Polymer Volatilization and VOC Recovery via Segmented Condensation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The recovery of VOC components from polymer reaction products is inefficient due to the need for high temperature and high vacuum conditions, leading to increased energy consumption and overload on freezers.
Innovation Solution
A method involving the supply of a monomer stream and a solvent stream to a reactor for polymerization, followed by separation of the polymer from the reaction product in a volatilization device. The upper discharge stream is split into multiple streams and supplied to multiple condensers, allowing for efficient condensation and separation of VOC components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If VOC components are recovered under high temperature and high vacuum conditions, then recovery effectiveness is improved, but energy consumption increases and freezer overload occurs
Solution Approach 1:
The patent divides the condensation process into multiple stages using a multi-stage condenser system. The first condenser operates at a higher temperature to condense high-boiling-point VOC components, while the second condenser operates at a lower temperature to condense low-boiling-point VOC components. This segmentation allows effective VOC recovery without requiring the entire system to operate under extreme high vacuum and low temperature conditions simultaneously, thereby reducing energy consumption and freezer overload.
2Productivity
If VOC components are recovered under high vacuum conditions, then condensation efficiency is improved, but freezer overload occurs due to very low condensation temperature requirement
Solution Approach 1:
The condensation process is segmented into two independent stages with different temperature and pressure requirements. The first condenser handles high-boiling-point components under milder conditions, while the second condenser handles low-boiling-point components under more stringent conditions. This segmentation allows the freezer to operate at moderate capacity for the first stage, reducing the overall freezer capacity requirement while maintaining high condensation efficiency for all VOC components.
Solution Approach 2:
The patent changes the operating parameters (temperature and pressure) between the two condensation stages. The first condenser operates at a higher temperature and lower vacuum level, while the second condenser operates at a lower temperature and higher vacuum level. This parameter change strategy allows each stage to be optimized for its specific function, improving overall condensation efficiency without requiring the freezer to maintain extremely low temperatures throughout the entire process.
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 method effectively recovers VOC components with increased condensation efficiency, reducing energy consumption and raw material costs, while minimizing wastewater treatment costs.
Implementation Method 1
supplying a reactor discharge stream to a volatilization device, separating a polymer from a lower portion of the volatilization device
Implementation Method 2
condensing and separating the unreacted monomer and the solvent in each of the condensers
Data Source
AI summary
Provided is a method of preparing a polymer including: supplying a monomer stream and a solvent stream to a reactor and performing a polymerization reaction to prepare a reaction product; supplying a reactor discharge stream to a volatilization device, separating a polymer from a lower portion of the volatilization device, splitting an upper discharge stream including an unreacted monomer, a solvent, and an inert gas into two or more streams, and divisionally supplying the split streams to a plurality of condensers, respectively; condensing and separating the unreacted monomer and the solvent in each of the condensers and supplying a gaseous stream therefrom to a condenser installed at a rear end of each condenser; and supplying a gaseous stream discharged from a condenser installed at the rearmost end to a vacuum unit.