Reciprocating Piston Catalyst Delivery System for Polymerization Vessels
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Solution Overview
Problem
Existing catalyst delivery systems face issues with clogging and fouling due to undesired polymer build-up in reaction vessels, leading to downtime for cleaning and equipment replacement during polymerization reactions.
Innovation Solution
A positive displacement reciprocating piston system is used to deliver catalysts into polymerization reaction vessels, featuring a piston with a top and bottom section and an annular catalyst holding space, which moves between positions to prevent catalyst flow issues and reduce polymer accumulation, utilizing a cam driven by a motor for precise catalyst delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If metering technology is used to deliver catalyst to polymerization reaction vessel, then precise catalyst delivery is achieved, but polymer build-up occurs in the reaction vessel and feed lines causing clogging and fouling
Solution Approach 1:
The harmful interaction between monomer vapor and catalyst is eliminated by extracting the catalyst delivery point from the reaction vessel environment. The catalyst is delivered directly into the liquid monomer phase through a dip tube, bypassing the vapor space where unwanted polymerization occurs. This extraction of the catalyst from harmful environmental exposure prevents fouling and clogging in feed lines and valves.
Solution Approach 2:
A positive displacement pump system acts as an intermediary between the catalyst source and the reaction vessel. This intermediary mechanism provides precise metering control while maintaining catalyst isolation from monomer vapor until the moment of delivery. The pump system includes isolation valves and a dip tube that serve as intermediate components to protect the catalyst delivery path from polymer build-up.
2Productivity
If catalyst is fed into reaction vessel, then polymerization reaction is enabled, but polymer build-up along vessel walls disrupts catalyst flow and causes downtime
Solution Approach 1:
The catalyst delivery system performs preliminary actions to prevent polymer build-up before it can disrupt operations. The dip tube delivers catalyst directly to the liquid monomer surface, and the system maintains positive pressure in the catalyst feed line to prevent monomer vapor ingress. These preliminary protective measures prevent the formation of disruptive polymer deposits on vessel walls and in the catalyst delivery path, eliminating cleaning downtime.
3Ease of operation
If monomer vapor contacts catalyst in feed lines, then unwanted polymerization occurs, but this clogs and fouls feed lines and valves
Solution Approach 1:
The catalyst delivery point is extracted from the vapor-exposed feed line environment and placed directly into the liquid monomer phase. The dip tube extends into the liquid phase, and catalyst is delivered at the liquid surface where vapor contact is minimized. This extraction eliminates the vulnerability of feed lines and valves to monomer vapor ingress and unwanted polymerization, simplifying the system by removing the need for complex vapor barrier protections.
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
The system significantly reduces polymer build-up and fouling, minimizing downtime by ensuring consistent and controlled catalyst delivery, thereby maintaining reactor efficiency and extending equipment lifespan.
Implementation Method 1
A positive displacement reciprocating piston system is connected to the polymerization reaction vessel... the piston is movable between a first position and second position... catalyst is discharged from the annular catalyst holding space into the cavity of the polymerization reaction vessel
Data Source
AI summary
Described herein are systems and methods for delivering catalyst to a reaction vessel. The methods include the use of a positive displacement reciprocating piston system having a catalyst delivery housing that contains a piston system. The piston system includes a top section, a bottom section, and a catalyst holding space between the top and bottom section such that the piston system is movable between a first and a second position to inject catalyst from the catalyst holding space into the reaction vessel when the piston system is in the second position and fill the catalyst holding space with catalyst from a catalyst feed supply when the piston system is in the first position.