Polymerization in Plug Flow Reactor Reducing Foaming and Heat Flux

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Solution Overview

Problem

Conventional polymerization processes for polyamides face challenges with excessive foaming, undesired polymer branching (gelling), and high energy consumption due to high heat flux and large volumes of heat transfer fluids, which affect conversion rates and efficiency.

Innovation Solution

A process utilizing a plug flow reactor configuration with a shell side and tube side, where the aqueous monomer solution is evaporated to form a concentrated solution, then polymerized, reducing heat flux and skin temperature, and featuring a high heat transfer area ratio to minimize foaming and improve conversion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a conventional polymerization reactor with large volume of heat transfer fluid is used, then the polymerization reaction can be carried out, but excessive foaming and polymer branching (gelling) occur due to high heat flux and high skin temperature

Engineering Contradiction:

Improvepolymerization reactionVSAvoidfoaming and gelling

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent changes the physical state of the monomer solution from aqueous to concentrated non-aqueous by removing water, and adjusts temperature parameters to operate below the melting point of the polymer. This prevents foaming and gelling while maintaining polymerization reaction reliability

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent utilizes phase transition by evaporating water from the monomer solution to create a concentrated solution, and by controlling the polymerization temperature to be below the polymer melting point, preventing phase separation and foaming during the reaction

Inventive Principle:

Principle #36Phase transitions

2Reliability

If a conventional polymerization reactor with large volume of heat transfer fluid is used, then the polymerization reaction can be carried out, but high energy consumption occurs due to high heat flux

Engineering Contradiction:

Improvepolymerization reactionVSAvoidenergy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent changes the concentration parameter of the monomer solution by removing water, which reduces the heat capacity and allows for lower operating temperatures. This decreases the heat flux required for polymerization while maintaining reaction reliability, thereby reducing energy consumption

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses a smaller volume of heat transfer fluid compared to conventional processes, applying only the necessary heat required for polymerization rather than using excessive heat transfer fluid, thus reducing energy consumption while maintaining adequate reaction conditions

Inventive Principle:

Principle #16Partial or excessive action

3Speed

If the temperature of the inlet process fluid is increased to initiate polymerization, then the polymerization reaction can proceed, but water bubble formation and steam disengagement increase causing excessive foaming

Engineering Contradiction:

Improvepolymerization reaction rateVSAvoidfoaming

Core Design Contradiction:

SpeedVSObject-generated harmful factors

Solution Approach 1:

The patent changes the composition parameter by removing water from the monomer solution, creating a non-aqueous concentrated solution. This eliminates water bubble formation and steam disengagement during heating, allowing temperature increase to initiate polymerization without causing foaming

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent performs preliminary water removal from the monomer solution before initiating polymerization. This preliminary concentration step prevents water bubble formation during the subsequent heating and polymerization process, eliminating foaming while allowing temperature-driven reaction initiation

Inventive Principle:

Principle #10Preliminary action

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 process achieves high conversion rates of amide monomers to polyamides with reduced foaming, gelling, and energy efficiency by lowering heat flux and skin temperature, while maintaining high molecular weight polyamide production.

Implementation Method 1

The tube side has a heat transfer area... heating of the aqueous solution... heat flux during polymerization

Methodology Applied

Scientific EffectHeat conduction: Conduction (thermal)

Implementation Method 2

The concentrated monomer solution flows on the shell side from the inlet to the outlet... heat transfer fluid flows through the tubes

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 3

evaporating the aqueous monomer solution to form a concentrated monomer solution

Methodology Applied

Scientific EffectEvaporation: Evaporation

Data Source

PatentUS10927217B2Process for preparing polymers

Publication Date: 2021.02.23 ASCEND PERFORMANCE MATERIALS OPERATIONS LLC

AI summary

The present disclosure relates to a process for preparing polymers using a plug flow reactor. The process includes providing an aqueous monomer solution comprising amide monomers; evaporating the aqueous monomer solution to form a concentrated monomer solution; and polymerizing the concentrated monomer solution in a plug flow reactor comprising a shell side and a tube side to form a first process fluid comprising polymers. The concentrated monomer solution flows on the shell side from the inlet to the outlet.