Carbomer production system and process thereof

Abstract

The invention provides a carbomer production system and process, the carbomer production system comprises a raw material mixing mechanism, a polymerization reaction kettle, a solvent recovery mechanism, a product dehydration mechanism and a packaging mechanism, the raw material mixing mechanism comprises a plurality of storage tanks, a metering pump and an efficient mixer, the storage tanks are respectively used for storing monomers, cross-linking agents and initiators, and the metering pump is connected with the efficient mixer; the top of each storage tank is provided with a sealing cover and an exhaust port, and the bottom of each storage tank is connected to a metering pump through a pipeline. The carbomer production system and process have the advantages of being efficient, environmentally friendly, stable and automatic, the carbomer production efficiency is remarkably improved, the high quality of products is guaranteed, and meanwhile energy consumption and environmental pollution are greatly reduced. And through comprehensive sensor monitoring and a central control system, the safety and intelligent operation of the production process are ensured. In addition, due to the modular design of the equipment and the flexibility of the process, the system can be widely applied to manufacturing requirements of different production scales and various carbomer products.

Description

Technical Field

[0001] The invention relates to the technical field of carbomer preparation, in particular to a carbomer production system and a process thereof. Background Art

[0002] Carbomer is a commonly used high molecular polymer, widely used in medicine, cosmetics and industrial fields as a thickener, suspending agent and stabilizer. The basic composition of carbomer is a high molecular network structure formed by crosslinking agents with acrylic acid as the main monomer. Its properties mainly include good thickening effect, high viscosity, good rheological properties and sensitivity to pH. These properties make it widely used in colloidal systems.

[0003] However, the existing carbomer production process and equipment still have some technical problems in the industrialization process:

[0004] 1. Uneven mixing. In the traditional production process, the mixing efficiency of acrylic acid, crosslinking agent and initiator is low, which easily leads to uneven distribution of materials, thus affecting the stability of the polymerization reaction and the performance of carbomer products. The existing high-efficiency mixer is not well designed and can hardly meet the needs of fast and uniform mixing.

[0005] 2. Control of unstable reaction conditions: The polymerization reaction of carbomer has strict requirements on temperature, pressure and stirring speed. However, the temperature control system and stirring device of existing polymerization equipment are often not accurate enough, making it difficult to adjust the reaction conditions in real time, resulting in an increase in side reactions during the polymerization process and large fluctuations in the quality of the final product.

[0006] 3. Solvent volatilization and environmental pollution. The solvents used in the production process (such as isopropanol and ethanol) are volatile to a certain extent. If the solvent recovery equipment is not designed properly, it is easy to cause excessive solvent volatilization, which not only increases production costs but also pollutes the environment. In addition, solvent volatilization also poses a potential threat to the health of workshop operators.

[0007] 4. The efficiency of product post-processing is low. The efficiency of product dehydration process in the existing technology is low, and the design of vacuum drying or centrifugal separation equipment has not been fully optimized, which often leads to high energy consumption and low production capacity, and affects the drying quality of carbomer products.

[0008] 5. The system is not modular enough. Many existing Carbomer production equipment lack modular design, and the equipment maintenance and replacement costs are high. It is difficult to flexibly adapt to different production scales and process requirements, which limits the application scope and production efficiency of the equipment.

[0009] In view of the above problems, the development of an efficient, stable and environmentally friendly carbomer production system has become an urgent need for the development of the industry. By optimizing the equipment design and process flow, not only can the production efficiency and product performance of carbomer be improved, but also the energy consumption and environmental impact in the production process can be reduced. In view of these technical problems, the present invention proposes an improved carbomer production system and production process thereof to solve the defects in the prior art. Summary of the invention

[0010] The present invention aims to provide a carbomer production system and process to improve production efficiency, stabilize product quality, and reduce impact on the environment.

