Stacked Disc Centrifuge for Continuous Catalyst Separation
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Solution Overview
Problem
Existing catalyst separation processes using laboratory-scale spin tube centrifuges are limited by low capacity and require manual removal of separated catalyst, leading to longer processing times and infeasibility for pilot or commercial scales, especially for nonfilterable catalysts smaller than 5 microns.
Innovation Solution
Utilizing a stacked disc centrifuge with auto-discharging functionality to separate catalysts from mother liquor, applying centrifugal forces of 8,000 G to 15,000 G, enabling automatic solids discharge and continuous operation, suitable for pilot and production scales.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a laboratory scale spin tube centrifuge is used to separate catalyst from mother liquor, then separation can be achieved, but the capacity is limited to a few liters and manual removal is required
Solution Approach 1:
The centrifugal separation field is segmented into multiple disc layers stacked vertically, creating multiple separation zones within a single device. This allows simultaneous processing of multiple batches, increasing capacity from a few liters to hundreds of liters while maintaining efficient separation of fine catalyst particles.
Solution Approach 2:
The system implements continuous operation through automatic solids discharge functionality that operates at well-defined intervals. The centrifuge continuously separates catalyst from mother liquor and automatically discharges accumulated solids, eliminating manual intervention and enabling sustained high-capacity processing without interruption.
2Ease of operation
If a laboratory scale spin tube centrifuge is used, then separation is possible, but manual catalyst retrieval and cleaning are required
Solution Approach 1:
The centrifuge is equipped with automatic solids discharge functionality that enables the device to service itself by automatically discharging accumulated catalyst solids at predetermined intervals. This self-discharging mechanism eliminates the need for manual catalyst retrieval and cleaning operations, making the system suitable for unattended continuous operation at high capacity.
3Productivity
If conventional filtration techniques are used for catalyst separation, then filtration can be performed, but flux through filter medium is very low due to high resistance
Solution Approach 1:
The patent replaces the filtration mechanism (which relies on pressure differential through a filter medium) with a centrifugal separation mechanism. The centrifugal force generated by rotation creates a mechanical field that separates particles based on density and size, achieving high flux and throughput without the clogging and resistance problems inherent in conventional filtration of fine catalyst particles.
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 process significantly reduces separation time by up to 50% and achieves a total suspended solids content of <0.2 wt% in the centrate, allowing efficient catalyst recovery and continuous operation without manual intervention.
Implementation Method 1
utilizing a stacked disc centrifuge with auto-discharging functionality to separate catalysts from mother liquor, applying centrifugal forces of 8,000 G to 15,000 G
Implementation Method 2
The stacked disc centrifuge is capable of discharging isolated solids at well-defined intervals in a short time span
Data Source
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AI summary
A process for separating a catalyst component from a catalyst-containing slurry by centrifugation including separating the catalyst component from the mother liquor of the catalyst-containing slurry using a stacked disc centrifuge equipped with an auto-discharging functionality. The solids discharge from the stacked disc centrifuge is enhanced by adding a washing solution to the bowl and the solids discharge chute of the stacked disc centrifuge.