Devolatilization Plates for Polymer Viscosity Control
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Solution Overview
Problem
Current devolatilization methods face challenges in effectively removing solvents and monomers from polymer melts due to slow diffusion in viscous bulk polymers, requiring improved techniques to avoid damaging the polymer at optimal temperatures and pressures.
Innovation Solution
A devolatilization vessel with multiple sets of plates, including a first and second set of devolatilization plates with differently sized holes and flow paths, allows for controlled residence time and surface renewal of polymer solutions, enhancing volatiles removal by directing polymer solutions through specific sets of plates based on viscosity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If polymer solution is subjected to devolatilization at optimized temperature and pressure, then volatiles removal efficiency is improved, but polymer quality deteriorates due to damage from excessive temperature and pressure
Solution Approach 1:
The devolatilization process is segmented into multiple stages with different temperature and pressure conditions. The patent uses a multi-zone devolatilization system where the polymer solution first undergoes flash devolatilization at high temperature and low pressure, followed by secondary devolatilization at milder conditions, allowing efficient volatile removal while protecting polymer quality through staged processing
Solution Approach 2:
The patent dynamically changes temperature and pressure parameters throughout the devolatilization process. The system employs controlled pressure reduction and temperature adjustment in different zones to optimize volatile removal at each stage while preventing polymer degradation, transforming fixed parameter processing into a dynamic multi-parameter control system
2Adaptability or versatility
If devolatilization plates are changed to handle different viscosity ranges, then processing adaptability is improved, but device complexity and downtime increase
Solution Approach 1:
The patent designs devolatilization plates with universal functionality that can handle different viscosity ranges without requiring plate changes. The plates incorporate adjustable geometric parameters and multiple flow path configurations that can be adapted to process both low-viscosity and high-viscosity polymer solutions using the same physical hardware, eliminating the need for multiple specialized plate sets
Solution Approach 2:
The patent introduces dynamic adjustability to the devolatilization plates through movable components and adjustable parameters. The plate system can dynamically adapt its configuration (such as hole size, spacing, and flow distribution) to match different polymer viscosities during operation, transforming static plates into dynamically adaptable structures that maintain optimal performance across varying conditions
3Quantity of substance
If residence time is increased to enhance volatiles removal, then devolatilization efficiency is improved, but productivity decreases due to longer processing time
Solution Approach 1:
The devolatilization process is segmented into multiple sequential stages, each removing a portion of the volatiles. The first stage (flash devolatilization) removes the bulk of volatiles quickly under harsh conditions, while subsequent stages (secondary and tertiary devolatilization) remove remaining volatiles under milder conditions. This segmentation allows the system to achieve high overall removal efficiency while maintaining high throughput by distributing the residence time requirement across multiple parallel and sequential processing zones
Solution Approach 2:
The patent employs periodic or pulsed flow patterns in the devolatilization process, where polymer solution is introduced in controlled batches or pulses that optimize residence time distribution. This periodic action allows efficient volatile removal during high-residence-time periods while maintaining overall productivity through continuous operation and rapid cycle turnover between batches
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 effectively removes volatiles from polymer solutions across a wide viscosity range, ensuring the polymer quality and reducing downtime by maintaining consistent devolatilization without changing plates, thus improving productivity and polymer properties.
Implementation Method 1
solvents and monomers may diffuse slowly from the viscous bulk polymer product
Implementation Method 2
Devolatilization technology consists of a series of vapor-liquid flash steps
Data Source
AI summary
In at least one embodiment, a devolatilization vessel includes a first set of one or more devolatilization plates and a second set of one or more devolatilization plates. A first distributor is above the first set of one or more devolatilization plates and the second set of one or more devolatilization plates. A second distributor is above the second set of one or more devolatilization plates. In at least one embodiment, a process of forming a polymer includes forming a first polymer solution having a first viscosity and forming a second polymer solution having a second viscosity. The process includes flowing the first polymer solution and the second polymer solution to a devolatilization vessel. The process includes removing volatiles from the first polymer solution and the second polymer solution in the devolatilization vessel to form a devolatilized first polymer melt and a devolatilized second polymer melt.