Polymer Production Cooling with Phase Separation to Reduce Reactor Deposits
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Solution Overview
Problem
The formation of red particles and surface defects in workpieces produced from polymers, particularly styrene-acrylonitrile copolymers, due to the accumulation of deposits and growths in the reactor during polymerization, which are caused by inefficient heat removal and vapor condensation processes.
Innovation Solution
A process and system where reaction heat is removed via a boiling cooler, with gaseous vapors from the reactor being fed to the cooler, and a product stream containing condensed vapors is recycled through a separation vessel to separate an aqueous phase before returning to the reactor, ensuring components are introduced via gravity flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If reaction heat is removed via a condenser by feeding gaseous vapors to the condenser, then heat removal efficiency is improved, but red particles and deposits form in the reactor
Solution Approach 1:
The invention extracts and removes the harmful aqueous phase from the product stream using a separating vessel positioned between the condenser and reactor. This prevents the aqueous phase from returning to the reactor and forming deposits, while maintaining effective heat removal through the condenser.
Solution Approach 2:
The separating vessel acts as an intermediary device between the condenser and reactor. It separates the condensed product stream into organic and aqueous phases, allowing only the organic phase to return to the reactor, thereby preventing deposit formation while maintaining heat removal efficiency.
2Loss of energy
If a standard condenser is used for heat removal, then heat dissipation is achieved, but surface defects occur in injection-molded workpieces
Solution Approach 1:
The harmful aqueous phase is extracted from the product stream using the separating vessel, preventing it from returning to the reactor and causing surface defects in molded workpieces, while maintaining effective heat dissipation.
Solution Approach 2:
The system implements feedback by continuously separating and removing the aqueous phase from the condensed vapors before they return to the reactor. This prevents accumulation of harmful substances that would otherwise cause surface defects in the final polymer product.
3Temperature
If vapors are condensed and returned directly to the reactor, then heat management is improved, but deposits accumulate in the reactor
Solution Approach 1:
The separating vessel extracts and removes the aqueous phase from the condensed product stream, preventing it from returning to the reactor and forming deposits, while maintaining effective heat management through continuous condensation.
Solution Approach 2:
The separating vessel serves as an intermediary that separates the condensed vapors into organic and aqueous phases. Only the organic phase returns to the reactor, preventing deposit accumulation while maintaining heat management 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
Reduces the formation of red particles and reactor deposits, enhancing the quality of polymers by improving heat management and component separation, thereby minimizing surface defects in injection-molded workpieces.
Implementation Method 1
reaction heat generated in the reactor is removed via a boiling cooler by feeding gaseous vapors generated in the reactor to the boiling cooler
Implementation Method 2
the product stream is cooled in a heat exchanger before entering the separating vessel
Implementation Method 3
an aqueous phase is separated from the product stream in the separating vessel and wherein the product stream flows from the separating vessel into the reactor under gravity
Data Source
Figure 1
Figure 2
AI summary
A method for producing a polymer from a first component and a second component using a reactor (50) offers technical advantages, wherein reaction heat produced in the reactor (50) is discharged via a boiling cooler (40) by supplying gaseous vapors produced in the reactor (50) to the boiling cooler (40). A product flow containing condensed vapors is returned to the reactor (50) from the boiling cooler (40) via a separation vessel (60), and an aqueous phase is separated from the product flow in the separation vessel (60). A system is provided for producing a polymer from a first component and a second component, comprising a reactor (50) and a boiling cooler (40) for discharging reaction heat produced in the reactor (50). A separation vessel (60) is arranged between the boiling cooler (40) and the reactor (50) such that a product flow containing condensed vapors is returned to the reactor (50) from the boiling cooler (40) via the separation vessel (60).