Conical Reactor Design for Continuous Polymerization
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Solution Overview
Problem
Existing polymerization processes in reactors with conical shapes suffer from incomplete monomer polymerization due to unreacted monomer solution adhering to the reactor walls, leading to contamination and operational issues, particularly in controlling the extrusion rate and requiring additional steps to remove unreacted monomer, which can degrade over time.
Innovation Solution
A fully conical reactor with an angle between the top diameter and inner wall of 45° to 90° is used for continuous polymerization, allowing the gel-like mixture to be squeezed out using inert gas, minimizing unreacted monomer content by optimizing reactor design and operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conical reactor with vertical tube and conical bottom is used for polymerization, then the reactor can be used for batch-wise preparation of polymer, but it does not allow continuous preparation of polymer
Solution Approach 1:
The reactor design transitions from static batch operation to dynamic continuous operation by implementing a fully conical configuration with controlled monomer feeding and inert gas pressure application, enabling continuous polymer production while maintaining effective mixing and residence time
2Manufacturing precision
If monomer solution adheres to the inner walls of the reactor, then polymerization time is reduced, but unreacted monomer leaves the reactor with the polymer causing contamination
Solution Approach 1:
The fully conical reactor design with optimized angle promotes uniform flow patterns and prevents stagnant zones where monomer solution would adhere to walls, ensuring consistent residence time and complete polymerization throughout the reaction volume
Solution Approach 2:
Inert gas is applied at the bottom of the reactor to squeeze the gel-like mixture upward through the conical section, creating uniform flow that prevents wall adhesion and ensures all monomer receives adequate polymerization time before exiting
3Manufacturing precision
If unreacted monomer is removed by treatment with further initiator, then polymer purity is improved, but polymer degradation occurs over time
Solution Approach 1:
The reactor design and operating conditions are optimized to achieve complete monomer conversion during the primary polymerization process, eliminating the need for subsequent initiator treatment and preserving polymer stability
4Ease of operation
If solution of unreacted monomer acts as lubricant, then extrusion rate changes, but control of top pressure becomes difficult
Solution Approach 1:
The conical geometry creates uniform flow characteristics that prevent lubrication effects from unreacted monomer, maintaining consistent friction and extrusion behavior that is easily controllable through top pressure application
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 continuous polymer production with low unreacted monomer content, reducing contamination and operational complexities, and avoids the need for additional purification steps, resulting in a more stable and efficient polymerization process.
Implementation Method 1
squeezing the gel-like aqueous mixture comprising the polymer out of the bottom of the reactor using inert gas
Implementation Method 2
the reactor is either a vertical fully conical reactor having an angle (α) between top diameter (d1) of the reactor and inner wall of the reactor of smaller than 90° but larger than 45°
Data Source
AI summary
The present invention provides a process for the preparation of polymer which comprises the steps of i) feeding an aqueous mixture comprising a monoethylenically unsaturated monomer or a mixture of monoethylenically unsaturated monomers and an initiator into the top of a reactor ii) polymerizing the monoethylenically unsaturated monomer to form a gel-like aqueous mixture comprising the polymer, iii) squeezing the gel-like aqueous mixture comprising the polymer out of the bottom of the reactor using inert gas, wherein the reactor is either a vertical fully conical reactor having an angle (alpha) between top diameter (d1) of the reactor and inner wall of the reactor of smaller than 90° but larger than 45° or is made up of 2 to 5 connected vertical fully conical parts, which are on top of one another, each having an angle between top diameter of the part and inner wall of the part of smaller than 90° but larger than 45°.