In-line Polymer Blending via Parallel Reactor Separation
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Solution Overview
Problem
Traditional polymer production methods using reactors in series face limitations in modifying microstructure and molecular weight distribution, and existing parallel configuration blending processes are inefficient due to low polymer concentration and unwanted polymerization, requiring additional separators and catalyst killers.
Innovation Solution
An in-line blending process using two or more reactor-low pressure separator units in parallel configuration, where each reactor is fluidly connected to a low pressure separator with a recycling line, allowing for independent operation and separation of polymer-enriched and polymer-lean phases to produce a homogeneous polymer blend.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If reactors are operated in series configuration, then different process conditions can be used to modify polymer properties, but the individual polymerization is limited and microstructure adaptation possibilities are reduced
Solution Approach 1:
The invention divides the polymerization system into multiple independent parallel reactor-low pressure separator units, each capable of independent operation. This segmentation allows each reactor to be optimized for specific polymerization conditions while maintaining independence, thereby improving microstructure adaptation possibilities without requiring a complex series configuration.
Solution Approach 2:
The invention transitions from a traditional series reactor configuration to a parallel configuration with independent recycling loops. This dimensional change in process architecture enables simultaneous operation of multiple reactors under different conditions, expanding the degrees of freedom for microstructure control while simplifying the overall system logic.
2Stability of the object's composition
If traditional blending processes are used for parallel reactor configuration, then polymer production is achieved, but homogeneity of final blends is poor especially for resins with very different molecular weight
Solution Approach 1:
The invention changes the pressure parameter in the separation process by using low pressure separators instead of high pressure separators. This parameter change enables better phase separation and improves blend homogeneity while maintaining catalyst activity and avoiding unwanted polymerization, thereby resolving the contradiction between homogeneity and productivity.
3Manufacturing precision
If high pressure separation is used to separate polymer-enriched liquid streams, then separation is achieved, but unwanted polymerization occurs downstream requiring catalyst killers which complicate monomer recovery
Solution Approach 1:
The invention applies preliminary anti-action by using low pressure separation conditions that prevent catalyst deactivation and unwanted polymerization before they can occur. The low pressure environment maintains catalyst activity while achieving effective separation, eliminating the need for catalyst killers and simplifying downstream monomer recovery operations.
Solution Approach 2:
The low pressure separator creates an inert environment that is incompatible with unwanted polymerization reactions. By operating at low pressure, the system establishes conditions where catalyst remains active but polymerization cannot proceed, effectively preventing harmful side reactions while maintaining separation efficiency.
4Quantity of substance
If liquid-liquid high pressure separators are used for blending, then polymer separation is achieved, but polymer concentration in liquid streams is low requiring additional downstream separators
Solution Approach 1:
The invention changes the pressure parameter from high to low in the separation process. This parameter change fundamentally alters the separation mechanism and outcome, enabling high polymer concentration in the liquid streams to be achieved in a single separator, thereby eliminating the need for additional downstream separators and simplifying the overall process configuration.
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 process enhances the homogeneity and efficiency of polymer blending by maintaining catalyst activity and preventing unwanted polymerization, allowing for broader microstructure variation and improved space-time-yield in polymer production.
Implementation Method 1
whereby the temperature and pressure of the low pressure separators (3,9) is adjusted such that a liquid phase and a vapour phase are obtained, whereby yielding a polymer-enriched liquid phase and a polymer-lean vapour phase
Implementation Method 2
reintroducing the polymer-lean vapour streams from step (e) via recycling lines (5,11) into the corresponding reactors (2,8)
Data Source
AI summary
An in-line blending process for polymers comprising: (a) providing two or more reactor-low pressure separator units (1,7) in parallel configuration, each reactor-low pressure separator unit comprising one reactor (2,8) fluidly connected to one low pressure separator (3,9) downstream and further a recycling line (5,11) connecting the low pressure separator (3,9) back to the corresponding reactor (2,8); (b) polymerizing olefin monomers having two or more carbon atoms in each of the reactors (2,8) in solution polymerisation; (c) forming an unreduced reactor effluents stream including a homogenous fluid phase polymer-monomer-solvent mixture in each of the reactors (2,8), (d) passing the unreduced reactor effluents streams from each of the reactors (2,8) through the corresponding low pressure separators (3,9), whereby the temperature and pressure of the low pressure separators (3,9) is adjusted such that a liquid phase and a vapour phase are obtained, whereby yielding a polymer-enriched liquid phase and a polymer-lean vapour phase, and (e) separating the polymer-lean vapour phase from the polymer-enriched liquid phase in each of the low-pressure separators (3,9) to form separated polymer-lean vapour streams and separated polymer-enriched liquid streams; (f) combining the polymer-enriched liquid streams from step (e) in a further low-pressure separator and/or a mixer (13) to produce a combined polymer-enriched liquid stream (16); (g) reintroducing the polymer-lean vapour streams from step (e) via recycling lines (5,11) into the corresponding reactors (2,8).