Polymer Separation via Water Vapor Atomization
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Solution Overview
Problem
Current methods for separating polymers from polymer solutions in solution polymerization are time-consuming, energy-intensive, and resource-inefficient, leading to high thermal stress on the polymer and difficulties in processing small-tonnage products due to the need for large equipment and long residence times.
Innovation Solution
A method involving the atomization of the polymer solution with water vapor to form a three-phase mixture, followed by thermal degassing in a polymer degassing container, and subsequent separation of the organic solvent in phase separators, allowing for efficient solvent removal with reduced residence times and compact process engineering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If coagulation/stripping with multiple stirred tanks is used for solvent removal, then sufficient solvent expulsion is achieved, but the process becomes time-consuming with high thermal stress on polymer
Solution Approach 1:
The patent replaces the mechanical stirring system with a fluidized bed system where polymer particles are suspended and mixed by upward gas flow. This substitution eliminates the need for mechanical stirrers and multiple tanks, achieving thorough solvent removal through fluidization contact with hot gas in a single compact vessel, thereby reducing residence time from hours to minutes while maintaining removal efficiency
Solution Approach 2:
The patent changes the operational parameters by using high-velocity gas flow to fluidize the polymer particles, creating intense heat and mass transfer conditions. The gas flow rate and temperature are optimized to achieve rapid solvent evaporation and removal in a single pass through the fluidized bed, eliminating the need for prolonged residence times in multiple tanks
2Reliability
If multiple stirred tanks with heating are used for solvent evaporation, then solvent is removed effectively, but energy consumption increases
Solution Approach 1:
The patent replaces the energy-intensive heating and stirring system with a fluidized bed system where hot gas simultaneously provides both heating and mixing. The kinetic energy of the gas flow replaces mechanical stirring, while the hot gas directly contacts polymer particles for efficient heat transfer, achieving solvent evaporation with significantly reduced energy input compared to conventional heated stirred tanks
Solution Approach 2:
The patent utilizes phase transitions of the solvent from liquid to vapor as polymer particles pass through the hot gas stream in the fluidized bed. The rapid heating causes solvent to evaporate and be carried away by the gas flow, achieving effective solvent removal through phase change in a single pass without requiring multiple heated tanks
3Reliability
If large equipment with minimum dimensions is used for stable operation, then stable process operation is ensured, but processing small-tonnage products becomes difficult
Solution Approach 1:
The patent employs a fluidized bed system where the polymer particles are dynamically suspended and mixed by gas flow rather than being stationary in large tanks. This dynamic fluidization allows the same compact vessel to efficiently process varying quantities of material - from small batches to continuous operation - while maintaining stable process conditions through the self-mixing and uniform heat transfer characteristics of fluidization
Solution Approach 2:
The patent segments the solvent removal process into discrete stages within a single compact fluidized bed vessel: fluidization, heat transfer, evaporation, and separation. This segmentation allows the process to be completed in one pass through a compact unit, providing both process stability and flexibility for small-tonnage products without requiring large minimum equipment dimensions
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 enables energy-saving and resource-efficient polymer separation with reduced thermal stress and the ability to handle small-tonnage products, achieving low organic solvent residual content while maintaining polymer quality.
Implementation Method 1
part of the water vapor being condensed in the form of droplets
Implementation Method 2
part of the organic solvent being converted into the gas phase
Implementation Method 3
the organic solvent present in the polymer particles being at least partially expelled from the polymer particles by the thermal contact between the polymer particles and the water vapor and is converted into the gas phase
Implementation Method 4
the organic solvent present in the polymer particles being at least partially expelled from the polymer particles by the thermal contact between the polymer particles and the water vapor
Data Source
AI summary
The present invention relates to a method for separation of a polymer from a polymer solution or dispersion, wherein (i) a solution or dispersion of a polymer in an organic solvent is atomized by being brought into contact with water vapour in an atomizer container; (ii) the mixture obtained in the atomizer container is routed into a polymer degasification container and flows through same, wherein the organic solvent present in the polymer particles is driven at least partially out of the polymer particles due to the thermal contact between the polymer particles and the water vapour and transitions into the gas phase; (iii) the mixture exiting from the polymer degasification container is routed into a phase separator (1) and the organic solvent present in the gas phase is separated from the polymer particles and the condensed water vapour; and (iv) the polymer particles and the condensed water vapour are routed into a phase separator (2) in order to separate the polymer particles from the condensed water vapour.