A static mixing reactor

Abstract

The application relates to a static mixing reactor, which comprises a jacketed cylinder 4, a reactor upper head 13, a reactor inner cylinder 3, and a reactor lower head 26; the reactor upper head is arranged at the top of the reactor inner cylinder 3; the reactor inner cylinder is arranged in the jacketed cylinder; and the reactor lower head 26 is arranged at the lower end of the reactor inner cylinder 3. The static mixing reactor has the advantages of small energy consumption, high heat exchange efficiency, reduced resistance, compact structure and easy large-scale production; the static mixing reactor can achieve the maximum mixing in the plane perpendicular to the flowing direction of the reactant, can realize temperature division of the reaction area, and can reduce the problems of wall sticking, blockage and explosive polymerization of the reactor.

Description

Technical Field

[0001] This invention relates to a static mixing reactor, and more particularly to a static mixing reactor suitable for various polymers, especially for solution polymerization and bulk polymerization of high-viscosity reaction liquids such as ABS, POE, and polybutene-1. Background Technology

[0002] (I) Technical solutions of existing technologies

[0003] ABS plastic is a terpolymer of acrylonitrile (A), butadiene (B), and styrene (S). It combines the properties of all three components: acrylonitrile provides high hardness and strength, heat resistance, and corrosion resistance; butadiene provides impact resistance and toughness; and styrene provides high gloss, easy coloring, and easy processing. These characteristics make ABS plastic a thermoplastic with excellent overall performance, characterized by its strength, toughness, and rigidity, and it is widely used in automotive, electronics, office and communication equipment, and other fields.

[0004] Currently, the main industrial production methods for ABS resin include emulsion grafting-bulk SAN blending and continuous bulk polymerization. The emulsion grafting-bulk SAN blending method involves preparing polybutadiene latex through butadiene emulsion polymerization, followed by grafting polymerization with a certain amount of styrene and acrylonitrile to obtain ABS grafted powder. This ABS grafted powder is then blended with SAN resin in a specific ratio to obtain the ABS resin product. While the emulsion grafting-bulk SAN blending method produces a wide variety of products with excellent performance, it is an intermittent process with numerous control points, complex post-processing, low product cleanliness, and generates large amounts of wastewater that is difficult to treat, resulting in severe environmental pollution. With increasingly stringent national environmental protection requirements for enterprises, the industrial application of the emulsion grafting-bulk SAN blending method is becoming increasingly restricted, while continuous bulk polymerization is gradually becoming the preferred technology for newly built plants in China.

[0005] Continuous bulk polymerization involves dissolving toughening rubber components in styrene, acrylonitrile, and a solvent in a specific ratio. The resulting solution is then subjected to a graft polymerization process via free radical reaction under controlled temperatures and with the aid of an initiator and molecular weight regulator. The final ABS resin product is obtained through devolatilization and granulation. This continuous bulk polymerization process utilizes a multi-stage, series-connected polymerization system, resulting in a simple and compact production process. The ABS resin product exhibits high cleanliness and is characterized by low waste, minimal pollution, and environmental friendliness.

[0006] Existing technologies for bulk polymerization of ABS resin primarily employ two types of reactors: continuous stirred tank reactors (CSTRs) and stirrered plug flow reactors (stir-PFRs). Mitsui Toya Chemical Co., Ltd.'s multi-stage series continuous stirred tank reactor (CSTR) exhibits varying residence times, with a loading coefficient typically less than 75%, resulting in non-full-bottle operation. This leads to a wide molecular weight distribution, a yellowish color, and poor performance in the produced ABS product. In contrast, Dow Chemical's multi-stage series plug flow reactor (stir-PFR), exemplified by its use in Dow Chemical, ensures uniform residence times, operates at full capacity, mitigates reactor wall adhesion issues, and produces products with better performance and color. However, multi-stage series plug flow reactors suffer from low rubber grafting efficiency, inflexible product variety, and significant process fluctuations at each reactor stage due to delayed heat removal, resulting in poor system stability and the potential for explosive polymerization.

[0007] In the continuous bulk polymerization process for producing ABS resin, uniform mixing of reactants, removal of heat of reaction, and prevention of reactor wall adhesion are crucial. As the polymerization reaction proceeds, the high viscosity of the reactants often makes uniform mixing and heat removal in the polymerization reactor extremely difficult, easily leading to polymer adhesion and blockage. Current technologies rely on agitators to achieve uniform mixing and improve heat transfer, increasing surface renewal frequency and reducing wall adhesion. However, to achieve better mass and heat transfer, existing ABS bulk polymerization processes require high-power agitators, resulting in high equipment investment and maintenance costs. Therefore, there is a need to develop a polymerization reactor with low energy consumption, high production efficiency, compact structure, fast surface renewal frequency, good mass and heat transfer efficiency, and controllable temperature to meet the production requirements of high-viscosity polymerization reactants such as ABS, POE, and polybutene-1. Summary of the Invention

[0008] (a) Technical problems to be solved

[0009] To address the aforementioned problems in existing technologies, this invention provides a static mixing reactor that features low energy consumption, high heat exchange efficiency, reduced resistance, compact structure, and ease of large-scale development. This static mixing reactor achieves maximum mixing on a plane perpendicular to the flow direction of the reactants, enabling temperature segmentation of the reaction zone and reducing problems such as reactor wall adhesion, blockage, and explosive polymerization. It is particularly suitable for high-viscosity reaction systems such as ABS, POE, and polybutene-1.

