Drag Reducing Polymer Production Using Disposable Receptacle Liners
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Solution Overview
Problem
Existing methods for producing drag reducing polymers face challenges such as high exothermic polymerization reactions leading to reduced molecular weight and contamination issues due to polymer adherence to reactor vessels.
Innovation Solution
The use of an elongate receptacle made of a plastic film material, which is not self-supporting and is preferably flaccid when not containing polymer, to contain the drag reducing polymer. This receptacle is designed to be easily manipulated and allows for efficient isolation of the polymer from the receptacle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If bulk polymerization is used to produce high yield, then productivity is improved, but the exothermic reaction reduces polymer molecular weight
Solution Approach 1:
The bulk polymerization process is segmented into multiple smaller reactors rather than one large reactor. This allows better heat control in each segment while maintaining high overall productivity. The polymerization reaction is divided into stages, with each reactor handling a portion of the total production, thereby managing the exothermic nature of the reaction without sacrificing yield or molecular weight.
2Productivity
If polymer is produced in conventional reactors, then productivity is improved, but polymer adheres to reactor walls causing contamination
Solution Approach 1:
The invention employs disposable reactor liners or coatings that are discarded after a single use. These temporary reactor surfaces prevent polymer adhesion during the reaction, and are then discarded rather than cleaned. This eliminates polymer contamination of downstream processes while maintaining high productivity, as the disposable component is inexpensive and quickly replaced.
Solution Approach 2:
A reactive intermediary layer or coating is introduced between the polymer and the reactor wall. This intermediary prevents direct adhesion of the polymer to the reactor surface, allowing easy removal of the polymer product without contamination. The intermediary layer acts as a mediator that protects the reactor and ensures clean polymer recovery for downstream applications.
3Temperature
If complex multi-layer reactor vessels are used, then heat exchange capability is improved, but device complexity increases and separation becomes difficult
Solution Approach 1:
The heat exchange function is extracted from the reactor vessel structure itself and separated into a distinct, removable heat exchange system. This allows the reactor to have a simple, easy-to-clean structure while still providing efficient heat removal through an external or detachable heat exchange unit. The complexity of heat management is separated from the reactor design, simplifying polymer recovery and reactor preparation.
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 the production of drag reducing polymers in large quantities with consistent quality, reduces contamination risks, and facilitates easy handling and downstream processing of the polymer.
Implementation Method 1
The invention relates to polymeric materials and particularly, although not exclusively, relates to drag reducing polymers
Implementation Method 2
These polymerization reactions tend to be very efficient, producing relatively high yield when carried out in bulk. However, they also tend to be highly exothermic
Data Source
AI summary
A combination including a receptacle of defined internal volume, which contains a chemical reaction product. The product may be made in apparatus for undertaking a chemical reaction which comprises an elongate housing and a receptacle. The elongate housing may include a cooling means and end fittings which may include ports where fluids may be introduced and/or removed.