[0011] To achieve the above object, the present invention proposes the following technical solution: a carbomer production system, comprising:

[0012] A raw material mixing mechanism, the raw material mixing mechanism includes a plurality of storage tanks, a metering pump and a high-efficiency mixer. The storage tanks are used to store monomers, crosslinking agents and initiators respectively. A sealing cover and an exhaust port are provided on the top of each storage tank. The bottom of the storage tank is connected to the metering pump through a pipeline. The metering pump is connected to the bottom of the storage tank and is used to transport the raw materials to the high-efficiency mixer according to a set ratio. The high-efficiency mixer is connected to the metering pump through a feed pipe, and the high-efficiency mixer has a built-in multi-blade high-speed stirring blade.

[0013] A polymerization reactor, which is connected to the outlet of the high-efficiency mixer and is equipped with a high-precision temperature control system, an agitator and an airtight sealing structure;

[0014] The temperature control system includes a plurality of temperature sensors, a heating unit and a cooling unit, and the temperature in the kettle is adjusted through a jacket structure. The stirrer is located in the kettle and is driven by a variable speed motor, and the stirring speed is adjusted according to the reaction viscosity;

[0015] The sealing structure includes a sealing ring and an exhaust valve, which are arranged on the kettle cover to prevent the solvent from volatilizing;

[0016] A solvent recovery mechanism, which is connected to the exhaust valve of the polymerization reactor through a pipeline and is used to recover the solvent volatilized during the production process;

[0017] The solvent recovery mechanism comprises a condenser and an adsorption device, wherein the condenser condenses the volatile solvent into a liquid, the adsorption device is connected to the condenser outlet through a pipeline, and the adsorption device has built-in activated carbon or adsorption resin for further absorbing the uncondensed solvent;

[0018] A product dehydration mechanism, the product dehydration mechanism is connected to the discharge port at the bottom of the polymerization reactor, and the product dehydration mechanism is used to remove water and solvent from the carbomer reaction product;

[0019] The product dehydration mechanism includes a vacuum dryer and a centrifugal separation device. The vacuum dryer includes a heating plate and a vacuum pump for removing solvents in a low temperature environment. The centrifugal separation device separates excess liquid and solids through centrifugal force.

[0020] The packaging mechanism comprises an automatic weighing device and a sealing device for packaging the dehydrated finished product. The packaging mechanism comprises an automatic weighing device and a sealing device. The automatic weighing device is connected to the outlet of the dehydration device for accurate weighing. The sealing device comprises a sealing machine and a vacuum packaging device for sealing and packaging the finished product.

[0021] Furthermore, in the present invention, the inner wall of the polymerization reactor body is made of corrosion-resistant material, and a jacket heating structure is provided on the outside to heat or cool the reaction liquid.

[0022] Furthermore, in the present invention, the storage tank, metering pump, and high-efficiency mixer are connected by quick-install pipes; the polymerization reactor and the solvent recovery mechanism are connected by a high-temperature resistant pipe, and a flow control valve is provided on the pipe; the polymerization reactor and the product dehydration mechanism are connected by a delivery pump, and a filter screen is provided at the inlet of the delivery pump to prevent solid particles from clogging the pipe; all equipment are fixed on a standardized base, and unified control is achieved through a central control system.

[0023] Furthermore, in the present invention, the polymerization reactor is provided with a temperature sensor and a pressure sensor, which are used to detect the reaction conditions; a gas concentration sensor in the solvent recovery mechanism, which is used to monitor the volatilization of the solvent; a humidity sensor in the dehydration mechanism, which is used to determine whether the dehydration process is completed;

[0024] The polymerization reactor is provided with a pH sensor, a viscometer and a solid content analyzer;

[0025] A heating unit and a pressure control unit are arranged in the polymerization reactor. The heating unit is an electric heater, and the pressure control unit is a pressure valve.

