Dual Screw Conveyor System for Polymer Gel Drying
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Solution Overview
Problem
The existing methods for producing water-absorbing polymer particles face challenges in efficiently conveying and drying particulate polymer gel, leading to potential compaction and reduced conversion of residual monomers, which affects the quality and efficiency of the final product.
Innovation Solution
A process involving the use of a first conveyor device to remove polymer gel from a residence time container and a second conveyor device to convey it in the opposite direction, with specific screw conveyor configurations and speeds, to prevent compaction and facilitate drying, allowing for the use of larger containers with reduced filling height and controlled atmosphere to enhance monomer conversion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single conveyor device is used to remove polymer gel from the residence time container, then the device complexity is reduced, but the polymer gel compacts during conveying which reduces drying efficiency and monomer conversion
Solution Approach 1:
The conveying system is segmented into two distinct conveyor devices: a first conveyor device that removes polymer gel from the residence time container, and a second conveyor device that conveys gel back into the container. This segmentation allows each conveyor to perform its specific function optimally without causing compaction, thereby maintaining high monomer conversion efficiency while managing system complexity through functional division.
Solution Approach 2:
Instead of using a single conveyor to both load and unload the residence time container, the invention uses two conveyors where the second conveyor performs the reverse action of the first conveyor. The first conveyor removes gel from the container while the second conveyor returns gel to the container, creating a circulation pattern that prevents compaction and maintains productivity.
2Quantity of substance
If the residence time container is filled to a higher level to increase storage capacity, then the quantity of polymer gel that can be processed is improved, but the polymer gel becomes compacted which makes drying more difficult
Solution Approach 1:
The system dynamically manages the polymer gel in the residence time container through continuous circulation. The first conveyor continuously removes gel from the container while the second conveyor continuously returns gel, creating a dynamic equilibrium that prevents static compaction. This dynamic approach allows the container to be filled to optimal levels for storage capacity while maintaining gel porosity for easy drying.
3Productivity
If the first conveyor device operates at high speed to increase throughput, then the productivity is improved, but the polymer gel becomes compacted during rapid conveying
Solution Approach 1:
The second conveyor device acts as an intermediary that receives polymer gel from the first conveyor and returns it to the residence time container. This intermediary conveyor allows the first conveyor to operate at high speeds for increased throughput while the second conveyor gently returns the gel to the container, preventing compaction and maintaining gel porosity through the mediation of the second conveyor.
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 prevents compaction, allows for easier drying, and improves the conversion of residual monomers, resulting in higher quality water-absorbing polymer particles with enhanced properties such as centrifuge retention capacity and absorption under pressure.
Implementation Method 1
the intermediately stored particulate polymer gel is conveyed by at least one second conveyor device above the first conveyor device in the direction of the first conveyor device
Implementation Method 2
The polymer gel is removed from the residence time container by means of at least one first conveyor device, preferably by means of at least one screw conveyor
Implementation Method 3
a polymer gel is removed from a polymerization reactor
Data Source
Figure 1A~1B
Figure 2A~2B
AI summary
The invention relates to a method for producing water-absorbing polymer particles, wherein a polymer gel is taken from a polymerization reactor, kept temporarily as a particulate polymer gel in a residence time container, removed by means of a first conveying device at the lower end of the residence time container and dried and wherein the temporarily stored particulate polymer gel in the residence time container is conveyed by means of at least a second conveying device above the first conveying device in the direction of the first conveying device.