Horizontal Inclined Rotating Reactor for Polyester Polymerization
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Solution Overview
Problem
Conventional solid phase polymerization processes face limitations in increasing polyester molecular weight and production capacity due to issues like granule sticking, agglomeration, and inefficient purge gas usage, which restrict the achievement of high intrinsic viscosity and throughput.
Innovation Solution
The process employs a horizontal, inclined, rotating reactor (HCIRR) with controlled granule flow and purge gas management to maintain plug flow and reduce sticking, allowing for higher molecular weight increases and increased production capacity while optimizing energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional solid phase polymerization is used to increase molecular weight, then polymerization reaction occurs, but granule sticking and agglomeration occur frequently
Solution Approach 1:
The polymerization process is divided into multiple stages with different temperature profiles. The process starts at lower temperature to prevent sticking, then progressively increases temperature to achieve desired molecular weight, segmenting the thermal treatment into controlled phases
Solution Approach 2:
The reactor operates with dynamic temperature adjustment and controlled granule flow rates. The system dynamically adapts temperature and flow parameters to maintain optimal conditions, preventing sticking while achieving polymerization
2Productivity
If higher temperature is applied to increase reaction rate, then molecular weight increases faster, but granule sticking and agglomeration worsen
Solution Approach 1:
The temperature is applied periodically in controlled steps rather than continuously at high levels. The process uses periodic temperature increases followed by maintenance phases, allowing polymerization to proceed at enhanced rates while providing periodic relief to prevent agglomeration
Solution Approach 2:
Multiple parameters including temperature, granule flow rate, and purge gas flow are changed and optimized simultaneously. The system adjusts these parameters dynamically to achieve high polymerization rates while maintaining granule flow and preventing sticking
3Manufacturing precision
If longer residence time is used to increase molecular weight, then intrinsic viscosity increases, but production capacity decreases
Solution Approach 1:
The system uses dynamic temperature adjustment during the residence time to maximize polymerization efficiency. By progressively increasing temperature and optimizing flow rates during the residence period, the process achieves high intrinsic viscosity with reduced residence time, thereby increasing production capacity
Solution Approach 2:
The reactor maintains continuous polymerization activity through optimized granule flow and temperature control. The continuous operation with controlled residence time ensures consistent polymerization progression, achieving high molecular weight without sacrificing production capacity
4Productivity
If conventional vertical moving-bed reactor is used, then polymerization occurs, but plug flow behavior is insufficient and molecular weight distribution is broad
Solution Approach 1:
The reactor is segmented into multiple zones with different temperature profiles and flow characteristics. This segmentation creates multiple regions that promote uniform plug flow behavior, ensuring all granules experience similar conditions and producing narrow molecular weight distribution
Solution Approach 2:
The system transitions from conventional vertical flow to horizontal inclined rotating flow, adding spatial dimensionality to the reaction process. This dimensional change improves plug flow behavior and uniformity of processing conditions
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 achieves higher molecular weight increases, prevents agglomeration, and enhances production capacity with reduced energy consumption and purge gas costs, resulting in a more homogeneous and efficient polymerization process.
Implementation Method 1
the polyester gradually moves towards the bottom of the vertical reactor
Implementation Method 2
the purge gas primarily functions to carry off unwanted by-products such as glycols, water and acetaldehyde
Implementation Method 3
temperatures comprised in the range 180-245° C. are applied
Data Source
AI summary
A process for the solid phase continuous polymerization of polyester in order to achieve a molecular weight increase, measurable by the intrinsic viscosity IV increase of the polyester, wherein the use of at least a reactor (15) is provided, the reactor (15) being cylindrical, rotary around its own central axis (S), substantially horizontal, slightly inclined so as to produce the polymerization of the polyester granules passing through the reactor by gravity thanks to the inclination and the rotation of the reactor (15), inside the reactor there being produced a purge gas flow having the same or the opposite direction with respect to the flow of the polyester granules.