[0010] (II) Technical Solution

[0011] To achieve the above objectives, the present invention adopts the following technical solution:

[0012] A static mixing reactor of the present invention includes an upper reactor head 13, an inner reactor cylinder 3, a lower reactor head 26, a jacketed upper head 15, a jacketed cylinder 4, a jacketed lower head 27, and a heat exchange piping system; the upper reactor head 13 is provided with a reactant inlet 17, a central tube heat transfer oil inlet 16, a jacketed heat transfer oil 1 outlet 18, and a heat transfer oil 1 outlet (19); the jacketed cylinder 4 is provided with a jacketed heat transfer oil 1 inlet 7, a jacketed heat transfer oil 2 inlet 2, a jacketed heat transfer oil 3 inlet 33, a jacketed heat transfer oil 2 outlet 22, and a jacketed heat transfer oil 3 outlet 24 on its side; the inner reactor cylinder 3 is provided with a heat transfer oil 1 inlet 6, a heat transfer oil 2 inlet 1, a heat transfer oil 3 inlet 32, a heat transfer oil 2 outlet 21, and a heat transfer oil 3 outlet 23 on its side; the lower reactor head 26 is provided with a central tube heat transfer oil outlet 28 and a reactant outlet 29;

[0013] The reactor inner cylinder 3 is provided with a heat transfer oil distribution plate 11 and a material distribution plate 10 at the top. Inside the reactor inner cylinder 3, a straight tubular central tube 8 is provided on the central axis of the jacket cylinder 4. The inner side of the central tube 8 is closely attached to the tube wall and is provided with a central tube heat transfer oil winding tube 9 made of multiple tubes. The outer side of the central tube is also provided with a reactor inner heat transfer oil winding tube 20 made of multiple layers of tubes. The rotation direction of the inner and outer adjacent central tube inner heat transfer oil winding tubes 9 and the reactor inner heat transfer oil winding tubes 20 is opposite.

[0014] The upper ends of the heat transfer oil coils 9 inside the central tube are fixed to the heat transfer oil distribution plate 11 at the top of the reactor inner cylinder, and the lower ends are fixed to the reactor lower head 26. One end of the heat transfer oil coils 9 inside the central tube is connected to the heat transfer oil inlet 16 inside the central tube, and the other end is connected to the heat transfer oil outlet 28 inside the central tube. The heat transfer oil coils 20 inside the reactor are coils that wrap around the outside of the central tube. The uppermost group of coils 20-1 to 6 are fixed sequentially from the heat transfer oil distribution plate 11 at the top of the reactor inner cylinder to the top of the reactor inner cylinder. The material distribution plates 10 are arranged between the materials in the reactor and are coiled inside the reactor and then fixed to the side wall of the inner cylinder 3 of the reactor. One end of the coiled tubes 20-1 to 6 is connected to the inlet 6 of the heat transfer oil 1 and the other end is connected to the outlet 19 of the heat transfer oil 1. One end of the middle group of coiled tubes 20-7 to 12 is connected to the inlet 1 of the heat transfer oil 2 and the other end is connected to the outlet 21 of the heat transfer oil 2. One end of the bottom group of coiled tubes 20-13 to 18 is connected to the inlet 32 ​​of the heat transfer oil 3 and the other end is connected to the outlet 23 of the heat transfer oil 3.

[0015] The jacket cylinder 4 is divided into three regions: upper, middle, and lower. The temperature of the three regions is adjusted by controlling the temperature of the heat transfer oil inlet in the central tube 9 and the heat transfer oil inlet in the reactor heat transfer oil inlet 20.

[0016] The upper end of the central tube 8 is supported on the material distribution plate 10 and welded to the material distribution plate 10. The lower end of the central tube 8 is supported on six evenly distributed support ribs 30. Both the upper and lower ends of the central tube 8 are closed, preventing the reactants from entering the central tube 8.

[0017] The reactant inlet 17 is connected to a flange at one end and welded to the center opening of the heat transfer oil distribution plate 11 at the top of the reactor inner cylinder 3 at the other end; the heat transfer oil inlet 16 of the central tube is connected to a flange at one end and fixed to the inner end of the heat transfer oil inlet 12 of the central tube inside the reactor upper end 13, and is connected to the heat transfer oil winding pipe 9 inside the central tube. By controlling the inlet temperature of the heat transfer oil, the wall temperature inside the central tube 8 can be adjusted.

[0018] The reactant outlet 17 is a flanged flange with a support rib 30 welded on it to support the central tube 8. The support rib 30 also serves to break vortices. The heat transfer oil inside the central tube is directly and evenly welded to the lower end of the reactor head 26 via the lower end of the tube 9. The heat transfer oil enters the heat transfer oil outlet 28 on the lower end of the jacket 27 of the reactor head 26 through the flow channel in the jacket and is discharged. The wall temperature inside the central tube 8 can be adjusted by controlling the temperature of the heat transfer oil inlet.

