste, as the solvent is reused in subsequent reaction cycles.
Solution Approach 2:
The continuous recirculation of solvent and unreacted molecules ensures that the solvent serves multiple reaction cycles, maintaining high reaction rates while maximizing solvent utilization and minimizing waste.
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 reaction yield by allowing unreacted molecules to react further, driving incomplete reactions to completion, and conserves solvent by recycling it, thereby increasing product formation efficiency and reducing solvent consumption.
Implementation Method 1
The collector may include one or more of the following components. In certain embodiments, the collector includes an electrostatic precipitator.
Implementation Method 2
In certain embodiments, a cryogenic condenser is used.
Implementation Method 3
An exemplary liquid degassing unit is one that includes a semi-permeable membrane within the vacuum chamber.
Data Source
AI summary
The invention generally relates to systems and methods for increasing reaction yield. In certain embodiments, the invention provides systems for increasing a yield of a chemical reaction that include a pneumatic sprayer configured to generate a liquid spray discharge from a solvent. The solvent includes a plurality of molecules, a portion of which react with each other within the liquid spray discharge to form a reaction product. The system also includes a collector positioned to receive the liquid spray discharge including the unreacted molecules and the reaction product. The system also includes a recirculation loop connected from the collector to the pneumatic sprayer in order to allow the unreacted molecules and the reaction product to be recycled through the pneumatic sprayer, thereby allowing a plurality of the unreacted molecules to react with each other as the unreacted molecules cycle again through the system.