Shared Reflux Unit for Series Diester Reactors
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Solution Overview
Problem
Existing diester-based plasticizer production processes, such as batch and continuous processes, face limitations in improving reflux efficiency, productivity, and energy consumption, particularly due to the need for separate reflux units for each reactor, which increases space and cost requirements.
Innovation Solution
A system where multiple reactors are connected in series and share a single reflux unit, incorporating a reflux column, condenser, and layer separator to recover and recycle unreacted alcohol, reducing energy consumption and installation costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate reflux units are installed for each reactor, then each reactor can independently control its reflux process, but the space requirements and installation costs increase significantly
Solution Approach 1:
The patent combines multiple separate reflux units into a single shared reflux unit that serves multiple reactors. The reflux unit includes a reflux column, condenser, and layer separator that are shared among reactors, allowing them to process mixed gases from multiple reactors simultaneously. This merging approach reduces the total space required for installation while maintaining reflux functionality for each reactor.
Solution Approach 2:
The shared reflux unit is designed to handle mixed gases from multiple different reactors through a universal interface. The reflux column receives mixed gases from multiple reactors, the condenser condenses the mixed gas, and the layer separator separates the components. This multi-functional design allows a single unit to perform what previously required multiple dedicated units.
2Reliability
If separate reflux units are installed for each reactor, then each reactor has dedicated reflux capability, but the installation and equipment costs increase
Solution Approach 1:
The patent merges multiple separate reflux units into one shared unit, directly reducing equipment purchase costs, installation costs, and maintenance costs. Instead of buying and installing multiple identical reflux units, the system uses one shared unit that serves multiple reactors, significantly reducing the overall investment required.
Solution Approach 2:
The shared reflux unit is designed with universal capabilities to handle mixed gases from multiple reactors, making it a cost-effective solution that replaces multiple expensive dedicated units. The unit includes a reflux column, condenser, and layer separator that can process gases from different reactors simultaneously or sequentially.
3Productivity
If multiple separate reflux units are used, then each reactor can be optimized independently, but energy consumption increases due to redundant condensation processes
Solution Approach 1:
The patent combines the condensation processes of multiple reactors into a single condenser. Instead of having each reactor's mixed gas condensed separately by dedicated condensers, the shared condenser receives mixed gases from multiple reactors and performs a single condensation process, eliminating redundant energy consumption while maintaining reflux efficiency for each reactor.
4Ease of manufacture
If a batch process is used for diester-based plasticizer production, then the process is simple to implement, but productivity remains very low
Solution Approach 1:
The patent implements a continuous process where reactors operate continuously rather than in batch mode. The shared reflux unit continuously receives mixed gases from multiple reactors, continuously condenses the gases, and continuously separates and recycles the alcohol. This continuous operation eliminates the idle time between batches and significantly increases production output while maintaining process simplicity.
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 integrated reflux system enhances production efficiency and economic feasibility by minimizing energy use and reducing the need for multiple reflux units, thereby optimizing the overall process.
Implementation Method 1
a reflux column for receiving the mixed gas and unreacted alcohol in a liquid state from the first reactor and then transferring the mixed gas to a condenser and the unreacted alcohol in a liquid state to the first reactor
Implementation Method 2
the condenser for condensing all of the mixed gas
Implementation Method 3
a layer separator for separating alcohol and water in a condensate passed through the condenser to discharge a water layer and to allow an alcohol layer to be recovered
Data Source
AI summary
The present disclosure relates to a system which increases the efficiency of an entire process by integrating a reflux unit in a system for producing a diester-based composition in which a plurality of reactors are connected in series.