Tapered Plate Distributor for Polymer Devolatilization
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing devolatilization processes face challenges in efficiently separating polymers from volatile components while maintaining a single liquid phase for effective heat transfer and predictable heat transfer rates, often resulting in inefficient volatile release and potential polymer degradation.
Innovation Solution
A distributor comprising a core and stacked plates with conduits that radially transport the polymer solution, facilitating heat transfer and pressure reduction, which creates polymeric foam bubbles for efficient volatile diffusion and separation, with a design that minimizes pressure drop and interference between foam layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the polymer solution is heated to a temperature higher than the boiling point of volatiles to facilitate devolatilization, then the volatile removal efficiency is improved, but the polymer degradation increases
Solution Approach 1:
The patent utilizes phase transition by introducing steam into the polymer solution, causing water to transition from liquid to vapor phase. This steam injection creates micro-bubbles that enhance mass transfer and volatile removal without requiring excessive heating, thereby improving volatile removal efficiency while minimizing polymer degradation through controlled phase change rather than thermal degradation alone
Solution Approach 2:
The patent changes the pressure parameter by operating in a reduced pressure environment (vacuum). By lowering the system pressure, the boiling point of volatiles decreases, allowing efficient volatile removal at lower temperatures. This parameter change enables high volatile removal efficiency while avoiding the polymer degradation that would occur at high temperatures
2Productivity
If the polymer solution is transported through a heat exchanger and then into a zone of reduced pressure for devolatilization, then the volatile separation is improved, but the heat transfer efficiency decreases due to phase change complexity
Solution Approach 1:
The patent applies preliminary action by pre-heating the polymer solution in a heat exchanger before introducing it to the reduced pressure zone. This preliminary heating prepares the solution for efficient steam injection and volatile removal, ensuring the polymer is at the appropriate temperature for the phase change process while maintaining controlled energy input
Solution Approach 2:
The patent introduces steam as an intermediary substance into the polymer solution. The steam acts as a mass transfer mediator, creating micro-bubbles that enhance the separation of volatiles from the polymer. This intermediary approach improves volatile separation efficiency while the steam condensation process provides controlled heat transfer, avoiding the inefficiencies of direct thermal processing
3Productivity
If foam bubbles are produced to separate polymer from volatiles, then the volatile release is improved, but the interference between foam layers increases
Solution Approach 1:
The patent segments the foam generation process by introducing steam at multiple injection points along the extruder length. This creates distributed micro-bubbles throughout the polymer solution rather than a single large foam layer, reducing interference between foam layers and improving volatile release efficiency through multiple separation zones
Solution Approach 2:
The patent transitions from a conventional single-phase continuous foam layer to a multi-dimensional distribution of micro-bubbles throughout the polymer solution. By dispersing bubble formation in the radial and axial dimensions rather than creating a single planar foam interface, the system reduces foam layer interference while enhancing volatile release through increased surface area for mass transfer
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 distributor enables efficient separation of volatiles from polymers, maintaining a liquid phase for effective heat transfer and reducing polymer degradation, while ensuring even flow distribution and high reliability through a tapered plate design with few weld connections.
Implementation Method 1
a plurality of conduits for radially transporting the polymer solution from the core to the periphery of the distributor while reducing the polymer solution temperature by means of vaporization and simultaneously reducing its pressure
Implementation Method 2
comprise a plurality of tubes in a vessel, which are heated via a heating fluid which transfers the heat to the polymer solution
Implementation Method 3
The hot polymer solution is then discharged into a devolatilization vessel where a reduced pressure permits the volatiles to flash
Implementation Method 4
The process to separate the polymer from the volatiles involves the production of foam bubbles. These bubbles generally comprise a polymeric skin in which is trapped the volatiles
Data Source
Figure 1A
Figure 1B
Figure 2
AI summary
Disclosed herein is a distributor comprising a first conduit; where the first conduit has an inlet port for charging a heating fluid into the distributor; a second conduit; where the first conduit lies inside the second conduit to define a first annular space therebetween; where the second conduit has an exit port for removing the heating fluid from the distributor; a plurality of plate stacks disposed around the second conduit to define a narrowing second annular space from top to bottom of the distributor; where each successive plate stack has smaller inner diameter than the plate stack located above it; where each plate stack comprises a plurality of plates; where the plurality of plates further define a plurality of conduits, each conduit having a varying width over its length and extending radially outwards from the central passage.