DISTILLATION DEVICE
BACKGROUND OF THE INVENTION
1.Field of the Invention
This invention relates to vacuum distillation devices, in particular, to devices which create a vacuum without the use of a vacuum pump or other entrainment device.
2.Description of Related Art The process of distillation has long been in use for the production of clean water and other liquids. The feedwater enters a boiler or evaporator where it is evaporated.
The steam then passes through a cooling chamber or condenser where it condenses to form droplets of pure water that pass to the distillate outlet. Distillation is the only water purification process that removes, with certainty any solids contained in the feedwater.
There are a number of recognized disadvantages in distillation systems when compared to other purification technologies. The first is the high energy consumption required to boil the water to steam and then to remove the excess heat to form the distillate. Another practical disadvantage is the tendency to scaling that occurs when hard water is
distilled at high boiling temperatures. Water hardness reflects the amount of calcium carbonate and magnesium sulfate present in the feedwater. In the case of large-scale distillation systems, a number of solutions to these disadvantages have already been developed. For instance to conserve energy, multistage distillation is used, where some of the latent heat of evaporation is recovered from one distillation stage to provide heat for the next stage.
Another such solution is the use of a vapor compression distillation device that reduces even further the energy requirements of large-scale distillation systems. In vapor compression distillation, the water is evaporated by boiling and the resulting vapor is then compressed, which increases the vapor pressure and therefore temperature. This vapor is then used to heat up the water in the boiler and in this manner, the latent heat is recovered. Once the vapor compression distillation cycle is started, little further heat is required and the only energy requirement is for the vapor compressor itself.
In the case of small-scale distillation systems, in the order of 100 gallons per day or less, the capital costs of multistage distillation and inadequate reliability of vapor compression distillation make these alternatives unacceptable. Thus most small-scale distillation systems use simple distillation at atmospheric pressure where the water boils at 212° F. Therefore, energy consumption and scaling are the major problems in small-scale standard atmospheric distillers.
SUMMARY OF THE INVENTION
The present invention overcomes these recognized problems of conventional distillers, and, in particular, of small-scale standard atmospheric distillers. In one aspect, the distillation device of the invention creates a vacuum without a mechanical pump or other entrainment device, and, in another aspect, combines the normally separate boiler and condenser into one integrated unit. The result of these innovations is a system that produces high purity distilled water at lower temperature in a batch process, for considerably less energy consumption than the standard atmospheric distillation method. Also, another advantage of
low temperature distillation in the present invention is the elimination of scaling from the impurities that normally exist in water.
The device of the present invention for batch distilling a liquid comprises an evaporator section having a valved entry port through which a batch of liquid in a first atmospheric condition is added to the evaporator section. An accumulator section receives distillate and is in communication with the evaporator section. A heating element is disposed in the evaporator section for timed intermittent vaporizing of the liquid to form a first and second vapor. A valved vent is provided for sealing said device from the outside atmosphere to form a second atmospheric condition sealed from the atmosphere, after the heating element vaporizes said liquid into an initial sufficient amount of the first vapor to purge the first atmospheric condition from the device through the valved vent. A condenser is disposed between the evaporator section and the accumulator section for condensing a sufficient amount of the first vapor to form a third atmospheric condition at a pressure below the first atmospheric condition, and for condensing the second vapor to produce distillate. A preferred version of the device further comprises an automatic controlling means (electronic controlling means) communicating with the valves, condenser, and heating element(s) for timed operation of the device.
Accordingly, a main object and advantage of the batch distillation device of the invention and method of the invention is creating a vacuum in the device without a mechanical vacuum pump or other entrainment device.
Another object and advantage of this invention is a novel vacuum distillation process for the production of high purity water at low operating temperature, using less energy than conventional simple distillation systems.
Another object and advantage of the present invention is the reduction of scaling on the boiler and condenser units achieved in the present invention by a lower boiling point, thus eliminating the need for descaling and the use of descalant chemicals.
Another object and advantage of the present invention is the use of lower-cost materials due to the lower operating temperatures of the device.
Another object and advantage of the present invention is that the lower boiling temperature makes the device safer to handle and operate.
Another object and advantage of the present invention is the combining of the normally separate chambers for boiling or evaporating and condensing functions into a single chamber.
Another object and advantage of the present invention is an innovative method of using an enhanced circulation heat transfer device, which allows a significant reduction in the overall size of the boiler.
Another object and advantage of the present invention is the ease of integration of the invention into the design of a standard refrigeration system, where the refrigerator's condenser and evaporator components serve, respectively, as the heating and condensing elements of the distiller made integral with the same components in the distiller device.
Another object and advantage of the present invention is sterilization of the condenser carbon filter and accumulator that automatically occurs when steam is used to purge the air out of the device.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is a diagram of a prior art standard atmospheric distiller.
Figure 2 is the device of the present invention.
Figure 3 is the device of the present invention with a pre-evaporator section.
Figure 4 is the device of the present invention with a pre-evaporator section and where the evaporator section does not have a heating element.
Figure 5 is an embodiment of the invention in which a first chamber is incompletely partitioned into a pre-evaporator section and main boiling section.
Figure 6 is an embodiment of the invention in which a first chamber comprises two heating elements.
Figure 7 is the device of the present invention with a pre-evaporator section and refrigeration cycle system.
Figure 8 is a stand alone batch process distillation unit of the invention.
Figure 9 is a partial cross section of a stand alone batch process distillation unit, showing the various components of the design.
Figure 10 is a schematic of a typical standard household refrigerator showing the location of the batch process water distillation unit.
Figure 11 is a partial cross section of a batch process distillation unit with its own refrigerant evaporator and integrated into a standard household refrigerator.
Figure 12 is a partial cross section of a batch process distillation unit without its own refrigerant evaporator and integrated into a standard household refrigerator.
Figure 13 is a block diagram of a vacuum distillation device in accordance with the invention, showing the logic of the electronic controlling means.
