Processing Liquid Recovery via Heat-Integrated Regeneration
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Solution Overview
Problem
Industrial processes face challenges in efficiently recovering processing liquids from gas purification systems, as they become contaminated with both volatile and less volatile components, leading to energy inefficiencies and increased capital expenditures due to the need for frequent replenishment and disposal of contaminated liquids.
Innovation Solution
A process involving a regenerator column with a first separation zone where the feed mixture is heated, allowing for the volatilization of water and volatile components, and subsequent degassing of the processing liquid, with heat energy recovery and recycling to minimize energy consumption and recover a substantial portion of the processing liquid.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional separation processes are used to recover processing liquid, then the processing liquid can be separated from contaminants, but energy consumption increases and capital expenditures rise
Solution Approach 1:
The patent combines the separation of volatile and non-volatile contaminants with heat recovery in a single integrated system. The vapor generated during separation is condensed and the resulting condensate is used as process water, merging two functions (separation and water recovery) into one process that reduces overall energy consumption.
Solution Approach 2:
The patent changes the operating parameters of the separation process by controlling pressure and temperature conditions to optimize energy efficiency. By adjusting these parameters, the system achieves effective separation while minimizing energy input requirements and maximizing heat recovery potential.
2Reliability
If conventional separation processes are used to recover processing liquid, then the processing liquid can be separated from contaminants, but capital expenditures increase
Solution Approach 1:
The patent designs a multi-functional system that performs separation, condensation, and water recovery in one integrated unit. This universal approach reduces the need for separate equipment for each function, thereby lowering capital expenditures while maintaining reliable processing liquid recovery.
Solution Approach 2:
Instead of discarding the condensate from the separation process, the patent recovers and reuses it as process water. This recovery approach eliminates the need for separate water treatment or disposal systems, reducing capital expenditures while ensuring reliable contaminant removal.
3Reliability
If processing liquid is frequently replenished and disposed of, then contamination levels are controlled, but energy usage and capital expenditures increase
Solution Approach 1:
The patent implements a continuous recovery process that continuously separates and recovers processing liquid from contaminants. This continuous operation maintains processing liquid purity without the need for frequent batch replenishment and disposal, significantly reducing energy usage associated with repeated processing cycles.
Solution Approach 2:
The system incorporates feedback mechanisms that monitor contaminant levels and automatically adjust the separation process to maintain processing liquid purity. This feedback control enables sustained operation without frequent replenishment, reducing energy waste from repeated contamination and recovery cycles.
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 process achieves energy-efficient separation and recovery of processing liquids, reducing energy usage by up to 95% and minimizing capital expenditures by continuously recycling and purifying the processing liquid, thereby extending its usability and reducing waste.
Implementation Method 1
heating said stream of feed mixture (1) by heat transfer from a heated first residuum recycle stream (9, 11, 13) contacting the feed mixture (1, 3)
Implementation Method 2
at least a portion of said water and a portion of the processing liquid is volatilized to produce a hot, vapor stream (8) comprising volatilized water and said volatilized portion of said processing liquid
Implementation Method 3
using heat energy from said hot vapor stream (8) in said regenerator column (60) to degas said spent processing liquid (66) and produce a substantially degassed processing liquid stream (65)
Data Source
Figure 1
Figure 2
AI summary
A process for recovering a processing liquid used in gas purification systems, e.g., to remove greenhouse gases, and containing water, the processing liquid, components having higher and lower boiling points than water and a component less volatile than the processing liquid, wherein the feed mixture is heated and introduced into a first separation zone, a portion of the water and the processing liquid being volatilized to produce a hot vapor stream comprising volatilized water and processing liquid. There is also produced a first residuum stream which contains some of the less volatile components and the unvolatilized portion of the water in the processing liquid. The hot vapor stream is introduced into the separation system forming part of a gas purification system. The majority of the energy in the hot vapor stream is recovered for use in the separation system forming part of the gas purification system. A substantially degassed processing liquid stream is recovered from the separation system forming part of the gas purification system. There is also recovered, from the separation system forming part of the gas purification system, the feed stream to the first separation zone.