Distillation process using microchannel technology

A process for distilling a fluid mixture in a microchannel distillation apparatus, the microchannel distillation apparatus comprising a plurality of microchannel distillation units, each microchannel distillation unit comprising a plurality of microchannel distillation sections, each microchannel distillation unit having one or more unit inlets, the microchannel distillation apparatus having an apparatus inlet and one more more channel inlets connecting the apparatus inlet to the unit inlets, each microchannel unit having a distillate end and a bottoms end, the fluid mixture comprising a more volatile component and a less volatile component, the process comprising:

• flowing a vapor phase through each microchannel distillation unit towards the distillate end of each microchannel distillation unit;
• flowing a liquid phase through each microchannel distillation unit towards the bottoms end of each microchannel distillation unit;
• flowing the fluid mixture through the apparatus inlet, channel inlets and unit inlets into the microchannel distillation units, part of the more volatile component transferring from the fluid mixture to the vapor phase to form a more volatile component rich vapor phase, part of the less volatile component transferring from the fluid mixture to the liquid phase to form a less volatile component rich liquid phase;
• flowing the more volatile component rich vapor phase through a plurality of the microchannel distillation sections in each microchannel distillation unit towards the distillate end of each microchannel distillation unit, the more volatile component rich vapor phase contacting the liquid phase in each microchannel distillation section and becoming enriched with the more volatile component;
• flowing the less volatile component rich liquid phase through a plurality of the microchannel distillation sections in each microchannel distillation unit towards the bottoms end of each microchannel distillation unit, the less volatile component rich liquid phase contacting the vapor phase in each microchannel distillation section and becoming enriched with the less volatile component.

A process for distilling a fluid mixture in a microchannel distillation unit, the microchannel distillation unit comprising at least one process microchannel and a plurality of microchannel distillation sections in the process microchannel, the process microchannel comprising an area to permit flow of the vapor phase and an area to permit flow of the liquid phase, the process microchannel having an interior wall in the area for vapor phase flow and an interior wall in the area for liquid phase flow, each of the walls being opposite each other and having surface features to enhance the mixing of the vapor phase with the liquid phase, the microchannel distillation unit having at least one feed inlet, the fluid mixture comprising a more volatile component and a less volatile component, the process comprising:

• flowing a vapor phase through the microchannel distillation unit in a first direction;
• flowing a liquid phase through the microchannel distillation unit in a second direction that is counter-current to the first direction;
• and
• flowing the fluid mixture through the feed inlet into at least one microchannel distillation section, part of the more volatile component transferring from the fluid mixture to the vapor phase to form a more volatile component rich vapor phase, part of the less volatile component transferring from the fluid mixture to the liquid phase to form a less volatile component rich liquid phase.

A process for distilling a fluid mixture in a microchannel distillation unit, the microchannel distillation unit comprising a plurality of microchannel distillation sections, the microchannel distillation unit having at least one feed inlet, the fluid mixture comprising a more volatile component and a less volatile component, the process comprising:

• flowing a vapor phase through the microchannel distillation unit in a first direction;
• flowing a liquid phase through the microchannel distillation unit in a second direction that is counter-current to the first direction;
• and
• flowing the fluid mixture through the feed inlet into at least one microchannel distillation section, part of the more volatile component transferring from the fluid mixture to the vapor phase to form a more volatile component rich vapor phase, part of the less volatile component transferring from the fluid mixture to the liquid phase to form a less volatile component rich liquid phase;
• the microchannel distillation sections having heat exchange channel zones thermally communicating with the microchannel distillation sections, a heat exchange fluid flowing in the heat exchange channel zones, the heat exchange fluid undergoing partial boiling in the heat exchange channel zones, the pressure of the heat exchange fluid in each of the heat exchange channel zones being different.