Figure 14 is a flowchart of the operation of the electronic controlling mean.
Figure 15 is a chart of a control sequence of the electronic controlling means.
Operation of the Invention
The basic principle in the proposed batch process distillation device is to boil a batch of water or other liquid in the evaporator section to generate a first vapor to purge the device of air through a valved vent. When the device is purged, the valved vent is closed, sealing the device from the atmosphere. The condenser is turned on, turning the vapor, e.g. steam coming in contact with the condenser into liquid, thereby reducing the pressure in the device to a sub-atmospheric pressure, which then allows the batch of liquid in the evaporator section to boil at a lower temperature, producing a second vapor. The second vapor, e.g., steam, is then condensed into a distillate of distilled water or other liquid. The structure, method of distilling, and operation of a standard atmospheric distiller is shown in Figure 1. The device of this invention is shown in detail, in Figures 2-6. Automatic control elements of the device is shown in Figures 13-15. Figures 7-12 show versions of the device incorporating a refrigeration system for heating and condensing.
Standard Atmospheric Distiller
A standard atmospheric distiller as illustrated in Figure 1, is the simplest form of distillation and is the dominant type currently being sold. Water at one atmosphere of pressure is added to a boiler or evaporator section 66 and is heated to 212° F, by a heater 14, whereupon it turns water into a vapor e.g. steam. The steam passes from the evaporator section 66 to a condenser 24 or second chamber, through a connector tube 41 and is then condensed by passing inside condenser coils 24, air being blown across the outside of the condenser coils by a fan 13. The pressure in this distiller is one atmosphere, and remains at one atmosphere throughout the distillation process. The steam condenses in the condenser 24 to form distillate water droplets which fall down into a second receptacle or reservoir 50 which is open to the atmosphere through a vent 48 as the water is boiled into steam from the
evaporator 66 and collects as a distillate of distilled water. The distilled water is then removed by opening the valve 52 in the reservoir. The heater 14 is turned off once the water in the boiler falls to a prescribed level. Once the distillation is complete, the valve 38 at the bottom of the boiler is opened and the water remaining in the boiler 66 is removed and discarded. A fresh charge of water is added to the boiler 66 through an entry port valve 36 and the process repeats.
The Present Invention - Basic Device
As shown in Figure 2, a device for batch distilling a liquid is provided in which the evaporator section 66 and accumulator section 40 are disposed in separate chambers which are in communication through a first tube or conduit 41. Distinguishing the present invention from a standard atmospheric distiller is an accumulator section 40 including a valved vent (44 ) for sealing the device from the atmosphere during the distillation process, and accumulating the distillate 17, which, in cooperation with operation of the condenser 24, as explained below, forms a vacuum for batch distilling a liquid.
The device 42 comprises an evaporator section or first chamber 66 connected to an accumulator section 40 or second chamber 40. The accumulator section 40 is in communication with the evaporator section 66 via a first tube or conduit (41). A heating coil 14 for timed intermittent vaporizing of the liquid is situated in the evaporator section 66, which allows the evaporator section 66 to operate as a boiler to sequentially form a first and second vapor. Downstream of the first tube 41, the condenser coils 24 are in the form of a tube continuous with the first tube 41, and a fan 13, situated near the condenser 24, blows a sufficient amount of air over the condenser coils to cool it a sufficient amount for vapor contained in the condenser tube to condense as distillate. The condenser can also be an externally finned coil, over which the fan 13 blows or draws cooling air onto the fins (not shown) and the vapor coming from the first chamber condenses on the inside surface of the condenser tube and then drops down into the accumulator section 40. Alternately, the condenser 24 can be either a coiled tube which is filled with cold gas or liquid, located inside the accumulator section 40 and over which tube the steam contacts and condenses as distillate
on the outside of the condenser coil and is delivered by dropping into the accumulator section 40.
The present invention further comprises a reservoir section (50) as shown in Figure 2. The reservoir section 50 is connected to the accumulator section 40 by a second connection tube (46 ). A valved vent (44) is disposed from the accumulator section 40, and in one version is disposed on the second connection tube 46 between the accumulator section and reservoir section. The distillate collected in the reservoir 50 can be removed for use, by opening valve 52.
It will be appreciated that the device and the method of the invention can be understood in terms of the following phases: water filling, vacuum generating, distillate producing and distillate discharging. Although the device can be manually controlled, the preferred versions of the device and method involve "automatic controlling means", which, as used herein, comprise electronic controlling means, as described in detail below. Other automatic controlling means involve check valves in combination with electronic controlling means as described below.
The evaporator 66 and condenser 24 sections can also be adapted for demountable sealable attachment for quick removal of the first chamber from the device and for quick sealable attachment of the first chamber to the device.
Water Filling
In operation, under a first atmospheric condition of one atmosphere, the evaporator section 66 is filled through a valved entry port (36 ) with a batch of liquid 64, e.g. water, to be vaporized in a later step. The evaporator 66 and the heating element 14 sections can also be adapted with a sealable attachment 37 for quick removal of the evaporator 66 and for quick sealable attachment of the evaporator 66 to the device. A typical sealable
attachment used in the device involves a gasket or O-ring assembly which with suitably seals the vacuum condition insider the device during operation and allows repeated sealing and unsealing to allow filling the device with liquid and emptying distillate from the device.
Vacuum Generating
The heating element 14 is turned on and the liquid 64 is converted to a first vapor, e.g., steam which mixes with and entrains the air inside the device. The vapor/air mixture is then driven through the connecting tube 41 into the condenser 24 with fan 13 in the off position, i.e., the cooling function of the condenser being off. The vapor/air mixture then exits the condensing chamber 40 through a valved sealable vent (44) in a first opened position. Typically, in the vacuum generating phase, it takes several minutes for the heating element 14 to form an initial sufficient amount of a first vapor, e.g. steam, to purge the first atmospheric condition from the device through the open valved vent 44. That is to say, most of the air in the device has been driven out of the device through the valved sealable vent 44 to form a second atmospheric condition of vapor. A portion of the steam/air mix condenses to distillate inside the reservoir section 50 and the air escapes from an air discharge vent (48 ) at the top of the reservoir section 50.
