WO2010126848A1 - Distillation par compression de vapeur à plusieurs étages - Google Patents

Distillation par compression de vapeur à plusieurs étages Download PDF

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Publication number
WO2010126848A1
WO2010126848A1 PCT/US2010/032463 US2010032463W WO2010126848A1 WO 2010126848 A1 WO2010126848 A1 WO 2010126848A1 US 2010032463 W US2010032463 W US 2010032463W WO 2010126848 A1 WO2010126848 A1 WO 2010126848A1
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WO
WIPO (PCT)
Prior art keywords
vapor compression
evaporator
compression distillation
stage
condenser
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PCT/US2010/032463
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English (en)
Inventor
Bruce D. Kaufman
David C. Walther
Pamela Reilly Contag
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Cobalt Technologies, Inc.
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Publication of WO2010126848A1 publication Critical patent/WO2010126848A1/fr

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D1/00—Evaporating
    • B01D1/28—Evaporating with vapour compression
    • B01D1/2887—The compressor is integrated in the evaporation apparatus
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D3/00—Distillation or related exchange processes in which liquids are contacted with gaseous media, e.g. stripping
    • B01D3/007—Energy recuperation; Heat pumps

Definitions

  • ABE acetone-butanol-ethanol
  • four distillation columns, or multiple batch distillations in a batch still may be required.
  • up to four columns have been employed.
  • ABE mixture concentrations such as those encountered by those skilled in the art of ABE fermentations
  • an initial concentration is performed in a stripping or beer column.
  • the distillate from this primary column is distilled to remove acetone and ethanol from butanol and water.
  • Two distillations then separate acetone from ethanol and water from butanol.
  • the columns remove solvents from the fermentation broth based on relative volatility differences between the components, and separate and purify the acetone, ethanol, butanol and any remaining water. This distillation process takes a large amount of energy.
  • VCD vapor compression distillation
  • this invention provides a device comprising a plurality of vapor compression distillation units, each vapor compression distillation unit comprising an evaporator stage and a condenser stage, wherein the device is configured to transfer heat from the condenser stage of a prior vapor compression distillation unit to the evaporator stage of a subsequent vapor compression distillation unit.
  • each vapor compression distillation unit comprises a plurality of adjacent plate members which together alternatively define a series of evaporating and condensing chambers.
  • the condenser stage of the prior vapor compression distillation unit is configured to transfer heat to the evaporator stage of the subsequent vapor compression distillation unit by conduction, radiation, or convection.
  • the condenser stage of the prior vapor compression distillation unit is configured to transfer heat to the evaporator stage of the prior compression distillation unit.
  • the prior vapor compression distillation unit is in direct contact with the subsequent vapor compression distillation unit.
  • the condenser stage of a prior vapor compression distillation unit is in thermal contact with the evaporator stage of a subsequent vapor compression distillation unit.
  • the device further comprises at least one liquid conduit connecting either the evaporator stage or the condenser stage of the prior vapor compression distillation unit to the evaporator stage of the subsequent vapor compression distillation unit.
  • the device further comprises a pressure sensor operably connected to at least one of: the evaporator stage or the condenser stage of a vapor compression distillation unit.
  • the device further comprises at least one compressor per vapor compression distillation unit.
  • the device further comprises one compressor for the device operably connected to each of the vapor compression distillation units of the device.
  • a plate of a condensing chamber defining one end of the prior vapor compression distillation unit is in thermal contact with the plate of an evaporating chamber defining one end of the subsequent vapor compression distillation unit.
  • the device further comprises the device comprises a plurality of adj acent plate members which together alternatively define a series of evaporating and condensing chambers for the vapor compression distillation units such that the plates alternatingly incorporate the plurality of vapor compression distillation units.
  • the device further comprises a component configured to separate a mixture by a separation method other than distillation.
  • the component is a decanter, centrifuge, centrifugal contactor, coalescer, or holding tank.
  • this invention provides a method of distilling a solution comprising: providing a first vapor compression distillation unit comprising a first evaporator and first condenser, and a second vapor compression distillation unit comprising a second evaporator and second condenser; receiving an initial solution in the first evaporator; distilling the solution from the first evaporator to produce a first distillate and a first residual solution and condensing the first distillate to the first condenser; and transferring heat from the first condenser to the second evaporator.
  • the method further comprises transferring the first residual solution or the first distillate from the first vapor compression distillation unit to the second vapor compression distillation unit.
  • the first residual solution is transferred from the first evaporator to the second evaporator.
  • the first distillate is transferred from the first condenser to the second evaporator.
  • the method further comprises transferring heat from the first condenser to the first evaporator.
  • the initial solution is ABE fermentation broth comprising acetone, butanol, ethanol, and water.
  • the first distillate is an acetone, butanol, ethanol, and water mixture.
  • the method further comprises receiving the first distillate in the second evaporator.
  • the method further comprises distilling the first distillate from the second evaporator and condensing a second distillate to the second condenser.
  • the second distillate includes acetone.
  • the method further comprises providing a third vapor compression distillation unit comprising a third evaporator and third condenser, and a fourth vapor compression distillation unit comprising a fourth evaporator and fourth condenser.
  • the method further comprises: receiving in the third evaporator a second residual solution comprising butanol, ethanol, and water; distilling the second residual solution to form a third distillate comprising an ethanol and water azeotrope and condensing the third distillate to the third condenser; receiving in the fourth evaporator a third residual solution comprising butanol and water from the third evaporator; and distilling the third residual solution to form a fourth distillate comprising a butanol and water azeotrope and condensing the fourth distillate to the fourth condenser.