A process for distilling a fluid mixture in a microchannel distillation unit, the microchannel distillation unit comprising a plurality of microchannel distillation sections, the microchannel distillation unit having at least one feed inlet, the fluid mixture comprising a more volatile component and a less volatile component, the process comprising:

• flowing a vapor phase through the microchannel distillation unit in a first direction;
• flowing a liquid phase through the microchannel distillation unit in a second direction that is counter-current to the first direction;
• and
• flowing the fluid mixture through the feed inlet into at least one microchannel distillation section, part of the more volatile component transferring from the fluid mixture to the vapor phase to form a more volatile component rich vapor phase, part of the less volatile component transferring from the fluid mixture to the liquid phase to form a less volatile component rich liquid phase;
• the microchannel distillation sections having heat exchange channel zones thermally communicating with the microchannel distillation sections, a heat exchange fluid flowing in the heat exchange channel zones, the heat exchange fluid undergoing partial boiling in the heat exchange channel zones, the temperature in each microchannel distillation section being different.

A process for distilling a fluid mixture in a microchannel distillation unit, the microchannel distillation unit comprising a plurality of microchannel distillation sections, the microchannel distillation unit having at least one feed inlet, the fluid mixture comprising a more volatile component and a less volatile component, the process comprising:

• flowing a vapor phase through the microchannel distillation unit in a first direction;
• flowing a liquid phase through the microchannel distillation unit in a second direction that is counter-current to the first direction;
• and
• flowing the fluid mixture through the feed inlet into at least one microchannel distillation section, part of the more volatile component transferring from the fluid mixture to the vapor phase to form a more volatile component rich vapor phase, part of the less volatile component transferring from the fluid mixture to the liquid phase to form a less volatile component rich liquid phase;
• wherein the microchannel distillation unit is in a microchannel distillation assembly comprising a plurality of microchannel distillation units, some of the microchannel distillation units being active and some of the microchannel distillation units being inactive.

A process for distilling a fluid mixture in a microchannel distillation assembly, the microchannel distillation assembly comprising at least one microchannel distillation unit, the microchannel distillation unit comprising a plurality of microchannel distillation sections, the microchannel distillation unit having a feed inlet, a distillate end, and a bottoms end, the fluid mixture comprising a more volatile component and a less volatile component, the process comprising:

• flowing a vapor phase through the microchannel distillation unit towards the distillate end of the microchannel distillation unit;
• flowing a liquid phase through the microchannel distillation unit towards the bottoms end of the microchannel distillation unit;
• flowing the fluid mixture through the feed inlet for the microchannel distillation unit into at least one microchannel distillation section within the microchannel distillation unit, part of the more volatile component transferring from the fluid mixture to the vapor phase to form a more volatile component rich vapor phase, part of the less volatile component transferring from the fluid mixture to the liquid phase to form a less volatile component rich liquid phase;
• flowing the more volatile component rich vapor phase through a plurality of the microchannel distillation sections in the microchannel distillation unit towards the distillate end of the microchannel distillation unit, the more volatile component rich vapor phase contacting the liquid phase in each microchannel distillation section and becoming enriched with the more volatile component;
• flowing the less volatile component rich liquid phase through a plurality of the microchannel distillation sections in the microchannel distillation unit towards the bottoms end of each microchannel distillation unit, the less volatile component rich vapor liquid phase contacting the vapor phase in each microchannel distillation section and becoming enriched with the less volatile component;
• wherein each microchannel distillation section comprises a liquid region, a vapor region positioned above the liquid region, and a bubble cap tray positioned above the vapor region.

A process for distilling a fluid mixture in a microchannel distillation assembly, the microchannel distillation assembly comprising at least one microchannel distillation unit, the microchannel distillation unit comprising a plurality of microchannel distillation sections, the microchannel distillation unit having a feed inlet, a distillate end, and a bottoms end, the fluid mixture comprising a more volatile component and a less volatile component, the process comprising:

• flowing a vapor phase through the microchannel distillation unit towards the distillate end of the microchannel distillation unit;
• flowing a liquid phase through the microchannel distillation unit towards the bottoms end of the microchannel distillation unit;
• flowing the fluid mixture through the feed inlet for the microchannel distillation unit into at least one microchannel distillation section within the microchannel distillation unit, part of the more volatile component transferring from the fluid mixture to the vapor phase to form a more volatile component rich vapor phase, part of the less volatile component transferring from the fluid mixture to the liquid phase to form a less volatile component rich liquid phase;
• flowing the more volatile component rich vapor phase through a plurality of the microchannel distillation sections in the microchannel distillation unit towards the distillate end of the microchannel distillation unit, the more volatile component rich vapor phase contacting the liquid phase in each microchannel distillation section and becoming enriched with the more volatile component;
• flowing the less volatile component rich liquid phase through a plurality of the microchannel distillation sections in the microchannel distillation unit towards the bottoms end of each microchannel distillation unit, the less volatile component rich vapor liquid phase contacting the vapor phase in each microchannel distillation section and becoming enriched with the less volatile component;
• wherein each microchannel distillation section comprises a tray, the tray comprising a capture structure for collecting liquid and an opening for permitting the flow of the vapor phase through the tray.

A process for distilling a fluid mixture in a microchannel distillation assembly, the microchannel distillation assembly comprising at least one microchannel distillation unit, the microchannel distillation unit comprising a plurality of microchannel distillation sections, the microchannel distillation unit having a feed inlet, a distillate end, and a bottoms end, the fluid mixture comprising a more volatile component and a less volatile component, the process comprising:

• flowing a vapor phase through the microchannel distillation unit towards the distillate end of the microchannel distillation unit;
• flowing a liquid phase through the microchannel distillation unit towards the bottoms end of the microchannel distillation unit;
• flowing the fluid mixture through the feed inlet for the microchannel distillation unit into at least one microchannel distillation section within the microchannel distillation unit, part of the more volatile component transferring from the fluid mixture to the vapor phase to form a more volatile component rich vapor phase, part of the less volatile component transferring from the fluid mixture to the liquid phase to form a less volatile component rich liquid phase;
• flowing the more volatile component rich vapor phase through a plurality of the microchannel distillation sections in the microchannel distillation unit towards the distillate end of the microchannel distillation unit, the more volatile component rich vapor phase contacting the liquid phase in each microchannel distillation section and becoming enriched with the more volatile component;
• flowing the less volatile component rich liquid phase through a plurality of the microchannel distillation sections in the microchannel distillation unit towards the bottoms end of each microchannel distillation unit, the less volatile component rich vapor liquid phase contacting the vapor phase in each microchannel distillation section and becoming enriched with the less volatile component;
• wherein the microchannel distillation unit comprises at least one process microchannel, the process microchannel comprising an open area to permit flow of the vapor phase and a wicking region to permit flow of the liquid phase;
• wherein each microchannel distillation section comprises a liquid inlet for permitting liquid to flow into the open area from the wicking region, a liquid outlet for permitting liquid to flow out of the open area into the wicking region, 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;
• and
• wherein the capture structure comprises wire mesh.

A process for distilling a fluid mixture in a microchannel distillation assembly, the microchannel distillation assembly comprising at least one microchannel distillation unit, the microchannel distillation unit comprising a plurality of microchannel distillation sections, the microchannel distillation unit having a feed inlet, a distillate end, and a bottoms end, the fluid mixture comprising a more volatile component and a less volatile component, the process comprising:

• flowing a vapor phase through the microchannel distillation unit towards the distillate end of the microchannel distillation unit;
• flowing a liquid phase through the microchannel distillation unit towards the bottoms end of the microchannel distillation unit;
• flowing the fluid mixture through the feed inlet for the microchannel distillation unit into at least one microchannel distillation section within the microchannel distillation unit, part of the more volatile component transferring from the fluid mixture to the vapor phase to form a more volatile component rich vapor phase, part of the less volatile component transferring from the fluid mixture to the liquid phase to form a less volatile component rich liquid phase;
• flowing the more volatile component rich vapor phase through a plurality of the microchannel distillation sections in the microchannel distillation unit towards the distillate end of the microchannel distillation unit, the more volatile component rich vapor phase contacting the liquid phase in each microchannel distillation section and becoming enriched with the more volatile component;
• flowing the less volatile component rich liquid phase through a plurality of the microchannel distillation sections in the microchannel distillation unit towards the bottoms end of each microchannel distillation unit, the less volatile component rich vapor liquid phase contacting the vapor phase in each microchannel distillation section and becoming enriched with the less volatile component;
• wherein the microchannel distillation unit comprises at least one process microchannel, the process microchannel comprising an open area to permit flow of the vapor phase and a wicking region to permit flow of the liquid phase;
• wherein each microchannel distillation section comprises a liquid inlet for permitting liquid to flow into the open area from the wicking region, a liquid outlet for permitting liquid to flow out of the open area into the wicking region, 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;
• and
• wherein the capture structure comprises one or more inverted cones, liquid-nonwetting porous structures, liquid-wetting porous structures, perforated foils, fibers, or a combination of two or more thereof.

A process for distilling a fluid mixture in a microchannel distillation assembly, the microchannel distillation assembly comprising at least one microchannel distillation unit, the microchannel distillation unit comprising a plurality of microchannel distillation sections, the microchannel distillation unit having a feed inlet, a distillate end, and a bottoms end, the fluid mixture comprising a more volatile component and a less volatile component, the process comprising:

• flowing a vapor phase through the microchannel distillation unit towards the distillate end of the microchannel distillation unit;
• flowing a liquid phase through the microchannel distillation unit towards the bottoms end of the microchannel distillation unit;
• flowing the fluid mixture through the feed inlet for the microchannel distillation unit into at least one microchannel distillation section within the microchannel distillation unit, part of the more volatile component transferring from the fluid mixture to the vapor phase to form a more volatile component rich vapor phase, part of the less volatile component transferring from the fluid mixture to the liquid phase to form a less volatile component rich liquid phase;
• flowing the more volatile component rich vapor phase through a plurality of the microchannel distillation sections in the microchannel distillation unit towards the distillate end of the microchannel distillation unit, the more volatile component rich vapor phase contacting the liquid phase in each microchannel distillation section and becoming enriched with the more volatile component;
• flowing the less volatile component rich liquid phase through a plurality of the microchannel distillation sections in the microchannel distillation unit towards the bottoms end of each microchannel distillation unit, the less volatile component rich vapor liquid phase contacting the vapor phase in each microchannel distillation section and becoming enriched with the less volatile component;
• wherein the microchannel distillation unit comprises at least one process microchannel and at least one heat exchange channel;
• wherein an exothermic process is conducted in the heat exchange channel, the exothermic process comprising a water-gas shift reaction, a methanol synthesis reaction or an ammonia synthesis reaction.

A process for distilling a fluid mixture in a microchannel distillation assembly, the microchannel distillation assembly comprising at least one microchannel distillation unit, the microchannel distillation unit comprising a plurality of microchannel distillation sections, the microchannel distillation unit having a feed inlet, a distillate end, and a bottoms end, the fluid mixture comprising a more volatile component and a less volatile component, the process comprising:

• flowing a vapor phase through the microchannel distillation unit towards the distillate end of the microchannel distillation unit;
• flowing a liquid phase through the microchannel distillation unit towards the bottoms end of the microchannel distillation unit;
• flowing the fluid mixture through the feed inlet for the microchannel distillation unit into at least one microchannel distillation section within the microchannel distillation unit, part of the more volatile component transferring from the fluid mixture to the vapor phase to form a more volatile component rich vapor phase, part of the less volatile component transferring from the fluid mixture to the liquid phase to form a less volatile component rich liquid phase;
• flowing the more volatile component rich vapor phase through a plurality of the microchannel distillation sections in the microchannel distillation unit towards the distillate end of the microchannel distillation unit, the more volatile component rich vapor phase contacting the liquid phase in each microchannel distillation section and becoming enriched with the more volatile component;
• flowing the less volatile component rich liquid phase through a plurality of the microchannel distillation sections in the microchannel distillation unit towards the bottoms end of each microchannel distillation unit, the less volatile component rich vapor liquid phase contacting the vapor phase in each microchannel distillation section and becoming enriched with the less volatile component;
• wherein the microchannel distillation unit comprises at least one process microchannel and at least one heat exchange channel;
• wherein an endothermic process is conducted in the heat exchange channel, the endothermic reaction comprising a steam reforming process or dehydrogenation process.