At this point, vacuum generation is then achieved by closing the valved vent
44, turning off the heater 14 and turning on the fan 13, preferably by automatic controlling means, as described in detail below. By closing the valved vent 44, the second atmospheric condition is sealed from the outside atmosphere. By turning off the heater 14 and turning on the fan 13, the vapor in the second atmosphere condenses, causing a reduction in pressure of the second atmosphere, thus creating a third atmospheric condition which is a sub-atmospheric condition or vacuum condition inside the device, including the space 68 over the top of the water boiling in the evaporator section 66. Effectively, the internal pressure of the device has been reduced below the outside pressure, that is, reducing the inside pressure to less than one atmosphere.
Distillate Producing
As the pressure in the device drops, the boiling temperature of the liquid in the evaporator section 66 also drops and so the liquid continues to boil, producing a second vapor even though the heater in the evaporator section has already been turned off. The vapor is condensed to distillate in the condenser 24. Distillate production continues as the fan 13 continues to run and eventually an equilibrium is reached where the vacuum increases, causing more liquid to boil off, producing a second vapor and removing heat from the liquid in the evaporator section 66 until eventually the liquid ceases to boil. Accordingly, the heater 14 in the evaporator section 66 is turned on again, at full or partial power and the remaining liquid 64 heats up and continues to boil, producing a second vapor at a much lower temperature, such as approximately 140° F which is then condensed in the condenser 24 and the distillate is collected in the accumulator section 40.
Distillate Discharging
Once the liquid level in the evaporator section 66 drops to a certain level, the heater 14 is turned off. The vacuum in the device is then broken by opening either one or all of the valved ports, i.e. the valved sealable entry port 36 or the demountable sealable attachment 37 of the evaporator section 66 or the valved vent 44. The distillate 17 collected in the accumulator section 40 then runs out of the accumulator section 40 through valve 44, into the reservoir section 50. Distillate 17 is then removed from the reservoir section 50 through a valve 52 for use.
A new batch of water is then added through the valved entry port 36 or the demountable sealable attachment 37, to the evaporator section 66, and the process is repeated.
While the device of the invention relies on the timed operation of the valves, heating element, and condenser, and this can be done manually, it will be understood that a preferred version of this device comprises automatic controlling means (Figures 13-15) for automatic timed operation of the valves, heating element and condenser.
In this version, the operation of the device is under control of automatic controlling means as described below. The valved entry port 36, valved vent 44, heater 14 and fan 13 are automatically operated in a timed sequence by the electronic controlling means to achieve batch distilling of a liquid at sub-atmospheric pressure without the aid of a vacuum pump or entrainment device to create or maintain a vacuum. In an alternate version of the device, valved vent 44 is a one-way mechanical valve, commonly known as a check valve, which operates independently of the electronic controlling means such that sub-atmospheric pressure achieved in the device when the condenser is turned on in the second atmospheric condition causes the check valve to close of its own accord, sealing the device from the outside atmosphere.
Vacuum Distiller with Reservoir and Pre-evaporator
Figure 3 illustrates an embodiment of the present invention, which includes a pre-evaporator section (70 ) that operates as a pre-boiler. The terms 'pre-evaporator' and
'pre-boiler' are used interchangeably. In addition to an evaporator section 66 an accumulator section 40, and a reservoir section 50, this embodiment comprises a pre-evaporator section (70) which functions as a pre-boiler. Also disclosed in this embodiment are related valves and connection tubes.
Initially, in operation, all valved ports and valved vents are closed. Valve (36 ), which is a valved entry port for the evaporator section, is opened. Through valved entry port 36 the evaporator section 66 is partially filled with a batch of liquid 64 to be distilled. Valved entry port 36 is then closed.
Under a first atmospheric condition that is, one atmosphere, the pre-boiler section 70 is filled with liquid from the evaporator section 66 through supply tube 30, or from the accumulator section 40 through supply tube 80 or from the reservoir section 50 through supply tube 84, or alternatively, the pre-boiler can be filled from a valved tube 82 from an external liquid source. This water from the above sources fills the pre-boiler to a predetermined level and the appropriate valve 29, 78, 86 or 82 is shut.
The valve 76 is then opened and then the heater 32 is turned on, in the pre- boiler 70 and rapidly boils the small volume of liquid water 72 in the pre-boiler. In one alternate version, the valve 76 can be opened all the time. The liquid is quickly converted to a first vapor or steam which passes out of the pre-boiler 70 through the valved outlet tube 74 and enters above section 68 of the evaporator section 66, and mixes with the air, then passes out of the evaporator section 66 through the connecting tube 41 into the condenser 24 shaped as a condenser coil. The vapor/air mixture passes through the condenser 24 and enters the accumulator section 40 and mixes with the air in the accumulator section 40, and then passes out of the bottom of the accumulator section through valved vent 44 and through the second tube 46 enters the reservoir section 50.
The vapor condenses underneath the distillate 17 surface, in the reservoir section 50 and the air purged from the device then leaves the reservoir section 50 through the vent (48 ) into the outside air. After several minutes, most of the air has been driven from the device and the pre-boiler heater 32 is turned off and the condenser fan 13 turned on. Valved vent 44 and valve 76 are closed, in effect sealing the device from the outside atmosphere, and trapping a second atmosphere condition within the device. Alternately the valve 76 can be left open, which will include the pre-boiler in the device area containing the second atmosphere condition.
