Polymerization Reactor with Tangential Inlets and Internal Heat Exchanger
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Solution Overview
Problem
Liquid phase polymerization in tubular reactors experiences poor mixing, leading to non-uniform reaction temperatures and catalyst concentrations, which affects the uniformity of polymer properties, and is limited by high viscosity and poor heat transfer.
Innovation Solution
A reactor design with tangentially disposed inlets and internal spiral heat exchangers, where the introductory flow transitions into a main flow orthogonal to the heat exchanger, reducing temperature variations and improving mixing by dissipating momentum before entering the heat exchanger.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If liquid phase polymerization is performed in a tubular reactor, then the reactor can handle higher polymer concentrations, but the mixing becomes poorer resulting in non-uniform reaction temperature and monomer concentration
Solution Approach 1:
The reactor is divided into multiple zones: a reaction zone with internal heat exchanger for intense mixing and heat removal, and a quiescent zone for uniform polymerization. This segmentation allows high polymer concentration in the reaction zone while ensuring uniform properties through controlled transition to the quiescent zone.
Solution Approach 2:
Different regions of the reactor are designed with different flow characteristics - the reaction zone has high turbulence and mixing for heat removal, while the quiescent zone has laminar flow for uniform polymerization. This local differentiation resolves the contradiction between handling high polymer concentration and maintaining uniform polymer properties.
2Device complexity
If liquid phase polymerization is performed in a tubular reactor, then the reactor structure is simpler, but the mixing is poorer leading to non-uniform reaction temperature
Solution Approach 1:
The internal heat exchanger is nested within the tubular reactor structure, with the heat exchanger coil positioned inside the reaction zone. This nested configuration provides intense mixing and heat removal capabilities without requiring a completely different reactor design, maintaining relative simplicity while improving temperature uniformity.
3Productivity
If polymer concentration is increased in solution polymerization, then the production rate increases, but the viscosity increases leading to poorer heat transfer
Solution Approach 1:
The internal heat exchanger performs preliminary heat removal in the reaction zone before the polymerization completes. By removing heat early when polymer concentration is high and viscosity is elevated, the system maintains heat transfer efficiency despite high production rates, preventing energy loss from poor heat transfer.
4Productivity
If liquid phase polymerization is performed in a tubular reactor, then the reactor operation is continuous, but the mixing is insufficient affecting monomer and catalyst concentration uniformity
Solution Approach 1:
The continuous flow is segmented into a reaction zone with intense mixing for homogeneous monomer and catalyst distribution, followed by a quiescent zone for uniform polymerization. This segmentation maintains continuous operation while ensuring concentration uniformity through the mixing-enhanced reaction zone.
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 reduces or eliminates hot spots, improves mixing, and enhances heat transfer, resulting in more uniform polymer properties and increased production rates with lower pressure drop.
Implementation Method 1
enhances heat transfer
Implementation Method 2
internal heat exchanger
Implementation Method 3
improves mixing by dissipating momentum
Implementation Method 4
At least a portion of the monomer of the streams is polymerized in the reaction zone
Data Source
AI summary
In one embodiment, a reactor includes a reactor body and a reactor head. The reactor head has a reactor head body and one or more inlets disposed tangentially to the reactor head body. In one embodiment, a polymerization process for forming polymer includes introducing in a first direction a stream including a monomer. The stream and a catalyst system are flowed in a second direction through at least one internal heat exchanger. The second direction is substantially orthogonal to the first direction. The reaction zone includes at least one internal heat exchanger. At least a portion of the monomer of the stream is polymerized in the reaction zone to produce a polymer product. The polymer product is recovered from the reaction zone.