Horizontal Polymer Melt Reactor with Segmented Rotor for Degassing
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Solution Overview
Problem
Conventional polymer melt reactors are inefficient at high throughputs, with most of the reactor volume unused, leading to increased investment and operational costs, and are not optimized for modern pre-reactor systems or high-capacity production.
Innovation Solution
A horizontally aligned reactor with a compartmentalization element featuring a rotor with a weir arrangement divides the reactor into inner and outer compartments, allowing controlled flow and extended residence time of the polymer melt, along with mixing and transport elements to enhance degassing and homogenization, and a jacket heater for temperature control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If conventional reactor design is used to ensure homogeneous product, then product homogeneity is improved, but reactor volume utilization deteriorates (only 18-22% occupied)
Solution Approach 1:
The reactor is divided into inner and outer compartments using a rotor with impermeable wall, creating segmented flow paths that improve volume utilization while maintaining homogeneity through controlled transfer between compartments
Solution Approach 2:
The compartmentalization element extends along the longitudinal axis of the reactor, utilizing the longitudinal dimension to create multiple compartments that increase effective reaction volume without increasing external reactor dimensions
2Device complexity
If conventional reactor design is used, then structural simplicity is maintained, but investment costs and operational complexity increase due to oversized reactor
Solution Approach 1:
The reactor is divided into inner and outer compartments using a rotor with impermeable wall, creating segmented flow paths that improve volume utilization while maintaining homogeneity through controlled transfer between compartments
Solution Approach 2:
The compartmentalization element serves multiple functions: it divides the reactor volume, provides mixing through rotor rotation, controls flow between compartments via weir arrangement, and extends residence time, thereby reducing the need for separate equipment
3Ease of operation
If conventional reactor design is used, then ease of operation is maintained, but productivity deteriorates at high throughputs
Solution Approach 1:
The rotor is designed to rotate within the reactor, dynamically adjusting the flow between inner and outer compartments and enhancing mixing efficiency to maintain high throughput while preserving product homogeneity
Solution Approach 2:
The compartmentalized design with rotor rotation ensures continuous mixing and transfer of polymer melt between compartments, maintaining consistent reaction conditions and productivity throughout the operation
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 design effectively utilizes reactor volume, reduces polymer deposit risk, and enhances degassing and homogenization, enabling more efficient production with improved flowability and reduced viscosity-related issues at high throughputs.
Implementation Method 1
a compartmentalization element arranged horizontally therein, which has a rotor with a rotor wall that is impermeable to the polymer melt, the rotor having at least one opening delimited by a weir arrangement in the direction of an end wall of the reactor housing
Implementation Method 2
After the polymer melt has entered the reactor, it can be mixed and conveyed in the direction of the outlet with the help of ring-shaped elements that are attached to a rotatably mounted rotor
Implementation Method 3
a jacket heater for heating the reactor
Implementation Method 4
the reactors in which the prepolymer melt or polymer melt is freed from gaseous reaction and by-products
Data Source
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AI summary
The invention relates to a reactor for the degassing of a polymer melt and for polycondensation, comprising a horizontally oriented reactor housing. The reactor housing has two end walls, at least one outlet for the degassed polymer melt, and at least one exhaust vapor port. The reactor of the invention is characterized in that, in the interior of the reactor housing, there is a horizontally arranged compartmenting element, which contains a rotor. The rotor has at least one opening toward an end wall of the reactor housing, which opening is delimited by a dam arrangement. Furthermore, the rotor has a rotor wall, which is impermeable to the polymer melt, and divides the interior of the reactor housing into an inner reactor compartment and an outer reactor compartment. In addition, the reactor according to the invention has a tube for supplying the polymer melt, which tube runs through the inlet-side end wall. Said tube ends in the interior of the rotor such that the polymer melt is introduced into the inner reactor compartment.