In the second atmospheric condition, the vapor, e.g., steam, inside the sealed device coming into contact with the condenser 24 is then cooled and turns into distillate, e.g. water, creating a third atmospheric condition, which is sub-atmospheric or a vacuum, inside the device. Once the vacuum reaches about 25 inches Hg, the evaporator section 66 heater 14 is turned on and heats up the water in the main boiler to about 134° F and under continuing heating from heater 14, the water in the main boiler boils, forming a second vapor. The boiled water converted to steam passes through the connecting tube 41 to the condenser 24 and is condensed to distillate 17, falling into the accumulator section 40 under vacuum.
Once the water in the evaporator section 66 falls to a prescribed level, the heater 14 is turned off, the valved vent 44 and inlet valve 36 are opened, breaking the vacuum (the third atmospheric condition), and the distillate 17 is collected in the reservoir section 50 through valve 44 on connecting tube 46. In particular, the inlet valve 36 or the sealable attachment 37, is opened to break the vacuum (the third atmospheric condition), and the valved vent 44 is then opened to flow or discharge the distillate 17, in the accumulator section 40 to the reservoir section 50. Distillate 17 can then be drawn off from the reservoir 50 through valve 52 for use.
A new batch of water to be distilled enters the evaporator section through the sealable valved entry port 36 or the demountable sealable attachment 37 and the device is ready to repeat the process. A feature of accumulator section 40 is a small reservoir section 19, in the base which allows a volume of distillate to be collected for subsequent discharge through connecting tube 80 into the pre-boiler 70.
It will be understood that a preferred version of this device comprises automatic controlling means. In this version, the operation of the device is under control of automatic controlling means as described below. At least the valved entry port 36, valved vent 44, heaters in the evaporator section 66 and/or pre-evaporator section 72 and condenser fan 13 are automatically operated in a timed sequence by the automatic controlling means to achieve batch distilling of a liquid at sub-atmospheric pressure without the aid of a vacuum pump or entrainment device to create or maintain a vacuum. The evaporator 66 and the heating element 14 sections can also be adapted with demountable sealable attachment 37 for quick removal of the evaporator 66 and for quick sealable attachment of the evaporator 66 to the device. An alternate embodiment involves using a check valve for valve 44 as described above.
Another version of the device which comprises a pre-evaporator section 70 is shown in Figure 4. This version, is identical to the device described in Figure 3 above, except the evaporator section 66 does not have a heating element. In the vacuum generating phase, the heater 32 in the pre-boiler 70 is turned on to a high setting, quickly boiling the water inside
the pre-boiler, and creating steam which exits the pre-boiler and purges air out of the device 42 through valve 44, as before.
Once the air is purged from the device to form a second atmospheric condition, the heater is turned off and the fan 13 is turned on. Valve 44, which may be under control of the electronic controlling means or which may be a mechanical check valve (one-way valve) that operates independently of the electronic controlling means closes automatically as the steam is condensed and a vacuum is created.
After a prescribed time, the heater 32 is switched to a lower power setting and boils the water in the pre-boiler below 212 ° F, for example at about 140° F in a sub- atmospheric (vacuum) condition and valve 29 is opened. Alternately valve 29 may be left open through the entire process. As the water boils off and goes into the condenser 24, more water feeds through tube 30 from the evaporator 66, into the pre-boiler by simple gravity and the process continues. Then, once the water drops in the pre-boiler and evaporator section, to a prescribed level the heater 32 sensors off. Removal of distillate in this version and the control means used, is the same as that described in Figure 3 above. The evaporator 66 and the heating element 14 sections can also be adapted with demountable sealable attachment 37 for quick removal of the evaporator 66 and for quick sealable attachment of the evaporator 66 to the device.
Vacuum Distiller with Pre-Evaporator Section and Removable Evaporator Section
In this embodiment, the pre-boiler and the main boiler are integrated into one vessel and similarly the accumulator and the reservoir are combined into another as shown in Figure 5.
A first chamber 69 is incompletely partitioned by a partition 71 into a smaller pre-boiler section and a larger main boiling chamber 66. The preboiler section 70 is positioned to one side of the first chamber 69. A heating element 32 positioned is in the middle of the pre- boiler cavity 70. The base of the pre-boiler 70 is connected to the base of the main boiler 66 with a connecting tube 30 which feeds liquid from the main boiler liquid 64 into the pre-boiler cavity liquid 72 by gravity. The integrated pre-boiler/main boiler first chamber 69 is
detachably connected at sealable connection 37 to the condenser connector tube 41 and can easily be removed by means of a handle, and filled with the liquid to be distilled, from a faucet or from another container. The first chamber 69 is then placed back in position in the distiller body.
Similarly, the accumulator and the reservoir are also integrated into one vessel 40 (second chamber) with a suitable handle, (not shown) for ease of removal and repositioning. The combined accumulator/reservoir is also detachably connected to the condenser section outlet 25. Vessel 40 can be emptied of distillate through the outlet 47, which contains valve 44 and then repositioned in the body of the distiller. Once both vessels (69 and 40) are placed in their respective positions, the condenser 24, which is hinged at one side, (not shown) is lowered and mechanically closes the gas-tight connections at the top of the pre-boiler/main boiler 37 and the top of the accumulator/reservoir vessel 25.
When the pre-boiler heating element 32 is then switched on, the liquid 72 in the pre-boiler cavity boils rapidly and exits the top of the pre-boiler cavity and enters the main boiler section 66 and mixes with, and purges the air in the pre-boiler 70 and main boiler 66 and drives it out the exit port 37 at the top of the main boiler and the vapor/air mixture passes into the condenser tube 41 and then into the condenser 24. The vapor/air mixture then leaves the condenser 24 and enters the integrated accumulator/reservoir vessel 40 through the port 25 at the top of the accumulator, passes into the accumulator/reservoir vessel 40 and exits the accumulator/reservoir 40 through the exit port 47 at the top, through a one-way valve 44. While following this path, the vapor purges more and more of the air from the enclosed cavity inside the distiller until after a number of minutes, the majority of the air has been removed from the cavity.
