Polymer Membrane Wafer Assembly for Isothermal Aromatic Separation
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Solution Overview
Problem
Conventional pervaporation processes for separating aromatics from hydrocarbon fuels face challenges such as temperature limitations, adhesive failure in spiral-wound membranes, and non-isothermal heating, leading to inefficient and costly separation processes, especially for high-temperature applications like gasoline, naphtha, and diesel fuel.
Innovation Solution
The use of a polymeric membrane wafer assembly with a thin film polymer membrane, heat transfer means, and ceramic support materials, which allows for isothermal heating and efficient separation of aromatics by regulating pressure and concentration gradients across the membrane, enabling the separation of aromatics from hydrocarbon streams at higher temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional spiral-wound membranes are used for pervaporation separation, then separation of aromatics from hydrocarbon fuels can be achieved, but temperature limitations and adhesive failure occur at high temperatures
Solution Approach 1:
The patent employs composite membrane structures combining organic polymers with inorganic support layers (such as porous ceramics or metals). This composite approach allows the membrane to withstand high temperatures while maintaining separation functionality, as the inorganic support provides thermal stability and mechanical strength at elevated temperatures where conventional organic membranes would fail.
Solution Approach 2:
The patent modifies operating parameters including temperature, pressure, and feed composition to optimize separation performance. By controlling the temperature gradient across the membrane and adjusting pressure differential, the system achieves effective aromatic separation at higher temperatures without causing adhesive failure or membrane degradation.
2Use of energy by stationary object
If non-isothermal heating is applied in conventional pervaporation processes, then heating can be achieved, but temperature gradients adversely affect separation quality and economics
Solution Approach 1:
The patent implements isothermal heating conditions across the membrane surface by optimizing heat transfer design and maintaining uniform temperature distribution. This eliminates temperature gradients that would otherwise cause variations in permeation rates across different regions of the membrane, ensuring consistent separation quality and preventing the formation of concentration polarization zones.
Solution Approach 2:
The system incorporates temperature monitoring and control mechanisms that detect and correct temperature variations in real-time. By maintaining feedback control on the heating process, the system ensures isothermal conditions are preserved, optimizing both energy efficiency and separation performance.
3Temperature
If conventional heating methods are used, then heating can be provided, but adhesive failure occurs in spiral-wound membranes
Solution Approach 1:
The use of composite membrane structures with inorganic support layers eliminates the adhesive bonding issues inherent in spiral-wound configurations. The rigid support structure provides mechanical stability and distributes thermal stresses uniformly, preventing the adhesive failure that occurs in conventional flexible spiral-wound membranes under high-temperature heating conditions.
Solution Approach 2:
The patent employs thin-film membrane configurations that are supported on rigid substrates. This thin-film approach reduces the mass and thermal capacity of the membrane, allowing for more uniform and rapid heating without creating the thermal gradients and mechanical stresses that lead to adhesive failure in thicker spiral-wound structures.
4Productivity
If discrete equipment steps are used for separation, then separation can be achieved, but interconnection for large flow rates becomes expensive
Solution Approach 1:
The patent integrates multiple separation stages and heat transfer functions into a single unified membrane module design. By combining the separation function with integrated heating and cooling zones within the same module, the system achieves large flow rate处理能力 without requiring expensive interconnection of discrete equipment, reducing both capital cost and operational complexity.
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 the separation efficiency and economic viability by maintaining isothermal conditions, improving permeation temperature control, and uniformly managing bulk phase molecular concentrations, thus overcoming the limitations of existing technologies.
Implementation Method 1
a desired feed component, e.g., the aromatic component, of a mixed liquid feed is preferentially dissolved into the membrane film. For membranes selective for the desired component, the desired component is preferentially adsorbed by the membrane
Implementation Method 2
the liquid compound adsorbed migrates through the membrane via the well-known solution-diffusion mechanism
Implementation Method 3
providing a heated fluid to the heat transfer means in order to heat the permeate zone and the polymer membrane as the first stream is being conducted through the first wafer assembly
Implementation Method 4
A low-pressure vacuum is maintained on one side of the membrane media to provide a low energy approach to vaporizing liquid materials
Implementation Method 5
The pervaporation process is a technique of separation of liquid mixtures
Data Source
AI summary
A method and system for blending components obtained from a feed stock. The method includes flowing a first stream through a membrane member, with the membrane member having a first wafer assembly comprising a first thin film polymer membrane, a first permeate zone, and heat transfer means for transferring heat from the first permeate zone to the polymer membrane. The method includes exposing the first stream to the polymer membrane and providing a heated fluid to the heat transfer means in order to heat the permeate zone and the polymer membrane as the first stream is being flown through the first wafer assembly. The method further includes removing a permeate stream from the permeate zone. The permeate stream may be conducted to at least one refinery process unit for further processing. In the preferred embodiment, the feed stock is a naphtha. The system includes a wafer assembly adapted to receive the first stream, with the first wafer assembly comprising a plurality of wafers, and a first and second membrane member having a thin film polymer member. The system also includes heat transfer means for heating a permeate zone and the polymer membrane, as the first stream is being flown through the wafer assembly, and means for processing the produced permeate.