Method for manufacturing bisphenol F in solid form

Abstract

A method for producing bisphenol F in solid form is disclosed. The method comprises the steps of: supplying bisphenol F to an extruder at a temperature in the range of 130-170°C; processing the supplied bisphenol F in a first mixing zone maintained at a temperature in the range of 110-130°C of the extruder, and then processing it in a second mixing zone maintained at a temperature in the range of 100-110°C of the extruder; transporting the processed bisphenol F to an discharge zone maintained at a temperature in the range of 75-100°C of the extruder; discharging the processed bisphenol F; and obtaining bisphenol F in solid form.

Description

Technology Field

[0001] The present invention relates to a method for producing bisphenol F in solid form. More specifically, the present invention relates to a method for producing bisphenol F in solid form in a desired shape and size without dust. Background Technology

[0002] Bisphenol F is used in various general consumer goods, for example, coatings for beverage and food cans, composites, chemical-resistant floor coatings, metal coatings, pipe coatings, construction, dental materials, and adhesives. It is commonly used in the manufacture of plastics such as polycarbonate, phenolic resin, benzoxazine, and epoxy resin, and is used to increase the chemical resistance, mechanical resistance, and heat resistance of materials.

[0003] For the safer use of chemicals, the more desirable form of bisphenol F is pellets or granules. However, bisphenol F consists of various isomers, such as 2,4'-dihydroxydiphenylmethane, 2,2'-dihydroxydiphenylmethane, and 4,4'-dihydroxydiphenylmethane, as well as several other oligomers. Since different ratios of isomers can provide different physical, chemical, and performance properties, the melting points of bisphenol F can vary. This poses challenges to the processing of bisphenol F through pelletization and flaking. Due to the wide melting point range of bisphenol F, processing it via conventional flaking and spray drying processes is inconvenient. The extended melting point requires longer cooling times for granules formed by spray drying; therefore, taller spray dryers and coolers are used to compensate for these extended cooling times. As a result, the treatment of bisphenol F by spray drying is a very uneconomical and time-consuming process, making scale-up difficult.

[0004] To produce epoxy resin using bisphenol F, the compound is usually first dissolved in an organic solvent, and then the solvent is removed through a drying process. This increases the processing time of bisphenol F and also poses serious health risks due to the use of solvents in the process.

[0005] KR101360908B1 discloses a method for producing bisphenol F pellets using a solvent for slurry mixing. The disclosed method is not economically desirable due to the use and recovery of organic solvents. In addition, the use of organic solvents poses health risks to the environment.

[0006] WO1988005345A1 discloses a method for manufacturing bisphenol granules using a drum flaker. The disclosed method has the disadvantage that excessive dust is generated during the manufacturing process, posing a health risk. The process also requires an additional screening step to obtain a product of the required size, which results in a long processing time.

[0007] JPS5612328A discloses a method for producing dihydroxydiphenylmethane by solidifying and grinding paste-like or molten dihydroxydiphenylmethane in a kneader. The compound is solidified and ground in an extruder and extruded into pellets. The described process is time-consuming and inefficient because the compound must be slowly cooled in the extruder itself. The problem to be solved

[0008] JP04145367B2 describes a continuous granulation process of bisphenol F. The disclosed process is time-consuming because it requires a four-step process including kneading, solidification, granulation, and finally, cooling of the compound. In addition, this process is also costly because different equipment is required to perform one or more steps. means of solving the problem

[0009] The present disclosure relates to a method for producing bisphenol F in solid form. The method comprises the steps of: feeding bisphenol F to an extruder at a temperature in the range of 130-170°C; processing the fed bisphenol F in a first mixing zone maintained at a temperature in the range of 110-130°C of the extruder, and then processing it in a second mixing zone maintained at a temperature in the range of 100-110°C of the extruder; transporting the processed bisphenol F to an discharge zone maintained at a temperature in the range of 75-100°C of the extruder; discharging the processed bisphenol F; and obtaining bisphenol F in solid form. Specific details for implementing the invention

[0010] Embodiments of the present disclosure will now be described in detail. The terms used in the description provided herein are not intended to be interpreted in a restrictive or limiting manner, as they are used simply in conjunction with the detailed description of specific embodiments of the invention. Furthermore, embodiments of the invention may include several features, none of which are solely responsible for the preferred attributes or are essential for practicing the invention described herein.

