Polymerization Reactor Knockers Prevent Wall Caking
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Solution Overview
Problem
Existing methods for producing powdered poly(meth)acrylate through droplet polymerization often result in deposit formation on the reactor walls, leading to undesirable caking and reduced efficiency.
Innovation Solution
A reactor design with a device for dripping a monomer solution featuring holes, a gas addition point above the dripping device, and a fluidized bed, where the reactor's hydraulic inner diameter decreases, equipped with knockers that generate impact energy to prevent caking, and a truncated cone-shaped head to improve gas and drop interaction, reducing wall contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If droplet polymerization is used to produce powdered poly(meth)acrylate, then productivity is improved, but deposit formation on reactor walls occurs leading to caking
Solution Approach 1:
The patent applies mechanical vibration through a vibrating element that contacts the reactor wall in the conical section. This vibration mechanically disrupts and prevents polymer deposit formation on the wall surface, eliminating the caking problem while maintaining the high productivity benefits of droplet polymerization.
2Manufacturing precision
If the reactor has a constant hydraulic inner diameter, then manufacturing precision is improved, but droplet-wall contact increases causing adhesion
Solution Approach 1:
The patent introduces asymmetry by implementing a conical section with continuously decreasing hydraulic inner diameter in the lower part of the reactor. This asymmetric geometry creates a diverging wall angle that redirects droplets away from the wall surface, preventing adhesion while the upper cylindrical section maintains constant diameter for manufacturing precision.
3Ease of operation
If gas injection is added above the dripping device, then droplet formation is improved, but complex device structure results
Solution Approach 1:
The patent uses pneumatic assistance by injecting gas above the dripping device to promote droplet formation and dispersion. This pneumatic approach simplifies the overall structure compared to mechanical atomization systems while achieving improved droplet quality and preventing wall contact.
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
Significantly reduces or eliminates caking on the reactor walls, enhancing the production efficiency and quality of powdered poly(meth)acrylate by ensuring better gas and drop interaction and preventing premature adherence to the reactor walls.
Implementation Method 1
The droplet formation mechanism can be turbulent or laminar jet breakup
Implementation Method 2
The droplet formation mechanism can be turbulent or laminar jet breakup
Implementation Method 3
The droplets fall downwards in the reactor, where the monomer reacts to form a polymer
Implementation Method 4
A fluidized bed is located in the lower part of the reactor, into which the polymer particles formed from the droplets fall
Implementation Method 5
A secondary reaction then takes place in the fluidized bed
Data Source
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Figure 2
AI summary
The invention relates to a device for producing poly(meth)acrylate in powder form, comprising a reactor (1) for droplet polymerisation that has a device (5), with holes through which a monomer solution is introduced, for dropletising said monomer solution so as to produce the poly(meth)acrylate, a gas supply point (13) above said dropletisation device (5), at least one gas extraction point (19) on the periphery of the reactor (1), and a fluidised bed (11), said reactor (1) having, above the gas extraction point (19), a region that has a constant hydraulic inner diameter and, below said gas extraction point (19), a hydraulic inner diameter that continually reduces. In the region with the continually-reducing hydraulic inner diameter, knockers (35) are mounted on the outer side of the reactor (1), each of said knockers (35) generating an impact energy of between 25J and 165J, and the number of knockers (35) being selected such that a surface-specific impact energy of between 1 and 7J/m² is applied.