Horizontal Solid-State Polymerization Reactor Design
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Solution Overview
Problem
Existing polymerization processes for polyester and polyamide polymers face challenges such as high energy consumption, expensive gas circulation systems, complex reactor designs, and non-uniform product quality due to the need for large reactors and inefficient heat transfer in both vertical and horizontal reactors, particularly during solid-state polymerization.
Innovation Solution
A continuous solid-state polymerization process using a horizontal reactor with a rotatable tubular design or cradle, operating under vacuum or inert gas, which allows for efficient heat transfer and uniform treatment of granules without rotary feedthroughs, reducing energy consumption and enhancing product brilliance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If nitrogen gas is used in circulating systems to remove process vapors during solid state polymerization, then the harmful vapors are removed from the system, but the energy consumption and equipment cost increase due to complex cleaning equipment and high gas circulation requirements
Solution Approach 1:
The patent applies inert atmosphere principle by using nitrogen to blanket the reactor and prevent oxygen ingress, while process vapors are removed through a vacuum system rather than gas circulation. This eliminates the need for energy-intensive gas circulation and complex cleaning equipment, as the inert atmosphere is maintained passively through the vacuum removal system.
2Manufacturing precision
If large amounts of gas are circulated through the SSP reactor to achieve uniform flow and residence time, then uniform treatment of polymer is achieved, but the equipment complexity and energy consumption increase
Solution Approach 1:
The patent applies dynamics principle by introducing mechanical movement of the polymer granules through reactor rotation or agitation mechanisms. This dynamic approach ensures uniform treatment and residence time distribution without requiring large volumes of circulating gas, thereby simplifying the gas circulation system and reducing energy consumption while maintaining manufacturing precision.
3Productivity
If vertical fixed-bed reactors are used for solid state polymerization, then the process can be carried out continuously, but the structural height increases requiring building heights of up to 50 m
Solution Approach 1:
The patent applies dimensionality change principle by transitioning from vertical to horizontal reactor configuration. This allows the continuous polymerization process to be maintained while significantly reducing the structural height requirement, as the reactor extends in the horizontal dimension rather than requiring 50 meters of vertical space.
4Length of stationary object
If horizontal rotating reactors are used for solid state polymerization, then the structural height is reduced, but the mechanical design becomes complicated and expensive due to gas-tight rotary feedthroughs
Solution Approach 1:
The patent applies extraction principle by removing the complex gas-tight rotary feedthrough system from the horizontal reactor design. Instead, the reactor is operated under vacuum with polymer feed and gas introduction/ removal through stationary ports, eliminating the need for rotating feedthroughs while maintaining the horizontal configuration's space efficiency.
5Device complexity
If discontinuous processes in tumble or cone dryers are used for solid state polymerization, then the equipment design is simpler, but the throughput is low due to required size and residence time
Solution Approach 1:
The patent applies continuity principle by implementing a continuous horizontal reactor design where polymer granules continuously move through the reaction zone. This maintains simpler equipment design compared to complex rotating systems while achieving high throughput through continuous operation, eliminating the throughput limitations of discontinuous batch processes.
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 a more efficient and cost-effective polymerization process with improved product uniformity and reduced energy consumption by maintaining the granules in motion, avoiding back-mixing, and utilizing vacuum conditions to minimize oxygen exposure and enhance heat exchange.
Implementation Method 1
The continuous solids polymerisation is carried out in such a way that the particles are at least partially polymerized and/or treated in at least one horizontal reactor at a pressure below atmospheric pressure
Implementation Method 2
The granules produced in this way are then subjected to solid-phase polymerization, in which the viscosity is increased
Implementation Method 3
the particles (e.g. the granules) being able to be moved back and forth in the cradle
Data Source
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AI summary
The invention relates to a process and to an apparatus for continuous solid-state polymerization of particles, especially of a granule of polyesters and polyamides, characterized in that the particles (20) are polymerized and/or treated in at least one reactor (12), the at least one reactor (12) having a pressure below atmospheric pressure or being present in a chamber (12A) under a protective gas atmosphere.