A further embodiment of the invention is shown below in Figure 6. In this embodiment, the main boiler 66 consists of a single vessel with two heating elements 14, 32 in its base. The accumulator and the reservoir are combined into a single vessel 40 as shown in Figure 6. The boiler 66 is detachably connected to the condenser inlet 41 by a connector 37 and can easily be removed by means of a handle, (not shown) and filled with the liquid to be
distilled, from a faucet or from another container. The boiler 66 is then placed back in position in the distiller body.
Similarly, the accumulator and the reservoir are also integrated into one vessel 40 with a suitable handle, (not shown) for ease of removal and repositioning. The combined accumulator/reservoir is also detachably connected to the condenser section outlet 25. The reservoir can be emptied of distillate through the detachable outlet port 47, which contains valve 44 and then repositioned in the body of the distiller. Once both vessels 40 and 66 are placed in their respective positions, the condenser 24, fan 13 and condenser tube 41 which are integrally connected and hinged at one side, (not shown) is lowered and mechanically closes the gas-tight connections at the ports on top of the pre-boiler/main boiler 37 and the top of the accumulator/reservoir vessel 25.
When both heating elements 14 and 32 are switched on, the liquid 64 in the boiler 66 boils rapidly, and the vapor generated mixes with, and purges the air in the boiler 66 out the exit port 37 at the top of the boiler 66 and the vapor/air mixture passes through the connector tube 41 into the condenser 24. The vapor/air mixture passes through and then leaves the condenser 24 and enters the integrated accumulator/reservoir vessel 40 through the port at the top of the accumulator 25, purges air from inside the vessel 40 and finally exits the vessel 40 through the exit port 47 at the top, through the one-way valve 44. While following this path, the vapor from the boiler purges more and more of the air from the enclosed cavity inside the distiller until after a number of minutes, the majority of the air has been removed from the distiller cavity.
Once the purging step is completed, one of the boiler heating elements 32 is turned off, heating element 14 is left on and the fan 13 is turned on. As the vapor condenses in the condenser 24, as heat is drawn away by the fan 13, the one-way valve 44 at the exit of the reservoir vessel 40 closes, sealing the internal cavity of the distiller and thus a vacuum is formed inside the distiller cavity and so the boiling temperature in the boiler drops. As more steam is condensed, the boiling temperature continues to drop until a minimum boiling temperature of about 140° F is achieved. Boiling is now continued until the liquid 64 in the
boiler 66 drops to a prescribed level as determined by a sensor (not shown) and then the heating element 14 is turned off. A button (not shown) is pushed to break the vacuum inside the distiller and then the condenser assembly is swung open on its hinge (not shown), breaking the sealed connections 25, 37 at the top of the two vessels as described above. The accumulator/reservoir vessel 40 is then removed and the distillate 17 poured out through the accumulator/reservoir vessel intake port 47 into another container. The pre-boiler/main boiler vessel 66 is also removed and filled with new liquid to be distilled and the process repeats.
It is understood that embodiments of Figures 5 and 6 further comprise electrical connections between the distillation device and the removable first and second chambers (40 and 69 in Figure 5; 66 and 40 in Figure 6), and the logic and control elements disclosed in Figures 13 and 14 which comprise the automatic controlling means as described herein.
Vacuum Distiller with Refrigeration System
The design of a vacuum distiller of the present invention combined with a refrigeration system is illustrated in Figure 7. This embodiment combines the embodiment described above (Figure 3) having a pre-evaporator 70 and reservoir section 50 and further comprises refrigeration equipment to achieve heating of the batch of water 44 in the evaporation section 66 and the condensing of the steam in the accumulator section 40, with a refrigeration cycle.
In this embodiment, the heating element 14 comprising a condensing coil of a refrigeration system gives up heat to the water 44 to be distilled and the condensing section 24 comprising the refrigeration system evaporator draws heat from the steam, condensing it to distillate in the condensing section 40. Figure 7 shows that the steam condenses on the outside of the refrigeration condenser coils 24 and falls into the accumulator section 40. The pre-boiler 70 is used to produce a first vapor steam to create the vacuum system as before. However, in the embodiment utilizing a refrigeration system the degree of vacuum is much higher than the embodiment which employs a fan cooled condenser. A vacuum condition of as
much as 29" Hg is achieved because of the lower temperature in the refrigeration evaporator coils 24. This corresponds to a boiling temperature in the evaporator section 66 of about 76 F, making the heating and boiling of the water much easier and requiring less energy.
In operation, the process is the same as described above for Figure 3. A sub- atmospheric condition or vacuum is created by boiling water to steam in the pre-boiler 70 using a heater 32 and using this steam to drive the air out of the device, then the device is sealed from the atmosphere by closing the valved vent 44. To avoid overheating of the refrigeration system, during the vacuum generating phase, a tube 28 connecting the accumulator section 24 and the refrigeration compressor 10 is passed through the evaporator section 66 under immersion in the water 64. The heating element 14 comprising the refrigeration condenser coil is immersed in the water in the evaporator section 66 then heats the water in the evaporator section up to 76° F and it starts to boil.
An advantage of the refrigeration system is that due to its coefficient of performance,
(COP, up to 5.0), the energy requirements to boil a gallon of water drops up to 80% when compared to a standard distillation system. This is a significant energy savings, especially in areas where electric power is expensive. This energy savings is offset by the extra capital expense of the refrigeration system. A more detailed description of the operation of the refrigerated version of the device is included in Figure 6.
Refrigeration Cycle Distilling Device
Figure 8 shows a preferred embodiment of the present invention using a refrigeration cycle, which integrates the pre-boiler 70, evaporator 66 and accumulator section 40 inside one vessel. The integrated vessel (42) as shown in Figure 8, combines a water evaporator heating element (14) disposed in an evaporator section (66), in the bottom portion of the integrated vessel 42, a pre-boiler or pre-evaporator section (70) in which is disposed another heating element (32), a steam condenser (24 ) and a accumulator section or distillate collector (40 ), in one integrated device or unit. The embodiment also contains a radiator (20 ) and a reservoir section or distillate reservoir (50 ). The integrated vessel also has a valved entry port (water
inlet valve) (36 ), and a distillate discharge valve (44) and a drainage valve (38 ). The refrigeration lines 12,29,18,23 go through the walls of the integrated vessel.