A process for distilling a fluid mixture in a microchannel distillation assembly, the microchannel distillation assembly comprising at least one microchannel distillation unit, the microchannel distillation unit comprising a plurality of microchannel distillation sections, the microchannel distillation unit having a feed inlet, a distillate end, and a bottoms end, the fluid mixture comprising a more volatile component and a less volatile component, the process comprising:

• flowing a vapor phase through the microchannel distillation unit towards the distillate end of the microchannel distillation unit;
• flowing a liquid phase through the microchannel distillation unit towards the bottoms end of the microchannel distillation unit;
• flowing the fluid mixture through the feed inlet for the microchannel distillation unit into at least one microchannel distillation section within the microchannel distillation unit, part of the more volatile component transferring from the fluid mixture to the vapor phase to form a more volatile component rich vapor phase, part of the less volatile component transferring from the fluid mixture to the liquid phase to form a less volatile component rich liquid phase;
• flowing the more volatile component rich vapor phase through a plurality of the microchannel distillation sections in the microchannel distillation unit towards the distillate end of the microchannel distillation unit, the more volatile component rich vapor phase contacting the liquid phase in each microchannel distillation section and becoming enriched with the more volatile component;
• flowing the less volatile component rich liquid phase through a plurality of the microchannel distillation sections in the microchannel distillation unit towards the bottoms end of each microchannel distillation unit, the less volatile component rich vapor liquid phase contacting the vapor phase in each microchannel distillation section and becoming enriched with the less volatile component;
• wherein the microchannel distillation sections have heat exchange channel zones thermally communicating with the microchannel distillation sections, a heat exchange fluid flows in the heat exchange channel zones, the heat exchange fluid undergoes partial boiling in the heat exchange channel zones, the pressure of the heat exchange fluid in each of the heat exchange channel zones being different.

A process for distilling a fluid mixture in a microchannel distillation assembly, the microchannel distillation assembly comprising at least one microchannel distillation unit, the microchannel distillation unit comprising a plurality of microchannel distillation sections, the microchannel distillation unit having a feed inlet, a distillate end, and a bottoms end, the fluid mixture comprising a more volatile component and a less volatile component, the process comprising:

• flowing a vapor phase through the microchannel distillation unit towards the distillate end of the microchannel distillation unit;
• flowing a liquid phase through the microchannel distillation unit towards the bottoms end of the microchannel distillation unit;
• flowing the fluid mixture through the feed inlet for the microchannel distillation unit into at least one microchannel distillation section within the microchannel distillation unit, part of the more volatile component transferring from the fluid mixture to the vapor phase to form a more volatile component rich vapor phase, part of the less volatile component transferring from the fluid mixture to the liquid phase to form a less volatile component rich liquid phase;
• flowing the more volatile component rich vapor phase through a plurality of the microchannel distillation sections in the microchannel distillation unit towards the distillate end of the microchannel distillation unit, the more volatile component rich vapor phase contacting the liquid phase in each microchannel distillation section and becoming enriched with the more volatile component;
• flowing the less volatile component rich liquid phase through a plurality of the microchannel distillation sections in the microchannel distillation unit towards the bottoms end of each microchannel distillation unit, the less volatile component rich vapor liquid phase contacting the vapor phase in each microchannel distillation section and becoming enriched with the less volatile component;
• wherein the microchannel distillation sections have heat exchange channel zones thermally communicating with the microchannel distillation sections, a heat exchange fluid flows in the heat exchange channel zones, the heat exchange fluid undergoes partial boiling in the heat exchange channel zones, the temperature in each microchannel distillation section being different.