[0019] The reactor upper head 13 and the heat transfer oil distribution plate 11 at the top of the reactor inner cylinder 3 form the first chamber; the heat transfer oil distribution plate 11 at the top of the reactor inner cylinder 3 and the material distribution plate 10 form the second chamber; and the material distribution plate 10 at the top of the reactor inner cylinder 3 and the lower reactor inner cylinder 3 and reactor lower head 26 form the third chamber. The medium flowing in the first chamber is heat transfer oil, the medium flowing in the shell side of the second and third chambers is reactant, and the medium flowing in the tube side of the second and third chambers is heat transfer oil.

[0020] The central tube 8, which is set on the central axis inside the inner cylinder of the reactor, is a hollow straight tube. The heat transfer oil coil 9 inside the central tube is not connected to the heat transfer oil coil 20 inside the reactor outside the central tube and does not come into direct contact with the reactants. It only serves the function of heat exchange.

[0021] The heat transfer oil winding tube 9 in the central tube and the heat transfer oil winding tube 20 in the reactor have the same diameter and wall thickness, and the two ends of the tubes are linearly distributed radially and fixed to the heat transfer oil distribution plate at the top of the inner cylinder of the reactor.

[0022] The top of the reactor inner cylinder 3 is connected to the reactor upper head 13, and the bottom of the reactor inner cylinder 3 is connected to the reactor lower head 26 by welding. The reactant inlet 17, reactant outlet 29, heat transfer oil inlet 16 in the central tube, heat transfer oil outlet 28 in the central tube, heat transfer oil inlet 1 in the jacket 7, heat transfer oil inlet 2 in the jacket 2, heat transfer oil inlet 33 in the jacket 3, heat transfer oil outlet 18 in the jacket 2, heat transfer oil outlet 22 in the jacket 3, heat transfer oil outlet 34 in the jacket 3, heat transfer oil inlet 6 in the jacket 1, heat transfer oil inlet 1 in the jacket 2, heat transfer oil inlet 32 ​​in the jacket 3, heat transfer oil outlet 19 in the jacket 1, heat transfer oil outlet 21 in the jacket 2, and heat transfer oil outlet 23 are all connected to the outside by flanges.

[0023] The reactor upper head 13, reactor inner cylinder 3, and reactor lower head 26 are provided with jackets on their outer surfaces. The jacket cylinder 4 is divided into three sections, which are separated by jacket partitions 31. Heat transfer oil is used as the heating medium, and the wall temperature inside the reactor upper head 13, reactor inner cylinder 3, and reactor lower head 26 is controlled by controlling the inlet temperature of the heat transfer oil. The outer jackets of the reactor upper head 13, reactor inner cylinder 3, and reactor lower head 26 are provided with guide plates to prevent dead zones in the flow of heat transfer oil and make the heat transfer more uniform.

[0024] (III) Beneficial effects of the technical solution of the present invention:

[0025] 1. Compared to conventional static mixers, the static mixing reactor of this invention is more suitable for high-viscosity polymer polymerization reactors. Its internal mixing elements are similar to those of conventional static mixers, enabling excellent mixing and reaction of different fluids entering the reactor. However, unlike conventional static mixers, its internal mixing elements are not made of sheet metal but of tubing. Heating or cooling media can be introduced into the tubing, thus achieving both mass transfer and heat transfer, improving production efficiency and polymerization conversion rate, reducing equipment investment and production costs, and avoiding problems such as reactor wall adhesion, polymer blockage, and explosive polymerization found in existing technologies.

[0026] 2. By selecting appropriate structural forms, pipe diameters, and changing the geometric dimensions of the components, the static mixing reactor of the present invention can make the mixing elements have a sufficiently large heat transfer specific area (heat transfer area per unit equipment volume), greatly improving the heat transfer intensity per unit reaction volume. Even when the fluid in the reactor is in a highly viscous state, it still achieves a good heat transfer and mixing effect, meeting the heat and mass transfer requirements of the polymerization reaction.

[0027] 3. Compared with traditional plug flow reactors and fully mixed flow reactors, the static mixing reactor of the present invention has the advantages of low energy consumption, high heat exchange efficiency, reduced resistance, compact structure, and easy large-scale production. Furthermore, because there are no rotating parts, maintenance costs are greatly reduced.

[0028] 4. The static mixing reactor provided by this invention has a straight tubular central tube installed on the central axis of the reactor's inner cylinder. Multiple layers of heat-conducting oil coils, made of tubing, are arranged around the outside of the central tube, with adjacent inner and outer coils rotating in opposite directions. This heat exchange method offers high heat transfer efficiency, ensuring uniform cooling or heating rates of the polymer material. Furthermore, this heat exchange is always synchronized with the polymerization reaction, allowing the polymerization reaction to be controlled within a suitable temperature range regardless of heating or cooling, thus effectively controlling the polymerization reaction. Similarly, heat-conducting oil coils, also made of tubing arranged in the same direction, are arranged close to the inner wall of the central tube. This maintains the wall temperature of the central tube surface in the static mixing reactor, ensuring that the polymer viscosity does not increase due to a decrease in the central tube surface temperature, improving heat transfer efficiency, and reducing polymer adhesion, blockage, and explosive polymerization.

