Separator Vessel Cleaning Nozzle for Polymer Fouling Removal
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Solution Overview
Problem
High pressure separator vessels in polymerization reactors face operability issues due to polymer accumulation and fouling, which requires frequent cleaning, but existing methods are time-consuming and labor-intensive, especially since heavy top covers need to be removed and re-tightened.
Innovation Solution
A process and system for cleaning high pressure separator vessels without removing the top cover, utilizing a fluid fitting with a cleaning hole and a rotatable cleaning nozzle that can be raised and lowered to direct pressurized liquid onto the inner walls, removing accumulated waste without disassembling the top cover or fluid fitting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the top cover is removed for cleaning, then polymer waste can be accessed and removed from the interior walls, but the cleaning process becomes time-consuming and labor-intensive due to handling heavy covers and bolts
Solution Approach 1:
The cleaning system is segmented into modular components: a telescoping rod with multiple segments that can extend and retract, a separate cleaning nozzle, and an independent pressurized fluid supply system. This allows the cleaning function to be accessed through a small opening without removing the entire top cover assembly.
Solution Approach 2:
A pressurized fluid (water or other cleaning agent) is introduced as an intermediary medium to transfer the cleaning action to the polymer waste. The fluid delivers the mechanical force needed to remove fouling without requiring direct mechanical contact or disassembly of the separator vessel.
Solution Approach 3:
The manual mechanical cleaning process (using scrapers, brushes, or manual removal tools requiring cover removal) is replaced with a pressurized fluid system. The kinetic energy of the pressurized fluid substitutes for manual mechanical force, enabling cleaning through a small access hole without heavy disassembly.
2Ease of operation
If the top cover is removed for cleaning, then the interior walls can be cleaned, but the operation becomes complex requiring special hydraulic tensioning equipment
Solution Approach 1:
The cleaning system is designed to be universally applicable to different separator vessel sizes and configurations. The telescoping rod can extend to various lengths, the nozzle can be adjusted for different angles, and the pressurized fluid system can accommodate different flow rates and pressures, making the same basic system work across multiple vessel types without requiring specialized equipment for each.
Solution Approach 2:
The system allows for easy adjustment of cleaning parameters including fluid pressure, flow rate, nozzle angle, and rod extension length. These parameters can be modified to match different cleaning requirements and vessel configurations without changing the fundamental system architecture or requiring specialized equipment.
3Object-generated harmful factors
If chemical methods are used to reduce fouling, then polymer accumulation is reduced, but chemical additives are required in the polymerization process
Solution Approach 1:
The separator vessel is equipped with self-cleaning capability through integrated cleaning ports and a pressurized fluid system that can be activated during or between production cycles. The system serves its own cleaning needs without requiring external chemical additives or manual intervention, removing polymer waste through mechanical-flush action rather than chemical modification of the polymerization process.
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 method significantly reduces cleaning time and avoids the need to handle heavy top covers, allowing for efficient removal of polymer waste while maintaining operational integrity of the reactor system.
Implementation Method 1
supplying a pressurized liquid to the cleaning nozzle, and gradually raising and/or lowering and rotating the cleaning nozzle through the inside of the high pressure separator vessel from the bottom to a top thereof, such that the pressurized liquid is directed into contact with an inner wall of the high pressure separator vessel and removes accumulated waste material
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3B
AI summary
A process and system for cleaning a high pressure separator vessel (100) in a polymerization reactor without removing the top cover (110) and its associated bolts by providing a cleaning hole (220) in a fluid fitting (120) above and adjacent to the top cover (110), through which a cord or cable (150) is fed and affixed to a rotatable cleaning nozzle (160). The cleaning nozzle (160) is gradually raised, lowered and rotated to direct a high pressure liquid onto the interior walls of the vessel to remove accumulated waste material.