  • the method further comprises: removing the first residual solution comprising water from the first evaporator; removing the second distillate comprising acetone from the second condenser; removing the third distillate comprising an ethanol and water azeotrope from the third condenser; removing a fourth residual solution comprising butanol from the fourth evaporator; and removing the fourth distillate comprising a butanol and water azeotrope from the fourth condenser.
  • the second distillate includes acetone and ethanol.
  • the method further comprises providing a third vapor compression distillation unit comprising a third evaporator and third condenser, and a fourth vapor compression distillation unit comprising a fourth evaporator and fourth condenser.
  • the method further comprises: receiving in the third evaporator a second distillate comprising acetone and ethanol; distilling the second distillate to form a third residual solution comprising ethanol and a third distillate comprising acetone and condensing the third distillate to the third condenser; receiving in the fourth evaporator a second residual solution from the second evaporator comprising butanol and water; and distilling the second residual solution to form a fourth distillate comprising a butanol and water azeotrope and condensing the fourth distillate to the fourth condenser.
  • the method further comprises: removing the first residual solution comprising water from the first evaporator; removing the third residual solution comprising ethanol from the third evaporator; removing the third distillate comprising acetone from the third condenser; removing a fourth residual solution comprising butanol from the fourth evaporator; and removing the fourth distillate comprising a butanol and water azeotrope from the fourth condenser.
  • this invention provides a method of distilling a solution comprising: providing a device comprising a plurality of vapor compression distillation units, each vapor compression distillation unit comprising an evaporator stage and a condenser stage; receiving an incoming solution in the evaporator stage of a vapor compression distillation unit; distilling a component of the incoming solution from the evaporator stage and condensing the distillate to the condenser stage of the vapor compression distillation unit; and transferring heat from the condenser stage of a prior vapor compression distillation unit to the evaporator stage of a subsequent vapor compression distillation unit.
  • the method further comprises transferring the incoming solution or the distillate from the prior vapor compression distillation unit to the subsequent vapor compression distillation unit.
  • the distillate is transferred from the evaporator stage of the prior vapor compression distillation unit to the evaporator stage of the subsequent vapor compression distillation unit.
  • the distillate is transferred from the condenser stage of the prior vapor compression distillation unit to the evaporator stage of the subsequent vapor compression distillation unit.
  • the prior vapor compression distillation unit is in direct contact with the subsequent vapor compression distillation unit.
  • the device comprises at least three vapor compression distillation units transferring heat from the condenser stage of every prior vapor compression distillation to unit to evaporator stage of every subsequent vapor compression distillation unit.
  • this invention provides a method of distilling a solution comprising: providing a device comprising a plurality of vapor compression distillation units, each vapor compression distillation unit comprising an evaporator stage and a condenser stage, wherein the condenser stage of a prior vapor compression distillation unit is in thermal contact with the evaporator stage of a subsequent vapor compression distillation unit; receiving an incoming solution in the evaporator stage of a vapor compression distillation unit; and distilling a component of the incoming solution from the evaporator stage to the condenser stage of the vapor compression distillation unit.
  • the method further comprises transferring a solution from a prior vapor compression distillation unit to a subsequent vapor compression distillation unit.
  • the component of the incoming solution is transferred from the evaporator stage of the prior vapor compression distillation unit to the evaporator stage of the subsequent vapor compression distillation unit.
  • the component of the incoming solution is transferred from the condenser stage of the prior vapor compression distillation unit to the evaporator stage of the subsequent vapor compression distillation unit.
  • the device comprises at least three vapor compression distillation units, wherein the condenser stage of every prior vapor compression distillation to unit is in thermal contact with the evaporator stage of every subsequent vapor compression distillation unit.
  • Fig. 1 shows an example of plate type heat exchangers which act as heat transfer plates to form alternating evaporating and condensing chambers of an evaporator/condenser (EC) core.
  • EC evaporator/condenser
  • Fig. 2 shows a nested shell and tube arrangement.
  • Fig. 3 shows an interspersed shell and tube arrangement.
  • Fig. 4 shows an embodiment for acetone-butanol-ethanol (ABE) distillation where the vapor compression distillation (VCD) units are separate from one another.
  • ABE acetone-butanol-ethanol
  • VCD vapor compression distillation
  • Fig. 5 shows an embodiment for ABE distillation where heat is transferred by conduction.
  • Fig. 6 shows an embodiment for ABE distillation where heat is transferred by radiation.
  • Fig. 7 shows an example of interwoven chambers for ABE broth.
  • Fig. 8 shows an insulated multi-core VCD.
  • Fig. 9A shows a modified multistage VCD device, which may be used to separate ABE fermentation broth.
  • Fig. 9B shows a modified multistage VCD device, which may be used to separate ABE fermentation broth according to an alternate flow path.
  • Fig. 10 shows examples of heat transfer between two stages of a multistage VCD device where there is good thermal contact.
  • Fig. 11 shows examples of heat transfer between two stages of a multistage VCD device where there is poor thermal contact.
  • Fig. 12 shows several compressor configurations.
  • the invention provides systems and methods for multistage vapor compression distillation (VCD).
  • VCD multistage vapor compression distillation
  • Various aspects of the invention described herein may be applied to any of the particular applications set forth below or for any other type of separation or distillation processes.
  • the invention may be applied as a standalone system or method, or as part of an application, such as fuel production. It shall be understood that different aspects of the invention can be appreciated individually, collectively, or in combination with each other.
  • a VCD unit produces a distillate and a residual solution from an incoming solution.