[0029] 5. The static mixing reactor provided by this invention has a special structural design, which allows the reactants to flow in the gaps between the tubes after entering the static mixing reactor. This ensures that the high-viscosity polymer is fully and uniformly mixed, resulting in a good mixing effect. Furthermore, this static mixing method ensures that the polymer material of this invention is completely free from backmixing in the flow direction, while achieving maximum mixing on the plane perpendicular to the flow direction, exhibiting a plug flow. This can make the molecular weight distribution of the polymer product more uniform, thereby improving the performance and quality of the polymer product.

[0030] 6. The viscosity of polymer reaction systems is significantly affected by the polymerization temperature, making temperature control crucial for mass and heat transfer efficiency. The static mixing reactor provided by this invention divides the internal static mixing unit into three distinct temperature zones. By controlling the temperature of the heat transfer oil in the heat exchange tubes within these three zones, the polymerization temperature can be adjusted to meet the production requirements of different polymerization reactions.

[0031] 7. The static mixing reactor provided by this invention has strong resistance to fluctuations in operating conditions, extremely low risk of leakage, no risk of vibration failure, high reliability, and good stability. Attached Figure Description

[0032] Figure 1 This is a schematic diagram of the upper part of the present invention;

[0033] Figure 2 This is a schematic diagram of the central structure of the present invention;

[0034] Figure 3 This is a schematic diagram of the lower part of the present invention;

[0035] Figure 4 This is an enlarged schematic diagram of the heat exchange tube distribution on the heat transfer oil distribution plate 11 of the present invention;

[0036] Figure 5 This is an enlarged schematic diagram of the heat exchange tubes and material tube holes on the material distribution plate 10 of the present invention;

[0037] Figure 6 This is an enlarged schematic diagram showing the distribution of heat-conducting oil around the central tube 9 of the present invention;

[0038] Figure 7 This is an enlarged schematic diagram of the distribution of heat transfer oil in the reactor of the present invention, with the oil wound around the pipes 20-1 to 6.

[0039] Figure 8 This is an enlarged schematic diagram of the side view of the heat transfer oil winding pipes 20-1 to 6 inside the reactor at the inlet 6 of the heat transfer oil 1 of the present invention;

[0040] Figure 8 In the middle: the pipe ends are evenly distributed along the circumference on the side wall of the reactor cylinder 3;

[0041] Figure 9 This is an enlarged schematic diagram of the side view of the heat transfer oil winding pipe 20-7 to 12 inside the reactor at the heat transfer oil inlet 1 of the present invention;

[0042] Figure 9 In the middle: the pipe ends are evenly distributed along the circumference on the side wall of the reactor cylinder 3;

[0043] Figure 10 This is an enlarged schematic diagram of the side view of the heat transfer oil winding pipe 20-13 to 18 inside the reactor at the inlet 32 ​​of the heat transfer oil 3 of the present invention;

[0044] Figure 10 In the middle: the ports of each pipe are evenly distributed along the circumference on the side wall of the reactor cylinder 3.

[0045] Figure label:

[0046] 1. Heat transfer oil inlet 2; 2. Jacketed heat transfer oil inlet 2; 3. Reactor inner cylinder; 4. Jacketed cylinder; 5. Jacket inner baffle; 6. Heat transfer oil inlet 1; 7. Jacketed heat transfer oil inlet 1; 8. Central tube; 9. Heat transfer oil winding inside the central tube; 10. Material distribution plate; 11. Heat transfer oil distribution plate; 12. Inner end cap of the central tube; 13. Reactor top end cap; 14. Baffle plate inside the end cap; 15. Jacket top end cap; 16. Heat transfer oil inlet inside the central tube; 17. Reactant inlet; 18. Jacketed heat transfer oil outlet 1; 19. Heat transfer oil outlet 1; 20. Heat transfer oil winding inside the reactor; 21. Heat transfer oil outlet 2; 22. Jacketed heat transfer oil outlet 2 ; 23. Heat transfer oil outlet 3; 24. Jacketed heat transfer oil outlet 3; 25. Reactor lug support; 26. Reactor lower head; 27. Jacketed lower head; 28. Heat transfer oil outlet in the central tube; 29. ​​Reactant outlet; 30. Support rib; 31. Jacketed partition; 32. Heat transfer oil inlet 3; 33. Jacketed heat transfer oil inlet 3; 34. First chamber; 35. Second chamber; 36. Third chamber; 37. Material distribution hole; 20-1~6: The uppermost group of tubes in the heat transfer oil winding tubes inside the reactor; 20-7~12: The middle group of tubes in the heat transfer oil winding tubes inside the reactor; 20-13~18: The lowermost group of tubes in the heat transfer oil winding tubes inside the reactor. Detailed Implementation

[0047] The following examples are used to illustrate the present invention, but are not intended to limit the scope of the invention.

