Poly(meth)acrylate Reactor Gas Flow and Discharge Design
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Solution Overview
Problem
Conventional droplet polymerization reactors for producing powdered poly(meth)acrylate face issues with high inert gas consumption and gas penetration, leading to reduced yield and potential reactor contamination due to air or oxygen ingress.
Innovation Solution
A reactor design with a frustoconical head for monomer solution dripping, a gas addition point above the droplet formation device, peripheral gas extraction, and a product discharge system featuring a damming segment to minimize gas loss and penetration, along with a fluidized bed for post-crosslinking, and fine dust separation to manage gas flow and particle entrainment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If gas is added above the droplet formation device and extracted through the annular channel, then the polymerization reaction proceeds, but high gas velocities cause polymer material to be entrained and deposited on walls
Solution Approach 1:
The gas extraction system is divided into multiple extraction points distributed around the reactor periphery, preventing excessive gas velocity at any single location and reducing polymer entrainment in the annular channel
Solution Approach 2:
A fluidized bed is introduced as an intermediary zone between the droplet formation area and the gas extraction channel, allowing gas to pass through while preventing direct contact between high-velocity gas and polymer particles that would cause wall deposits
2Productivity
If conventional product discharge devices are used, then solid product is removed, but inert gas is continuously lost or air penetrates into the reactor
Solution Approach 1:
The discharge device is designed to maintain the inert atmosphere within the reactor by using a lock chamber that seals during product discharge, preventing air ingress and inert gas loss while allowing continuous operation
Solution Approach 2:
The discharge device uses dynamic sealing mechanisms that adapt to pressure differences, maintaining inert atmosphere integrity during the cyclic discharge operation without requiring continuous inert gas flow
3Speed
If gas velocities in the ring channel are high, then gas flow is maintained, but polymer material is entrained and yield is reduced
Solution Approach 1:
Multiple gas extraction points are distributed around the reactor periphery, dividing the gas flow into several streams and reducing velocity at each extraction point, thereby minimizing polymer entrainment while maintaining overall gas flow efficiency
Solution Approach 2:
Gas is extracted at multiple peripheral locations rather than through a single annular channel, removing gas at lower velocities before it can entrain polymer particles and cause yield loss
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 design minimizes inert gas consumption, reduces particle adherence and contamination, and maintains a controlled inert atmosphere, enhancing the efficiency and yield of poly(meth)acrylate production while preventing gas ingress into the reactor.
Implementation Method 1
When the monomer solution is introduced into the reactor, it breaks up into droplets. The mechanism of droplet formation can be turbulent or laminar jet breakup or droplet formation.
Implementation Method 2
A first gas stream is introduced above the droplet formation device and a second gas stream is introduced from below through the fluidized bed. The direction of flow of the gas streams is opposite.
Implementation Method 3
In the lower area of the reactor there is a fluidized bed, into which the polymer particles formed from the droplets by the reaction fall. An after-reaction then takes place in the fluidized bed.
Implementation Method 4
a device for product discharge from the fluidized bed, the device for product discharge comprising a discharge device and a damming segment being arranged above the discharge device
Data Source
Figure 1
AI summary
The invention relates to a device for producing poly(meth)acrylate in powder form, said device comprising: a reactor (1) for droplet polymerization having a device (5) for dropletizing a monomer solution for the production of the poly(meth)acrylate which has holes through which the solution is introduced; a feed point (13) for a gas above the device (5) for dropletizing; at least one gas discharge point (19) at the periphery of the reactor (1); a fluidized bed (11) and a device (33) for discharging the product from the fluidized bed (11). The device (33) for discharging the product comprises a discharge device (49), an accumulation segment (39) being situated above the discharge device (49).