Non Adiabatic Biphasic Polymerization Heat Transfer
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Solution Overview
Problem
Existing polymerization processes in single liquid phases face challenges in heat transfer efficiency and polymer concentration, leading to increased costs and reduced production rates.
Innovation Solution
Operating a non-adiabatic polymerization reactor under conditions that maintain a liquid/liquid biphasic system, using aliphatic cyclic, straight, and branched C3-12 hydrocarbon solvents to facilitate phase separation, and controlling pressure to enhance heat transfer to a cooling medium.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a single liquid phase is used in polymerization, then the reaction mixture is homogeneous and easy to handle, but heat transfer efficiency is poor leading to increased energy usage
Solution Approach 1:
The reaction mixture is segmented into two liquid phases: a polymer-rich phase and a solvent-rich phase. This segmentation creates distinct regions with different thermal properties, where the polymer-rich phase provides excellent heat transfer to the cooling medium while the solvent-rich phase maintains reaction homogeneity. The phase separation thus resolves the contradiction by allowing both efficient heat removal and adequate mixing.
Solution Approach 2:
The invention utilizes liquid-liquid phase transition to create a biphasic system. By controlling temperature and composition to maintain two liquid phases rather than a single phase, the system exploits the different thermal conductivities and heat capacities of each phase. The polymer-rich phase, being in direct contact with cooling surfaces, efficiently transfers heat, while the overall system maintains stability through controlled phase equilibrium.
2Productivity
If polymer concentration is increased in single liquid phase, then production rate improves, but heat transfer becomes less efficient and equipment size must increase
Solution Approach 1:
The system segments the polymer and solvent into separate phases, allowing the polymer to concentrate in one phase while the other phase facilitates heat transfer. This enables high polymer concentration (improving productivity) without sacrificing heat transfer efficiency, because the polymer-rich phase can be efficiently cooled through the interface with the cooling medium.
Solution Approach 2:
The solvent-rich phase acts as an intermediary that facilitates heat transfer from the polymer-rich phase to the cooling medium. This intermediary phase allows high polymer concentration to be maintained while still achieving effective heat removal, thus resolving the contradiction between productivity and heat transfer efficiency.
3Loss of energy
If cooling is improved in single liquid phase, then heat transfer efficiency increases, but polymer concentration must be reduced
Solution Approach 1:
By segmenting the system into polymer-rich and solvent-rich phases, the invention allows the polymer concentration to be high in the polymer-rich phase while the solvent-rich phase provides the heat transfer pathway. This segmentation enables both high polymer concentration and effective cooling to coexist, resolving the contradiction.
Solution Approach 2:
Different regions of the reaction mixture have different qualities: the polymer-rich phase has high polymer concentration optimized for productivity, while the solvent-rich phase has properties optimized for heat transfer. This local differentiation of qualities allows the system to achieve both high polymer concentration and efficient cooling simultaneously.
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 approach improves heat transfer efficiency, allows higher polymer concentrations, and increases production rates by forming two distinct liquid phases, one rich and one lean in polymer, thereby reducing equipment size and energy usage.
Implementation Method 1
The 2-phase system can improve heat transfer to the cooling medium
Implementation Method 2
adding a solvent chosen from aliphatic cyclic, straight and branched C3-12 hydrocarbon solvents that will facilitate formation of the liquid/liquid biphase
Data Source
AI summary
Disclosed are methods and conditions for manufacturing a polyethylene polymer or copolymer in a liquid/liquid biphasic non-adiabatic reaction, and the compositions and articles made therefrom.