[0048] A static mixing reactor of the present invention includes an upper reactor head 13, an inner reactor cylinder 3, a lower reactor head 26, a jacketed upper head 15, a jacketed cylinder 4, a jacketed lower head 27, and a heat exchange piping system. The upper reactor head 13 is provided with a reactant inlet 17, a central tube heat transfer oil inlet 16, a jacketed heat transfer oil 1 outlet 18, and a heat transfer oil 1 outlet 19. The jacketed cylinder 4 is provided with a jacketed heat transfer oil 1 inlet 7, a jacketed heat transfer oil 2 inlet 2, a jacketed heat transfer oil 3 inlet 33, a jacketed heat transfer oil 2 outlet 22, and a jacketed heat transfer oil 3 outlet 24 on its side. The inner reactor cylinder 3 is provided with a heat transfer oil 1 inlet 6, a heat transfer oil 2 inlet 1, a heat transfer oil 3 inlet 32, a heat transfer oil 2 outlet 21, and a heat transfer oil 3 outlet 23 on its side. The lower reactor head 26 is provided with a central tube heat transfer oil outlet 28 and a reactant outlet 29.

[0049] The diameter of the reactor inner cylinder 3 is The top of the cylinder is provided with a heat transfer oil distribution plate 11 and a material distribution plate 10. Inside the inner cylinder 3 of the reactor, a straight tubular central tube 8 is provided on the central axis. The inner side of the central tube 8 is closely attached to the tube wall and is provided with a central tube heat transfer oil winding tube 9 made of multiple tubes. The outer side of the central tube is also provided with a reactor internal heat transfer oil winding tube 20 made of multiple layers of tubes. The rotation direction of the inner and outer adjacent central tube internal heat transfer oil winding tubes 9 and the reactor internal heat transfer oil winding tubes 20 is opposite. The upper and lower layers of winding tubes 20 are staggered.

[0050] The upper ends of the heat transfer oil coils 9 inside the central tube are fixed to the heat transfer oil distribution plate 11 at the top of the reactor inner cylinder, and the lower ends are fixed to the reactor lower end cap 27. One end of the heat transfer oil coils 9 inside the central tube is connected to the heat transfer oil inlet 16 inside the central tube, and the other end is connected to the heat transfer oil outlet 28 inside the central tube. The heat transfer oil coils 20 inside the reactor are coils that surround the outside of the central tube. The uppermost group of coils 20-1 to 6 are fixed sequentially from the heat transfer oil distribution plate 11 at the top of the reactor inner cylinder to the top of the reactor inner cylinder. The material distribution plates 10 are arranged between the tubes and coiled in the reactor and then fixed to the side wall of the inner cylinder 3 of the reactor. One end of the tubes 20-1 to 6 is connected to the inlet 6 of the heat transfer oil 1, and the other end is connected to the outlet (19) of the heat transfer oil 1. One end of the tubes 20-7 to 12 in the middle group of the heat transfer oil coils in the reactor is connected to the inlet 1 of the heat transfer oil 2, and the other end is connected to the outlet 21 of the heat transfer oil 2. One end of the tubes 20-13 to 18 in the bottom group of the heat transfer oil coils in the reactor is connected to the inlet 32 ​​of the heat transfer oil 3, and the other end is connected to the outlet 23 of the heat transfer oil 3.

[0051] Wherein, the inner diameter of the jacket cylinder 4 is The jacketed cylinder is divided into three regions: upper, middle, and lower. The temperature of the three regions is adjusted by controlling the temperature of the heat transfer oil inlet in the central tube 9 and the heat transfer oil inlet in the reactor 20.

[0052] The upper end of the central tube 8 is supported on the material distribution plate 10 and welded to the material distribution plate 10. The lower end of the central tube 8 is supported on six evenly distributed support ribs 30. Both the upper and lower ends of the central tube 8 are closed, preventing the reactants from entering the central tube 8.

[0053] The reactant inlet 17 is connected to a flange at one end and welded to the center opening of the heat transfer oil distribution plate 11 at the top of the reactor inner cylinder 3 at the other end; the heat transfer oil inlet 16 of the central tube is connected to a flange at one end and fixed to the inner end of the heat transfer oil inlet 12 of the central tube inside the reactor upper end 13, and is connected to the heat transfer oil winding pipe 9 inside the central tube. By controlling the inlet temperature of the heat transfer oil, the wall temperature inside the central tube 8 can be adjusted.

[0054] The reactant outlet 17 is a flanged flange, and a support rib 30 for supporting the central tube 8 is welded on the flanged flange. The support rib 30 also serves to break vortices. The heat transfer oil inside the central tube is directly and evenly welded to the lower end of the reactor head 26 by the lower part of the tube 9. The heat transfer oil enters the heat transfer oil outlet 28 of the central tube on the lower end of the jacket 27 of the lower end of the reactor head 26 through the guide channel in the jacket. The wall temperature inside the central tube 8 can be adjusted by controlling the temperature of the heat transfer oil inlet.

[0055] The reactor upper head 13 and the heat transfer oil distribution plate 11 at the top of the reactor inner cylinder 3 form the first chamber; the heat transfer oil distribution plate 11 at the top of the reactor inner cylinder 3 and the material distribution plate 10 form the second chamber; and the material distribution plate 10 at the top of the reactor inner cylinder 3 and the lower reactor inner cylinder 3 and reactor lower head 26 form the third chamber. The medium flowing in the first chamber is heat transfer oil, the medium flowing in the shell side of the second and third chambers is reactant, and the medium flowing in the tube side of the second and third chambers is heat transfer oil.

