Polymerization Effluent Separation via Flash Vaporization
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Solution Overview
Problem
Conventional methods for recycling feedstock components from polymerization reaction effluents are costly and inefficient, requiring extensive equipment and energy, and lack sufficient control parameters to prevent process delays and inefficiencies.
Innovation Solution
A system comprising a polymerization reactor, flash-line heater, flash chamber, first and second columns, and accumulators is used to separate and recycle components from the effluent stream, optimizing the separation process by minimizing equipment and energy consumption and enhancing control parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional purification processes with multiple distillation columns, compressors, and refrigeration units are used, then high purity feedstock components are achieved, but equipment costs and energy consumption increase significantly
Solution Approach 1:
The patent extracts and removes unnecessary equipment (compressors, refrigeration units, multiple distillation columns) from the conventional purification process, retaining only the essential flash chamber and single distillation column while achieving the same purification effect through optimized process parameters
Solution Approach 2:
The patent changes operating parameters including temperature, pressure, and flow rate conditions to optimize the flash vaporization and distillation processes, enabling high purity separation with reduced energy input and simplified equipment
2Manufacturing precision
If conventional purification processes with numerous distillation columns and equipment are used, then high purity feedstock components are achieved, but device complexity increases
Solution Approach 1:
The patent removes redundant equipment including multiple distillation columns, compressors, and refrigeration units, retaining only the essential flash chamber and single distillation column while achieving the same purification effect
Solution Approach 2:
The patent combines multiple separation functions into a simplified integrated system where the flash chamber performs initial separation and the single distillation column completes purification, replacing the conventional multi-column arrangement
3Quantity of substance
If conventional purification processes are used, then feedstock components are recovered, but process time increases leading to delays and inefficiencies
Solution Approach 1:
The patent uses flash vaporization to rapidly separate components in a single stage process, skipping the multiple sequential distillation steps required in conventional processes and significantly reducing processing time
Solution Approach 2:
The patent performs preliminary separation in the flash chamber before the distillation column, pre-concentrating the feedstock components and reducing the burden on subsequent purification steps to accelerate overall processing
4Quantity of substance
If conventional purification processes are used, then feedstock components are recovered, but equipment and energy costs represent a significant proportion of total production cost
Solution Approach 1:
The patent removes expensive equipment including compressors, refrigeration units, and multiple distillation columns from the process, retaining only essential components while achieving the same feedstock recovery objective
Solution Approach 2:
The patent optimizes operating parameters to reduce energy consumption in the flash vaporization and distillation processes, directly lowering the energy cost component of total production cost
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 system effectively recycles reusable components, reduces costs and process complexity, and improves control over the recycling process, leading to increased efficiency and reduced downtime.
Implementation Method 1
heating the effluent stream
Implementation Method 2
separating the heated effluent stream into a polymer product stream and a flash gas stream
Implementation Method 3
routing the flash gas stream to a first fractionation column... routing a second stream to a second fractionation column
Data Source
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AI summary
A method of treating a polymerization reactor effluent stream comprising: recovering the effluent stream from the polymerization reactor, flashing the effluent stream to form a flash gas stream, feeding the flash gas stream into a first column, recovering a first overhead stream, a first bottom stream, and a side stream, from the first column, wherein the side stream substantially comprises hexane, feeding the first overhead stream into an accumulator vessel, recovering a second overhead stream and a second bottom stream from the accumulator vessel, wherein the second bottom stream substantially comprises isobutane, feeding the second overhead stream to a second column, and recovering a third overhead stream and a third bottom stream from the second column, wherein the third bottom stream is substantially olefin-free.