As described below, the valves, condenser, heating element and other specified elements of the embodiment are under control of electronic controlling means, which functions as an automatic control system to turn on the heater(s), make vapor, purge the device, seal the device from the atmosphere, turn off the heater(s) and turn on the condenser to generate vacuum, and continue the production of distillate and discharge or collection of distillate as described below in detail in the following four phases, water filling, vacuum generating, distillate producing and distillate discharging.
Water Filling
Since the invention involves a batch process, the first step involves the filling of the evaporator section 66, with water. To accomplish this, distillate/air outlet valve, i.e. valved vent 44 and water inlet valve, i.e. valved entry port 36 are opened and drainage valve 38 is closed. The heater element 32 in pre-evaporator section is turned off At one atmosphere of pressure, the evaporator section of the device 66 is sufficiently filled with water through valved entry port 36 until liquid level is above the heater element 32, then, valved entry port 36 is closed. The system has now been charged with water at a first atmospheric condition, equal to one atmosphere of pressure.
Vacuum Generating
The following device and method of creating a vacuum creates a vacuum within the device without a vacuum pump or entrainment device and is based on a simple heating device which operates as follows: Turn on heater element 32 disposed in the pre-evaporator section 66 to generate a first vapor e.g. steam, while the water is continuously supplied to the pre- evaporator 70 from evaporator section 66 through connector tube 30. In a version of the device comprising a refrigeration system (Figures 7-12), the first vapor steam generated by the heater element 32 also heats the refrigerant vapor inside the refrigerant evaporator 24 to a
superheated state. In order to cool the superheated refrigerant, the heat exchanger 28 immersed in the water in the evaporator section 66, will reduce the superheated refrigerant temperature sufficiently, to allow the vacuum cycle to proceed.
The first vapor generated by heater element 32 is pushed out along with the air initially trapped in device 42, through distillate/air outlet valve (i.e. valved vent) 44, connector tube 46, and distillate reservoir 50 and is finally released from the top air discharge vent 48 of distillate reservoir 50. Some vapor will be condensed in distillate reservoir 50 when some cold distillate is present.
The inside of the device 42 is lined with a insulator liner 43 to reduce the condensation of steam on its surface which would stop the steam from displacing air from the vessel. The steam generated by heater element 32 will dilute the air in the device 42 until after a few minutes, the device is eventually filled almost entirely with steam, forming a second atmospheric condition. Then distillate/air outlet valve (i.e. valved vent) 44 is closed and heater element 32 is turned off.
From this point on, the pressure in the device 42 will correspond to the steam temperature. When the refrigerant compressor 10 is turned on, and condenser 24 cools the steam to water, the steam pressure in the device 42 will drop down with steam temperature, thus achieving a third atmospheric condition which is sub-atmospheric or a vacuum condition during operation of the device. The refrigeration cycle will produce vacuum conditions in the range of 27- 29" Hg. This occurs even though the incoming water has not been degassed.
Distillate Producing
The process of distillate production is presented in two parts as follows: (a) water evaporating and refrigerant condensing, and (b) steam condensing and refrigerant evaporating.
Water evaporating and refrigerant condensing
In the version of the device which comprises a refrigeration system, the compressor 10 is now turned on and the superheated refrigerant vapor is discharged from the compressor 10. The refrigerant superheated vapor is routed to the top portion of the refrigerant condenser or heating element 14 disposed in the evaporator section 66. The heating element is in the form of a tube coil extending from the point 12 to point 18, and disposed in the evaporator section. The refrigerant condenser coil 14 is divided into two portions. The top portion of the coil 14 is contained inside the cylindrical portion of shroud 16 and the bottom portion of the coil 14 is covered by the disk-shaped portion of shroud 16. The batch of water in the evaporator section 66 is heated by the refrigerant under vacuum conditions.
The water is preheated at the bottom portion of the refrigerant condenser 14 and continues to heat up to the top portion of the refrigerant condenser 14. Water that is 1-2 inches below the water level, reaches a superheated condition and creates a steam/water mixture. The steam/water mixture bursts out from inside of the top portion of the shroud 16 and hits the vapor separator 34.
The steam rises through the vapor separator 34 to the refrigerant evaporator/steam condenser 24, while the water falls down to the outside of the shroud 16. Due to the density difference between steam and liquid, the water outside the top of the cylindrical portion of shroud 16 is forced downwards and then feeds under the bottom plate portion of the shroud 16 and then rises up the inside of the cylindrical part of the shroud 16. This enhanced circulation heat transfer device raises the convection heat transfer between the water 64 and the refrigerant in the refrigerant condenser 14.
Meanwhile, the refrigerant is continuously condensed by the water, in evaporator section 66. The low vapor ratio saturated refrigerant is then routed to the radiator 20 and continuously condenses to a liquid state.
Steam condensing/refrigerant evaporating
The refrigerant now flows through the refrigerant pressure reducing device 22 (e.g. expansion valve or capillary tube), into the refrigerant evaporator/steam condenser 24. The liquid refrigerant temperature drops markedly during the expansion process.
The refrigerant evaporating temperature is selected above 32° F for water, to prevent freezing. The refrigerant inside the refrigerant evaporator/steam condenser 24, absorbs energy from the steam and the refrigerant evaporator/stem condenser 24 acts as an evaporating tube to evaporate the refrigerant, inside the tube.
