Shell and Plate Heat Exchanger for High Viscosity Polymers
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Solution Overview
Problem
Existing shell-and-tube heat exchangers are inefficient in handling high viscosity polymer solutions due to high pressure drops and reduced heat transfer rates, and are unable to maintain the polymer and solvent in a single phase at temperatures above 150°C.
Innovation Solution
A shell and plate heat exchanger design where a plurality of plates are stacked to form a central passage and radially extending conduits, allowing for efficient heat transfer and pressure control to maintain the polymer solution in a single phase during temperature changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If shell-and-tube heat exchangers are used to heat high viscosity polymer solutions, then heat transfer can be achieved, but pressure drop becomes excessively high and heat transfer rate is reduced
Solution Approach 1:
The heat exchanger is segmented into multiple plates with numerous narrow conduits arranged in parallel. This segmentation divides the single large flow path into many small channels, increasing the total heat transfer surface area while reducing the pressure drop across each individual channel. The polymer solution flows through multiple conduits simultaneously, distributing the flow and reducing resistance.
Solution Approach 2:
The invention transitions from the traditional shell-and-tube three-dimensional flow path to a plate-based two-dimensional flow configuration. Multiple plates stacked together create a planar heat transfer surface with radially extending conduits, effectively adding surface area in the dimensional space while maintaining compact overall geometry. This dimensional change enables better heat transfer efficiency for high viscosity fluids.
2Temperature
If shell-and-tube heat exchangers are used, then heat transfer occurs, but the polymer and solvent separate into phases at temperatures above 150°C
Solution Approach 1:
The invention carefully controls operating parameters including temperature, pressure, and flow velocity to maintain the polymer solution in a single phase. By optimizing these parameters and ensuring the solution remains below the phase separation threshold, the system achieves effective heat transfer while preserving compositional stability and preventing polymer-solvent separation.
3Temperature
If shell-and-tube heat exchangers are used for high viscosity polymer solutions, then heat exchange can occur, but heat transfer rate is significantly reduced
Solution Approach 1:
The plate heat exchanger segments the heat transfer process into numerous parallel conduits, dramatically increasing the total heat transfer surface area. This segmentation allows the polymer solution to contact multiple heat transfer surfaces simultaneously, thereby increasing the overall heat transfer rate despite the high viscosity of the fluid.
Solution Approach 2:
By transitioning to a plate-based configuration with radially extending conduits, the invention utilizes two-dimensional heat transfer surfaces stacked in three-dimensional space. This dimensional approach maximizes the heat transfer area within a compact volume, enabling efficient heat exchange for high viscosity polymer solutions.
4Temperature
If conventional heat exchangers are used, then heat transfer is achieved, but the device complexity and inability to handle high viscosities limits applicability
Solution Approach 1:
The invention optimizes operational parameters including pressure, temperature, and flow velocity to maintain single-phase stability of high viscosity polymer solutions. By carefully controlling these parameters, the system achieves effective heat transfer while preserving fluid homogeneity and preventing phase separation, thereby extending applicability to high viscosity materials.
Solution Approach 2:
The plate heat exchanger design with multiple parallel conduits segments the flow path, reducing the hydraulic diameter and consequently the pressure drop. This segmentation enables the system to handle high viscosity polymer solutions that would be impossible to process through conventional shell-and-tube heat exchangers, significantly improving adaptability.
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 apparatus effectively raises or lowers the temperature of high viscosity polymer solutions by more than 10°C while minimizing pressure drop, maintaining the polymer solution in a single phase and handling viscosities from 100 to 2,000,000 centipoise.
Implementation Method 1
A shell and plate heat exchanger design where a plurality of plates are stacked to form a central passage and radially extending conduits, allowing for efficient heat transfer
Data Source
Figure 1A
Figure 1B
Figure 2
AI summary
Disclosed herein is an apparatus comprising a shell; the shell having an inlet port for introducing a polymer solution into the shell and an outlet port for removing the polymer solution from the shell; wherein the polymer solution comprises a polymer and a solvent that is operative to dissolve the polymer; a plurality of plates in the shell; where the plurality of plates is stacked one atop the other to define a central passage that is in fluid communication with the inlet port of the shell; where the plurality of plates further defines a plurality of conduits, each conduit extending radially outwards from the central passage, where the plurality of conduits is in fluid communication with the central passage; and where the apparatus is operated at a pressure and a temperature effective to maintain the polymer solution in a single phase during its travel through the apparatus.