Segmented Distillation Column Cells for Energy Efficiency
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Solution Overview
Problem
Large-scale distillation processes are energy-intensive, leading to stability and cost issues due to the need for tall columns and inefficient energy use in existing distillation devices, particularly in distributing a two-phase liquid/steam mixture across evaporator stages.
Innovation Solution
A distillation device with three or more cells arranged vertically in the column bottom for multi-stage heating and partial evaporation, allowing for independent heating and partial evaporation of liquid streams using suitable energy sources, with partial returns of liquid between cells to optimize energy use and reduce column height.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the bottom liquid is heated in several stages using evaporators connected in series vertically, then the separation efficiency is improved, but the column height increases leading to stability problems and higher costs
Solution Approach 1:
The column bottom is segmented into multiple cells (first cell, second cell, third cell) that are arranged horizontally adjacent to each other rather than vertically stacked. Each cell contains evaporator stages, allowing multi-stage heating to occur in a horizontal sequence. This segmentation maintains the separation efficiency of multi-stage heating while avoiding the stability issues associated with tall vertical columns.
2Length of stationary object
If evaporator stages are arranged horizontally one behind the other, then the column height is reduced, but the distribution of two-phase liquid/steam mixture becomes problematic
Solution Approach 1:
A liquid distributor is introduced as an intermediary device between the evaporator stages in the horizontal arrangement. This distributor ensures proper distribution of the two-phase liquid/steam mixture from one evaporator stage to the next, solving the distribution problem that arises in horizontal configurations while maintaining the advantage of reduced column height.
3Loss of energy
If existing energy sources are used for individual evaporator stages, then energy costs are reduced, but the device complexity increases
Solution Approach 1:
The system is designed to accept multiple types of energy sources (steam, hot condensate, electrical heaters) for the evaporator stages, allowing existing energy sources from different parts of the process to be utilized. This multi-functionality approach enables energy recovery and reuse without requiring a completely new energy supply system, thus reducing energy costs while limiting complexity increases.
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 design enhances energy efficiency, reduces energy costs, and prevents stability issues by allowing for the use of existing energy sources, achieving effective separation of substances while maintaining column stability and reducing height.
Implementation Method 1
multi-stage heating and partial evaporation of the liquid flowing through the cells
Implementation Method 2
each obtaining a partially evaporated stream (4,5)
Implementation Method 3
separating a feed stream (1) into a top product stream (2), a bottom product stream (3)
Implementation Method 4
The bottom stream from the first cell (I) in the flow direction is withdrawn in liquid form and applied to a heat exchanger (WT1), in which the stream is heated
Data Source
Figure 1
Figure 1A~1B
Figure 1C
AI summary
The invention relates to a distillation device comprising a column (K) for separating a feed stream (1) into a head product stream (2), a bottom product stream (3) and optionally one or more side extraction streams, having three or more cells (I, II, III) in series through which fluid flows, wherein at least the first cell is integrated into the bottom of the column (K), for multi-stage heating and partial evaporation of the liquid flowing through the cells with the exception of the liquid from the last cell in an evaporation stage.