Three-Circuit Quench Tower Retrofit for Higher Plant Loads
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Solution Overview
Problem
Existing quench towers in steam cracking processes face challenges in handling increased plant loads due to flooding of cascade trays and insufficient mass and heat transfer, necessitating costly alternatives like building a new quench tower or parallel column.
Innovation Solution
Converting an existing two-circuit quench water wash to a three-circuit system by modifying coolant circuits, including removing and installing new components, such as chimney trays and coolant distribution arrangements, to enhance quenching capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the number of coolant circuits is increased from two to three, then the plant load capacity increases by 30%, but the device complexity increases
Solution Approach 1:
The quench tower is divided into three separate coolant circuits instead of two, with each circuit having its own feed line, withdrawal line, and associated tower internals. This segmentation allows independent optimization of each circuit's cooling capacity, enabling the overall system to handle 30% higher plant loads while maintaining manageable complexity through modular configuration
Solution Approach 2:
The patent introduces an additional vertical dimension to the coolant circuit arrangement by optimizing the vertical positioning of feed and withdrawal lines within the tower. The third coolant circuit is strategically positioned to utilize underutilized vertical space, allowing increased cooling capacity without significantly expanding the tower's horizontal footprint or overall structural complexity
2Productivity
If the quench tower is modified to handle increased load, then the productivity increases, but the investment costs increase
Solution Approach 1:
The patent performs preliminary optimization of the coolant circuit configuration before implementing the load increase. By pre-calculating and pre-positioning the feed and withdrawal lines, and pre-arranging the tower internals for three circuits, the modification process becomes more efficient and cost-effective, reducing unexpected costs during implementation while achieving the desired 30% productivity increase
Solution Approach 2:
The patent modifies operational parameters such as coolant flow rates, temperatures, and distribution patterns across the three circuits to optimize performance at the increased load. These parameter adjustments allow the existing tower structure to handle higher loads without requiring proportionally higher investment in structural modifications, achieving cost-effective scalability
3Use of energy by moving object
If the coolant circuits are optimized for higher capacity, then the energy efficiency improves, but the manufacturing complexity increases
Solution Approach 1:
The patent implements optimized coolant distribution arrangements in each of the three circuits that respond to process conditions by dynamically adjusting coolant flow and temperature. This feedback mechanism improves energy efficiency by ensuring optimal cooling at each stage of the quenching process, while the modular circuit design keeps the control system manageable through standardized configurations that can be replicated across circuits
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
Enables a 30% increase in plant load capacity while maintaining economic viability by reducing coolant content, fouling, and hydraulic load, and improving energy efficiency.
Implementation Method 1
quench towers are used, in particular in addition to further cooling units, for reducing or 'quenching' the temperature of a process gas
Implementation Method 2
a contacting arrangement and a coolant collecting arrangement
Data Source
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AI summary
A method as proposed herein involves upgrading a quench tower (100) by substituting its existing first coolant circuits (20a, 20b) with a larger number of second coolant circuits (20c - 20e). This quench tower features a gas feed line (11) entering and a gas withdrawal line (12) exiting at different vertical positions, defining a vertical space. Both the original and new coolant circuits include components such as a coolant feed line (21), coolant withdrawal line (22), and tower internals in the form of coolant distribution, contacting, and collecting arrangements located within this vertical space. This vertical arrangement facilitates efficient gas and coolant interaction, with each feed and withdrawal points of the coolant circuits (20a, 20b, 20c - 20e) also defining their operational spatial relationship within the quench tower (100). A corresponding quench tower (100), and a method and an apparatus (1000) for producing a reaction product are also provided herein.