[0026] Furthermore, in the present invention, a control system is included, the control system includes a PLC, the temperature sensor, the pressure sensor, the pH sensor, the viscometer stirrer and the electric heater are all connected to the PLC, and the PLC performs the following process to adjust the temperature of the polymerization reaction:

[0027] Step 1: data collection and preprocessing;

[0028] The following variables are collected from the sensors:

[0029] Temperature-T measured (t), pressure Pmeasured (t), viscosity η measured (t), pH measured (t);

[0030] Denoising, using the sliding average method to smooth the collected raw data and filter out noise: Among them, X(t) is the real-time collection value, and N is the size of the sliding window;

[0031] Calculate the error. The error calculation formula is as follows:

[0032] e T (t) = T target -T filtered (t);

[0033] e P (t) = P target -P filtered (t);

[0034] e S (t) = η target -η filtered (t)

[0035] e T (t): temperature error, the temperature error at time t, unit: °C;

[0036] T target : Target temperature, preset ideal temperature value, unit: °C;

[0037] T measured (t): the current measured temperature value, in °C;

[0038] e P (t): pressure error, pressure error at time tt, unit: MPa;

[0039] P target : Target pressure, preset ideal pressure value, unit: MPa;

[0040] P measured (t): currently measured pressure value, the pressure obtained by real-time monitoring of the system, unit: MPa;

[0041] e S (t): stirring speed error, viscosity error at time tt, mPa·s;

[0042] η target : Target viscosity, preset ideal viscosity value, unit: mPa·s;

[0043] η measured(t): currently measured viscosity value, the viscosity obtained by real-time monitoring of the system, unit: mPa·s;

[0044] Step 2: fuzzy control rules;

[0045] The input error e T 、e P 、e S The membership function is defined by the output adjustment values ​​ΔT, ΔP, and ΔS, using a triangular distribution: a, b, and c are the thresholds of the membership function;

[0046] If e T is "high", then increase ΔT; if e P is "low", then reduce ΔP; if e S If it is "high", reduce ΔS;

[0047] Fuzzy control output calculation:

[0048]

[0049]

[0050]

[0051] ΔT: Temperature adjustment value, adjusts the output of the heating or cooling system;

[0052] ΔP: pressure adjustment value, adjusts the output of the pressure system;

[0053] ΔS: stirring speed adjustment value, adjust the speed of the stirrer;

[0054] w i : The weight value of the ii-th fuzzy rule, indicating the influence of the rule on the final adjustment amount;

[0055] μ(e T ): Temperature error e T The membership function value of represents the fuzzy membership of temperature error;

[0056] μ(e P ): Pressure error e P The membership function value of represents the fuzzy membership of the pressure error;

[0057] μ(e S ): stirring speed error e S The membership function value of represents the fuzzy membership of the stirring speed error;

[0058] n: the number of fuzzy rules, each rule will give an adjustment value;

[0059] Step 3: PID controller parameter self-tuning;

[0060] Each adjustment amount is calculated through PID control, and the formula is as follows:

[0061]

[0062]

[0063]

[0064] Δu T (t): The adjustment amount of temperature control, that is, adjusting the control output of the heating / cooling system according to the temperature error;

[0065] K pT : Proportional gain of temperature control, indicating the weight of the proportional control part;

[0066] K iT : Integral gain of temperature control, indicating the weight of the integral control part;

[0067] K dT : The differential gain of temperature control, which indicates the weight of the differential control part;

[0068] e T (t): temperature error, which represents the difference between the target temperature and the current temperature;

[0069] ∫e T (t): The integral part of the temperature error, indicating the cumulative value of the error;

[0070] : The differential part of the temperature error, indicating the rate of change of the error;

[0071] PID controller parameters are dynamically adjusted through fuzzy control:

[0072]

[0073]

[0074]

[0075] K pT , K iT , K dT is the gain parameter of the PID controller, μ(e T ) is the fuzzy controller output;

[0076] The same applies to the adjustment of PID control parameters for pressure and stirring speed.

