Distillation process using microchannel technology

A process for distilling a fluid mixture in a microchannel distillation unit, the microchannel distillation unit comprising a plurality of microchannel distillation sections, the fluid mixture comprising a more volatile component and a less volatile component, the process comprising:

• flowing a vapor phase of the fluid mixture in a first microchannel distillation section in contact with a liquid phase of the fluid mixture, part of the more volatile component transferring from the liquid phase to the vapor phase to form a more volatile component rich vapor phase, part of the less volatile component transferring from the vapor phase to the liquid phase to form a less volatile component rich liquid phase;
• separating the more volatile component rich vapor phase from the less volatile component rich liquid phase;
• flowing the less volatile component rich liquid phase to another microchannel distillation section upstream from the first microchannel distillation section;
• and
• flowing the more volatile rich vapor phase to another microchannel distillation section downstream from the first microchannel distillation section;
• wherein each microchannel distillation section comprises at least one process microchannel and at least one adjacent liquid channel, the liquid channel comprising a wicking region;
• and
• wherein for each microchannel distillation section the process microchannel comprises a liquid inlet for permitting liquid to flow into the process microchannel, a liquid outlet for permitting liquid to flow out of the process microchannel, an interior wall extending from the liquid inlet to the liquid outlet;
• and a capture structure, the liquid outlet being downstream from the liquid inlet.

A process for distilling a fluid mixture in a microchannel distillation unit, the microchannel distillation unit comprising a plurality of microchannel distillation sections, the fluid mixture comprising a more volatile component and a less volatile component, the process comprising:

• flowing a vapor phase of the fluid mixture in a first microchannel distillation section in contact with a liquid phase of the fluid mixture, part of the more volatile component transferring from the liquid phase to the vapor phase to form a more volatile component rich vapor phase, part of the less volatile component transferring from the vapor phase to the liquid phase to form a less volatile component rich liquid phase;
• separating the more volatile component rich vapor phase from the less volatile component rich liquid phase;
• flowing the less volatile component rich liquid phase to another microchannel distillation section upstream from the first microchannel distillation section;
• and
• flowing the more volatile rich vapor phase to another microchannel distillation section downstream from the first microchannel distillation section;
• wherein each microchannel distillation section comprises a liquid channel, a first process microchannel, a second process microchannel, a first vapor channel, a second vapor channel, a third vapor channel, a vapor inlet and a vapor outlet, the first process microchannel and the second process microchannel being adjacent to the liquid channel, the liquid channel comprising a wicking region, part of the wicking region forming a wall of the first process microchannel and a wall of the second process microchannel,
• the liquid phase flowing through the wicking region,
• the vapor phase flowing through the vapor inlet into the first vapor channel, through the first vapor channel into the first process microchannel, through the first process microchannel in contact with at least part of the liquid phase in the wicking region, from the first process microchannel into the second vapor channel, through the second vapor channel into the second process microchannel, through the second process microchannel in contact with at least part of the liquid phase in the wicking region, from the second process microchannel into the third vapor channel, and through the third vapor channel into the vapor outlet.

A process for distilling a fluid mixture in a microchannel distillation unit, the microchannel distillation unit comprising a plurality of microchannel distillation sections, the fluid mixture comprising a more volatile component and a less volatile component, the process comprising:

• flowing a vapor phase of the fluid mixture in a first microchannel distillation section in contact with a liquid phase of the fluid mixture, part of the more volatile component transferring from the liquid phase to the vapor phase to form a more volatile component rich vapor phase, part of the less volatile component transferring from the vapor phase to the liquid phase to form a less volatile component rich liquid phase;
• separating the more volatile component rich vapor phase from the less volatile component rich liquid phase;
• flowing the less volatile component rich liquid phase to another microchannel distillation section upstream from the first microchannel distillation section;
• and
• flowing the more volatile rich vapor phase to another microchannel distillation section downstream from the first microchannel distillation section;
• wherein each microchannel distillation section comprises at least one process microchannel and at least one adjacent liquid channel, the liquid channel comprising a wicking region, the wicking region comprising a wicking surface, the wicking surface comprising grooves in one or more interior walls of the liquid channel;
• and
• wherein the grooves are aligned parallel to the direction of flow of the vapor phase in the process microchannel.

