Alternating Lateral Flow Tubes for Polymer Devolatilization
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Solution Overview
Problem
Current devolatilization processes in polymerization reactors are limited by inefficient surface area utilization in devolatilizer nozzles, leading to suboptimal removal of volatiles and polymer throughput.
Innovation Solution
A vessel header design featuring a plurality of lateral flow tubes arranged in a parallel configuration with alternating header penetrations, minimizing spacing between tubes and increasing usable surface area for improved fluid distribution and devolatilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional devolatilizer nozzle design is used, then device complexity is reduced, but productivity and volatile removal efficiency deteriorate
Solution Approach 1:
The header is divided into multiple lateral flow tubes arranged in parallel, each tube receiving polymer through separate header penetrations. This segmentation increases the total surface area for polymer distribution and volatile removal, directly improving productivity while the modular parallel structure manages the complexity through systematic repetition of standardized components
Solution Approach 2:
The design transitions from a single central flow path to a multi-dimensional array of lateral flow tubes extending in parallel. By utilizing alternating header penetrations and distributing flow tubes across multiple spatial dimensions, the system maximizes surface area utilization and throughput capacity without proportionally increasing overall header volume
2Area of stationary object
If lateral flow tubes are arranged in parallel with alternating header penetrations, then surface area for devolatilization increases, but manufacturing complexity increases
Solution Approach 1:
The header assembly is segmented into standardized lateral flow tube modules that can be manufactured independently and then assembled into the final configuration. Each flow tube is a discrete component with consistent dimensions and penetration patterns, allowing for standardized manufacturing processes and simplified quality control despite the complex overall geometry
Solution Approach 2:
The design utilizes consistent geometric parameters and repeating patterns across all lateral flow tubes, including uniform spacing, standardized penetration locations, and identical tube dimensions. This parameter standardization simplifies manufacturing by reducing the variety of unique components needed while still achieving the required increased surface area
3Productivity
If flow tube spacing is minimized, then productivity increases, but device complexity increases
Solution Approach 1:
The flow tubes are arranged in a parallel configuration utilizing alternating header penetrations, effectively distributing tubes across multiple spatial dimensions rather than simply increasing density in a single plane. This dimensional distribution maximizes throughput capacity by optimizing space utilization while maintaining manageable inter-tube spacing
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design enhances polymerization reaction throughput by 10% and volatile removal by 5-10%, compared to conventional designs, while allowing for easier maintenance and repair.
Implementation Method 1
a plurality of lateral flow tubes arranged in a parallel configuration and entering the vessel header through alternating header penetrations with a single header penetration per lateral flow tube
Implementation Method 2
volatiles may be removed by vacuum distillation, flash devolatilization, stripping
Implementation Method 3
volatiles may be removed by vacuum distillation, flash devolatilization, stripping
Implementation Method 4
As the strands fall in the devolatilization vessel, the unreacted monomer and solvent is released while the polymer strands collect at the bottom of the vessel
Data Source
AI summary
A vessel header comprising a plurality of lateral flow tubes arranged in a parallel configuration and entering the vessel header through alternating header penetrations with a single header penetration per lateral flow tube. A method of increasing the throughput of a polymerization reaction comprising conducting the polymerization reaction in a reaction vessel comprising a plurality of lateral flow tubes arranged in a parallel configuration and entering the vessel header through alternating header penetrations with a single header penetration per lateral flow tube wherein the polymerization reaction displays an increase in throughput of 10% and a decrease in volatiles of from 5% to 10% when compared to a polymerization reaction carried out in a reaction vessel lacking a plurality of lateral flow tubes arranged in a parallel configuration and entering the vessel header through alternating header penetrations with a single header penetration per lateral flow tube.