Steam Jet Atomization for Polycarbonate Drying

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Solution Overview

Problem

Conventional steam precipitation methods for producing polycarbonate resin powder result in a wet product with high water content, requiring multiple downstream dryers and high energy consumption, which is costly and environmentally impactful.

Innovation Solution

The method involves introducing multiple smaller resin solution streams into a steam jet instead of a single inlet, improving atomization and energy efficiency, and utilizing additive manufacturing to create complex jet designs that enhance particle size distribution and reduce water content.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional steam precipitation method with single inlet jet is used, then the process is simple, but the product has high water content requiring multiple downstream dryers and high energy consumption

Engineering Contradiction:

Improveprocess simplicityVSAvoidenergy consumption

Core Design Contradiction:

Ease of manufactureVSUse of energy by moving object

Solution Approach 1:

The single resin solution inlet is divided into multiple smaller inlets (e.g., 3-5 inlets) arranged in a circular pattern within the jet. This segmentation improves atomization of the resin solution into finer droplets, enhancing heat and mass transfer efficiency during steam precipitation, which reduces water content in the product and decreases the need for downstream drying operations

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention changes the physical parameters of the jet system by introducing multiple inlets with specific diameter ratios (smaller inlets relative to the jet diameter), inlet spacing, and angular arrangements. These parameter changes optimize the spray pattern and droplet size distribution, improving energy efficiency in the steam precipitation process

Inventive Principle:

Principle #35Parameter changes

2Use of energy by moving object

If multiple smaller resin solution streams are introduced into steam jet, then energy efficiency and atomization improve, but jet design complexity increases

Engineering Contradiction:

Improveenergy efficiencyVSAvoidjet design complexity

Core Design Contradiction:

Use of energy by moving objectVSDevice complexity

Solution Approach 1:

The jet is designed with multiple resin solution inlets segmented around the perimeter, each feeding into a common steam flow path. This segmentation achieves better atomization and energy efficiency while the common outlet structure maintains relative design simplicity

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Multiple resin solution streams from separate inlets are merged into a single steam flow path within the jet, allowing individual inlets to be optimized for atomization while the combined flow maintains a unified exit structure, balancing complexity with performance

Inventive Principle:

Principle #5Merging (Combining)

3Ease of manufacture

If conventional single inlet jet design is used, then manufacturing is simple, but particle size distribution is poor

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidparticle size distribution

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The resin solution is introduced through multiple smaller inlets instead of a single large inlet, creating a more uniform distribution of droplet sizes. This segmentation of the feed stream results in improved particle size distribution in the final precipitated product

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the jet cross-section receive resin solution through optimally positioned inlets, creating local variations in droplet formation that collectively produce a more uniform overall particle size distribution in the precipitated polymer

Inventive Principle:

Principle #3Local quality

4Loss of substance

If steam precipitation is used to vaporize methylene chloride, then solvent removal is efficient, but steam condenses on particles forming wet powder with 25-60% water content

Engineering Contradiction:

Improvesolvent vaporization efficiencyVSAvoidwater content in powder

Core Design Contradiction:

Loss of substanceVSQuantity of substance

Solution Approach 1:

The resin solution is atomized into finer droplets through multiple small inlets, increasing the surface area-to-volume ratio. This enhances the efficiency of methylene chloride vaporization while the controlled droplet size reduces excessive steam condensation, lowering water content in the resulting powder

Inventive Principle:

Principle #1Segmentation

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 reduces energy consumption, decreases the need for downstream drying, and produces a drier polycarbonate powder with improved particle size distribution, leading to cost savings and reduced environmental impact.

Implementation Method 1

the steam itself simultaneously partially condenses on the particles, forming a wet powder

Methodology Applied

Scientific EffectEvaporation: Evaporation

Implementation Method 2

the steam itself simultaneously partially condenses on the particles, forming a wet powder

Methodology Applied

Scientific EffectCondensation: Condensation

Data Source

PatentUS11040320B2Drying systems

Publication Date: 2021.06.22 SABIC GLOBAL TECHNOLOGIES BV

AI summary

Provided are improved steam-drying systems, the systems being configured so as to multiple resin streams into steam streams.