[0077] A carbomer production process, using the above carbomer production system, also includes the following steps:

[0078] Step 1: Prepare raw materials, including 100 parts of acrylic acid, 0.5-1 parts of cross-linking agent, 0.2-0.5 parts of initiator, 100-150 parts of solvent, appropriate amount of pH adjuster, and 50-100 parts of water. Acrylic acid is used as the main monomer to provide the basic structure of carbomer. Acrylic acid, cross-linking agent, initiator and solvent are weighed in proportion and placed in storage tanks respectively; water is added to the reactor, stirring is started, and a uniform liquid environment is maintained;

[0079] Step 2: Mix the solutions, slowly add acrylic acid and crosslinking agent into the reaction kettle while stirring; add initiator solution, control the stirring speed at 100-300 rpm to ensure uniform mixing; control the temperature at 25-35°C to avoid too high a reaction rate;

[0080] Step 3: Polymerization reaction: start the heating system and raise the temperature of the reactor to 65-80°C; when the reaction starts, observe the viscosity change of the system and adjust the stirring speed; the reaction time is 2-4 hours, and a transparent gel polymer will be formed after the reaction is completed;

[0081] Step 4: Post-treatment: transfer the reaction product to a vacuum drying device, control the temperature below 60°C, remove the solvent and moisture; adjust the pH to a range of 6.0-7.0 to ensure that the carbomer has good application performance; if powdered carbomer is required, it can be further processed by crushing and sieving;

[0082] Step 5: Packaging: The dried carbomer is transferred to a packaging machine, automatically weighed and sealed according to specifications to prevent moisture absorption.

[0083] Furthermore, in the present invention, the crosslinking agent is one or both of ethylene glycol diacrylate and pentaerythritol triacrylate, and the crosslinking agent imparts a network structure to the carbomer gel.

[0084] Furthermore, in the present invention, the initiator is one or both of ammonium persulfate and benzoyl peroxide, and the initiator is used to initiate the polymerization reaction.

[0085] Furthermore, in the present invention, the solvent is isopropanol or ethanol, and the solvent serves as a dispersion medium to reduce by-products of the reaction process.

[0086] Furthermore, in the present invention, the pH regulator is sodium hydroxide or triethanolamine.

[0087] Beneficial effects: The technical solution of this application has the following technical effects:

[0088] The carbomer production system and process of the present invention are characterized by high efficiency, environmental protection, stability and automation, which significantly improves the production efficiency of carbomer, ensures the high quality of the product, and greatly reduces energy consumption and environmental pollution. Through comprehensive sensor monitoring and central control system, the safety and intelligent operation of the production process are ensured. In addition, the modular design of the equipment and the flexibility of the process make the system widely applicable to the manufacturing needs of different production scales and various carbomer products.

[0089] It should be appreciated that all combinations of the foregoing concepts, as well as additional concepts described in greater detail below, may be considered to be part of the inventive subject matter of the present disclosure, provided such concepts are not mutually inconsistent.

[0090] The foregoing and other aspects, embodiments and features of the present invention can be more fully understood from the following description in conjunction with the accompanying drawings. Other additional aspects of the present invention, such as the features and / or beneficial effects of the exemplary embodiments, will be apparent from the following description or learned from the practice of the specific embodiments according to the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0091] The drawings are not intended to be drawn to scale. In the drawings, each identical or nearly identical component shown in various figures may be represented by the same reference numeral. For clarity, not every component is labeled in every figure. Embodiments of various aspects of the present invention will now be described by way of example and with reference to the accompanying drawings, in which:

[0092] Figure 1 Schematic diagram of the system of the present invention.

[0093] Figure 2 It is a schematic diagram of the structural arrangement of the present invention.

