Rotating Horizontal Reflux Column for Single-Pass Ethanol Purity
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Solution Overview
Problem
Traditional ethanol distillation processes, particularly in vertical columns, face inefficiencies in achieving high purity ethanol, often requiring multiple passes and resulting in lower than desired ethanol purity due to condensation issues and the need for reintroduction of condensate for re-distillation.
Innovation Solution
A substantially horizontal, rotatable reflux distillation system with a reflux distillation column angled between 10-20 degrees from horizontal, incorporating a vapor reduction system, thermocouples for temperature control, and a drive assembly for rotation, allowing for a single-pass distillation process that achieves 95.5% ethanol purity by ensuring homogenization and azeotropic temperature control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a vertical distillation column is used, then alcohol steam can be maintained within the column, but condensation occurs on the sides when not perfectly vertical, reducing purity
Solution Approach 1:
The patent inverts the traditional vertical distillation column orientation by using a horizontal configuration. This fundamental orientation change eliminates the condensation problem on column sides that plagues vertical columns, as the horizontal design prevents alcohol steam from contacting the column walls where condensation would occur.
Solution Approach 2:
The invention transitions from the traditional vertical (one-dimensional) column orientation to a horizontal (different dimensional orientation) configuration. This dimensional change fundamentally alters the steam flow path and prevents wall condensation, achieving higher purity without requiring multiple passes.
2Manufacturing precision
If multiple distillation passes are performed, then ethanol purity increases to 95.5%, but process time and complexity increase
Solution Approach 1:
The horizontal distillation column implements continuous reflux where condensate is automatically returned to the column for repeated condensation and vaporization cycles within a single continuous pass. This continuous action achieves 95.5% purity in one operation rather than requiring multiple discrete distillation passes.
Solution Approach 2:
The system performs preliminary condensation and reflux cycles within the single horizontal column before final distillate collection. The condensate is pre-treated and returned to the column multiple times during the single pass, preparing the ethanol for high-purity extraction without requiring separate additional distillation passes.
3Productivity
If a horizontal rotatable column is used, then single-pass high purity distillation is achieved, but device complexity increases
Solution Approach 1:
The patent introduces rotational capability to the horizontal distillation column, allowing it to rotate about its longitudinal axis. This dynamic feature enhances the reflux action and mixing of vapors and liquids, improving distillation efficiency and purity achievement in a single pass, while the added mechanical complexity is offset by the elimination of multiple distillation passes.
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 system achieves greater than 90% ethanol purity in a single pass, improving efficiency and reducing the need for multiple distillation passes while being portable and deployable, utilizing sustainable energy sources like sugar-containing biological waste for heating.
Implementation Method 1
The vapor reduction system causes vapor traveling upward in the reflux distillation system to reduce into condensate liquid and return back downward into the reflux distillation column
Implementation Method 2
temperature monitoring using the lower thermocouple and the upper thermocouple determines that an entirety of an internal volume of the reflux distillation column is homogenized in an azeotropic temperature state
Implementation Method 3
The drive assembly operatively is associated with the reflux distillation column that rotates the reflux distillation column
Implementation Method 4
utilizing sustainable energy sources like sugar-containing biological waste for heating
Data Source
AI summary
A rotatable, reflux distillation system is disclosed that includes a rotatable, reflux distillation column, a lower end transition pipe, an upper end transition pipe, a rotational drive assembly, and a vapor reduction system. The rotatable, reflux distillation column is angled between 10-20 degrees from horizontal, and has a lower vapor input end and an upper fluid exit end. The lower end of the reflux distillation column is operatively associated with a lower seal housing, and the upper end of the reflux distillation column is operatively associated with an upper seal housing. The lower end transition pipe is operatively associated with the lower end of the reflux distillation column and includes a lower thermocouple, while the upper end transition pipe is operatively associated with the upper end of the reflux distillation column and includes an upper thermocouple and a fluid exit gate. The rotational drive assembly rotates the reflux distillation column. The vapor reduction system reduces the vapor into condensate liquid.