[0011] Those skilled in the art will understand that the foregoing general description and the following detailed description are intended to explain the invention and are not intended to limit the invention.

[0012] The terms "a," "an," and "the" are used to indicate "one or more" (i.e., at least one) grammatical objects of the article.

[0013] Throughout this specification, references to "one aspect," "another aspect," or similar language mean that a particular feature, structure, or characteristic described in relation to an embodiment is included in at least one embodiment of the present invention.

[0014] The terms “comprising,” “comprising,” or other variations thereof are intended to include non-exclusive inclusion and are not interpreted as “consisting only of,” so that a process or method including a list of steps does not include only these steps and may include other steps that are not explicitly listed or are not unique to such process or method.

[0015] Likewise, the terms "having" and "including" and their grammatical variations are intended to be non-restrictive, so that the citation of the above items in the list does not exclude other items that may be replaced or added to the listed items.

[0016] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as generally understood by those skilled in the art to which this disclosure pertains. Any method and material similar or equivalent to that described herein may be used to practice or test this disclosure, but preferred methods and materials are described hereafter. All publications mentioned herein are incorporated herein by reference.

[0017] The present disclosure relates to the processing of bisphenol F. Specifically, the present disclosure relates to processing bisphenol F into a solid form of a desired shape and form. Accordingly, the present invention discloses a method for producing bisphenol F in a solid form. The method comprises the steps of: feeding bisphenol F into an extruder at a temperature in the range of 130-170°C; processing the supplied bisphenol F in a first mixing zone maintained at a temperature in the range of 110-130°C of the extruder, and then processing it in a second mixing zone maintained at a temperature in the range of 100-110°C of the extruder; transporting the processed bisphenol F to an discharge zone maintained at a temperature in the range of 75-100°C of the extruder; discharging the processed bisphenol F; and obtaining bisphenol F in a solid form.

[0018] According to one embodiment, bisphenol F is fed to an extruder at a temperature in the range of 130-150°C.

[0019] According to one embodiment, the first mixing zone is maintained at a temperature in the range of 115-130°C.

[0020] According to one embodiment, the second mixing zone is maintained at a temperature in the range of 105-110°C.

[0021] According to one embodiment, the discharge zone is maintained at a temperature in the range of 75-95°C.

[0022] Any suitable extruder may be used to carry out the disclosed method. The extruder may be a single-screw extruder, a twin-screw extruder, and a multiple-screw extruder. In some embodiments, the extruder is a counter-rotating or co-rotating twin-screw extruder. In certain embodiments, the extruder is a co-rotating twin-screw extruder.

[0023] The total residence time of bisphenol F in the extruder is in the range of 0.2 to 10 minutes. In certain embodiments, the total residence time is in the range of 0.2 to 5 minutes.

[0024] Bisphenol F is known to exist as a mixture of various isomers, such as 2,4'-dihydroxydiphenylmethane, 2,2'-dihydroxydiphenylmethane, and 4,4'-dihydroxydiphenylmethane, and several other oligomers. In various embodiments of the present disclosure, bisphenol F comprises 35-45 wt% of 2,4'-dihydroxydiphenylmethane, 25-35 wt% of 4,4'-dihydroxydiphenylmethane, and 10-20 wt% of 2,2'-dihydroxydiphenylmethane.

[0025] The treated bisphenol F is discharged in a semi-solid or semi-molten state. In various embodiments, the discharged bisphenol F is in the form of a semi-solid slurry, paste, or semi-solid noodle.

[0026] Bisphenol F in solid form can be obtained using any suitable method and / or equipment, e.g., a cutting die, a compression molding device, an injection molding device, or a moving belt having a shaped cavity. In one embodiment, the extruder is equipped with a die and a cutter system to convert the discharged bisphenol F into pellets. According to one embodiment, the discharged bisphenol F is cooled with a refrigerant and then converted into a solid form using a cutter, a chopper, or a die. In another embodiment, the discharged bisphenol F is cooled and simultaneously cut to obtain a solid form. According to one embodiment, the discharged bisphenol F is transported to an injection molder to convert it into a solid form and subsequently cooled. In another embodiment, the discharged bisphenol F is transported to a moving belt plating device having a mold on the belt to convert it into a solid form and subsequently cooled.

