Spiral-Flow Fluidized-Bed Crystallization for Self-Cleaning Heat Transfer
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Solution Overview
Problem
Existing cooling crystallization methods, such as dividing wall, natural, and direct contact cooling, face issues with low heat transfer efficiency, high energy consumption, difficulty in maintaining product quality, and limited scalability, leading to environmental pollution and resource waste.
Innovation Solution
A spiral-flow type fluidized-bed cooling crystallization system with scraping particles in heat transfer pipes that induce a spiral flow field, enhancing heat transfer, self-cleaning, and controlling crystallization, using fluidized-bed crystallizers in series for controlled cooling and crystal growth.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If dividing wall cooling is used, then cooling crystallization can be achieved, but the heat transfer surface is easy to scar and difficult to clean, reducing cooling effect and increasing energy consumption
Solution Approach 1:
The fluidized bed system uses the crystallization process itself to clean the heat transfer surface. Crystals in the fluidized bed continuously collide with and scrape the heat transfer surface, automatically removing scale and deposits without requiring external cleaning operations, thus eliminating the cleaning difficulty and energy loss associated with traditional dividing wall cooling systems
Solution Approach 2:
The invention changes the operating parameters by using fluidized bed technology where particles are suspended and circulated at controlled velocities. This dynamic parameter control allows the system to maintain optimal heat transfer conditions while the fluidized particles continuously clean the heat transfer surface, preventing scale buildup and maintaining high cooling efficiency throughout operation
2Loss of energy
If dividing wall cooling is used, then cooling crystallization can be achieved, but stirring is required during crystallization which increases equipment operation energy consumption
Solution Approach 1:
The invention replaces the mechanical stirring system with a fluidized bed system where gas or liquid flow suspends and circulates the crystallization particles. This substitution eliminates the need for mechanical stirrers while maintaining effective mixing and heat transfer, thereby reducing operation energy consumption while preserving crystallization efficiency
Solution Approach 2:
The system uses pneumatic or hydraulic flow to fluidize the particle bed and achieve mixing and heat transfer without mechanical stirring. The fluidizing medium creates uniform particle suspension and circulation, providing effective mixing for crystallization while eliminating the energy consumption associated with mechanical stirrers
3Device complexity
If natural cooling is used, then equipment is simple and operation is convenient, but the crystallization process cannot be controlled and production capacity is small
Solution Approach 1:
The invention segments the cooling process into controlled stages within the fluidized bed system. By dividing the crystallization into nucleation and growth zones with controlled particle circulation, the system achieves both equipment simplicity and enhanced production capacity through staged, controllable cooling that maintains process control while scaling up production
4Temperature
If heat transfer surface is not cleaned, then cooling effect is reduced, but frequent cleaning and maintenance increase operational complexity
Solution Approach 1:
The fluidized bed system performs self-cleaning of the heat transfer surface through continuous particle circulation and collision. The crystallization particles in the fluidized state automatically scrape and clean the heat transfer surface during normal operation, maintaining optimal cooling effect without requiring external cleaning systems or maintenance interventions
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
Improves heat transfer efficiency, reduces energy consumption, ensures product purity and uniformity, and enhances production efficiency by controlling crystallization and crystal growth, facilitating resource recovery and environmental sustainability.
Implementation Method 1
the feed liquid forms a spiral flow field inside the heat transfer pipe via the spiral spray head
Implementation Method 2
fluidized-bed cooling crystallization by utilizing spiral-flow particles
Implementation Method 3
cooling crystallization is a method of separation or purification by using the difference in solubility of salt at different temperatures
Implementation Method 4
a centrifuge is connected to a discharge port and a feed mother liquor discharge port
Data Source
AI summary
The disclosure discloses a spiral-flow type fluidized-bed cooling crystallization system. The system comprises a first fluidized-bed crystallizer, a second fluidized-bed crystallizer, a crystal growing tank, a centrifuge, a circulating pump, a flow control valve, a densimeter and the like, wherein vertical heat transfer pipes are arranged in the first fluidized-bed crystallizer and the second fluidized-bed crystallizer, and scraping particles are contained in the heat transfer pipes. According to the invention, feed liquid exchanges heat with a cooling medium through the vertical heat transfer pipes; meanwhile, spiral spray heads at the bottoms of the heat transfer pipes are used for enabling the feed liquid in the pipes to form a spiral flow field, and the scraping particles are efficiently driven to continuously impact and crush crystals attached to heat transfer wall faces, so the effects of heat transfer enhancement, heat transfer wall face self-cleaning.