Fluid Separation System With Multi-Elevation Inlets For Polymer Reactor Shutdown
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Solution Overview
Problem
Large-scale polymerization reactors face challenges in safely and effectively separating particles from high mass flux fluid flows during emergency shut-downs, as existing separation systems are not well-suited to handle massive forces and vibrations associated with large reactor sizes.
Innovation Solution
A separation system that introduces fluid into a vessel through multiple fluid inlets positioned at different elevations, avoiding supersonic flow interactions and promoting less turbulent flow, with a coolant reservoir to quench particles and suppress static electricity, and a larger fluid outlet to manage pressure and vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a single large fluid inlet is used in existing separation systems, then the system can handle large mass flux fluid flows, but it generates massive forces and vibrations that compromise safety and separation effectiveness
Solution Approach 1:
The single large fluid inlet is divided into multiple smaller fluid inlets (first fluid inlet and second fluid inlet) positioned at different elevations in the vessel. This segmentation reduces the mass flux through each individual inlet, thereby reducing the forces and vibrations generated by each jet, while the combined capacity of all inlets maintains the overall handling capability for large mass flux fluid flows from high capacity reactors.
2Productivity
If the reactor size is increased to achieve high capacity production, then productivity improves, but the demands and forces on separation equipment increase
Solution Approach 1:
The system uses multiple fluid inlets positioned at different elevations to segment the total mass flux from large capacity reactors. This allows high productivity reactors to be connected to the separation system without generating excessive forces and vibrations, as each inlet handles a portion of the total flow.
Solution Approach 2:
The patent introduces vertical positioning (elevation dimension) of fluid inlets in addition to horizontal arrangement. By positioning inlets at different heights, the system distributes the load in three-dimensional space, reducing concentrated forces and vibrations on any single point of the separation equipment while maintaining high reactor capacity.
3Device complexity
If fluid inlets are positioned at the same elevation, then the structure is simpler, but supersonic flow interactions occur causing excessive vibrations
Solution Approach 1:
Instead of only horizontal positioning, the patent adds the vertical dimension by positioning fluid inlets at different elevations. This three-dimensional arrangement prevents supersonic flow interactions that occur when inlets are at the same elevation, reducing vibrations without significantly increasing structural complexity.
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
The system effectively separates polymer particles from fluids during reactor shut-downs, reducing internal surface pressures and vibrations, and preventing particle release into the atmosphere, ensuring safe and clean operation of large-scale reactors.
Implementation Method 1
a coolant reservoir to quench particles
Implementation Method 2
rapidly relieving the temperature and pressure conditions within the reactor
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
Systems and methods for separating particles from fluids are provided. The system comprises a vessel with at least two fluid inlets and a fluid outlet wherein one fluid inlet is positioned higher in the vessel than the other fluid inlet. The fluid inlets may be connected to a polymerization reactor and each fluid inlet may be configured to deliver fluid to the vessel from a different zone of the polymerization reactor. During shut-down of a polymerization reactor, reaction mixture is discharged to a separation system where polymer particles are removed from the mixture prior to being released into the atmosphere.