[0056] The central tube 8, located on the central axis inside the reactor's inner cylinder, is a hollow straight tube with an inner diameter of [missing information]. The heat transfer oil coil 9 inside the central tube is not connected to the heat transfer oil coil 20 inside the reactor outside the central tube, and does not come into direct contact with the reactants; it only serves as a heat exchanger.

[0057] Among them, the heat transfer oil winding tube 9 in the central tube and the heat transfer oil winding tubes 20-1 to 6 in the reactor have the same diameter and the same wall thickness. The two ends of the tubes are linearly distributed radially and fixed to the heat transfer oil distribution plate at the top of the inner cylinder of the reactor.

[0058] The top of the reactor inner cylinder 3 is connected to the reactor upper head 13, and the bottom of the reactor inner cylinder 3 is connected to the reactor lower head 26 by welding. The reactor inner cylinder 3 has the following components: reactant inlet 17, reactant outlet 29, central tube heat transfer oil inlet 16, central tube heat transfer oil outlet 28, jacketed heat transfer oil 1 inlet 7, jacketed heat transfer oil 2 inlet, jacketed heat transfer oil 3 inlet 33, jacketed heat transfer oil 1 outlet 18, jacketed heat transfer oil 2 outlet 22, jacketed heat transfer oil 3 outlet 24, and heat transfer oil 1... The inlet 6), inlet 1 of heat transfer oil 2, inlet 32 ​​of heat transfer oil 3, outlet 19 of heat transfer oil 1, outlet 21 of heat transfer oil 2, and outlet 23 of heat transfer oil 3 are all connected to the outside via flanges; the nominal diameters of the inlet 17 and outlet 29 of the reactant material are DN300mm; the nominal diameters of the inlet 16 and outlet 28 of the heat transfer oil in the central pipe are DN100mm; the nominal diameters of the inlet and outlet of the jacketed heat transfer oil are both DN100mm; and the nominal diameters of the inlet and outlet of the heat transfer oil are both DN150mm.

[0059] The reactor upper head 13, reactor inner cylinder 3, and reactor lower head 26 are provided with jackets on their outer surfaces. The jacket cylinder 4 is divided into three sections, each with a height of 3000 mm. The sections are separated by jacket partitions 31. Heat transfer oil is used as the heating medium, and the wall temperature inside the reactor upper head 13, reactor inner cylinder 3, and reactor lower head 26 is controlled by controlling the inlet temperature of the heat transfer oil. The outer jackets of the reactor upper head 13, reactor inner cylinder 3, and reactor lower head 26 are provided with guide plates to prevent dead zones in the flow of heat transfer oil and make the heat transfer more uniform.

[0060] A static mixing reactor is a fluid piping structure that enables fluid mixing reactions over a wide Reynolds number range using different fluid piping configurations, without any moving mechanical parts. For mixing two fluids, current technology generally employs stirring. This is a dynamic mixing device with moving parts. In contrast, the main component of a static mixing reactor, the static mixing unit, does not move during the mixing process. Instead, it relies on the pressure drop of the fluid itself as energy and the action of the static mixing unit to mix and react the fluids. There are no moving parts within the reactor.

[0061] The mixing reaction between two or more substances typically relies on diffusion, convection, and shear. For high-viscosity polymers, due to the viscosity of macromolecular movement, the effect of molecular diffusion in polymer mixing is negligible. Convection, without a strong driving force, has little effect. Turbulence can increase the convective distribution of polymer flocs, but because the flow of high-viscosity polymers is laminar, especially near the pipe wall where the fluid velocity is very low, the mixing of high-viscosity polymers mainly relies on shear force. During mixing, the polymer or flocs, acting as a dispersant, are dispersed in the continuous phase from high to low under shear force. During mixing, the shear force decreases with fluid flow. If the shear force is too low, adhesion to the container wall is likely to occur. If the surface is not refreshed in time, blockage or even explosive aggregation will occur after a period of time.

[0062] Since polymer polymerization typically occurs in high-viscosity systems, mass and heat transfer of small-molecule compounds within these systems is extremely difficult. The viscosity of the reaction system increases significantly as the reaction temperature decreases. Furthermore, the mass and heat transfer efficiency within the reactor is heavily influenced by the internal structure of the equipment and the mixing characteristics of the material flow. According to the heat transfer rate equation Q = KSΔt, enhancing heat transfer can be achieved by increasing the heat transfer coefficient K, the heat transfer area S, and the heat transfer temperature difference Δt. Given a fixed heat transfer area S and temperature difference Δt, the heat transfer effect of the reactor is often enhanced by increasing the heat transfer coefficient K on the side with higher thermal resistance.

[0063] This invention, through structural design, not only increases the heat transfer area per unit reactor volume but also enhances the heat transfer coefficients on both the inner and outer sides of the heat exchange tubes. Simultaneously, the impact of the radially forced flow of reactants within the gaps between the heat exchange tubes significantly reduces the thermal resistance of the stagnant inner layer at the tube wall, ensuring continuous renewal of the liquid in this layer. The radial flow also reduces the temperature gradient outside the stagnant inner layer, thus enhancing the mass and heat transfer efficiency of the static mixing reactor.