  • a VCD unit evaporates the incoming solution, compresses the overhead vapor and sends the vapor to a condenser, where some of the vapor is condensed. Some of the incoming solution remains in an evaporator to form a residual solution.
  • the condensed vapor in the condenser forms a distillate.
  • the energy of condensation is transferred back to the evaporator, thereby reducing the amount of heating energy that is required to boil and evaporate a solution.
  • Heat energy is transferred from a condenser of a VCD unit back to an evaporator of the VCD unit in various ways.
  • the process contains plate type, energy efficient, heat exchangers, which act as heat transfer plates to provide energy from a condenser to an evaporator. See generally U.S. Patent No. 4,978,429 and U.S. Patent No. 5,968,321.
  • plate members are arranged so that they form alternating evaporating and condensing chambers, as shown in Fig. 1.
  • the evaporating chambers are connected by a manifold that collects the residual solution.
  • the condensing chambers are connected by a manifold that collects the distillate.
  • the entire process is enclosed in an insulated shell to reduce heat loss to the environment.
  • the residual solution, distillate, and/or vapor is removed from an evaporator/condenser (EC) core of a VCD unit.
  • EC evaporator/condenser
  • any other type of distillation unit known in the art to produce a distillate and a residual solution from an incoming solution may be used.
  • shell and tube heat exchangers may also be employed, where one or more tube is disposed inside a shell, and different fluids may flow within the tube and within the shell outside the tube.
  • two multistage configurations can be envisioned to effectively couple excess enthalpy for the energy efficient distillation of a multiple component liquid as shown schematically in the attached figures.
  • one configuration consists of a nested set of tubes within a shell.
  • Fig. 3 consists of an interspersed tube arrangement.
  • Vapor compressors not shown in the figures would collect evaporated materials from manifolds and would supply compressed vapors to additional manifolds.
  • a VCD unit can be utilized in either batch or continuous distillation processes.
  • the ambient heat from a VCD unit or stage is used in part or in whole as an energy source for another VCD unit or stage. In some cases, the ambient heat is used as an energy source for a downstream VCD unit or stage.
  • the multiple units of a multistage VCD are incorporated into one device and the overall energy requirement for the separation of a solution are reduced.
  • the multiple units of a multistage VCD device are in thermal contact with one another. In some embodiments, the multiple units are adjacent to one another and physically connected to one another. There are sequential evaporation, vapor compression, and condensation processes, so that a prior VCD unit may be earlier in the sequence than a subsequent VCD unit.
  • heat exchangers from multiple VCD units define a series of evaporating and condensing chambers within each VCD unit.
  • an evaporating chamber of the first VCD unit is adjacent to a condensing chamber of the first VCD unit, which is adjacent to a another evaporating chamber of the first VCD unit, which is adjacent to a another condensing chamber of the first VCD unit, and so forth, until the last condensing chamber of the first VCD unit is adjacent to an evaporating chamber of the second VCD unit, which is adjacent to a condensing chamber of the second VCD unit, and so forth.
  • FIG. 4 An example of this design with respect to the preferred embodiment for ABE distillation is illustrated in Fig. 4.
  • This particular device contains four VCD units, each of which is separate from the adjacent unit, but each of which transfers heat to the adjacent unit by conduction (as shown in Fig. 4 and Fig. 5), radiation (as shown in Fig. 6), convection (not shown), or any combination thereof.
  • the first unit would distill acetone, butanol, and ethanol from water based on relative volatility differences between the components.
  • This distillate would then be taken from the condenser of the first unit to the evaporator of the second unit, where acetone and ethanol (the distillate) would be removed from butanol and water.
  • the butanol and water stream is then sent to the evaporator of a fourth unit, which removes water from butanol.
  • the third unit would be used to separate acetone and ethanol.
  • the entire process would be enclosed in an insulated encasement to prevent heat loss to the environment.
  • the multiple VCD units are incorporated into the device and into one another.
  • a VCD unit were made up of plate type heat exchangers
  • heat exchangers from multiple VCD units are alternatingly adjacent to one another.
  • an evaporating chamber of the first VCD unit can be adjacent to a condensing chamber of the first VCD unit, which can be adjacent to a evaporating chamber of the second VCD unit, which is adjacent to a condensing chamber of the second VCD unit, which is adjacent to an evaporating chamber of the first VCD unit, and so forth.
  • the VCD units are physically integrated with the individual components comprising the evaporator and condensing chambers interwoven.
  • FIG. 7 This concept of interweaving chambers is illustrated in Fig. 7.
  • the conventional approach to ABE distillation has been to remove the solvents (ABE) from water (which makes up the majority of the fermentation broth) at the beginning of the process, as this greatly reduces the cost of other downstream distillation processes.
  • this first distillation step is the most energy intensive of all, and so using the heat from this step for another downstream distillation step could greatly reduce energy costs.
  • two VCD units are incorporated into one device to perform two separation processes. First, ABE fermentation broth is sent to an evaporating chamber of the first VCD unit, where the distillate is compressed and then condensed, after which it is sent to the evaporating chamber of the second VCD unit.
  • a single device can be constructed to separate and remove n components, provided that there are at least n compressors and that the device be constructed in a way to allow for n different fluid paths. Having n different compressors is key, as the amount of compression for each step will determine the evaporating and condensing temperatures, necessary for controlling the heat flux from one plate to another, regardless of which particular VCD step one is looking to achieve.
  • the degree of thermal interconnection is variable.
  • two or more VCD units are completely interwoven as discussed previously so that all of their stages alternate. This also applies to any number of VCD units; the stages of any number of VCD units are arranged in an alternating manner so that they are completely interwoven.