[0094] In the figure, the meaning of each figure mark is as follows: 1: storage tank; 2: metering pump; 3: high-efficiency mixer; 4: feed pipe; 5: polymerization reactor; 6: high-precision temperature control system; 7: agitator; 8: airtight sealing structure; 9: condenser; 10: adsorption device; 11: vacuum dryer; 12: centrifugal separation device; 13: automatic weighing device; 14: sealing device; 15: central control system. DETAILED DESCRIPTION

[0095] In order to better understand the technical content of the present invention, specific embodiments are cited and described as follows in conjunction with the accompanying drawings. Various aspects of the present invention are described in this disclosure with reference to the accompanying drawings, in which many illustrative embodiments are shown. The embodiments of the present disclosure are not necessarily defined to include all aspects of the present invention. It should be understood that the various concepts and embodiments introduced above, as well as those described in more detail below, can be implemented in any of many ways, because the concepts and embodiments disclosed in the present invention are not limited to any implementation. In addition, some aspects disclosed in the present invention can be used alone, or in any appropriate combination with other aspects disclosed in the present invention.

[0096] like Figure 1 As shown, the present invention provides a carbomer production system, including a raw material mixing mechanism, a polymerization reactor 5, a solvent recovery mechanism, a product dehydration mechanism and a packaging mechanism, the raw material mixing mechanism includes a plurality of storage tanks 1, a metering pump 2 and a high-efficiency mixer 3, the storage tanks 1 are used to store monomers, crosslinking agents and initiators respectively, each storage tank 1 is provided with a sealing cover and an exhaust port on the top, the bottom of the storage tank 1 is connected to the metering pump through a pipeline, the metering pump 2 is connected to the bottom of the storage tank, and is used to transport the raw materials to the high-efficiency mixer 3 according to a set ratio; the high-efficiency mixer 3 is connected to the metering pump through a feed pipe 4, and the high-efficiency mixer 3 has a built-in multi-blade high-speed stirring blade;

[0097] The polymerization reactor 5 is connected to the outlet of the high-efficiency mixer 3, and the polymerization reactor 5 is equipped with a high-precision temperature control system 6, a stirrer 7 and an airtight sealing structure 8;

[0098] The temperature control system 6 includes a plurality of temperature sensors, a heating unit and a cooling unit. The cooling unit is a fan, which adjusts the temperature in the kettle through a jacket structure. The stirrer 7 is located in the kettle. The stirrer 7 is driven by a variable speed motor, and the stirring speed is adjusted according to the reaction viscosity.

[0099] The sealing structure 8 includes a sealing ring and an exhaust valve, which are arranged on the kettle cover to prevent the solvent from volatilizing;

[0100] The solvent recovery mechanism is connected to the exhaust valve of the polymerization reactor 5 through a pipeline to recover the solvent volatilized during the production process;

[0101] The solvent recovery mechanism includes a condenser 9 and an adsorption device 10. The condenser 9 condenses the volatile solvent into a liquid. The adsorption device 10 is connected to the outlet of the condenser 9 through a pipeline. The adsorption device 10 has built-in activated carbon or adsorption resin for further absorbing the uncondensed solvent.

[0102] The product dehydration mechanism is connected to the discharge port at the bottom of the polymerization reactor 5, and the product dehydration mechanism is used to remove water and solvent from the carbomer reaction product;

[0103] The product dehydration mechanism includes a vacuum dryer 11 and a centrifugal separation device 12. The vacuum dryer 11 includes a heating plate and a vacuum pump for removing solvents in a low temperature environment. The centrifugal separation device 12 separates excess liquid and solids by centrifugal force.

[0104] The packaging mechanism includes an automatic weighing device and a sealing device, which are used to package the dehydrated finished product. The packaging mechanism includes an automatic weighing device 13 and a sealing device 14. The automatic weighing device 13 is connected to the outlet of the dehydration device for accurate weighing. The sealing device 14 includes a sealing machine and a vacuum packaging device, which are used to seal and package the finished product.

[0105] In this embodiment, the inner wall of the polymerization reactor body 5 is made of corrosion-resistant material, and a jacket heating structure is provided on the outside to heat or cool the reaction liquid.

