Horizontal Polymerization Reactor Temperature Mapping for Agglomerate Control
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Solution Overview
Problem
Existing continuous gas phase polymerization processes using cylindrical horizontal reactors face challenges in suppressing the formation of aggregated polymers and ensuring stable, long-term operation, particularly when reaction heat is removed by the vaporization heat of liquefied monomer-containing liquids.
Innovation Solution
Monitor and control the temperature distribution in the circumferential direction of the reactor using a specific temperature parameter, defined by formulas involving the highest temperature, average temperature, and central angle differences, to prevent excessive temperature gradients, thereby controlling production conditions to suppress aggregated polymer formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the temperature distribution in the reactor is not monitored and controlled, then the process operation is simpler, but aggregated polymers form and stable long-term production cannot be achieved
Solution Approach 1:
The patent implements a feedback control system where the temperature distribution in the circumferential direction of the reactor is continuously measured and monitored. Based on the measured temperature data, control actions are taken to adjust the temperature distribution, thereby preventing aggregated polymer formation and ensuring stable long-term production. This closed-loop feedback mechanism directly addresses the contradiction by providing reliable production control through systematic temperature management.
2Object-generated harmful factors
If the temperature distribution parameter is not monitored, then the measurement and control system is simpler, but aggregated polymer formation cannot be suppressed
Solution Approach 1:
The patent employs non-contact infrared temperature measurement technology to monitor the temperature distribution in the circumferential direction of the reactor. This optical measurement method replaces traditional contact-based temperature sensors, enabling precise temperature field mapping without mechanical interference or intrusion into the reaction system. The high-resolution temperature data obtained allows for effective detection and suppression of aggregated polymer formation through targeted temperature control.
3Measurement precision
If infrared type thermometer is used to measure temperature distribution from a predetermined distance, then the measurement system is simpler, but the accuracy of temperature control decreases due to heat dissipation and outside temperature influence
Solution Approach 1:
The patent measures the temperature distribution in the circumferential direction (angular dimension) of the reactor rather than only in the radial or axial directions. By implementing temperature monitoring around the entire circumference of the reactor, the system can detect localized temperature variations and hot spots that would be missed by single-point measurements. This multi-dimensional temperature mapping approach significantly improves temperature control accuracy by providing comprehensive spatial temperature information while accounting for heat dissipation patterns and external temperature influences.
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 method effectively suppresses aggregated polymer formation, enhances long-term operability, and improves production efficiency in the continuous gas phase polymerization process.
Implementation Method 1
continuous gas phase polymerization process using cylindrical horizontal polymerization reactor in which reaction heat is removed by the vaporization heat of a liquefied monomer-containing liquid
Data Source
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AI summary
A method for producing a propylene-based polymer, wherein a propylene-based polymer is polymerized in the presence of a catalyst with a cylindrical horizontal polymerization reactor comprising an agitating mechanism rotatable around a horizontal axis inside the reactor, by a continuous gas phase polymerization which removes reaction heat by vaporization heat of a liquefied monomer-containing liquid; the catalyst is fed from an upper part of one end of the horizontal polymerization reactor; and the propylene-based polymer is discharged from a lower part of the other end of the horizontal polymerization reactor; wherein the method comprises: a temperature measuring step in which a temperature distribution of the cylindrical horizontal polymerization reactor in a circumferential direction, is measured so that a distance between adjacent measurement points is a central angle of π/10 (rad) or less, a calculating step in which a specific temperature distribution parameter (A) is calculated from the temperature distribution obtained by the temperature measuring step, and a monitoring step in which the temperature distribution parameter (A) is monitored so that the parameter is prevented from exceeding a predetermined value.