A process for distilling a fluid mixture in a microchannel distillation unit, the microchannel distillation unit comprising a plurality of microchannel distillation sections, the fluid mixture comprising a more volatile component and a less volatile component, the process comprising:

• flowing a vapor phase of the fluid mixture in a first microchannel distillation section in contact with a liquid phase of the fluid mixture, part of the more volatile component transferring from the liquid phase to the vapor phase to form a more volatile component rich vapor phase, part of the less volatile component transferring from the vapor phase to the liquid phase to form a less volatile component rich liquid phase;
• separating the more volatile component rich vapor phase from the less volatile component rich liquid phase;
• flowing the less volatile component rich liquid phase to another microchannel distillation section upstream from the first microchannel distillation section;
• and
• flowing the more volatile rich vapor phase to another microchannel distillation section downstream from the first microchannel distillation section;
• wherein each microchannel distillation section comprises at least one process microchannel and at least one adjacent liquid channel, the liquid channel comprising a wicking region, the wicking region comprising a wicking surface, the wicking surface comprising grooves in one or more interior walls of the liquid channel;
• and
• wherein the grooves are aligned tangentially to the direction of flow of the vapor phase in the process microchannel.

A process for distilling a fluid mixture in a microchannel distillation unit, the microchannel distillation unit comprising a process microchannel and an adjacent liquid channel, the fluid mixture comprising a more volatile component and a less volatile component, the process comprising:

• flowing a vapor phase of the fluid mixture in one direction through the process microchannel, the process microchannel comprising a plurality of microchannel distillation sections, each microchannel distillation section comprising an internal space for permitting vapor flow, an interior wall, a capture structure, a liquid inlet and a liquid outlet, the capture structure and the liquid outlet being downstream from the liquid inlet, the interior wall extending from the liquid inlet to the liquid outlet, the capture structure being suitable for capturing liquid and permitting vapor to flow through it, the liquid outlet being suitable for permitting the flow of the liquid from the capture structure through the liquid outlet into the liquid channel, the liquid inlet being suitable for permitting liquid to flow from the liquid channel into the process microchannel;
• flowing a liquid phase of the fluid mixture through the liquid channel in a direction opposite to the direction of flow of the vapor phase in the process microchannel, the liquid channel including a wicking region, the liquid phase flowing through the wicking region;
• the liquid phase flowing from the liquid channel through the liquid inlet in a first microchannel distillation section of the process microchannel and flowing as a thin film along the interior wall to the capture structure within the first microchannel distillation section, the vapor phase flowing through the first microchannel distillation section in contact with the liquid phase flowing along the interior wall, part of the more volatile component transferring from the liquid phase to the vapor phase to form a more volatile component rich vapor phase, part of the less volatile component transferring from the vapor phase to the liquid phase to form a less volatile component rich liquid phase, the less volatile component rich liquid phase contacting the capture structure and flowing from the capture structure through the liquid outlet of the first microchannel distillation section into the liquid channel, the more volatile component rich vapor phase flowing through the capture structure of the first microchannel distillation section.

A process for distilling a fluid mixture in a distillation apparatus comprising a plurality of microchannel distillation units, each microchannel distillation unit comprising a plurality of microchannel distillation sections, each microchannel distillation section comprising a liquid inlet and liquid outlet and a vapor inlet and vapor outlet, the fluid mixture comprising a more volatile component and a less volatile component, the process comprising:

• flowing a vapor phase of the fluid mixture in the first microchannel distillation section of at least one microchannel distillation unit in contact with a liquid phase of the fluid mixture, part of the more volatile component transferring from the liquid phase to the vapor phase to form a more volatile component rich vapor phase, part of the less volatile component transferring from the vapor phase to the liquid phase to form a less volatile component rich liquid phase;
• separating the more volatile component rich vapor phase from the less volatile component rich liquid phase;
• flowing the less volatile component rich liquid phase to the another microchannel distillation section in the microchannel distillation unit upstream from the first microchannel distillation section;
• and
• flowing the more volatile rich vapor phase to the another microchannel distillation section in the microchannel distillation unit downstream from the first microchannel distillation section.

A process for distilling a fluid mixture in a distillation apparatus comprising a plurality of microchannel distillation units, each microchannel distillation unit comprising a plurality of microchannel distillation sections, the fluid mixture comprising a more volatile component and a less volatile component, the process comprising:

• flowing a vapor phase of the fluid mixture in a first microchannel distillation section of at least one microchannel distillation unit in contact with a liquid phase of the fluid mixture, part of the more volatile component transferring from the liquid phase to the vapor phase to form a more volatile component rich vapor phase, part of the less volatile component transferring from the vapor phase to the liquid phase to form a less volatile component rich liquid phase;
• separating the more volatile component rich vapor phase from the less volatile component rich liquid phase;
• flowing the less volatile component rich liquid phase to another microchannel distillation section in the microchannel distillation unit upstream from the first microchannel distillation section;
• flowing the more volatile rich vapor phase to another microchannel distillation section in the microchannel distillation unit downstream from the first microchannel distillation section;
• and
• wherein the distillation process is conducted in some but not all of the microchannel distillation units in the distillation apparatus.