  • the chambers created by plate type heat exchangers are partially interwoven. For instance, a first VCD unit is arranged with evaporating and condensing chambers in an alternating fashion, and then the evaporating and condensing chambers of the first and a second VCD unit alternate, and then the evaporating and condensing chambers of only a second VCD unit alternate within a multistage VCD device.
  • Chambers can be arranged in any order; for example, the evaporating and condensing chambers of a first VCD unit are arranged in an alternating fashion, and then the evaporating and condensing chambers of a second VCD unit are arranged in an alternating fashion, and then the evaporating and condensing chambers of the first VCD unit are arranged in an alternating fashion within the multistage VCD device.
  • the various arrangements apply to any number of VCD units within a multistage VCD device.
  • VCD units have various configurations, whether separated, partially integrated, or completely integrated, that enable heat transfer between VCD units.
  • the operating pressures of the individual evaporation and condensation stages may be altered through absolute and differential pressures across these individual stages in order to most effectively transfer heat from one stage to another. Effective heat transfer is reliant on a differential temperature between the thermal reservoirs at such a level to maintain large energy fluxes, but not in large irreversibilities.
  • the primary energy recovery heat exchanger which is used to exchange heat energy between the exit streams from the evaporation and condensation chamber outlets with the feed stream for the purpose of energy recovery, may also be integrated with and / or adjacent to the evaporation and condensation chambers in conditions when it is beneficial for overall energy recovery.
  • a multistage VCD device includes insulation that decreases heat loss through the surface of the device.
  • the various potential arrangements of the VCD units are encased within an insulating cover for the device.
  • the device has partial insulation, so that only parts of the surfaces are insulated.
  • Fig. 8 where a four- VCD device is encased in an insulated core to prevent heat loss to the environment.
  • the different mechanisms for heat transfer between individual VCD units inside the device A three-dimensional model of Fig. 8 is shown in Fig. 4, which again demonstrates that different materials and designs can be used for heat transfer between VCD units.
  • FIG. 9A shows a multistage VCD device in accordance with an embodiment of the invention.
  • a VCD device comprises a plurality of VCD units, where each VCD unit comprises an evaporator stage and a condenser stage, wherein the device is configured to transfer heat from the condenser stage of a prior VCD unit to the evaporator stage of a subsequent VCD unit.
  • the condenser stage of a prior VCD unit is in thermal contact with a subsequent VCD unit.
  • the multistage VCD device of Fig. 9A could be used to separate acetone -butanol-ethanol (ABE) fermentation broth.
  • the multistage VCD device has four VCD units, such that a first VCD unit comprises a first evaporator stage and a first condenser stage, a second VCD unit comprises a second evaporator stage and a second condenser stage, a third VCD unit comprises a third evaporator stage and a third condenser stage, and a fourth VCD unit comprises a fourth evaporator stage and a fourth condenser stage.
  • Heat is transferred between the first condenser stage and the second evaporator stage, the second condenser stage and the third evaporator stage, and the third condenser stage and the fourth evaporator stage. In some cases, heat energy is transferred from the first condenser stage to the second evaporator stage, from the second condenser stage to the third evaporator stage, and from the third condenser stage to the fourth evaporator stage.
  • ABE fermentation broth is fed into the first evaporator stage of the first VCD unit.
  • Components of ABE fermentation broth are evaporated in the first evaporator stage, forming a first residual solution in the first evaporator stage comprising water, dissolved salts, and organic matter, and a vapor which forms a first distillate in the first condenser stage comprising ABE at concentrations determined by the relative volatility differences between the components or any azeotropes formed between ABE components and water.
  • the first residual solution comprising predominantly water is removed from the first evaporator.
  • the first distillate is fed into the second evaporator stage of the second VCD unit.
  • the first distillate which comprises an ABE solution in water, is evaporated in the second evaporator stage, forming a second residual solution in the second evaporator stage comprising butanol, ethanol, and water, and a vapor which forms a second distillate in the second condenser stage comprising predominantly acetone.
  • the second distillate comprising predominantly acetone is removed from the second condenser.
  • the second residual solution is fed into the third evaporator stage of the third VCD unit.
  • the second residual solution which comprises predominantly butanol, ethanol and water, is evaporated in the third evaporator stage, forming a third residual solution in the third evaporator stage comprising predominantly butanol and water, and a vapor which forms a third distillate in the third condenser stage comprising substantially an ethanol and water azeotrope.
  • the third distillate comprising substantially an ethanol and water azeotrope is removed from the third condenser.
  • the third residual solution is fed into the fourth evaporator stage of the fourth VCD unit.
  • the third residual solution which comprises substantially butanol and water, is evaporated in the fourth evaporator stage, forming a fourth residual solution in the fourth evaporator stage comprising substantially butanol, and a vapor which forms a fourth distillate in the fourth condenser stage comprising substantially a butanol and water azeotrope.
  • the fourth residual solution comprising substantially butanol is removed from the fourth evaporator and the fourth distillate comprising substantially a butanol and water azeotrope is removed from the fourth condenser.
  • the VCD apparatus may be used in conjunction with alternative separation and recovery components. Such components are configured to separate a mixture by a separation method other than distillation. In some cases, mechanical separation components are used.
  • thermodynamic properties of the mostly butanol water mixture involve a phase separation of the liquid phases.
  • a mechanical separation device is a centrifuge.
  • Other methods of non-distillation separation include using a centrifugal contactor, coalescer, or any holding tank with sufficient time for settling.
  • Figure 4 shows the potential use of these components to assist the separation process.