Meanwhile, the steam releases energy and is condensed on the outside of the refrigerant evaporator/steam condenser 24. The condensate falls down to the distillate collector (i.e., accumulator section) 40. The refrigerant routes into the heat exchanger 28 which extends from point 26 to the inlet of the compressor 10. All refrigerant leaving the heat exchanger is in single-phase vapor form.
The refrigerant leaving the heat exchanger 28, passes through the suction line 29 to the compressor 10. Here the compression process occurs. The high-pressure vapor then passes through the discharge line to the refrigerant condenser 14, thereby completing the vapor compression refrigeration cycle.
The above refrigeration cycle can also be replaced by an absorption refrigeration cycle. The absorption refrigeration cycle is different from the vapor compression refrigeration cycle as it uses thermal energy instead of mechanical energy to make a change in the conditions necessary to complete a refrigeration cycle.
The use of a refrigeration cycle creates a performance increase by the ratio of the amount of energy released from the refrigerant evaporator 24 divided by the energy input to the refrigerant compressor 10, thus creating a significant energy saving when compared to a simple distillation system.
The distilled water production is continuous from the above described water distillation loop until the liquid level in the evaporator section 66 drops to a certain level.
Distillate Discharging
The next part of the batch distillation process is discharge of the distillate 17 from the collector or accumulator section 40 into an external reservoir 50. First open inlet valve 36 which allows air to enter the device and break the vacuum. The distillate outlet valve valved vent) 44 is now opened and the distillate is discharged by gravity to the distillate reservoir 50 . The next cycle will restart at this point.
Figure 9 shows a detailed view of a stand-alone, commercial embodiment of the invention containing a refrigeration cycle. This embodiment shows a typical commercial version of the invention, with the compressor 10, radiator 20, distiller reservoir 50 located beneath the distiller vessel 42 (See Figure 8). The inlet valve 36 passes through the wall of the outer cover 4 as does the distillate discharge valve 52. A power chord 11 also passes through the outer cover 4 to supply electrical power to the compressor 10, and to the heat exchanger fan 21. The above mentioned components and the outer cover are rigidly connected to a support base 6.
Distillation System Integrated into a Standard Household Refrigerator.
Figure 10 shows a schematic of a typical embodiment of the present invention, integrated into a standard household refrigerator. The schematic shows a distiller vessel (42 ), a distiller reservoir 50, a radiator 20, a compressor 10, a power chord 11 contained inside a refrigerator body 8. The standard refrigerant evaporator (60 ) is shared by the present invention and used to cool the inside cavity of the refrigerator.
There are two basic preferred embodiments, for integration of the invention into a household refrigerator as described below.
Water Distillation Device with Refrigerant Evaporator
Figure 11 shows a detailed view of a partial cross section of a distillation unit, integrated into a standard household refrigerator and containing two connected refrigerant evaporator coils, one for the distiller and the other for the refrigerator. Details of the distillation unit is the same as described in Figure 6 above, except for the addition of three 3-way valves 54 , 56 and 62 and a refrigerant pressure reducing device 58, connected to the refrigerator evaporator 60.
This system is composed of two loops, one is the water distillation loop and the other is the refrigeration loop. The water distillation loop it is already described in Figure 8 above. The refrigeration loop is controlled by means of three 3-way valves 54 , 56 and 62. Thus the refrigerant leaving the compressor 10 to the radiator 20 and through the refrigerant pressure reducing device 58 enters the refrigerator evaporator 60 to complete the refrigeration cycle.
Water Distillation Device without its Own Internal Refrigerant Evaporator
Figure 12 is a partial cross section of a distillation unit as described in Figure 11 above except without an internal refrigerant evaporator 24, refrigerant pressure reducing device 22, two 3-way valves 56 and 62, or a heat exchanger 28. The refrigerant is now routed into the refrigerator evaporator 60 and the top of the distiller vessel 42 acts as the steam condenser when it is cooled by cold air on the outside surface, supplied from the refrigerator evaporator
60. This distillation unit is also integrated into a standard household refrigerator, the same as described in Figure 11 above.
The compact vacuum distillation system as described in detail in Figures 2-15 above, has the following advantages:
- it permits the reduction of energy consumption to less than (25-50)% of a standard atmospheric distiller.
- the size of the vacuum distillation system is reduced due to the combining of the communicating evaporator section and accumulator sections into one vessel and the generation of enhanced convection by use of a shroud in the water evaporator.
- it utilizes a device for creation of a vacuum without the use of a vacuum pump or entrainment device, thus allowing use of a refrigeration cycle as a heating source for producing steam.
- it produces distilled water with significantly reduced energy consumption when compared with simple distillation systems.
- the use of the heater vacuum generating device reduces the overall size of the unit.
- it reduces the formation of scaling due to the lower boiling temperature thus eliminating the need for descaling or the use of descalant chemicals.
- the design is easily integrated into a conventional refrigerator where the refrigerator's condensing and evaporating components can be made integral with same components in the device.
- it allows the use of lower-cost materials due to the lower temperatures used.
- it makes the device inherently more safe to use and operate due to the lower boiling temperature created by the vacuum.
Description of Automatic Controlling Means
It will be understood that a preferred version of this device comprises automatic controlling means. In this version, the operation of the device is under control of electronic controlling means as described below. At least the valved entry port 36, valved vent 44,
heaters 32 and 14, fan 21 and compressor 10 are automatically operated in a timed sequence by the electronic controlling means to achieve batch distilling of a liquid at sub-atmospheric pressure without the aid of a vacuum pump or entrainment device to create or maintain a vacuum.
Electronically Automated Vacuum Distiller
Preferred embodiments of the present invention (Figures 2-15) further comprise automatic controlling means (electronic controlling means) embodied in logic circuit for an automatic vacuum distillation device.
Vacuum Distiller Logic and Electronic Circuits.