A microchannel distillation unit, comprising:

• a process microchannel and a liquid channel;
• the liquid channel being adjacent to the process microchannel, the liquid channel comprising a wicking region;
• the process microchannel comprising a plurality of microchannel distillation sections, each microchannel distillation section comprising an internal space for permitting vapor flow, an interior wall for permitting liquid to flow as a thin film along the interior wall, a capture structure for capturing liquid and permitting vapor to flow through it, a liquid outlet for permitting liquid to flow from the capture structure into the liquid channel, and a liquid inlet for permitting liquid to flow from the liquid channel into the process microchannel;
• and
• wherein the microchannel distillation unit further comprises a heat exchange channel adjacent to the liquid channel, the process microchannel, or both the liquid channel and the process microchannel.

A process for distilling a fluid mixture in a microchannel distillation unit, the microchannel distillation unit comprising a plurality of microchannel distillation sections, the fluid mixture comprising a more volatile component and a less volatile component, the process comprising:

• flowing a vapor phase of the fluid mixture in a first microchannel distillation section in contact with a liquid phase of the fluid mixture, the first microchannel distillation section comprising at least one process microchannel and at least one liquid channel, the vapor phase and part of the liquid phase flowing in the process microchannel in a first direction, part of the liquid phase flowing in the liquid channel in a second direction, the first direction being counter-current to the second direction, part of the more volatile component transferring from the liquid phase to the vapor phase to form a more volatile component rich vapor phase, part of the less volatile component transferring from the vapor phase to the liquid phase to form a less volatile component rich liquid phase;
• separating the more volatile component rich vapor phase from the less volatile component rich liquid phase;
• flowing the less volatile component rich liquid phase to another microchannel distillation section upstream from the first microchannel distillation section;
• and
• flowing the more volatile rich vapor phase to another microchannel distillation section downstream from the first microchannel distillation section.

A process for distilling a fluid mixture in a microchannel distillation unit, the microchannel distillation unit comprising a plurality of microchannel distillation sections, the fluid mixture comprising a more volatile component and a less volatile component, the process comprising:

• flowing a vapor phase of the fluid mixture in a first microchannel distillation section in contact with a liquid phase of the fluid mixture, part of the more volatile component transferring from the liquid phase to the vapor phase to form a more volatile component rich vapor phase, part of the less volatile component transferring from the vapor phase to the liquid phase to form a less volatile component rich liquid phase;
• separating the more volatile component rich vapor phase from the less volatile component rich liquid phase;
• flowing the less volatile component rich liquid phase to another microchannel distillation section upstream from the first microchannel distillation section;
• and
• flowing the more volatile rich vapor phase to another microchannel distillation section downstream from the first microchannel distillation section;
• wherein for each microchannel distillation section the process microchannel comprises a liquid inlet for permitting liquid to flow into the process microchannel, a liquid outlet for permitting liquid to flow out of the process microchannel, an interior wall extending from the liquid entrance to the liquid exit, and a capture structure, the liquid outlet being downstream from the liquid inlet;
• and
• wherein the microchannel distillation unit further comprises a first supplemental vapor channel and a second supplemental vapor channel, each microchannel distillation section further comprising a supplemental vapor inlet and a supplemental vapor outlet, part of the vapor phase flowing from the first supplemental vapor channel through the supplemental vapor inlet into the microchannel distillation section, through the microchannel distillation section in contact with the liquid phase, and through the supplemental vapor outlet to the second supplemental vapor channel.

A microchannel distillation unit, comprising:

• a process microchannel and a liquid channel;
• the liquid channel being adjacent to the process microchannel, the liquid channel comprising a wicking region;
• the process microchannel comprising a plurality of microchannel distillation sections, each microchannel distillation section comprising an internal space for permitting vapor flow, an interior wall for permitting liquid to flow as a thin film along the interior wall, a capture structure for capturing liquid and permitting vapor to flow through it, a liquid outlet for permitting liquid to flow from the capture structure into the liquid channel, and a liquid inlet for permitting liquid to flow from the liquid channel into the process microchannel;
• wherein the microchannel distillation unit further comprises a first supplemental vapor channel and a second supplemental vapor channel, and each microchannel distillation section further comprises a supplemental vapor inlet and a supplemental vapor outlet, the first supplemental vapor channel and the supplemental vapor inlet being suitable for permitting vapor to flow from the first supplemental vapor channel into the microchannel distillation section, the second supplemental vapor channel and the supplemental vapor outlet being suitable for permitting vapor to flow from the microchannel distillation section to second supplemental vapor channel.