Thermocompression Plant Reverse-Sol Preheating
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Solution Overview
Problem
Existing thermocompression systems for producing crystals from brine inefficiently utilize excess heat, leading to increased energy consumption and manual control challenges due to indirect pressure regulation and heat release to the environment.
Innovation Solution
A method where non-compressed vapors are indirectly condensed to preheat brine in a countercurrent process, retaining latent heat within the system and using a steam control valve for direct pressure regulation, allowing for automatic control and increased crystal production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If hot condensate or hot mother liquor is used to preheat incoming brine in conventional preheaters, then the incoming brine can be heated to high temperatures, but the investment costs increase due to larger heat exchanger surfaces being required
Solution Approach 1:
The vapor flow is segmented into two separate paths: one path goes through the compressor for compression and condensation on preheaters, while the other path bypasses the compressor and directly condenses on a second preheater. This segmentation allows the system to achieve effective preheating without requiring a single large, expensive heat exchanger, thus reducing investment costs while maintaining high brine temperature.
2Ease of operation
If brine that is not heated to maximum possible temperature is added to the crystallizer, then crystal removal and grain size adjustment can be achieved, but the pressure control becomes less efficient and more brine must be added
Solution Approach 1:
The invention converts what would normally be waste heat (from vapors that are not compressed) into a useful resource by directing these uncompressed vapors to a second preheater where they condense and heat the incoming brine. This eliminates the need to release heat to the environment and allows the system to maintain efficient pressure control while still enabling crystal removal operations.
3Stress or pressure
If vapors are released to the environment or additional heat consumers, then pressure control can be achieved, but the latent heat is lost and no additional crystal production can be achieved
Solution Approach 1:
The vapor stream serves multiple functions: it provides pressure control by being available for release to the environment, it supplies heat to the first preheater through compression and condensation, and it supplies heat to the second preheater through direct condensation of the uncompressed portion. This multi-functionality ensures that no latent heat is wasted while maintaining effective pressure control.
4Use of energy by moving object
If additional preheaters or heat transfer improvement means are installed, then energy required to maintain the process can be reduced in heat shortage situations, but no additional product is generated and the costs are not economical
Solution Approach 1:
The invention ensures continuous utilization of vapor latent heat by creating two parallel condensation paths: one through the compressor and one direct condensation path. This continuous extraction of heat from all vapor streams eliminates heat shortage situations and reduces energy consumption without requiring external heat addition, thereby improving both energy efficiency and productivity simultaneously.
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 approach reduces specific energy consumption and enables automatic pressure control, enhancing crystal production while minimizing heat loss and energy waste.
Implementation Method 1
uncompressed vapors are condensed in a condenser indirectly on a partial flow of brine flowing to the crystallizer
Implementation Method 2
uncompressed vapors are condensed in a condenser
Implementation Method 3
the latent heat of the vapors is retained at a high temperature level in the system
Implementation Method 4
the vapors produced in the crystallizer are compressed mechanically or thermally
Implementation Method 5
the vapors produced in the crystallizer, which is the water vapor produced in the crystallizer
Data Source
Figure 1
Figure 2
AI summary
In a process where crystallizate is produced from brine in a crystallizer (CR) of a thermocompression plant with mechanical or thermal vapor compression and fresh brine preheating in a counterflow, uncompressed vapors are indirectly condensed on a partial stream (BS) of incoming brine that is not preheated to the maximum possible temperature with hot condensate. A thermocompression plant with which the process can be carried out is also described.