Injector Nozzle Asymmetry for Loop Reactor Mixing

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Solution Overview

Problem

In olefin slurry polymerization, achieving high solids concentration in loop reactors is limited by instabilities and homogeneity issues, which restrict production efficiency and polymer properties.

Innovation Solution

Designing an injector nozzle with a non-circular discharge orifice and a circular fluid conduit passage, optimized in geometry and position, to enhance reactant dispersion and mixing within the reactor, specifically positioned on an inner three-quarter circle above an elbow section of the reactor.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the solids concentration in the reactor is increased to improve production, then the production efficiency increases, but reactor instabilities occur and homogeneity deteriorates

Engineering Contradiction:

Improveproduction efficiencyVSAvoidreactor stability

Core Design Contradiction:

ProductivityVSStability of the object's composition

Solution Approach 1:

The injector nozzle is positioned upstream in the reactor (on the inner three-quarter circle of the elbow section) to introduce reactants before the main reaction zone. This preliminary action ensures that reactants are distributed early in the flow path, preventing local concentration spikes that would otherwise occur downstream and cause instabilities at high solids concentrations.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The injector nozzle features an asymmetric non-circular discharge orifice cross-section that differs from the circular fluid conduit passage. This asymmetric geometry creates specific flow patterns and turbulence characteristics that enhance mixing efficiency while maintaining reactor stability even at elevated solids concentrations.

Inventive Principle:

Principle #4Asymmetry

2Productivity

If the solids concentration in the reactor is increased to improve production, then the production efficiency increases, but the homogeneity of slurry deteriorates

Engineering Contradiction:

Improveproduction efficiencyVSAvoidslurry homogeneity

Core Design Contradiction:

ProductivityVSStability of the object's composition

Solution Approach 1:

By positioning the injector nozzle upstream on the inner three-quarter circle of the elbow section, reactants are introduced and begin mixing before entering the main reaction zone. This preliminary mixing action ensures more uniform reactant distribution throughout the slurry, maintaining homogeneity even at high solids concentrations.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The injector nozzle is positioned on the curved elbow section of the reactor, utilizing the existing curvature to enhance flow patterns. The non-circular discharge orifice also creates specific flow trajectories that leverage the curved geometry to improve mixing and maintain slurry homogeneity throughout the reactor volume.

Inventive Principle:

Principle #14Spheroidality (Curvature)

3Productivity

If the residence time is reduced to improve production, then the production efficiency increases, but the polymer properties are modified negatively

Engineering Contradiction:

Improveproduction efficiencyVSAvoidpolymer properties

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The upstream positioning of the injector nozzle allows reactants to be introduced and distributed before the main reaction zone, creating more uniform reaction conditions throughout the reactor. This enables longer effective residence time with better mixing, improving polymer properties while maintaining high production efficiency.

Inventive Principle:

Principle #10Preliminary action

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 configuration improves reactant distribution and mixing, increasing polymer production efficiency, allowing higher solids concentrations without reactor instabilities, and optimizing catalyst residence time and productivity.

Implementation Method 1

The injector nozzle according to the present invention provides the advantage of optimally injecting reactants into a loop reactor. The present injector nozzle provides the possibility of maximizing the dispersion, and allows optimized injection and mixing of the reactants into the region surrounding the injector nozzle.

Methodology Applied

Scientific EffectTurbulence: Turbulence

Implementation Method 2

Methodology Applied

Scientific EffectDispersion: Dispersion (of waves)

Data Source

PatentUS7494627B2Device and method for the optimization of the injection of reactants into a reactor

Publication Date: 2009.02.24 TOTAL PETROCHEMICALS RESEARCH FELUY

AI summary

The present invention relates to an injector nozzle defining a passage for a flow of reactants to be injected into a loop reactor suitable for olefin slurry polymerization, consisting essentially of a fluid conduit extending into a discharge orifice portion to be connected to an opening in the reactor wherein the passage of the discharge orifice portion has a non-circular cross-section and the passage of the fluid conduit has a circular cross-section. The invention also relates to the use of the injector nozzle for injecting reactants into a loop reactor suitable for olefin polymerization reaction, wherein said injector nozzle is connected on an inner three quarter circle on or above an elbow section of the reactor.