Reactor Temperature Interlock for Polymer Safety
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Solution Overview
Problem
Current polymer production processes face challenges in effectively removing residual monomers and hydrocarbons from polymer products, leading to potential explosive risks, environmental concerns, and unacceptable product quality, as existing degassing methods are influenced by complex factors including temperature, pressure, and polymer morphology, and may not adequately prevent hydrocarbon overload if reactor temperatures drop below desired levels.
Innovation Solution
An interlock system that monitors and compares reactor temperature to a threshold value, preventing polymer withdrawal if the temperature falls below the threshold to ensure safe degassing conditions, with the threshold potentially varying based on polymer grade, partial pressure of heavy hydrocarbons, or other parameters, and can be overridden for specific operational needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If polymer withdrawal is allowed when reactor temperature is low, then productivity is improved, but hydrocarbon removal efficiency deteriorates leading to safety risks
Solution Approach 1:
The interlock system performs preliminary verification of reactor temperature before allowing polymer withdrawal. By checking the temperature condition in advance and preventing withdrawal when temperature is below the threshold, the system ensures safe degassing conditions are met before the harmful effect (hydrocarbon overload) can occur.
Solution Approach 2:
The interlock system continuously monitors reactor temperature and uses this feedback to control polymer withdrawal. When temperature falls below the threshold, the system automatically prevents withdrawal, creating a closed-loop control mechanism that maintains safety while allowing productivity when conditions are favorable.
2Manufacturing precision
If reactor temperature is reduced to improve polymer quality, then manufacturing precision is improved, but hydrocarbon absorption increases making degassing difficult
Solution Approach 1:
The interlock system applies preliminary anti-action by preventing polymer withdrawal when temperature is low, thereby counteracting the harmful effect of increased hydrocarbon absorption before it can occur. This stops the problematic condition from propagating to the degassing stage.
Solution Approach 2:
The system uses temperature as a critical parameter to control the process. By monitoring and enforcing minimum temperature thresholds, the system ensures that polymer withdrawal only occurs when temperature conditions are favorable for effective degassing, thus preventing hydrocarbon overload while allowing quality improvements through controlled temperature variations.
3Device complexity
If degassing is performed under normal temperature conditions, then process simplicity is maintained, but hydrocarbon removal efficiency is insufficient
Solution Approach 1:
The interlock system performs preliminary temperature verification before allowing polymer to enter the degassing section. This preliminary action ensures that only polymer under suitable temperature conditions proceeds to degassing, thereby maintaining effective hydrocarbon removal without requiring complex additional degassing equipment or procedures.
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 interlock system effectively maintains safe degassing conditions by preventing polymer withdrawal when reactor temperatures are too low, reducing hydrocarbon overload and ensuring residual monomer levels are within safe limits, thereby enhancing process safety and product quality.
Implementation Method 1
measuring the temperature in the reactor or a temperature representative of the temperature in the reactor
Implementation Method 2
polymerisation is conducted in a fluidised bed reactor wherein a bed of polymer particles is maintained in a fluidised state by means of an ascending gas stream comprising the gaseous reaction monomer. During the course of polymerisation, fresh polymer is generated by the catalytic polymerisation of the monomer
Implementation Method 3
a bed of polymer particles is maintained in a fluidised state by means of an ascending gas stream
Implementation Method 4
subject the polymer to a pressure reduction, usually in entry to a suitable vessel, with the result that at least a portion of any hydrocarbons in liquid form vaporise
Implementation Method 5
contact the produced polymer with a gas in a purge vessel, usually a countercurrently flowing inert gas, such as nitrogen
Data Source
AI summary
The present invention relates to production of polymer, and in particular provides an interlock for use in a process for production of a polymer in a reactor, which process comprises: a. polymerising a monomer and optionally a comonomer in the reactor to produce polymer, optionally in the presence of an inert hydrocarbon, and b. withdrawing produced polymer from the reactor, said interlock being based on the temperature in the reactor, and comprising: 1. measuring the temperature in the reactor or a temperature representative of the temperature in the reactor, and 2. comparing said measured temperature to a threshold temperature, said interlock being characterised in that withdrawal is allowed if the measured temperature is greater than the tlireshold temperature but is prevented if the measured temperature is lower than the threshold temperature.