Hydrated Polymer Cutting for Homogeneous Aqueous Solutions
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Solution Overview
Problem
Existing methods for converting hydrated polymer gels into aqueous polymer solutions are energy-intensive, prone to equipment blockages, and result in uneven dissolution, leading to operational inefficiencies and maintenance issues due to the hygroscopic nature of water-soluble polymers.
Innovation Solution
A process involving cutting the hydrated polymer with high-pressure aqueous liquid streams to reduce its size, followed by dissolution in an aqueous liquid, utilizing a device with rotating nozzles and sieve trays to prevent lump formation and ensure uniform size reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If dry polymer powder is added to water for hydration, then aqueous polymer solution is produced, but lumps or agglomerates form making the solution non-homogeneous
Solution Approach 1:
The patent applies preliminary action by pre-hydrating the polymer powder in a hydrating chamber before dissolution. The polymer particles are exposed to moisture in the air within the sealed hydrating chamber, allowing controlled preliminary hydration that prevents lump formation during subsequent water addition. This pre-hydration step ensures uniform moisture distribution throughout the polymer mass before the dissolution phase begins.
Solution Approach 2:
The patent segments the polymer processing into distinct phases: a hydrating phase where polymer particles are exposed to controlled moisture in a sealed chamber, and a dissolution phase where pre-hydrated polymer is transferred to water. This segmentation allows each phase to be optimized independently, preventing the formation of agglomerates by controlling the timing and manner of water contact with polymer particles.
2Productivity
If polymer particles are fed into mixing equipment, then aqueous polymer solution is produced, but equipment becomes blocked due to premature hydration
Solution Approach 1:
The patent performs preliminary hydration in a controlled hydrating chamber before the polymer enters the mixing equipment. By pre-exposing the polymer to controlled moisture levels in a sealed environment, the polymer particles achieve uniform moisture distribution without becoming excessively sticky or blocking the feed mechanisms. This preliminary action prevents premature hydration that would otherwise cause equipment blockages.
Solution Approach 2:
The hydrating chamber acts as an intermediary between polymer storage and mixing equipment. This intermediate step provides a controlled environment where polymer hydration is managed before the material enters the mixing system, preventing direct contact between dry polymer and mixing equipment that would lead to blockages. The chamber serves as a buffer zone that mediates the transition from dry to hydrated state.
3Speed
If high energy input is used for polymer dissolution, then dissolution speed increases, but energy consumption increases
Solution Approach 1:
The patent applies preliminary hydration to prepare polymer particles before dissolution, which significantly reduces the energy required for subsequent dissolution. By pre-exposing particles to controlled moisture in the hydrating chamber, the polymer structure is partially prepared for water uptake, reducing the mechanical energy and time needed for complete dissolution in the mixing equipment.
Solution Approach 2:
The patent skips the intermediate step of gradual wetting by directly transferring pre-hydrated polymer from the hydrating chamber to the dissolution water. This eliminates the need for prolonged low-energy wetting phases and allows rapid dissolution to proceed efficiently, reducing total energy consumption while maintaining high dissolution speed.
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 efficiently converts hydrated polymer gels into homogeneous aqueous polymer solutions, reducing energy consumption, minimizing equipment blockages, and ensuring consistent product quality by maintaining polymer particles as individual entities during hydration.
Implementation Method 1
cutting the hydrated polymer with high-pressure aqueous liquid streams to reduce its size
Implementation Method 2
water-soluble polymers readily absorb water and become sticky
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
Process and apparatus for producing an aqueous polymer solution comprising the steps of • (a) providing a hydrated polymer that has been prepared by aqueous solution polymerisation of ethylenically unsaturated monomers, which hydrated polymer comprises at least 10% by weight active polymer; • (b) cutting the hydrated polymer by subjecting the hydrated polymerto at least one cutting stage comprising at least one stream of aqueous liquid at a pressure of at least 150 bar to reduce the size of the hydrated polymer, • (c) dissolving the hydrated polymer in an aqueous liquid so as to obtain an aqueous polymer solution.