Split flow reactor trays for vertical staged polycondensation reactors

A polymerization reactor having a vertically disposed outer shell, a liquid polymer reactor inlet near the top of the reactor, a liquid polymer reactor outlet near the bottom of the reactor, and a vapor outlet,

• comprising a plurality of vertically spaced, horizontally disposed, essentially circular split-flow tray assemblies which are fully enclosed within said reactor, and which extend to and are circumferentially attached to the outer shell;
• each tray assembly having a central open section forming a portion of a common vapor chimney connected to the vapor outlet, with open access to the liquid polymer surface on each tray afforded by vertical spacing between successive tray assemblies;
• each tray assembly having at least one aperture providing a free passageway to permit the discharge of a downwardly flowing liquid to the tray immediately below;
• each tray assembly constructed to facilitate traversal of at least two streams of liquid polymer over the floor of the tray in a plurality of flow channels from at least one tray inlet to at least one tray outlet;
• wherein flow of the liquid polymer is accomplished by means of a hydraulic gradient wherein the height of the fluid surface at the tray inlet is greater that the height of the fluid surface at the tray outlet, and the flow channels are defined by baffle walls having sufficient height to prevent spillage of liquid polymer, said baffle walls forming at least two flow channels each having at least two curved subsections, wherein each stream of the liquid polymer flows between subsections through a channel section defined by a substantially semi-circular turnaround region wherein the angular direction of the flow of liquid polymer within the channel is reversed.