Hyper Compressor Gas Velocity Control for Stable Polymerization

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Solution Overview

Problem

High-pressure polymerization processes suffer from pulsations and vibrations caused by the secondary compressor (hyper compressor), which negatively affect plant performance and require expensive measures to mitigate damage.

Innovation Solution

A process and apparatus that control the velocity of the gaseous reaction mixture within specific ranges in the discharge and suction pipe systems of the hyper compressor, using heat exchangers and mixing blocks to reduce gas pulsations and vibrations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If high-pressure polymerization is conducted in a slurry reactor with high catalyst activity, then productivity is improved, but gas holdup becomes uncontrolled and resin aggregates form

Engineering Contradiction:

Improvepolymerization productivityVSAvoidgas holdup control

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent changes the physical-chemical parameters of the gas-liquid mixture by controlling gas velocity within a specific range (0.05-0.5 m/s) and maintaining specific hydrodynamic conditions in the slurry reactor. This parameter optimization allows high catalyst activity and productivity while preventing gas holdup accumulation and resin aggregate formation through controlled fluid dynamics

Inventive Principle:

Principle #35Parameter changes

2Productivity

If high catalyst activity is used to increase productivity, then polymerization efficiency is improved, but resin aggregates are generated

Engineering Contradiction:

Improvepolymerization efficiencyVSAvoidresin aggregate formation

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent optimizes operational parameters including gas velocity (0.05-0.5 m/s), liquid circulation rate, and reactor hydrodynamics to maintain homogeneous slurry conditions. These parameter changes enable high catalyst activity to be utilized effectively while preventing resin aggregate formation through controlled mixing and gas-liquid distribution

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent implements monitoring and control of gas velocity and slurry hydrodynamics to maintain optimal conditions. By feedback control of these parameters, the system maintains high productivity while preventing resin aggregate formation, as the gas velocity is kept within the specific range that ensures proper gas-liquid-solid interaction without aggregation

Inventive Principle:

Principle #23Feedback

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 controlled gas velocity reduces pulsations and vibrations, leading to a steady flow with improved system stability and reduced wear on equipment, maintaining process efficiency.

Implementation Method 1

a gas phase and a liquid slurry phase are caused to move countercurrently

Methodology Applied

Scientific EffectGravity: Gravitation

Implementation Method 2

high-pressure polymerization process

Methodology Applied

Scientific EffectPolymerization: Photopolymerisation

Data Source

PatentEP4577580B1High-pressure polymerization process with controlled gas velocity

Publication Date: 2026.05.06 BASELL POLYOLEFINE GMBH

Figure 1

AI summary

A process for the polymerization or copolymerization of one or more ethylenically unsaturated monomers with a controlled gas velocity of the gaseous reaction as well as a high-pressure polymerization apparatus for carrying out the process of the present disclosure.