Slurry Polymer Separation via Two-Stage Heating and Pressure Reduction
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Solution Overview
Problem
Current slurry polymerization processes are limited by temperature constraints due to active catalyst systems, which restrict the separation efficiency of unreacted carrier fluid from polymer, leading to reduced operating rates and increased burden on downstream processing equipment.
Innovation Solution
A method involving a two-stage heating and separation process using jacketed pipes and separators at different pressures to increase the temperature of the slurry, allowing for more effective vaporization and recovery of unreacted carrier fluid, with the second heating stage occurring at a lower pressure than the first.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the slurry is heated to increase temperature for better separation of unreacted carrier fluid, then the separation efficiency improves, but the catalyst system may cause unfavorable additional reactions
Solution Approach 1:
The patent applies preliminary action by deactivating the catalyst system before the heating and separation steps. The slurry is treated with a quenching agent or transferred to a deactivation zone where the catalyst is neutralized, ensuring that subsequent high-temperature processing does not cause unwanted polymerization or degradation reactions.
Solution Approach 2:
The patent extracts the harmful element (active catalyst) from the system before the heating process. By removing or deactivating the catalyst prior to temperature increase, the system eliminates the source of unfavorable reactions while preserving the beneficial heating effect for carrier fluid removal.
2Quantity of substance
If the temperature of the slurry is increased to vaporize more unreacted carrier fluid, then the amount of carrier fluid extracted increases, but the operating rate of the polymerization unit is reduced
Solution Approach 1:
The patent utilizes phase transitions by heating the slurry to vaporize the unreacted carrier fluid, transitioning it from liquid to gas phase. This phase change enables efficient separation through vapor-liquid equilibrium, allowing more complete carrier fluid removal without requiring excessive temperature increases that would slow down the polymerization rate.
Solution Approach 2:
The patent applies parameter changes by optimizing the temperature-pressure profile during separation. By carefully controlling these parameters and deactivating the catalyst first, the system achieves high carrier fluid extraction efficiency while maintaining favorable polymerization kinetics and operating rate.
3Quantity of substance
If the pressure in the second separator is reduced to expand remaining unreacted carrier fluid, then separation efficiency improves, but the temperature of the enriched slurry drops significantly
Solution Approach 1:
The patent utilizes phase transitions in the second separator by reducing pressure to expand and vaporize the remaining unreacted carrier fluid. This pressure-induced phase change enables efficient removal of residual carrier fluid while the temperature drop is managed through system design and heat integration.
Data Source
AI summary
Provided for separating polymer from a slurry comprising polymer and unreacted carrier fluid is (a) a method comprising supplying slurry to a first heating means to increase the temperature of the slurry, using a first separator means to extract a portion of unreacted carrier fluid from the slurry to obtain a slurry enriched in polymer, supplying the enriched slurry to a second heating means to increase the temperature of the enriched slurry, and using a second separator means to extract an additional portion of unreacted carrier fluid from the enriched slurry to obtain a further enriched slurry, and (b) an apparatus comprising a first heating means, a first separator means, a second heating means and a second separator means.