Polyester Granule Temperature Control via Latent Heat Crystallization
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Solution Overview
Problem
Existing polymer granulation processes using latent heat crystallization lack flexibility and control over granule temperature, leading to issues such as granule sticking, oxidative damage, and operational disruptions during maintenance or system failures, which result in increased risks and costs.
Innovation Solution
A method and device for producing polyester and copolyester granules using latent heat crystallization, where the granule temperature is controlled by adjusting the contact time with the coolant, granule size, and coolant composition, allowing for flexible temperature management to prevent sticking and oxidative damage, and enabling continued operation during system malfunctions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the granules are rapidly cooled in the coolant to leave the granulator, then the granulation process is efficient and fast, but an amorphous state develops in the granules causing them to stick or clump during subsequent processing
Solution Approach 1:
The patent applies preliminary action by initiating crystallization before the granules leave the granulator. Crystallization nuclei are introduced into the molten granules while they are still in the granulator, so that crystallization begins during the granulation process itself. This preliminary crystallization ensures that the granules develop a crystalline structure before being discharged, preventing the amorphous state that causes sticking during subsequent processing.
Solution Approach 2:
The patent changes the temperature parameter during granulation by introducing crystallization nuclei that trigger exothermic crystallization. This causes the granule temperature to increase during the process, creating a self-heating effect that maintains the granules in a crystalline state rather than allowing them to cool into an amorphous state.
2Reliability
If latent heat crystallization is used to maintain granule temperature and avoid sticking, then granule flowability is improved, but the process lacks flexibility and control over granule temperature for maintenance and malfunction handling
Solution Approach 1:
The patent applies dynamics by making the crystallization process controllable and adjustable. The rate and extent of crystallization can be modified by controlling parameters such as the amount of crystallization nuclei introduced, the residence time in the granulator, and the temperature profile. This dynamic control allows the process to be adapted for different maintenance scenarios and malfunction conditions while maintaining granule flowability.
Solution Approach 2:
The patent enables parameter changes by allowing adjustment of crystallization conditions including temperature, time, and nucleation density. These parameter changes provide flexibility to control the degree of crystallization and resulting granule temperature, enabling the process to be adapted for maintenance operations and malfunction handling while preserving granule flowability.
3Use of energy by moving object
If the granules remain hot after granulation to enable latent heat crystallization, then energy consumption is reduced, but the granules are prone to oxidative damage and require immediate processing
Solution Approach 1:
The patent converts the potentially harmful effect of high temperature (which could cause oxidative damage) into a beneficial effect by using the heat to drive crystallization. The exothermic crystallization reaction generates additional heat that maintains granule temperature, creating a self-sustaining process that reduces energy consumption while the crystalline structure protects against oxidative damage.
Solution Approach 2:
The patent utilizes the phase transition from amorphous to crystalline state during granulation. This phase transition is exothermic, releasing latent heat that maintains granule temperature without requiring external heating. The crystalline structure formed during this phase transition also provides protection against oxidative damage that would affect amorphous granules.
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 controlled temperature adjustment of granules to facilitate safe storage and processing, reducing the risk of granule sticking and oxidative damage, and enabling continued polymer production even during system failures, thereby minimizing operational disruptions and costs.
Implementation Method 1
The crystallization of the polymers takes place using the inherent heat from the melt state of the polymer, which is also referred to as latent heat crystallization
Implementation Method 2
the temperature of the granules in a cooling device following granulation, if necessary, to be able to control subsequent temperature-dependent processes
Data Source
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Figure 3
AI summary
A method and a device for producing polyester or copolyester granules using the latent heat crystallization process are described, wherein the temperature of the granules is controlled, if necessary, in a cooling device following the granulation process by adjusting the contact time of the granules with the coolant, by changing the coolant composition, or by adjusting the particle size of the granules in the process, or can be controlled by the device.