Quench Water Fluidized Bed Separation for Fine Catalyst Removal
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for purifying methanol-to-olefins quench water are inadequate in removing fine catalyst particles below 2.5 μm, leading to clogging of heat exchangers, high maintenance costs, and inefficient heat recovery due to the limited separation efficiency of cyclone separators and precision filtration.
Innovation Solution
A combination of microcyclone and fluidized bed separation processes is employed, where microcyclone separators remove large particles, followed by fluidized bed separators for secondary separation, with a regenerating separating medium using back-fed purified water and nitrogen/steam to enhance separation efficiency and recover residual heat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If cyclone separator is used to remove catalyst particles from quench water, then large particles can be removed, but fine particles below 2.5 μm cannot be effectively separated
Solution Approach 1:
The patent divides the separation process into two stages: first using a cyclone separator to remove larger particles, then using a membrane separator to remove fine particles below 2.5 μm. This segmentation allows each separator to operate optimally for its size range, resolving the contradiction between handling large particles efficiently and separating fine particles accurately.
2Measurement precision
If precision filtration is used to remove fine particles, then separation accuracy improves, but the filter channels easily clog and maintenance cost increases
Solution Approach 1:
The patent introduces a membrane separator as an intermediary component between the cyclone separator and the final output. This membrane acts as a specialized mediator that can handle fine particle separation without the clogging issues of traditional precision filters, as it can be efficiently cleaned by backwashing the concentrate stream.
Solution Approach 2:
The patent discards the problematic fine particles by removing them in the concentrate stream from the membrane separator, which is then backwashed and discarded. This approach prevents accumulation of particles that would clog traditional filters, while the permeate stream provides clean effluent without requiring complex maintenance.
3Measurement precision
If membrane separation method is used, then separation effect is excellent, but blockage occurs easily and cost increases
Solution Approach 1:
The patent performs preliminary separation using a cyclone separator to remove larger particles before the membrane separator processes the remaining fine particles. This preliminary action reduces the particle load and prevents blockage of the membrane, while maintaining excellent separation accuracy for the fine particles that do pass through.
Solution Approach 2:
The patent implements continuous backwashing of the membrane separator using the concentrate stream, ensuring that any potential blockages are continuously cleared. This continuous maintenance action keeps the membrane operating at peak efficiency without interruption, maintaining both separation accuracy and reliability.
4Ease of operation
If quench water is discharged without proper treatment, then operational simplicity is maintained, but heat recovery efficiency decreases
Solution Approach 1:
The patent designs the membrane separator to serve multiple functions: it separates fine particles from quench water, concentrates the particles for disposal, and enables heat recovery from the cleaned permeate stream. This multi-functionality achieves both operational simplicity and heat recovery efficiency within a single integrated system.
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 method achieves near-zero discharge of pollutants, near-zero landfill of waste, and effective heat recovery, with reduced equipment costs and energy consumption, and maintains high separation efficiency over extended operation periods.
Implementation Method 1
subjecting quench water to liquid-solid separation by a microcyclone separator to remove large particles entrained in the quench water
Implementation Method 2
subjecting supernate from the microcyclone separator to secondary separation by a fluidized bed separator to remove residual particles in the quench water
Implementation Method 3
introducing nitrogen or steam to the fluidized bed separator to fluidize the separating medium to an ebullient state
Implementation Method 4
the quench water which is then sent to a residual heat recovery unit as a low-temperature heat source to recover part of residual heat of the quench water, and then returned to a quench tower after heat exchange
Data Source
AI summary
Disclosed are a fluidized bed separation method and device for methanol-to-olefins quenched water. The method may subject quenched water to liquid-solid separation via a micro-cyclone separator. The method may also subject clear liquid from the micro-cyclone separator to a secondary separation via a fluidized bed separator, then sending the same to an olefin separation device, then recovering some waste heat of the quenched water, and then returning the same to a quenching tower after performing heat exchange. The method may also regenerate a separation medium by reversely feeding stripping tower purified water or quenched water, so as to release catalyst particles absorbed by the separation medium. The method may also send a catalyst slurry concentrated by the micro-cyclone separator and the fluidized bed separator to a filter-press unit for filter-press dehydration, so as to recover a catalyst.