[0027] The refrigerant may be any suitable refrigerant that does not chemically react with bisphenol F. Examples of suitable refrigerants include, but are not limited to, air, water, and inert gases, e.g., nitrogen. In one embodiment, the refrigerant is at a temperature in the range of 0 to 70°C. In a specific embodiment, the refrigerant is at a temperature in the range of 20 to 55°C. Cooling may be performed by direct or indirect heat transfer.

[0028] The solid form can be of a desired shape and size. Examples of solid forms obtainable from the disclosed method include, but are not limited to, noodles, pellets, granules, flakes, frills, aggregates, particles, and balls.

[0029] The disclosed method is completely or substantially dust-free. According to one embodiment, about 98-99.99% of the supplied bisphenol F is converted into a solid form.

[0030] Examples

[0031] Example 1: Manufacture of Bisphenol F Pellet

[0032] 300g of molten bisphenol F was fed into the hopper of a twin-screw extruder at 140℃. The specifications of the extruder used are as follows:

[0033] Extruder Specifications: THMCO Thailand TW 16 MM Series Extruder (3-stage, Voltage: 380V, Motor: 1.5KW).

[0034] The supplied bisphenol F was processed in the first mixing zone of the extruder and then processed in the second mixing zone of the extruder. The processed bisphenol F was transported to the discharge zone of the extruder. The temperature profiles of the first mixing zone, the second mixing zone, and the discharge zone are provided in Table 1 below.

[0035]

[0036] The duration of this experiment was 1.25 minutes, which was evenly distributed among the three different zones mentioned above.

[0037] The paste-like noodles of the treated bisphenol F were discharged from the extruder. The noodles were cooled by blowing cold air at 30°C and then cut into long pellets.

[0038] Example 2: Manufacture of Bisphenol F Pellet

[0039] 250 g of molten bisphenol F was fed into the hopper of a twin-screw extruder at 150°C. The specifications of the extruder used are as follows:

[0040] Extruder Specifications: THMCO Thailand TW 16 MM Series Extruder (3-stage, Voltage: 380V, Motor: 1.5KW).

[0041] The supplied bisphenol F was processed in the first mixing zone of the extruder and then processed in the second mixing zone of the extruder. The processed bisphenol F was transported to the discharge zone of the extruder. The temperature profiles of the first mixing zone, the second mixing zone, and the discharge zone are provided in Table 2 below.

[0042]

[0043] The stay time for this experiment was 4.5 minutes, which was evenly distributed among the three different zones mentioned above.

[0044] The paste-like noodles of the treated bisphenol F were discharged from the extruder. The noodles were cooled with water at 20°C. The cooled noodles were cut into long pellets.

[0045] Example 3: Manufacture of Bisphenol F balls

[0046] 250 g of molten bisphenol F was fed into the hopper of a twin-screw extruder at 135°C. The specifications of the extruder used are as follows:

[0047] Extruder Specifications: THMCO Thailand TW 16 MM Series Extruder (3-stage, Voltage: 380V, Motor: 1.5KW).

[0048] The supplied bisphenol F was processed in the first mixing zone of the extruder and then processed in the second mixing zone of the extruder. The processed bisphenol F was transported to the discharge zone of the extruder. The temperature profiles of the first mixing zone, the second mixing zone, and the discharge zone are provided in Table 3 below.

[0049]

[0050] The stay time for this experiment was 1.5 minutes, which was evenly distributed among the three different zones mentioned above.

[0051] The noodles coming out of the extruder were fed into the mold of the injection molding device. The molding device was operated for a cycle time of less than 1 minute for molding and demolding. During this cycle time, the mold was cooled using water at 25°C. Bisphenol F was demolded at the end of the molding device to obtain a ball.

[0052] Example 4: Manufacture of Bisphenol F Pellet

[0053] 1,500 g of molten bisphenol F was fed into the hopper of a twin-screw extruder at 145°C. The specifications of the extruder used are as follows:

[0054] Extruder Specifications: THMCO Thailand TW 16 MM Series Extruder (3-stage, Voltage: 380V, Motor: 1.5KW).

