Loop Reactor Slurry Cavitation Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current olefin polymerization processes in loop reactors face challenges in maintaining efficient operation, including cavitation issues and suboptimal polymerization conditions, which affect the properties and yield of polyolefins.
Innovation Solution
The process involves circulating a slurry of olefin monomers, a liquid diluent, catalyst, and polyolefin particles within a loop reactor under specific conditions, including controlled cavitation numbers, circulation velocities, and temperature and pressure ranges, to enhance polymerization efficiency and polyolefin particle suspension.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If circulation velocity is increased to improve polymerization efficiency, then productivity increases, but cavitation occurs causing harmful effects
Solution Approach 1:
The patent changes the operating parameters by controlling the cavitation number within a specific range (0.5 to 5.0) and maintaining Euler number above 4.0, along with specific temperature (38-121°C) and pressure (27-50 bar) conditions, to achieve optimal polymerization efficiency while preventing harmful cavitation effects
Solution Approach 2:
The patent implements process control through continuous monitoring and adjustment of circulation velocity to maintain the cavitation number within the optimal range, using feedback mechanisms to balance productivity enhancement with cavitation prevention
2Productivity
If solids content is increased to improve polymer yield, then productivity increases, but slurry viscosity increases making circulation difficult
Solution Approach 1:
The patent optimizes the balance between solids content and circulation velocity by maintaining specific dimensionless numbers (cavitation number 0.5-5.0, Euler number ≥4.0), allowing high solids content (improved yield) while managing slurry viscosity through controlled flow conditions
3Temperature
If circulation velocity is increased to improve heat transfer, then temperature control improves, but energy consumption increases
Solution Approach 1:
The patent achieves optimal temperature control by operating at specific cavitation numbers (0.5-5.0) and Euler numbers (≥4.0), which provide sufficient heat transfer through controlled circulation without excessive energy consumption, balancing thermal management with energy efficiency
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 allows for improved polymerization processes with reduced cavitation, increased solids content, and optimized reactor operation, leading to higher quality polyolefins with enhanced properties and reduced operational costs.
Implementation Method 1
the process has a cavitation number (Ca) of from 6 to 60
Data Source
Figure 1
AI summary
Olefin polymerization processes are described herein. The processes generally include circulating a slurry including an olefin monomer selected from C2-C12 olefin monomers, a liquid diluent selected from C3-C7 alkanes, catalyst and polyolefin particles under polymerization conditions within a loop reactor. In one or more specific embodiments, in operation, the process has a cavitation number of from 6 to 60 and the polymerization conditions include a polymerization temperature of from 38°C to 121°C and a polymerization pressure of from 27 bar to 50 bar. In other embodiments, the process has a Euler Number (Eu) of at least (5).