Reactor Static Inserts for Polymerization Heat Transfer
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Solution Overview
Problem
Liquid phase polymerization in tubular reactors experiences poor mixing, leading to non-uniform reaction temperatures and polymer properties due to low heat transfer rates caused by growing thermal boundary layers, which affects the efficiency and uniformity of polymer production.
Innovation Solution
Incorporating static inserts between internal heat exchangers to rotate or translate flow paths, thereby separating boundary layers from channel walls, creating larger temperature gradients and increasing heat transfer coefficients.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If internal heat exchangers are used in tubular reactors for liquid phase polymerization, then heat transfer is improved, but thermal boundary layers grow along the flow path causing heat transfer rates to decrease
Solution Approach 1:
The patent introduces static inserts that create dynamic flow patterns within the tubular reactor. These inserts generate radial mixing and disrupt the laminar flow, preventing the formation and growth of thermal boundary layers along the heat exchanger surfaces. The flow transitions from steady laminar to a more dynamic pattern with enhanced mixing, maintaining high heat transfer coefficients throughout the reactor length.
Solution Approach 2:
Static inserts are introduced as intermediary elements between the heat exchanger and the bulk fluid. These inserts act as mediators that redirect flow paths, create turbulence, and enhance heat transfer by preventing boundary layer development. The inserts serve as intermediate structures that improve the overall heat transfer efficiency without requiring modification of the heat exchanger itself.
2Loss of energy
If flow paths continue unobstructed between heat exchangers, then pressure drop is minimized, but boundary layers propagate and heat transfer efficiency decreases
Solution Approach 1:
The patent applies partial obstruction through static inserts that block only portions of the flow path. This partial blocking is sufficient to disrupt boundary layers and create radial mixing, yet minimal enough to avoid excessive pressure drop. The inserts are designed with specific geometries and spacing that provide just enough obstruction to enhance heat transfer without causing significant energy loss.
3Temperature
If static inserts are introduced to rotate flow paths and disrupt boundary layers, then heat transfer coefficients increase, but device complexity increases
Solution Approach 1:
The reactor is segmented into sections with static inserts placed at specific locations. Rather than filling the entire reactor with complex mixing elements, the patent uses discrete inserts at strategic positions to achieve boundary layer disruption. This segmentation approach maintains relatively simple overall reactor structure while providing enhanced heat transfer where most needed.
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 configuration enhances heat transfer rates, reduces boundary layer growth, and improves the uniformity of polymer properties by maintaining larger temperature gradients at the heat exchanger walls, leading to more efficient polymerization processes.
Implementation Method 1
thermal boundary layers at the chilled or heated channel walls. These boundary layers grow in thickness along the length of the flow paths
Implementation Method 2
The thickness of the boundary layer is inversely proportional to the heat transfer coefficient, so as the boundary layers grow, the heat transfer rate decreases
Data Source
AI summary
In at least one embodiment, a reactor includes a reactor body. A first internal heat exchanger and a second internal heat exchanger are within the reactor body. One or more slabs of one or more static inserts are disposed between the first internal heat exchanger and the second internal heat exchanger. A plurality of flow paths is defined between the plurality of flow channels of the first internal heat exchanger and the plurality of flow channels of the second internal heat exchanger. Each static insert is configured to rotate or translate a flow path so that on average, the existing boundary layers formed in the first heat exchanger are moved away from the channel walls by a distance of equal or greater than the thickness of the boundary layers at the exit of the first heat exchanger.