  • a non-distillation separation technique may also be integrated with other techniques such as traditional distillation techniques, industrial chromatography, pervaporation and membrane techniques, adsorption and desorption techniques (such as molecular sieves), extractive fermentation techniques (such as liquid extraction and gas stripping), and extractive distillation techniques. Separation techniques may be integrated such that they can occur at several points along a separation process. In some cases, non-distillation separation techniques are used prior to distillation. Butanol and water mixtures form a heterogeneous azeotrope under certain conditions. In some cases, the fourth distillate from a multistage distillation process is removed to a decanter.
  • butanol and water mixtures may be separated into nearly pure components through the use of a decanter and two distillation columns.
  • One such column is aqueous (water) rich and the other is organic (butanol) rich.
  • the upper phase from the decanter is feed for the organic column and the lower phase becomes feed for the aqueous column.
  • the residual stream from the aqueous column is nearly pure water and the bottoms of the organic column is nearly pure butanol.
  • Fig. 9B and Fig. 4 show a modified multistage VCD device, which may be used to separate ABE fermentation broth according to an alternate flow path.
  • ABE fermentation broth is fed into the first evaporator stage of the first VCD unit.
  • Components of ABE fermentation broth are evaporated in the first evaporator stage, forming a first residual solution in the first evaporator stage comprising water, dissolved salts, and organic matter, and a vapor which forms a first distillate in the first condenser stage comprising ABE at concentrations determined by the relative volatility differences between the components or any azeotropes formed between ABE components and water.
  • the first residual solution comprising predominantly water is removed from the first evaporator.
  • the first distillate is fed into the second evaporator stage of the second VCD unit.
  • the first distillate which comprises an ABE solution in water, is evaporated in the second evaporator stage, forming a second residual solution in the second evaporator stage comprising butanol and water, and a vapor which forms a second distillate in the second condenser stage comprising predominantly acetone, ethanol, and/or an ethanol water azeotrope.
  • the second distillate is fed into the third evaporator stage of the third VCD unit.
  • the second distillate which comprises predominantly acetone, ethanol, and/or an ethanol water azeotope, is evaporated in the third evaporator stage, forming a third residual solution in the third evaporator stage comprising predominantly ethanol, and a vapor which forms a third distillate in the third condenser stage comprising substantially acetone.
  • the third residual solution comprising predominantly ethanol is removed from the third evaporator.
  • the third distillate comprising substantially acetone is removed from the third condenser.
  • the second residual solution is fed into the fourth evaporator stage of the fourth VCD unit.
  • the second residual solution which comprises substantially butanol, and water, is evaporated in the fourth evaporator stage, forming a fourth residual solution in the fourth evaporator stage comprising substantially butanol, and a vapor which forms a fourth distillate in the fourth condenser stage comprising substantially a butanol and water azeotrope.
  • the fourth residual solution comprising substantially butanol is removed from the fourth evaporator and the fourth distillate comprising substantially a butanol and water azeotrope is removed from the fourth condenser. In some cases, the fourth distillate is removed to a decanter.
  • Multistage VCD units have numerous applications including the isolation and/or purification of components of other fermentation broths or any multi-component solution.
  • Examples of fermentative products that can be isolated through the use of a multistage VCD unit include organic acids e.g., formate, acetate, lactate, pyruvate, butyrate, succinic, dicarboxylic acids, adipic acid, and amino acids, and solvents e.g., methanol, ethanol, propanol, butanol, butanone, iso-butanol, acetone, iso-propanol, 1,3 -propanediol, 2,3 -propanediol, acetaldehyde, butyraldehyde, 1,2-butanediol, 2,3-butanediol, 1,2,4-butanetriol, decanal, methyl- 1 -butanol, 3 -methyl- 1 -butanol, 2-
  • Fermentation broths can be produced by all manner of microorganisms including bacteria and fungi.
  • the term "fermentation broth” includes broths with products produced fementatively, metabolically, and synthetically, i.e., a genetically engineered synthetic pathway.
  • Bacteria covered by this invention include Gram-negative and Gram-positive bacteria.
  • Non-limiting examples of Gram-positive bacteria include bacteria found in the genera of Staphylococcus, Streptococcus, Bacillus, Mycobacterium, Enterococcus, Lactobacillus, Leuconostoc, Pediococcus, and Propionibacterium.
  • Gram-negative bacteria include bacteria found in the genera Pseudomonas, Zymomonas, Spirochaeta, Methylo sinus, Pantoea, Acetobacter, Gluconobacter, Escherichia and Erwinia.
  • the bacteria are strict anaerobes such as C. acetobutylicum.
  • the microorganisms are obligate anaerobes.
  • a non-limiting example of obligate anaerobes include Butyrivibrio f ⁇ rosolvens and Clostridium species such as C. pasteruianum.
  • the microorganisms are aerotolerant and are capable of surviving in the presence of small concentrations of oxygen.
  • the microorganisms are fungi and the fungi are yeasts. Examples of yeasts include, but are not limited to, Saccharomyces cerevisiae, S. bayanus, S.
  • anaerobic or aerotolerant fungi include, but are not limited to, the genera Neocallimastix, Caecomyces, Piromyces and other rumen derived anaerobic fungi.
  • Multistage VCD units can also be used in the place of distillation columns to separate components of an organic chemistry reaction including reactants, products and solvents. Additionally, multistage VCD units can be used to fractionate petroleum and petrochemicals.
  • a multistage VCD device comprises any number of VCD units, where each VCD unit comprises an evaporator stage and a condenser stage.
  • a multistage VCD device can be used to separate various initial solutions.