A process for distilling a fluid mixture in a microchannel distillation unit, the microchannel distillation unit comprising at least one microchannel distillation section, the microchannel distillation unit having at least one feed inlet, the fluid mixture comprising a more volatile component and a less volatile component, the process comprising:

• flowing the fluid mixture through the feed inlet into the microchannel distillation unit;
• flowing a vapor phase of the fluid mixture through the microchannel distillation unit in a first direction;
• flowing a liquid phase of the fluid mixture through the microchannel distillation unit in a second direction that is counter-current to the first direction;
• flowing the vapor phase and the liquid phase in the at least one microchannel distillation section and changing the direction of flow of either the vapor phase or the liquid phase in the microchannel distillation section to provide for the flow of the vapor phase and the liquid phase in the same direction;
• and
• contacting the vapor phase and the liquid phase in the microchannel distillation section, 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.

A process for distilling a fluid mixture in a microchannel distillation unit, the microchannel distillation unit comprising a plurality of microchannel distillation sections, the microchannel distillation unit having at least one feed inlet, the feed inlet comprising a feed inlet channel positioned adjacent to and parallel to the microchannel distillation unit, the microchannel distillation unit comprising a plurality of feed openings to permit the flow of the fluid mixture from the feed inlet channel through the feed openings into at least one microchannel distillation section, the fluid mixture comprising a more volatile component and a less volatile component, the process comprising:

• flowing a vapor phase through the microchannel distillation unit in a first direction;
• flowing a liquid phase through the microchannel distillation unit in a second direction that is counter-current to the first direction;
• and
• flowing the fluid mixture from the feed inlet channel through the feed openings into the at least one microchannel distillation section, part of the more volatile component transferring from the fluid mixture to the vapor phase to form a more volatile component rich vapor phase, part of the less volatile component transferring from the fluid mixture to the liquid phase to form a less volatile component rich liquid phase;
• wherein a barrier wall is positioned in the at least one microchannel distillation section, the fluid mixture flowing into the microchannel distillation section contacting the barrier wall, the direction of flow of the fluid mixture changing from being orthogonal to the flow of the vapor phase to being aligned with the flow of the vapor phase.

A process for distilling a fluid mixture in a microchannel distillation apparatus, the microchannel distillation apparatus comprising a plurality of microchannel distillation units, each microchannel distillation unit comprising a plurality of microchannel distillation sections, each microchannel distillation unit having one or more unit inlets, the microchannel distillation apparatus having an apparatus inlet and one more more channel inlets connecting the apparatus inlet to the unit inlets, each microchannel unit having a distillate end and a bottoms end, the fluid mixture comprising a more volatile component and a less volatile component, the process comprising:

• flowing a vapor phase through each microchannel distillation unit towards the distillate end of each microchannel distillation unit;
• flowing a liquid phase through each microchannel distillation unit towards the bottoms end of each microchannel distillation unit;
• flowing the fluid mixture through the apparatus inlet, channel inlets and unit inlets into the microchannel distillation units, part of the more volatile component transferring from the fluid mixture to the vapor phase to form a more volatile component rich vapor phase, part of the less volatile component transferring from the fluid mixture to the liquid phase to form a less volatile component rich liquid phase;
• flowing the more volatile component rich vapor phase through a plurality of the microchannel distillation sections in each microchannel distillation unit towards the distillate end of each microchannel distillation unit, the more volatile component rich vapor phase contacting the liquid phase in each microchannel distillation section and becoming enriched with the more volatile component;
• flowing the less volatile component rich liquid phase through a plurality of the microchannel distillation sections in each microchannel distillation unit towards the bottoms end of each microchannel distillation unit, the less volatile component rich liquid phase contacting the vapor phase in each microchannel distillation section and becoming enriched with the less volatile component;
• wherein the gas to liquid Reynolds number is in the range from about 500×(Suratmann Number)−0.67 to about 4500×(Suratmann Number)−0.67.