Water-Absorbent Resin Reactor Temperature Control to Prevent Pipe Blockages

Solution Overview

Problem

The production of water-absorbent resin by polymerization reaction faces issues with gelation and deposition of polymerization liquid, leading to polymer adhesion on reactor walls, which causes pipe blockages and decreases homogeneity due to the removal of polymerization heat, especially when using a heat exchanging structure.

Innovation Solution

An apparatus with a polymerization reactor and cooler system that adjusts temperatures to prevent polymer condensation, including a gas discharging portion, a channel for temperature adjustment, and a cooler to manage polymerization heat, ensuring the gas is not condensed and preventing polymer adhesion on inner surfaces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If a cooler such as a heat exchanging structure is connected to a polymerization reactor to remove polymerization heat, then the polymerization heat can be removed effectively, but polymer precipitates and adheres to the inner wall surface of the pipe, causing blockages and decreasing homogeneity

Engineering Contradiction:

Improvepolymerization heat removalVSAvoidpipe blockage and homogeneity

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The patent changes the temperature parameter of the gas flow by introducing a heating section between the polymerization reactor and the cooler. This heating section raises the gas temperature to prevent polymer condensation and adhesion on the pipe inner wall, while the cooler subsequently removes the polymerization heat. This parameter change resolves the contradiction by maintaining gas temperature within a range that prevents polymer precipitation during heat exchange.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent introduces a heating section as an intermediary component between the polymerization reactor and the cooler. This intermediary heating section serves as a mediator that prevents polymer adhesion on the pipe wall by heating the gas flow, while allowing the subsequent cooler to perform its heat removal function. The intermediary heating section resolves the contradiction by eliminating the harmful polymer adhesion effect without interfering with the polymerization heat removal process.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Loss of energy

If polymerization heat is removed by cooling the gas flow, then heat exchange efficiency is improved, but polymer condensation occurs on the inner wall surface of the pipe

Engineering Contradiction:

Improveheat exchange efficiencyVSAvoidpolymer condensation and adhesion

Core Design Contradiction:

Loss of energyVSObject-generated harmful factors

Solution Approach 1:

The patent changes the temperature parameter of the gas flow by introducing a heating section between the polymerization reactor and the cooler. This heating section raises the gas temperature to prevent polymer condensation and adhesion on the pipe inner wall, while the cooler subsequently removes the polymerization heat. This parameter change resolves the contradiction by maintaining gas temperature within a range that prevents polymer precipitation during heat exchange.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent introduces a heating section as an intermediary component between the polymerization reactor and the cooler. This intermediary heating section serves as a mediator that prevents polymer adhesion on the pipe wall by heating the gas flow, while allowing the subsequent cooler to perform its heat removal function. The intermediary heating section resolves the contradiction by eliminating the harmful polymer adhesion effect without interfering with the polymerization heat removal process.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 stabilizes the polymerization reaction, prevents pipe blockages, and maintains the homogeneity of the water-absorbent resin by ensuring the polymer does not adhere to the inner surfaces, thus ensuring consistent and efficient production.

Implementation Method 1

a cooler main body which is connected to the first channel portion, into which the gas flowing through the first channel of the first channel portion flows, and which cools inflow gas

Methodology Applied

Scientific EffectHeat exchange: Heat Exchanger

Implementation Method 2

a first channel portion temperature adjusting portion which adjusts a temperature of the first channel portion to fall within a predetermined temperature range in which the gas flowing through the first channel of the first channel portion is not condensed

Methodology Applied

Scientific EffectTemperature control: Temperature Gradient

Data Source

PatentUS9670292B2Apparatus for producing water-absorbent resin

Publication Date: 2017.06.06 SUMITOMO SEIKA CHEM CO LTD

AI summary

In an apparatus for producing the water-absorbent resin, gas heated by the polymerization heat accompanied by a polymerization reaction in a reactor main body flows through a first pipe into a heat exchanging structure, and a cooled fluid obtained by the cooling flows through a second pipe into the reactor main body. In the apparatus, a first pipe temperature adjusting portion adjusts a temperature of the first pipe to fall within a predetermined temperature range, and a polymerization reactor temperature adjusting portion adjusts a temperature of an upper portion of the reactor main body to fall within a predetermined temperature range.