[0106] In this embodiment, the storage tank 1, the metering pump 2, and the high-efficiency mixer 3 are connected by quick-install pipes; the polymerization reactor 5 is connected to the solvent recovery mechanism by a high-temperature resistant pipe, and a flow control valve is provided on the pipe; the polymerization reactor 5 is connected to the product dehydration mechanism by a delivery pump, and a filter screen is provided at the inlet of the delivery pump to prevent solid particles from clogging the pipe; all equipment is fixed on a standardized base and is uniformly regulated through a central control system 15.

[0107] In this embodiment, the polymerization reactor 5 is provided with a temperature sensor and a pressure sensor, which are used to detect the reaction conditions; a gas concentration sensor in the solvent recovery mechanism, which is used to monitor the volatilization of the solvent; a humidity sensor in the dehydration mechanism, which is used to determine whether the dehydration process is completed.

[0108] In this embodiment, a pH sensor, a viscometer and a solid content analyzer are arranged in the polymerization reactor 5 .

[0109] The working principle of this production system can be divided into five main stages: raw material mixing, polymerization reaction, solvent recovery, product dehydration, and product packaging. Specifically, the raw material mixing mechanism consists of a storage tank 1, a metering pump 2, and a high-efficiency mixer 3, which are used to accurately mix monomers (such as acrylic acid), crosslinking agents (such as ethylene glycol diacrylate), initiators (such as ammonium persulfate), and solvents (such as isopropanol) in proportion. Each raw material is stored in a different storage tank. A sealing cover and an exhaust port are provided on the top of the storage tank to prevent the volatilization of the raw materials while keeping the system airtight. According to the formula ratio, the metering pump transports each raw material to the high-efficiency mixer 3 through a pipeline. The high-efficiency mixer 3 is equipped with a multi-blade high-speed stirring blade, which is used to evenly mix the materials through high-speed rotation to avoid excessive or uneven local concentrations. The mixed raw materials enter the polymerization reactor 5 through the feed pipe 4.

[0110] Afterwards, a polymerization reaction is carried out, and the mixed raw materials enter the polymerization reactor 5, and a polymerization reaction is carried out under the set temperature and pressure conditions to generate carbomer gel. The temperature control system 6 uses a jacket structure and multiple temperature sensors to accurately control the reaction temperature through a heating unit and a cooling unit to ensure the stability of the reaction process. The agitator 7 is driven by a variable speed motor, and the stirring speed is automatically adjusted according to the reaction viscosity to ensure that the materials are fully mixed and prevent local overheating. The sealing ring and exhaust valve of the airtight sealing structure 8 effectively prevent the solvent from volatilizing and ensure that the reaction conditions are controlled. The temperature sensor, pressure sensor, pH sensor, viscometer and solid content analyzer in the reactor monitor the reaction conditions in real time to ensure product quality and reaction safety.

[0111] After that, the solvent is recovered. The solvent volatilized during the polymerization process enters the solvent recovery mechanism through the reactor exhaust valve to reduce the emission of volatile organic compounds (VOC). The volatile solvent is cooled to liquid in the condenser 9 and refluxed into the storage tank for reuse. The condensed solvent passes through the adsorption device 10 and is further absorbed by activated carbon or adsorption resin to ensure that the solvent emission is minimized. The gas concentration sensor monitors the solvent volatilization in real time and feeds back to the central control system to adjust the recovery parameters.

[0112] During the product dehydration process, the carbomer gel generated by the polymerization reaction contains more water and residual solvent, which is post-processed by the product dehydration mechanism. The solvent and water are removed by heating plates and vacuum pumps under low temperature and low pressure conditions to avoid the impact of high temperature on product performance. The excess liquid and solid are further separated by centrifugal force to improve the dehydration efficiency and reduce the subsequent drying burden. The humidity sensor monitors the humidity after dehydration in real time to ensure that the moisture content of the product meets the requirements.

