Continuous Solid-State Polymerization Reactor Column

Solution Overview

Problem

Direct solid-state polymerization processes for polyamides face challenges in scaling up due to high condensation water production, sticking, and agglomeration issues, as well as monomer loss and imbalance, making them economically inefficient and difficult to implement on an industrial scale.

Innovation Solution

A continuous solid-state polymerization process using a reactor column with successive multifunctional zones for heating and gas outlet sections, allowing for the removal of water vapor as superheated steam without inert gas, and introducing diamine downstream to maintain monomer balance, reducing sticking and agglomeration risks.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If direct solid-state polymerization is used to produce polyamide, then energy efficiency is improved, but condensation water production causes sticking and agglomeration

Engineering Contradiction:

Improveenergy efficiencyVSAvoidcondensation water production

Core Design Contradiction:

Use of energy by moving objectVSObject-generated harmful factors

Solution Approach 1:

The reactor column is divided into multiple multifunctional zones with alternating heating sections and gas outlet sections. This segmentation allows localized heating for polymerization while providing distributed gas outlets to continuously remove water vapor, preventing condensation water accumulation and sticking.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Water vapor is extracted from the reaction zone through gas outlet sections positioned to remove condensation water as it forms. The continuous removal of water vapor prevents it from condensing and causing sticking or agglomeration of the polyamide product.

Inventive Principle:

Principle #2Taking out (Extraction)

2Object-generated harmful factors

If condensation water is removed continuously, then sticking and agglomeration are reduced, but monomer loss occurs

Engineering Contradiction:

Improvesticking and agglomerationVSAvoidmonomer loss

Core Design Contradiction:

Object-generated harmful factorsVSLoss of substance

Solution Approach 1:

The reactor column creates different local conditions in heating sections (high temperature for polymerization) versus gas outlet sections (water vapor removal). This local quality differentiation allows continuous water removal while maintaining conditions that prevent monomer loss through selective positioning of functional zones.

Inventive Principle:

Principle #3Local quality

3Productivity

If scaling up is implemented, then production capacity increases, but sticking and agglomeration problems worsen

Engineering Contradiction:

Improveproduction capacityVSAvoidsticking and agglomeration

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The reactor column is divided into multiple multifunctional zones with alternating heating sections and gas outlet sections. This segmentation allows localized heating for polymerization while providing distributed gas outlets to continuously remove water vapor, preventing condensation water accumulation and sticking.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The continuous operation of the reactor column with constant feeding of solid diammonium dicarboxylate salt and continuous removal of water vapor through gas outlet sections prevents accumulation of condensation water. This continuous action maintains production capacity while preventing sticking and agglomeration that would occur in batch processes at scale.

Inventive Principle:

Principle #20Continuity of useful action

4Object-generated harmful factors

If inert gas is used to remove water vapor, then water vapor removal is effective, but process complexity and cost increase

Engineering Contradiction:

Improvewater vapor removalVSAvoidprocess complexity

Core Design Contradiction:

Object-generated harmful factorsVSDevice complexity

Solution Approach 1:

Water vapor is extracted from the reaction zone through gas outlet sections positioned to remove condensation water as it forms. The continuous removal of water vapor prevents it from condensing and causing sticking or agglomeration of the polyamide product.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The reactor column design allows water vapor to be removed using the water vapor itself as the driving force. The gas outlet sections are positioned to utilize the pressure differential created by water vapor generation to drive water vapor removal without requiring external inert gas.

Inventive Principle:

Principle #25Self-service

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 enables scalable, energy-efficient production with reduced risk of sticking and agglomeration, effective water vapor removal, and balanced monomer levels, facilitating large-scale industrial production of polyamides.

Implementation Method 1

heating the salt, respectively the polymerizing mixture and polyamide in the heating sections, thereby polycondensing the salt to form a polymerizing mixture

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

The preparation of polyamides from diamines and dicarboxylic acids involves the reaction between the amine groups in the diamines and the carboxylic acid groups in the dicarboxylic acids, resulting in amide groups with the formation of water as side product

Methodology Applied

Scientific EffectCondensation reaction: Condensation

Implementation Method 3

removing the water vapor via gas-outlet sections

Methodology Applied

Scientific EffectEvaporation: Evaporation

Implementation Method 4

removing the water vapor as superheated steam

Methodology Applied

Scientific EffectPhase change: Phase Change

Data Source

PatentUS20230054441A1Continuous solid-state polymerization process and reactor column for use therein

Publication Date: 2023.02.23 ENVALIOR BV

AI summary

The invention relates to a continuous solid-state polymerization process for preparing a polyamide derived from diamine and dicarboxylic acid, wherein the salt is polymerized in a reactor column comprising successive multifunctional zones comprising heating sections and gas-outlet sections, and a residence zone comprising at least one gas-inlet section, wherein the heating sections comprise static heat exchangers. The invention also relates to the reactor column and use thereof in a continuous solid-state polymerization process.