  • Each VCD unit has an incoming solution, which is distilled to form a residual solution and a distillate.
  • An incoming feed is received in an evaporator stage.
  • a residual solution is removed from an evaporator stage, and a distillate forms in and is removed from a condenser stage.
  • An incoming feed may be a residual solution or distillate removed from a VCD unit, or may come from an outside source.
  • An incoming solution is any solution to be distilled in the VCD unit. In some cases, vapor is removed from a condenser.
  • a multistage VCD device runs batch or continuous distillation.
  • a multistage VCD device comprises multiple VCD units where each VCD unit comprises an evaporator stage and a condenser stage.
  • a first VCD unit receives an initial solution, which is distilled to form a first residual solution in the evaporator stage and a first distillate in the condenser stage.
  • Either the first residual solution or the first distillate is transferred to a second VCD unit as a second incoming solution, which is received in the evaporator stage of the second VCD device.
  • the second VCD device distills the second incoming solution to form a second residual solution in the evaporator stage and a second distillate in the condenser stage.
  • Either the second residual solution or the second distillate is transferred to a third VCD unit as a third incoming solution, which is received in the evaporator stage of the third VCD device.
  • the third VCD device distills the third incoming solution to form a third residual solution in the evaporator stage and a third distillate in the condenser stage.
  • This process continues for any number of VCD units as are included in the VCD device. In some cases, vapor is removed from a condenser.
  • the residual solutions or distillates that are not transferred to another VCD unit are removed from the VCD device, in some cases after their heat has been transferred to other streams within the multistage VCD unit.
  • Solutions removed from an evaporator or condenser stage can be removed from the system or somehow reused in the system. For example, some solutions are removed from a VCD device and go into waste disposal. Alternatively, solutions are removed from a device as a desired product. Some solutions are fed back into the device as an incoming solution at any stage or VCD unit and are further distilled. Residual solutions or distillates from one VCD unit may be fed into any VCD unit of a VCD device. In one example, in a VCD device with three units, the residual solution of the first VCD unit is fed into the second VCD unit, and the distillate of the first VCD unit is fed into a third VCD unit.
  • a solution Another use for a solution is to use the heat from the solution to heat another incoming solution.
  • removed solutions such as spent fermentation broth
  • water, salts, and nutrients are recycled.
  • the vapor in the first, second, third, and fourth condensers are removed. Similar to removed solutions, the vapor is removed from the device as a waste or desired product. Alternatively, the vapor is somehow reused in the solution, whether it is somehow condensed elsewhere and brought in as an incoming solution, or used to heat a solution, etc.
  • compressed vapor from one stage is transferred to another stage's condenser.
  • compressed vapor from a first VCD unit can be transferred to a third VCD unit's condenser.
  • Vapor transfer occurs through any sort of conduit.
  • a conduit is any configuration that may enable a vapor to transfer from a first location to a second location.
  • vapor may be transferred through the use of lines, valves and controls.
  • Heat is transferred between one VCD unit and another VCD unit.
  • a VCD process there is sequential evaporation, vapor compression, and condensation processes, so that a prior VCD unit is earlier in the sequence than a subsequent VCD unit.
  • Heat is transferred between a prior VCD unit and a subsequent VCD unit.
  • heat is transferred between an immediately prior VCD unit and an immediately subsequent VCD unit, such as between a first VCD unit and a second VCD unit.
  • heat is transferred between VCD units that are not immediately prior or subsequent in the sequence, such as between a first VCD unit and a third VCD unit.
  • VCD units that are immediately prior or subsequent to one another in terms of sequence of steps may or may not be physically prior or subsequent to one another.
  • the VCD units may be arranged in any fashion so that any VCD unit transfers heat to another VCD unit within the multistage VCD device, thereby saving energy.
  • the device is configured to transfer heat from the condenser stage of a prior VCD unit to the evaporator stage of a subsequent VCD unit.
  • the condenser stage of a prior VCD unit is in thermal contact with a subsequent VCD unit.
  • a method of distilling a solution comprises the steps of providing a first VCD unit comprising a first evaporator and a first condenser and providing a second VCD unit comprising a second evaporator and a second condenser.
  • the method also includes the steps of receiving an initial solution in the first evaporator, distilling the solution from the first evaporator to produce a first distillate and a first residual solution and condensing the first distillate to the first condenser, and transferring heat from the first condenser to the second evaporator.
  • the method also comprises providing additional VCD units. Any number of VCD unit may be used.
  • Each VCD unit has an evaporator and condenser, such that each VCD unit receives an incoming solution in the evaporator and distills the incoming solution from the first evaporator to produce a distillate and residual solution, whereby the distillate is condensed in the condenser of the unit.
  • Heat is transferred from any of the condensers to the following evaporators.
  • the condensers and evaporators are in thermal contact with one another.
  • the method includes transferring heat from the condenser stage of a prior VCD unit to the evaporator stage of a subsequent VCD unit. Heat transfer occurs between VCD units that are or are not immediately prior and subsequent to one another.
  • the incoming solution comes from a prior VCD unit.
  • a prior VCD unit has at least one liquid conduit connecting either the evaporate stage or the condenser stage of the prior VCD unit with the evaporator stage of the subsequent vapor compression distillation unit.
  • the residual solution from a prior VCD unit feeds into the evaporator stage of a subsequent VCD unit.
  • a residual solution comprising butanol, ethanol and water from a second VCD unit feeds into the evaporator stage of a third VCD unit.
  • the distillate from a prior VCD unit feeds into the evaporator stage of a subsequent VCD unit.
