Polymer Devolatilization Nozzle Flash Evaporation
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Solution Overview
Problem
Current devolatilization processes for polymer melt feeds are inefficient, requiring stripping and leading to high energy consumption, capital expenditures, and potential polymer decomposition, with existing apparatuses being complex and difficult to maintain.
Innovation Solution
A devolatilization process and apparatus utilizing a nozzle with specific design parameters, including headers and apertures, to form polymer strands in a devolatilization vessel, optimizing throughput, pressure drop, and temperature for efficient volatile removal without stripping, resulting in a more robust, energy-efficient, and easier-to-maintain system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional devolatilization processes are used, then volatiles can be removed from polymer melt, but high energy consumption and potential polymer decomposition occur
Solution Approach 1:
The invention utilizes phase transition of volatiles from liquid to vapor state through flash evaporation when polymer melt is introduced into the devolatilization chamber. The sudden pressure drop causes volatiles to rapidly vaporize and be removed, achieving efficient devolatilization without excessive energy input or polymer decomposition
Solution Approach 2:
The invention replaces conventional mechanical stripping systems with a flash evaporation-based devolatilization chamber. By substituting mechanical removal methods with a controlled phase transition process, energy consumption is reduced while maintaining effective volatile removal
2Loss of substance
If conventional devolatilization apparatuses are used, then volatiles can be removed, but the apparatus is complex and difficult to maintain
Solution Approach 1:
The devolatilization apparatus is segmented into distinct functional modules: a devolatilization chamber, a nozzle assembly with interchangeable nosles, and a collection system. This modular segmentation simplifies maintenance and operation by allowing individual components to be independently accessed, cleaned, or replaced without affecting the entire system
Solution Approach 2:
The invention extracts and isolates the core devolatilization function into a dedicated chamber, separating it from other polymer processing functions. This extraction simplifies the overall apparatus design by eliminating unnecessary components and focusing only on the essential devolatilization process
3Loss of substance
If stripping is used for devolatilization, then volatiles can be removed, but capital expenditures and operating expenditures increase
Solution Approach 1:
The flash evaporation process is largely self-service, utilizing the inherent volatility of the components and the pressure differential to drive volatile removal. The system requires minimal external energy input or complex auxiliary systems, thereby reducing both capital and operating expenditures compared to active stripping processes
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
The process achieves efficient volatile removal with reduced energy consumption and minimal polymer modification, lowering capex and opex, and simplifying maintenance, while ensuring the polymer remains un-expanded and stable.
Implementation Method 1
The polymer strands provide increased surface area for devolatilization of the polymer within the vessel. As the strands fall in the devolatilization vessel, the unreacted monomer, co-monomer, and/or solvent may be released
Implementation Method 2
collecting the polymer strands in a collector by letting the polymer strands drop over a strand drop height into the collector
Data Source
AI summary
The present invention relates to a process for reducing volatiles in a polymer melt feed. The present invention also relates to a devolatilization apparatus for removing volatiles from a polymer melt feed.