Inverted Cone Purge Bin Insert for Uniform Resin Flow
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Solution Overview
Problem
In polyolefin polymerization processes, the removal of volatiles from polymer resin using a purge bin is inefficient due to uneven resin flow and inadequate distribution of purging gas, leading to damage and non-commercially viable products.
Innovation Solution
A system with an inverted cone and a member under the cone, promoting a constant velocity profile for solids flow and uniform gas distribution, ensuring consistent contact time with the purging gas for effective volatile removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the resin flow rate through the purge bin is decreased to ensure sufficient contact time with purging gas, then the volatile removal efficiency is improved, but the overall process productivity deteriorates
Solution Approach 1:
The patent applies local quality by creating different flow conditions in different regions of the purge bin. The inverted cone and insert structure generate a uniform cross-sectional flow rate distribution across the resin bed, ensuring that all portions of the resin receive adequate purging gas exposure. This localized flow uniformity optimization allows for improved volatile removal without requiring a blanket reduction in overall flow rate, thus resolving the contradiction between removal efficiency and process productivity
2Device complexity
If the purging gas is simply piped into the resin without considering flow distribution, then the device complexity is reduced, but the resin quality deteriorates due to damage and poor product viability
Solution Approach 1:
The patent introduces an inverted cone and insert structure as an intermediary element between the purging gas source and the resin. This intermediary component actively manages the gas distribution and flow patterns, ensuring uniform contact between the purging gas and resin throughout the purge bin. The intermediary structure prevents direct, uncontrolled gas injection that would cause resin damage, thereby maintaining resin quality while adding only moderate structural complexity
Solution Approach 2:
The patent employs parameter changes by modifying the flow velocity profile through the inverted cone and insert geometry. The structure creates a uniform cross-sectional flow rate distribution, transforming the velocity parameters from non-uniform to uniform across different radial positions. This parameter optimization ensures adequate contact time throughout the resin bed without causing localized damage from excessive velocity, thus improving resin quality with controlled structural additions
3Loss of time
If uneven flow patterns occur in the resin through the purge bin, then the contact time distribution becomes non-uniform, but the volatile removal efficiency deteriorates due to inconsistent purging across different portions
Solution Approach 1:
The patent applies local quality by creating different flow conditions in different regions of the purge bin. The inverted cone and insert structure generate a uniform cross-sectional flow rate distribution across the resin bed, ensuring that all portions of the resin receive adequate purging gas exposure. This localized flow uniformity optimization allows for improved volatile removal without requiring a blanket reduction in overall flow rate, thus resolving the contradiction between removal efficiency and process productivity
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 enhances the efficiency of volatile removal by maintaining a uniform resin flow and gas dispersion, reducing the time needed to achieve acceptable purging levels and preventing resin damage.
Implementation Method 1
solids passing therealong between the member and the barrier to have about a constant velocity profile thereacross
Implementation Method 2
remove unwanted volatiles from the polymer resin
Data Source
AI summary
A system in one embodiment includes a barrier; an inverted cone in the barrier; and a member under the inverted cone and having dimensions that cause solids passing therealong between the member and the barrier to have about a constant velocity profile thereacross. A method for purging a gas from a solid/gas mixture according to one embodiment includes adding solids to a barrier having an inverted cone therein and a member under the inverted cone, wherein the solids passing along the member have about a constant vertical velocity profile thereacross; and injecting a purge gas into the solids from at least one point adjacent the member.