  • a distillate comprising acetone, butanol, ethanol, water, and any associated azeotropes from a first VCD unit feeds into the evaporator stage of a second VCD unit.
  • a liquid conduit includes any configuration for transferring a liquid from a first location to a second location.
  • liquid conduits are formed of channels, pipes, lines, valves and controls.
  • Units can transfer heat from one another by being physically connected to one another. Physical connection enables heat by conduction.
  • One example of how units may are physically connected to one another is that they are affixed to one another along one side.
  • a VCD unit uses a plate type heat exchanger, which results in a first end of the VCD unit with an evaporator stage or chamber at the first end, and a second end of the VCD unit with a condenser stage or chamber at the second end, the second end of a prior VCD unit is bolted to the first end of a subsequent VCD unit. This allows transfer of heat from the condenser stage of the prior VCD unit to the evaporator stage of the subsequent VCD unit through conduction.
  • the ends of the VCD units are able to structurally support the VCD unit and enclose the chambers within the VCD unit.
  • Several examples of structures to form the end of the VCD units are solid plates, plates with gaps, pores, openings, or corrugations, plates of various shapes, ends with various flatness or curvature, or ends that are completely flat or that have protruding members and composite materials in which structural rigidity is maintained.
  • the structural ends may be connected by threaded rod or other tension providing connections in which a prescribed compression may be applied to the plate stack in a manner such as the frame elements of a plate and frame heat exchanger.
  • Multiple VCD elements may be mounted within the same frame structure.
  • the thermal and mechanical interconnection between VCD units can be carried out in any manner of ways. Independent
  • VCDs may be mounted and a mechanical contacting of two discrete endplates forms the thermal connection.
  • Independent VCDs may utilize a common endplate. Independent VCDs may have a prescribed spacing as defined by the tension elements to modulate the amount of heat transfer between adjacent end plates. Heat is transferred through the ends of the VCD units through the end structures. Ends are made of one or more materials capable of supporting the ends of the VCD units, such as metal (steel, aluminum, etc.), plastic, or glass. End materials are selected to enable desired heat transfer.
  • the second end of a prior VCD unit is in contact with a conductive material which is in contact with the first end of the subsequent VCD unit.
  • the conductive material is selected to allow a desired amount of heat transfer.
  • the conductive material covers the entire end of the VCD unit so that there are no gaps between.
  • the conductive material covers only portions of the ends of the VCD units, which allows parts of the ends of the VCD units that are exposed to air or pockets of air.
  • the conductive material is a corrugated material that includes channels that allow airflow.
  • VCD units may be in contact with any number of conductive materials.
  • a VCD unit is in contact with one material of a desired conductivity and structure, which is in contact with another material of desired conductivity and structure, which is in contact with another VCD unit.
  • the conductive materials may or may not be made of the same materials and may or may not have the same structure. In some cases, the use of multiple materials is desirable for heat transfer from one VCD unit to another to achieve the desired heat transfer characteristics.
  • VCD units are placed in contact either with one another or through intervening conductive materials through any number of techniques, such as bolting them together, clamping them together, applying pressure from external structures, applying an adhesive to the surfaces, or creating interlocking joints.
  • VCD units may also be in contact with one another through various arrangements. For example, rather than being arranged end to end, VCD units may be arranged side to side such that heat is transferred from the prior condenser stage to the subsequent evaporator stage. Likewise, in some cases, the units are arranged on top of one another.
  • FIG. 1 Another example of how units transfer heat from one another is through ambient heat transfer from units in close proximity to one another.
  • a VCD unit uses a plate type heat exchanger, which results in a first end of the VCD unit with an evaporator stage or chamber, and a second end of the VCD unit with a condenser stage or chamber, the second end of a prior VCD unit may be in close proximity to the first end of a subsequent VCD unit.
  • VCD unit through radiation
  • the ends of the VCD units are placed at a desired distance apart to allow a desired amount of ambient heat transfer. In some cases, the ends of the VCD units are within an enclosed space, so that there is little air flow over the ends of the VCD units. In other cases, the ends of the VCD units are in a more open space. As discussed later, the surfaces of the ends of the VCD units are treated or have properties to enable the desired amount of heat to be transferred.
  • the ends of the VCD devices have a mixture of conductive contact and open air spaces such that heat is transferred through a mixture of conduction and radiation.
  • the ends of VCD units are in contact with one another through conductive shapes, such as if there are bolts protruding from the ends of the units and contacting one another so that heat is transferred through conduction through the bolts.
  • there is space between the VCD units such that heat is transferred through radiation.
  • Finned structures may also be employed to increase heat transfer from the end plates or VCD edges to increase thermal energy transfer to/from the VCD unit to the ambient.
  • the VCD units may be integrated with a larger thermal reservoir to increase or decrease energy transfer.
  • the entire VCD apparatus may be submerged in a working fluid.
  • VCD units that allow ambient heat transfer from a prior condenser stage to a subsequent evaporator stage may be used.
  • Fig. 10 shows examples of heat transfer between two stages of a multistage VCD device where there is good thermal contact. Furthermore, in Fig. 4, good thermal contact leading to high conduction is shown between the four VCD stages. Fig. 4 is an exploded view and that in actuality, all VCD stages are physically touching. Good thermal contact is desired in situations where the VCD units have similar EC average temperatures. Good thermal contact is also useful to concentrate multiple component mixtures with similar boiling points, or to concentrate a simple mixture (i.e. water and ethanol) in a multieffect fashion.
  • a simple mixture i.e. water and ethanol
  • Good thermal contact may occur when heat is transferred by conduction.