[0064] The working principle of the ABS static mixing reactor of this invention:

[0065] The reactants enter the second chamber of the reactor through the reactant inlet 17. After contacting the heat transfer oil coil 9 in the central tube of the second chamber, the reactants undergo mass and heat transfer. They flow in the gaps between the heat transfer oil coils 9 in the central tube, and are mixed axially and radially. They then enter the third chamber of the reactor through the through holes on the material distribution plate 10 at the top of the inner cylinder 3. The third chamber has three different temperature zones. The reaction temperature in the first temperature zone is controlled and regulated by the inlet temperature of the heat transfer oil inlet 1 (6). After the reactants enter the first temperature zone, they come into contact with the heat transfer oil coils 20-1 to 6 in the reactor. Under the segmentation effect of the special structure of the heat transfer oil coils 20-1 to 6 in the reactor, the radial flow of the reactants is increased, which greatly thins the stagnant inner layer of the heat exchange tube. At the same time, it promotes the continuous renewal of the fluid in the stagnant inner layer at the tube wall, which reduces the temperature gradient of the reactants along the radial direction of the cylinder and further enhances the mass and heat transfer. The reactants from the first temperature zone enter the second temperature zone of the third chamber. The reaction temperature in the second temperature zone is controlled and regulated by the inlet temperature of the heat transfer oil 2 inlet (1). After the reactants come into contact with the heat transfer oil coils 20-7 to 12 in the reactor within the second temperature zone, the temperature reaches a certain value. Through the mass and heat transfer of the heat transfer oil coils 20-7 to 12 in the reactor within the second temperature zone, the polymerization reaction continues. The reactants from the second temperature zone directly enter the third temperature zone of the third chamber to continue the mass transfer, heat transfer, and reaction process. The reaction temperature in the third temperature zone is controlled and regulated by the inlet temperature of the heat transfer oil 3 inlet (32). After the reactants come into contact with the heat transfer oil coils (20-13 to 18) in the reactor within the third temperature zone, the temperature reaches a certain value. Through the mass and heat transfer of the heat transfer oil coils 20-13 to 18 in the reactor within the third temperature zone, the polymerization reaction continues. The material after polymerization in the third chamber exits through the reactant outlet 29 at the bottom of the reactor lower head 26 and enters the subsequent deashing unit.

Claims

1. A static mixing reactor, comprising an upper reactor head (13), an inner reactor cylinder (3), a lower reactor head (26), a jacketed upper head (15), a jacketed cylinder (4), a jacketed lower head (27), and a heat exchange piping system; characterized in that: The reactor upper head (13) is provided with a reactant inlet (17), a central tube heat transfer oil inlet (16), a jacket heat transfer oil outlet (18), and a heat transfer oil outlet (19). The jacket cylinder (4) is provided with a jacket heat transfer oil inlet (7), a jacket heat transfer oil inlet (2), a jacket heat transfer oil outlet (33), a jacket heat transfer oil outlet (22), and a jacket heat transfer oil outlet (24) on its side. The reactor inner cylinder (3) is provided with a heat transfer oil inlet (6), a heat transfer oil inlet (1), a heat transfer oil outlet (32), a heat transfer oil outlet (21), and a heat transfer oil outlet (23) on its side. The reactor lower head (26) The reactor is equipped with a central tube outlet (28) for heat transfer oil and an outlet (29) for reactants. The top of the reactor inner cylinder (3) is equipped with a heat transfer oil distribution plate (11) and a material distribution plate (10). Inside the reactor inner cylinder (3), a straight central tube (8) is located on the central axis of the cylinder. The inner side of the central tube (8) is fitted with a central tube heat transfer oil winding tube (9) made of multiple tubes, close to the tube wall. The outer side of the central tube is also equipped with multiple layers of reactor heat transfer oil winding tubes (20) made of tubes. The rotation direction of adjacent central tube heat transfer oil winding tubes (9) is opposite to that of the reactor heat transfer oil winding tubes (20). The upper and lower layers of the reactor inner cylinder are... The heat transfer oil coils (20) are arranged in a staggered manner; the upper ends of the heat transfer oil coils (9) inside the central tube are fixed on the heat transfer oil distribution plate (11) at the top of the reactor inner cylinder, and the lower ends are fixed on the reactor lower head (26). One end of the heat transfer oil coil (9) inside the central tube is connected to the heat transfer oil inlet (16) inside the central tube, and the other end is connected to the heat transfer oil outlet (28) inside the central tube. The heat transfer oil coils (20) inside the reactor are coils that surround the outside of the central tube. The uppermost group of tubes (20-1 to 6) inside the reactor are fixed sequentially from the heat transfer oil distribution plate (11) at the top of the reactor inner cylinder to the top of the reactor inner cylinder. The material distribution plate (10) of the part is coiled in the reactor and then fixed to the side wall of the inner cylinder (3) of the reactor. One end of the uppermost group of tubes (20-1 to 6) of the heat transfer oil coil is connected to the first heat transfer oil inlet (6), and the other end is connected to the first heat transfer oil outlet (19). One end of the middle group of tubes (20-7 to 12) of the heat transfer oil coil is connected to the second heat transfer oil inlet (1), and the other end is connected to the second heat transfer oil outlet (21). One end of the lowermost group of tubes (20-13 to 18) of the heat transfer oil coil is connected to the third heat transfer oil inlet (32), and the other end is connected to the third heat transfer oil outlet (23). The jacket cylinder (4) is divided into three regions: upper, middle and lower. The temperature of the three regions is adjusted by controlling the temperature of the heat transfer oil inlet in the central tube (9) and the heat transfer oil inlet in the reactor (20).