A typical embodiment of an electronic control logic circuit for an automatic vacuum distillation device with pre-boiler 70 is shown schematically in Figure 13, as a simplified block diagram illustrating the principal parts of the logic circuit, for batch distilling a liquid in accordance with the invention. A pre-boiler high level sensor 100 checks the high water level of the water in the pre-boiler (pre-evaporator section) and ensures that the pre-boiler is not overfilled. If so, the sensor closes and a stepper motor 128 is positioned to open a valve to avoid water flowing into the pre-boiler from the accumulator section 40 of the device 42 (not shown). The stepper motor 128 is also controlled by the microprocessor 118 and is instructed to rotate to the four preset positions which first allow a break in the vacuum condition third atmospheric condition within the device, and, second close the valved vent to seal off the device from the outside atmosphere to allow creation of a vacuum, and third allow distilled water to flow into the reservoir section from the accumulator section opening (not shown) and fourth, allow water to flow into the pre-boiler from the accumulator section.
The stepper motor controls the position of the valves and opens and closes these at the various control points of the water filling, vacuum generating, distillate producing and distillate discharging phases. Similarly, a lower level sensor 102 is used to check the water level in the pre-boiler and ensures that the water level is not too low. If the water level in the pre-boiler is below the sensor level, there is a danger of overheating the heater element (not
shown) causing a failure. If so, the sensor 102 opens and the pre-boiler heater (not shown) is deactivated. Similarly, a high level sensor 104 and a low level sensor 106 check the water levels in the main boiler (evaporator section) (not shown) and ensures that the water level is between the two levels to avoid any problems.
A main boiler connecting sensor 108 is used to ensure that the main boiler is connected correctly, i.e., in sealable connection 37 or sealable valve 36 to the device of the invention. If this sensor stays open, the seal (not shown) connecting the main boiler and the device distiller is not engaged and it will not be possible to generate a vacuum condition in the device.
Low pass filters 110, 112, 114, 116 are connected to the high and low level control sensors 100, 102, 104, 106, 108 and ensure that agitation in the water level does not trip the sensors at the wrong level. Instead, the low pass filters filter out fluctuations in the level sensor signal and so the sensor responds only to the mean value of the water level being sensed.
A microprocessor 118 electronically processes the input signals coming from the sensors 100, 102, 104, 106, 108 via the filters 110, 112, 114, 116 and interprets the information in the signals through the control logic contained in the read-only memory 120 of the microprocessor. Depending on the signal process result, an output from the microprocessor is routed to a speaker 122 which gives an audible sound, warning the user of a malfunction or error in filling the main boiler (too full or too empty) or a similar condition in the pre-boiler. Another signal is routed to the pre-boiler heater relay 124 instructing the relay to close and thus apply electric power to the pre-boiler heater 32. A similar signal is routed from the microprocessor to the main boiler heater 14. Also in a similar fashion a signal is sent to the electric fan 13 causing the fan to turn on and blow air over the condenser at the correct time in the distillation cycle.
Flowchart of Electronic Controller for Automatic Vacuum Distiller. A typical electronic controller flow chart for the present invention is illustrated in Fig.
14. The distillation process is essentially a batch process, due to the need to isolate and create
vacuum conditions in the device. The control sequence of this batch process is as follows: the control sequence starts with the power sensor 132 to the distiller being turned on. Then the controller (not shown) checks if the main boiler connecting sensor and low/high liquid level sensors are on, and, if not, a warning sound 135 is activated. If all sensors 104,106,108 are on 134 , then the controller checks to see if the pre-boiler high level sensor 100 is on 136.
If not, the stepper motor is positioned to position #4 (138) , to allow water to flow into the pre-boiler from the accumulator section (not shown).
If the specified period 140 is exceeded and the water level in the pre-boiler has not reached a high level sensor, then a warning light or sound 142 is activated instructing the user to check for malfunction.
If both level sensors 100, 102 are on, indicating that the water level in the pre-boiler (not shown) is in the correct range, then the stepper motor (not shown) is turned to position #3 (144). In order to ensure that the water in the accumulator section drains by gravity into the reservoir (not shown), the controller (not shown) checks the cumulative time from the beginning of the power sensor on 132.
If the cumulative time is for example, over 2 minutes, the pre-boiler heater is turned on 146. The controller then continually checks the condition of the pre-boiler low level sensor
148 and if it is still on, the pre-boiler heater is kept on. Once the pre-boiler low level sensor 102 turns off then the stepper motor 128 is turned to position #2 (150). After time delay 152, the pre-boiler heater is turned off 154, the fan 21 is turned on 156 which cools the first vapor steam in contact with the condenser 24, turning the steam vapor to water 21 and so begins to create a vacuum (third atmospheric condition) in the device, which is sealed from the outside atmosphere. After a time delay period 158, during which time the vacuum is drawn down to a desired level, the main boiler (evaporator section) heater is turned on 160.
The controller then checks the main boiler low level sensor 106 and if it is in the 'on' position, (which means that there is still plenty of water in the evaporator section or main boiler), the main boiler heater continues to boil the water forming second vapor. Once the
controller checks and finds that the low level sensor 166 is off, the main boiler heater 14 and fan 21 are turned off 162 and the stepper motor is turned to position #1 (164) for a time delay 166 to break the vacuum condition in the device. Then the stepper motor is turned to position #3 (168). When the stepper motor is in position #3 (168), the distilled water collected in the accumulator section (not shown), drains by gravity into the reservoir section connected below the accumulator section. This completes the batch process 170.
Figure 15 is a chart of a control sequence for operating the device. It is appreciated that the invention is not restricted to the control sequence disclosed in Figure 15.
As will be appreciated, the device of the invention for batch distilling liquids may be used for liquids other than water, including, but not restricted to ethylene glycol, sea water, brackish water, and alcohols.
Having thus described exemplary embodiments of the present invention, it should be noted by those skilled in the art that the disclosures herein are exemplary only and that various other alternatives, adaptations and modifications may be made within the scope of the present invention. Accordingly, the present invention is not limited to the specific embodiments as illustrated herein, but is only limited by the following claims.