[0113] Finally, the product is packaged, and the dehydrated carbomer product is weighed and packaged by the packaging mechanism to prepare the final product. The automatic weighing device 13 accurately measures the quality of the dehydrated carbomer to ensure the consistency of the packaging specifications. The sealing machine in the sealing device 14 heat-seals the packaging bag, and the vacuum packaging device is used to prevent the finished product from absorbing moisture and contamination. All equipment is uniformly controlled by the central control system 15. Parameter settings include temperature, pressure, stirring speed, flow rate, etc. The system adjusts the operating conditions by real-time monitoring of sensor data (such as temperature, pressure, humidity, gas concentration, etc.). Once an abnormality is detected (such as excessive temperature, excessive pressure or solvent leakage), the system automatically issues an alarm and takes emergency measures to ensure the safety of the production process.

[0114] In this embodiment, a heating unit and a pressure control unit are provided in the polymerization reaction kettle (5), wherein the heating unit is an electric heater and the pressure control unit is a pressure valve.

[0115] This embodiment also includes a control system, which includes a PLC. The temperature sensor, pressure sensor, pH sensor, viscometer stirrer and electric heater are all connected to the PLC. The PLC adjusts the temperature of the polymerization reaction through the following process:

[0116] Step 1: data collection and preprocessing;

[0117] The following variables are collected from the sensors:

[0118] Temperature-T measured (t), pressure P measured (t), viscosity η measured (t), pH measured (t);

[0119] Denoising, using the sliding average method to smooth the collected raw data and filter out noise: , where X(t) is the real-time collection value and N is the size of the sliding window;

[0120] Calculate the error. The error calculation formula is as follows:

[0121] e T (t) = T target -T filtered (t);

[0122] e P (t) = P target -P filtered (t);

[0123] e S (t) = η target -η filtered (t);

[0124] e T (t): temperature error, the temperature error at time t, unit: °C;

[0125] T target : Target temperature, preset ideal temperature value, unit: °C;

[0126] T measured (t): the current measured temperature value, in °C;

[0127] e P (t): pressure error, pressure error at time tt, unit: MPa;

[0128] P target : Target pressure, preset ideal pressure value, unit: MPa;

[0129] P measured(t): currently measured pressure value, the pressure obtained by real-time monitoring of the system, unit: MPa;

[0130] e S (t): stirring speed error, viscosity error at time tt, mPa·s;

[0131] η target : Target viscosity, preset ideal viscosity value, unit: mPa·s;

[0132] η measured (t): currently measured viscosity value, the viscosity obtained by real-time monitoring of the system, unit: mPa·s;

[0133] Step 2: fuzzy control rules;

[0134] The input error e T 、e P 、e S The membership function is defined by the output adjustment values ​​ΔT, ΔP, and ΔS, using a triangular distribution: a, b, and c are the thresholds of the membership function;

[0135] If e T is "high", then increase ΔT; if e P is "low", then reduce ΔP; if e S If it is "high", reduce ΔS;

[0136] Fuzzy control output calculation:

[0137]

[0138]

[0139]

[0140] ΔT: Temperature adjustment value, adjusts the output of the heating or cooling system;

[0141] ΔP: pressure adjustment value, adjusts the output of the pressure system;

[0142] ΔS: stirring speed adjustment value, adjust the speed of the stirrer;

[0143] w i : The weight value of the ii-th fuzzy rule, indicating the influence of the rule on the final adjustment amount;

[0144] μ(e T ): Temperature error e T The membership function value of represents the fuzzy membership of temperature error;

[0145] μ(eP ): Pressure error e P The membership function value of represents the fuzzy membership of the pressure error;

[0146] μ(e S ): stirring speed error e S The membership function value of represents the fuzzy membership of the stirring speed error;

[0147] n: the number of fuzzy rules, each rule will give an adjustment value;

[0148] Step 3: PID controller parameter self-tuning;

[0149] Each adjustment amount is calculated through PID control, and the formula is as follows:

[0150]

[0151]

[0152]

[0153] Δu T (t): The adjustment amount of temperature control, that is, adjusting the control output of the heating / cooling system according to the temperature error;

[0154] K pT : Proportional gain of temperature control, indicating the weight of the proportional control part;

