Resin Storage Cooling via Carrier Fluid Recirculation
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Solution Overview
Problem
Conventional seedbed storage systems for polymer resins in gas-phase polymerization processes face challenges with sintering during transfer, leading to operational discontinuity and potential off-grade resin production due to inadequate cooling, and the complexity and expense of dual conveying systems.
Innovation Solution
A process and system that uses a carrier fluid for transferring polymer resin into a container while simultaneously recirculating a portion of the resin to cool it to 50°C or less, utilizing a common flow line and control system to manage the transfer and recirculation, thereby reducing sintering risks and allowing continuous downstream operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If polymer resin is transferred at elevated temperatures using conventional pneumatic conveying systems, then transfer efficiency is maintained, but the resin sinters and accumulates in the seedbed container
Solution Approach 1:
The system changes the temperature parameter of the resin during transfer by introducing cooling means that reduce the resin temperature from elevated temperatures (60°C to 110°C) to below the sintering temperature (50°C or less), thereby preventing sintering while maintaining transfer efficiency
Solution Approach 2:
The system introduces a cooling medium as an intermediary substance that absorbs heat from the resin during transfer, acting as a heat exchange mediator between the resin and the external cooling system, thereby preventing temperature-related sintering
2Reliability
If a cooling/recirculation step is performed after transfer to avoid sintering, then resin stability is improved, but downstream operations must be shutdown and operating continuity is lost
Solution Approach 1:
The system performs cooling and recirculation simultaneously with the transfer operation, eliminating the need for separate shutdown steps. The resin is cooled and recirculated continuously during transfer, maintaining operating continuity while preventing sintering
3Loss of energy
If high solids to conveying fluid ratios are used in conventional conveying systems, then some cooling effect is achieved, but sufficient cooling to avoid sintering is not attained
Solution Approach 1:
The system introduces a dedicated cooling medium as an intermediary that provides additional heat removal capacity beyond what is achieved through conveying fluid alone, enabling sufficient cooling to prevent sintering
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 approach effectively minimizes sintering, provides flexibility in resin transfer, and offers surge capacity without additional cooling costs, ensuring continuous extrusion operations and reducing the need for larger product purge vessels.
Implementation Method 1
transferred at elevated temperatures (e.g., 60°C to 110°C), the resin may sinter if allowed to accumulate in the seedbed container without cooling
Implementation Method 2
re-circulating at least a portion of the resin in the container by withdrawing resin from the container and feeding the withdrawn resin into the flow line
Data Source
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AI summary
Improved systems and processes for storing resins are disclosed herein. These systems and processes are especially useful for reducing the tendency of resins to sinter. In polymerization processes, the improvements disclosed herein can reduce the tendency of resins to sinter while also allowing downstream operations to continue.