2. The static mixing reactor according to claim 1, characterized in that: The upper end of the central tube (8) is supported on the material distribution plate (10) and welded to the material distribution plate (10). The lower end of the central tube (8) is supported on six evenly distributed support ribs (30). The upper end of the central tube (8) and the lower end of the central tube (8) are both closed, so the reactants cannot enter the central tube (8).

3. A static mixing reactor according to claim 1, characterized in that: The reactant inlet (17) is connected to a flange at one end and welded to the center opening of the heat transfer oil distribution plate (11) at the top of the reactor inner cylinder (3) at the other end; the heat transfer oil inlet (16) in the central tube is connected to a flange at one end and fixed to the heat transfer oil inner end cap (12) in the upper end cap (13) of the reactor, and is connected to the heat transfer oil winding pipe (9) in the central tube. By controlling the inlet temperature of the heat transfer oil, the wall temperature inside the central tube (8) can be adjusted.

4. A static mixing reactor according to claim 1, characterized in that: The reactant outlet (29) adopts a flange, and a support rib (30) for supporting the central tube (8) is welded on the flange. The support rib (30) can also break the vortex. The heat transfer oil inside the central tube is directly and evenly welded to the lower end of the reactor (26) by the lower part of the tube (9). The heat transfer oil enters the heat transfer oil outlet (28) of the central tube on the lower end of the jacket (27) of the jacket through the guide channel in the jacket of the reactor (26). The wall temperature inside the central tube (8) can be adjusted by controlling the temperature of the heat transfer oil inlet.

5. A static mixing reactor according to claim 1, characterized in that: The first chamber is located between the upper head (13) of the reactor and the heat transfer oil distribution plate (11) at the top of the reactor inner cylinder (3). The second chamber is located between the heat transfer oil distribution plate (11) at the top of the reactor inner cylinder (3) and the material distribution plate (10). The third chamber is located between the material distribution plate (10) at the top of the reactor inner cylinder (3) and the lower reactor inner cylinder (3) and the lower head (26) of the reactor. The medium flowing in the first chamber is heat transfer oil. The medium flowing in the shell side of the second and third chambers is reactant. The medium flowing in the tube side of the second and third chambers is heat transfer oil.

6. A static mixing reactor according to claim 1, characterized in that: The central tube (8) set on the central axis inside the inner cylinder of the reactor is a hollow straight tube. The heat transfer oil coil (9) inside the central tube is not connected to the heat transfer oil coil (20) inside the reactor outside the central tube and does not come into direct contact with the reactants. It only serves as a heat exchanger.

7. A static mixing reactor according to claim 1, characterized in that: The heat transfer oil winding pipe (9) in the central tube and the heat transfer oil winding pipe (20) in the reactor have the same pipe diameter and wall thickness, and the pipe openings at both ends are linearly distributed radially and fixed on the heat transfer oil distribution plate at the top of the inner cylinder of the reactor.

8. A static mixing reactor according to claim 1, characterized in that: The top of the reactor inner cylinder (3) is connected to the reactor upper head (13), and the bottom of the reactor inner cylinder (3) is connected to the reactor lower head (26) by welding. The reactant inlet (17), reactant outlet (29), heat transfer oil inlet (16) in the central tube, heat transfer oil outlet (28) in the central tube, heat transfer oil inlet 1 (7) in the jacket, heat transfer oil inlet 2 (2) in the jacket, heat transfer oil inlet 3 (33) in the jacket, heat transfer oil outlet 1 (18) in the jacket, heat transfer oil outlet 2 (22) in the jacket, heat transfer oil outlet 3 (24) in the jacket, heat transfer oil inlet 1 (6), heat transfer oil inlet 2 (1), heat transfer oil inlet 3 (32), heat transfer oil outlet 1 (19), heat transfer oil outlet 2 (21), and heat transfer oil outlet 3 (23) are all connected to the outside by flanges.

9. A static mixing reactor according to claim 1, characterized in that: The outer surfaces of the reactor upper head (13), reactor inner cylinder (3) and reactor lower head (26) are provided with jackets. The jacket cylinder (4) is divided into three sections, which are separated by jacket partitions (31). Heat transfer oil is used as the heating medium. The wall temperature inside the static mixing reactor upper head (13), reactor inner cylinder (3) and reactor lower head (26) is controlled by controlling the inlet temperature of the heat transfer oil. The outer jackets of the reactor upper head (13), reactor inner cylinder (3) and reactor lower head (26) are provided with guide plates to prevent dead zones in the flow of heat transfer oil and make the heat transfer more uniform.

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