Polyester Drying Device Segmented Cooling Zones
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Solution Overview
Problem
Current processes for producing polyester pellets are energy-intensive and costly due to the need for extensive cooling, crystallization, and drying, which can lead to thermo-oxidative damage and reduce the intrinsic viscosity of the polymer, resulting in increased operating costs and material degradation.
Innovation Solution
A drying/degassing device with a tempering zone and a separate cooling zone allows for the direct transportation of high-temperature polyester pellets to preform machines, eliminating the need for pre-treatment cooling and drying, and utilizing latent heat crystallization to prevent sticking and maintain molecular weight, thereby reducing energy consumption and equipment requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If extensive cooling and drying processes are applied to polyester pellets, then the pellets are prepared for storage and transport, but energy consumption increases and thermo-oxidative damage occurs
Solution Approach 1:
The device segments the cooling process into two distinct zones: a first cooling zone that cools polyester pellets to a first temperature, and a second cooling zone that cools them to a lower second temperature. This segmentation allows selective removal of hot pellets after the first cooling zone, eliminating the need for complete cooling and drying before use, thereby reducing energy consumption while maintaining pellet quality.
Solution Approach 2:
The invention performs preliminary cooling in the first cooling zone to reduce the temperature of polyester pellets to a level that prevents severe sticking, then removes hot pellets before they undergo complete cooling and drying. This preliminary action maintains sufficient heat in the pellets for direct processing, avoiding the energy-intensive complete drying process while preventing quality degradation.
2Reliability
If complete cooling and drying processes are applied to polyester pellets, then pellets are prepared for storage, but equipment complexity and capital expenditure increase
Solution Approach 1:
The cooling device is segmented into two functional zones with a removal option positioned between them. This segmentation allows the system to provide partial cooling sufficient for preventing sticking, while eliminating the need for complete drying equipment, thereby reducing equipment complexity and capital expenditure while maintaining pellet usability.
Solution Approach 2:
The invention applies partial cooling action - enough to prevent severe sticking and maintain pellet integrity, but not complete cooling and drying. This partial action eliminates the need for extensive drying equipment while ensuring pellets are sufficiently prepared for direct processing, reducing both equipment complexity and capital requirements.
3Use of energy by moving object
If hot polyester pellets are transported directly to preform machines, then energy consumption is reduced, but pellet sticking may occur
Solution Approach 1:
The cooling device segments the cooling process into two zones, with the first cooling zone reducing pellet temperature to a level that prevents severe sticking. Hot pellets are removed after this first zone, maintaining sufficient heat for direct processing while eliminating the harmful sticking effect, thus resolving the contradiction between energy conservation and sticking prevention.
Solution Approach 2:
The invention changes the temperature parameter of polyester pellets through controlled cooling in the first cooling zone, reducing the temperature from the extrusion level to a level that prevents severe sticking, but not low enough to require complete drying. This parameter change allows direct transport to preform machines without sticking, while maintaining 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 significantly reduces energy and capital expenditures by eliminating the need for pre-treatment cooling and drying, while maintaining the intrinsic viscosity and quality of the polyester pellets, thus enhancing the economic efficiency of the process and preventing thermo-oxidative damage.
Implementation Method 1
a tempering zone (11) for tempering the polyester granules
Implementation Method 2
a cooling zone (12) for cooling the polyester granules
Implementation Method 3
utilizing latent heat crystallization to prevent sticking and maintain molecular weight
Implementation Method 4
the inherent heat remaining in the granules and the generated heat of crystallization were used directly
Data Source
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AI summary
The device (7) has an upper part that is arranged with a temperature zone and a lower part that is arranged with a cooling zone. A separate downstream cooling zone is formed, where the separate cooling zone and a container stay in a connection for temperature control. An inlet is arranged for polyester granules, where the inlet is arranged over a head side. An outlet pipe (17) is arranged for polyester granules. A withdrawal possibility (14) is arranged for removal of tempered polyester granules kept at moderate temperature. Independent claims are also included for the following: (1) a device for direct manufacturing of shaped bodies from polyester melt (2) a method for manufacturing of shaped bodies from polyester melt.