[0055] The supplied bisphenol F was processed in the first mixing zone of the extruder and then processed in the second mixing zone of the extruder. The processed bisphenol F was transported to the discharge zone of the extruder. The temperature profiles of the first mixing zone, the second mixing zone, and the discharge zone are provided in Table 4 below.

[0056]

[0057] The duration of this experiment was 2 minutes, which was evenly distributed among the three different zones mentioned above.

[0058] The paste-like noodles coming out of the extruder were fed into the mold of a moving belt flaker. The mold was filled for molding with a cycle time of less than 1 minute and cooled while moving along the length of the moving belt flaker. The mold was cooled using a 25°C water spray on the opposite side of the belt. Bisphenol F was demolded at the end of the moving belt flaker to obtain pellets.

[0059] The amount of supplied bisphenol F converted into solid form, i.e., the pellets and balls obtained in Examples 1-4, was calculated. This was done by weighing the bisphenol F supplied to the extruder, weighing the obtained pellets or balls using a standard laboratory weighing instrument, and calculating the difference between the weight of the supplied bisphenol F and the weight of the pellets or balls. A very small weight loss of up to 0.2% was observed.

[0060] Industrial applicability

[0061] The disclosed method is simple and economical. It is environmentally friendly as it does not use any organic solvents. The refrigerant used in this method can be filtered and recycled. This makes the method more economical and industrially feasible. This method generates minimal or no dust. Therefore, the solid form of bisphenol F obtained by this method is completely or substantially dust-free, exhibits lower discoloration, and is easy to package, transport, and handle. This method converts approximately 98-99.99% of bisphenol F into a solid form.

Claims

Claim 1 A method for producing bisphenol F in solid form, comprising the steps of: feeding molten bisphenol F at a temperature in the range of 130-170°C without the addition of an organic solvent to an extruder; processing the supplied bisphenol F in a first mixing zone maintained at a temperature in the range of 110-130°C of the extruder, and then processing it in a second mixing zone maintained at a temperature in the range of 100-110°C of the extruder; transporting the processed bisphenol F to an discharge zone maintained at a temperature in the range of 75-100°C of the extruder; discharging the processed bisphenol F; and obtaining bisphenol F in solid form such that 98-99.99% of the supplied bisphenol F is converted into a solid form. Claim 2 A method according to claim 1, wherein bisphenol F is supplied to the extruder at a temperature in the range of 130-150℃. Claim 3 A method according to claim 1, wherein the first mixing zone is maintained at a temperature in the range of 115-130℃. Claim 4 A method according to claim 1, wherein the second mixing zone is maintained at a temperature in the range of 105 to 110°C. Claim 5 A method according to claim 1, wherein the discharge zone is maintained at a temperature in the range of 75-95℃. Claim 6 A method according to claim 1, wherein the extruder is selected from the group consisting of a single screw extruder, a twin screw extruder, and a multiple screw extruder. Claim 7 In paragraph 6, the method wherein the extruder is a co-rotating or counter-rotating twin-screw extruder. Claim 8 A method according to claim 1, wherein the total residence time of bisphenol F in the extruder is in the range of 0.2 to 10 minutes. Claim 9 A method according to claim 1, wherein the total stay time is in the range of 0.2 to 5 minutes. Claim 10 A method according to claim 1, wherein bisphenol F comprises 35-45 wt% of 2,4'-dihydroxydiphenylmethane, 25-35 wt% of 4,4'-dihydroxydiphenylmethane, and 10-20 wt% of 2,2'-dihydroxydiphenylmethane. Claim 11 A method according to claim 1, wherein the discharged bisphenol F is in a semi-solid or semi-molten state. Claim 12 A method according to claim 11, wherein the discharged bisphenol F is in a form selected from the group consisting of a semi-solid slurry, a paste, and a semi-solid noodle. Claim 13 A method according to claim 1, wherein the solid form is selected from the group consisting of noodles, pellets, granules, flakes, frills, aggregates, particles, and balls. Claim 14 In paragraph 13, a method wherein the solid form is obtained by a cutting die, a compression molding device, an injection molding device, or a moving belt having a shape cavity. Claim 15 A method according to claim 1 in which 98-99.99% of the supplied bisphenol F is converted into a solid form.

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