Heat Accumulation Device for Polymerization Energy Recovery
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Solution Overview
Problem
Current polymerization plants face challenges in efficiently transferring and utilizing the energy generated by exothermic units operating continuously to endothermic units operating batchwise, particularly in the production of polymeric resins containing rubber, due to the mismatch in energy requirements and the inability to exploit reaction heat for heating the solvent, leading to suboptimal energy recovery and efficiency.
Innovation Solution
An energy accumulation device is introduced between the continuous exothermic and batch endothermic operations, using a service fluid to store and transfer heat from the exothermic unit to the endothermic unit, ensuring efficient energy integration and utilization across different thermal levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If low-pressure steam is used to heat the dissolution solvent, then the solvent can be heated to the desired dissolution temperature, but the energy required for heating is greater than the energy generated by the continuous polymerization reaction
Solution Approach 1:
The patent introduces a heat accumulation device that stores thermal energy in advance during periods when the polymerization reaction generates excess heat. This accumulated heat is then utilized during batch dissolution operations, eliminating the need for additional low-pressure steam and external energy sources. The preliminary accumulation of thermal energy resolves the contradiction between heating requirements and energy availability.
Solution Approach 2:
The heat accumulation device acts as an intermediary between the continuous exothermic polymerization reaction and the batch endothermic dissolution process. It buffers the temporal and thermal mismatch between these two operations, allowing heat generated continuously to be stored and then applied intermittently when dissolution requires heating, thereby eliminating the need for separate steam heating systems.
2Productivity
If the heating time of the solvent is reduced to shorten dissolution cycle times, then productivity increases, but the energy required for heating becomes greater than the energy produced by the reaction
Solution Approach 1:
By accumulating heat in advance during periods of excess thermal energy generation, the system prepares the necessary thermal energy before rapid heating is needed. This allows the dissolution process to be accelerated with high-energy heating when required, without compromising the overall energy balance, as the heat has already been stored from previous excess generation periods.
3Loss of energy
If a batch endothermic operation is coupled with a continuous exothermic operation for thermal integration, then energy recovery is improved, but the mismatch in operational modes makes coupling difficult
Solution Approach 1:
The heat accumulation device serves as a mediator that simplifies the coupling between batch and continuous operations. Rather than requiring complex real-time coordination systems, the accumulator passively stores thermal energy during continuous operation and releases it during batch operation, effectively decoupling the temporal synchronization requirements while achieving thermal integration and improving energy recovery.
4Temperature
If service fluids from cooling operations are used, then cooling function is performed, but the temperatures never reach the levels required for producing low-pressure steam
Solution Approach 1:
The system accumulates thermal energy in advance from the polymerization reaction at high temperatures. This accumulated heat is then transferred to the service fluids that need heating for dissolution. By using the accumulated heat directly rather than relying on cooled service fluids, the system achieves steam-generation temperatures without requiring external energy input, thus resolving the temperature gap issue.
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 enhances energy efficiency by recovering reaction enthalpy and reducing the energy required for the rubber dissolution process, saving approximately 5% of the total heat needed, while maintaining stable temperatures within the accumulation device above 80°C to ensure effective heating.
Implementation Method 1
The energy developed in an exothermic unit, preferably heat, is transferred to the accumulation device by means of a service fluid which serves the exothermic unit
Implementation Method 2
recovering the energy produced by an exothermic unit operating in continuous
Implementation Method 3
a section of the plant to be dedicated to the storage of the energy developed ('heat storing area') by an exothermic unit
Implementation Method 4
A part of it is therefore removed to provide heat... the heating phase of the solvent to the desired dissolution temperature
Data Source
Figure 1~2
Figure 3~4
AI summary
The present invention relates to a system for energy recovery and a polymerization plant having such a system comprising a. an exothermic device operating continuously (exothermic device interpreted as any apparatus able to produce heat and transfer it onto another body), b. a cooling device in fluid communication with said exothermic device, c. an endothermic device operating discontinuously (endothermic device interpreted as any apparatus able to receive heat from another body, i. e. to be heated); said system being characterized in that it comprises a device for the accumulation of the energy produced by the exothermic device in fluid communication with the discontinuous endothermic device, the exothermic device operating continuously and the cooling device using a service fluid.