Continuous Catalyst Mixing Chamber Design
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Solution Overview
Problem
Existing processes for supplying polymerization catalyst components to reactors are equipment-intensive and require careful inventory management due to the need for large mixing vessels and multiple pumps, leading to inefficiencies and potential catalyst waste.
Innovation Solution
A continuous process that mixes catalyst components with a diluent stream in a small, non-agitated mixing chamber with an enlarged cross-section, using the diluent stream's flow for mixing and transfer to the reactor, reducing residence time and eliminating the need for additional pumping or agitation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a large mixing vessel is used to prepare diluted catalyst slurry, then sufficient volume to fill a day tank can be prepared, but the equipment complexity and inventory management requirements increase
Solution Approach 1:
The patent implements continuous mixing and transfer of catalyst slurry from the reactor to the day tank, eliminating the need for large batch mixing vessels. The continuous action allows small incremental mixing while maintaining sufficient supply through uninterrupted flow, resolving the contradiction between volume requirements and equipment complexity
Solution Approach 2:
The patent combines the mixing chamber with the reactor outlet system, using the reactor's existing flow to perform mixing. The mixing chamber is positioned to receive slurry directly from the reactor, merging two functions (reactor discharge and catalyst dilution) into one integrated system, reducing overall equipment complexity while maintaining slurry volume
2Ease of operation
If multiple pumps and agitated vessels are used for catalyst slurry transfer, then adequate mixing and transfer can be achieved, but the number of equipment components increases
Solution Approach 1:
The patent uses the reactor's own slurry flow to perform mixing in the mixing chamber, eliminating the need for separate agitation equipment. The continuous flow from the reactor provides self-mixing capability, and the diluted slurry flows by gravity or reactor pressure to the day tank, eliminating the need for additional transfer pumps
Solution Approach 2:
The patent extracts the mixing function from traditional large agitated vessels and implements it in a compact mixing chamber that utilizes flow dynamics rather than mechanical agitation. This extraction reduces equipment complexity while maintaining mixing effectiveness through the enlarged cross-section design
3Volume of stationary object
If a small mixing chamber with short residence time is used, then equipment volume is reduced, but mixing effectiveness must be maintained
Solution Approach 1:
The patent employs an asymmetric mixing chamber design with an enlarged cross-section that creates specific flow patterns. The chamber geometry is optimized to promote turbulent mixing and adequate contact between catalyst slurry and diluent despite the reduced volume, maintaining mixing effectiveness through clever geometric design rather than size
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 enables efficient, continuous catalyst supply with reduced equipment requirements and extended time between cleanings, minimizing catalyst waste and improving process control.
Implementation Method 1
providing a diluent stream in a second line... contacting the first stream and the diluent stream to form a mixed stream... the volume of the mixing chamber is such that the residence time, based on the total volumetric flow rate of the mixed stream
Data Source
AI summary
The present invention relates to a process for supply of a polymerization catalyst component to a polymerization reactor which comprises:a. Providing a first stream comprising the catalyst component in a first line, which first line is connected to and downstream of a pump outlet or of a flow control valve,b. Providing a diluent stream in a second line,c. Contacting the first stream and the diluent stream to form a mixed stream and passing the mixed stream to a polymerization reactor,characterised in that the mixing of the first stream and the diluent stream takes place by providing the first stream from the first line and the diluent stream from the second line separately to a mixing chamber which has an enlarged cross-section compared to the first and second lines.