Methacrylic Polymer Production via Segmented Reactor Cooling
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Solution Overview
Problem
The existing methods for bulk polymerization of methacrylic polymers face challenges in increasing polymerization ratio due to depolymerization at high temperatures, leading to viscosity issues and reactor clogging, which hampers productivity and polymer quality.
Innovation Solution
The proposed solution involves a production apparatus comprising a complete mixing type reactor, serially connected tubular reactors, and a volatile removing instrument, where the reaction solution is cooled between reactors to control temperature and prevent clogging, allowing for improved polymerization ratios and reduced exposure to high temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If polymerization is conducted at high temperature to improve productivity, then polymerization rate increases, but depolymerization occurs and polymerization ratio decreases
Solution Approach 1:
The patent divides the polymerization process into multiple stages: a complete mixing type reactor for initial polymerization followed by one or more tubular reactors for continued polymerization. This segmentation allows different temperature and mixing conditions in each stage, enabling high initial polymerization rate while maintaining high final polymerization ratio through controlled conditions in subsequent stages.
Solution Approach 2:
The complete mixing type reactor performs preliminary polymerization at controlled temperature before the reaction solution enters the tubular reactor. This preliminary action converts a portion of monomer to polymer under controlled conditions, then the tubular reactor continues polymerization with added initiator at optimized temperature, preventing depolymerization while maintaining high productivity.
2Reliability
If polymerization temperature is lowered to raise polymerization ratio, then depolymerization is reduced, but reaction rate decreases and productivity drops
Solution Approach 1:
The patent segments the polymerization process into multiple reactors with different temperature optimizations: the complete mixing type reactor operates at temperatures favoring reaction rate, while tubular reactors operate at temperatures favoring polymerization ratio. This allows each stage to be optimized for its specific function without compromising overall productivity or polymerization ratio.
Solution Approach 2:
The patent changes temperature parameters between reactor stages and adjusts initiator concentration in the tubular reactor to optimize both reaction rate and polymerization ratio. By controlling temperature and initiator addition at different stages, the system achieves high polymerization ratio while maintaining acceptable productivity.
3Reliability
If a polymerization initiator is added to high temperature reaction solution and then cooled in the tubular reactor, then polymerization ratio increases, but viscosity increases and residence parts form causing clogging
Solution Approach 1:
The complete mixing type reactor performs preliminary polymerization to convert a portion of monomer to polymer before the reaction solution enters the tubular reactor. This preliminary conversion reduces the amount of monomer available for rapid polymerization later, preventing excessive viscosity increase and residence part formation in the tubular reactor while still achieving high final polymerization ratio.
Solution Approach 2:
The patent optimizes the temperature at which the reaction solution is cooled before entering the tubular reactor and controls the amount of initiator added. By adjusting these parameters, the system achieves high polymerization ratio while maintaining adequate fluidity and preventing clogging through controlled viscosity management.
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 enhances the polymerization ratio before solvent removal, reduces heat and time requirements for volatile removal, and improves polymer quality by minimizing dimer generation and maintaining reactor flow stability.
Implementation Method 1
at least two of said tubular reactors are connected via a cooler for cooling the reaction solution
Implementation Method 2
a polymerization initiator is further added to the reaction solution obtained in the previous step, then, polymerizing the reaction solution
Data Source
AI summary
Disclosed is an apparatus for producing a high-quality methacrylic polymer with good productivity, comprising a complete mixing type reactor 11, tubular reactors 12 and 13 which have been serially connected, and a volatile removing instrument 14, wherein at least two of the tubular reactors 12 and 13 are connected via a cooler 15 for cooling the reaction mixture. It is preferable that the cooler 15 is a multitubular cooler and the tubular reactors 12 and 13 are plug flow reactors.