  • two VCD units are in direct contact with one another, where the contact surfaces are highly thermally conductive.
  • a VCD unit is in contact with a material that is in contact with another VCD unit where the material is highly conductive.
  • a material with a desired conductivity level is used in order to obtain a desired heat transfer.
  • materials with high conductivity include metals or metal alloys, such as steel or aluminum.
  • Good thermal contact may also occur when heat is transferred by radiation.
  • two VCD units are in close proximity to one another, such that the ambient heat from one VCD unit is transferred to another VCD unit. Closer proximity allows a greater amount of heat transfer.
  • the proximity of the VCD units is chosen in order to obtain a desired heat transfer.
  • the surfaces of the VCD units that are in close proximity to one another are chosen to encourage radiation. For example, using a dark, non-reflective surface encourages heat absorption. In some cases, the surface is also chosen in order to obtain a desired heat transfer. Properties such as color, reflectivity, roughness, and the materials of the surfaces are varied.
  • Fig. 11 shows examples of heat transfer between two stages of a multistage VCD device where there is poor thermal contact. Poor thermal contact is desired in situations where the VCD units have different EC core average temperatures. Poor thermal contact is also useful to concentrate multiple component mixtures with different boiling points (i.e. to remove acetone from ABE fermentation broth), and subsequently to remove solvents from a remaining broth (i.e. at the second stage of ABE separation), and subsequently to remove water from a remaining broth (i.e. at the third stage of ABE separation).
  • Poor thermal contact may occur when heat is transferred by conduction.
  • two VCD units are in direct contact with one another, where the contact surfaces are made of poorly conductive material.
  • a VCD unit is in contact with a material that may be in contact with another VCD unit where the material is an insulator.
  • a material with a desired insulation level is used in order to obtain a desired heat transfer, including when the desired heat transfer is low.
  • the thickness of the material or contact surfaces are adjusted to achieve a desired amount of heat transfer. In some cases, thicker materials provide greater insulation.
  • increasing the number of layers of materials between one VCD unit and another VCD unit also decreases heat transfer. Any other factors that affect the heat transfer through conduction are adjusted to achieve the desired heat transfer.
  • Poor thermal contact may also occur when heat is transferred by radiation.
  • two VCD units are in proximity to one another, such that the ambient heat from one VCD unit is transferred to another VCD unit. Creating a greater space between the units allows a reduced amount of heat transfer.
  • the proximity of the VCD units is chosen in order to obtain a desired level of heat transfer.
  • the surfaces of the VCD units that are in proximity to one another can be chosen to discourage radiation. For example, using a light, reflective surface discourages heat absorption. The surfaces are also chosen in order to obtain a desired heat transfer. Any other factors that affect the heat transfer through radiation are adjusted to achieve the desired heat transfer.
  • Any methods of heat transfer may be used to transfer heat from the condenser stage of a VCD unit to the evaporator stage of another VCD unit. These methods are adjustable to achieve a desired level of heat transfer. For example, any of the methods discussed or a combination thereof may be used. The methods used between various VCD units may or may not be the same.
  • Fig. 12 shows several compressor configurations for a device with multiple VCD units.
  • a VCD unit evaporates the incoming solution, compresses the vapor, and sends the vapor to a condenser, where some of the vapor is condensed.
  • One or more compressors are used to compress the vapor and send the vapor to the condenser.
  • each VCD unit has its own compressor, where each compressor has its own drive shaft so that each compressor is able to operate independently of one another.
  • each VCD unit has its own compressor, where each compressor is connected to a common drive shaft. Only one motor is required to drive the common drive shaft.
  • the drive shaft operates each compressor, where each compressor is configured in order to administer the desired amount of compression for each
  • VCD unit This may occur by using different types or sizes of compressors.
  • Another example provides a multistage VCD device where one compressor is used for the entire device, instead of each unit having its own compressor.
  • the common compressor has a drive shaft.
  • the desired amount of compression for each unit is attained by using techniques such as valving. Different valves from the common compressor are used to attain different pressure changes.

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Vaporization, Distillation, Condensation, Sublimation, And Cold Traps (AREA)

Abstract

L'invention porte sur des systèmes et des procédés de distillation par compression de vapeur à plusieurs étages (VCD). Une pluralité d'unités VCD peuvent être combinées pour former un dispositif VCD, dans lequel la chaleur provenant d'une unité VCD précédente peut être transférée à une unité VCD suivante. Chaque unité VCD peut présenter un étage évaporateur et un étage condenseur, où la chaleur provenant de l'étage condenseur d'une unité VCD précédente peut être transférée à l'étage évaporateur de l'unité VCD suivante. La quantité de transfert de chaleur entre les unités peut être régulée. Un dispositif VCD à plusieurs étages peut être utilisé pour séparer un bouillon de fermentation acétone-butanol-éthanol.
PCT/US2010/032463 2009-04-28 2010-04-26 Distillation par compression de vapeur à plusieurs étages WO2010126848A1 (fr)

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US20160002131A1 (en) * 2013-02-21 2016-01-07 Butamax Advanced Biofuels Llc Vapor recompression
CN106693413B (zh) * 2017-03-07 2023-07-18 内蒙古碳谷科技有限公司 一种稳定的小流量液体蒸发装置及其蒸发工艺
US10823176B2 (en) 2018-08-08 2020-11-03 Fluid Handling Llc Variable speed pumping control system with active temperature and vibration monitoring and control means
CN113423666B (zh) * 2019-02-11 2023-10-27 阿曼特希股份有限公司 用于低成本水脱盐的完全再生蒸馏系统

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