[0155] K iT : Integral gain of temperature control, indicating the weight of the integral control part;

[0156] K dT : The differential gain of temperature control, which indicates the weight of the differential control part;

[0157] e T (t): temperature error, which represents the difference between the target temperature and the current temperature;

[0158] ∫e T (t): The integral part of the temperature error, indicating the cumulative value of the error;

[0159] : The differential part of the temperature error, indicating the rate of change of the error;

[0160] PID controller parameters are dynamically adjusted through fuzzy control:

[0161]

[0162]

[0163]

[0164] K pT , K iT , K dT is the gain parameter of the PID controller, μ(e T ) is the fuzzy controller output;

[0165] The same applies to the adjustment of PID control parameters for pressure and stirring speed.

[0166] Specific operation process initialization: set the target value T target , P target , η target , initialize PID parameter K p , K i , K d , real-time data collection: collect T per second measured (t), P measured (t), η measured (t). Calculate the error and make fuzzy inference: According to e T , e P , e S Calculate the fuzzy adjustment values ​​ΔT, ΔP, ΔS. Adjust the PID parameters according to the fuzzy reasoning results. Apply PID control and use the PID control formula to calculate the adjustment value Δu T , Δu P , Δu S . Adjust the stirring speed of the electric heater and stirrer. Feedback adjustment, update the collected data and control quantity once per second. Loop execution until the error e T , e P , e S Stable within the set threshold range.

[0167] For example, assuming the target temperature is T target =80℃, target pressure P target =0.8MPa, target viscosity η measured (t) = 2000 mPa\cdotps. Current temperature T measured =75°, error e T =5°; fuzzy reasoning yields: ΔT = +10%, cooling power ΔP = -5%; PID adjustment yields: increase the electric heater power by 8%, reduce the cooling unit power by 3%, and finally through real-time adjustment, the reaction conditions quickly stabilize.

[0168] The present invention enables efficient mixing and precise reaction control: advanced mixing and temperature control technologies are used to ensure uniformity of reaction materials and stability of the reaction process. Solvents can be effectively recovered, volatile substance emissions can be reduced, and resource utilization can be improved. The production process is modularly designed, and the central control system monitors in real time to improve production efficiency and product quality. The combination of vacuum drying and centrifugal separation greatly reduces energy consumption while improving the dehydration effect. Through the above working principles, the system achieves the goal of efficient, environmentally friendly, safe and high-quality output of carbomer production.

[0169] Example 1: High-efficiency raw material mixing test

[0170] Purpose of the experiment: To verify whether the combination of storage tank, metering pump and high-efficiency mixer can achieve efficient and uniform mixing.

[0171] Experimental conditions:

[0172] Monomer: 100 parts of acrylic acid;

[0173] Cross-linking agent: 0.7 parts of ethylene glycol diacrylate;

[0174] Initiator: 0.3 parts of ammonium persulfate;

[0175] Solvent: 120 parts of isopropanol;

[0176] Temperature: 30℃;

[0177] Mixing time: 10 minutes;

[0178] Stirring speed: 200RPM;

[0179] Experimental data:

[0180] Viscosity uniformity test (sampling 5 times at the mixer outlet): viscosity uniformity error is less than 2%; component analysis (determined by GC-MS): the deviation of each component in the material is within ±1%;

[0181] Conclusion: Through the action of the efficient mixer, the raw material mixing is achieved quickly and evenly distributed, ensuring the stability of subsequent reactions.

[0182] Example 2: Precision reaction control test

[0183] Experimental purpose: To verify the effect of different temperature control conditions on the stability of polymerization reaction.

[0184] Experimental conditions:

[0185] The formula is the same as in Example 1;

[0186] The temperature settings were 65°C, 70°C, and 75°C;

[0187] Reaction time: 2 hours;

[0188] Stirring speed: 250RPM;

[0189] Experimental data:

[0190]

[0191] Conclusion: The high-precision temperature control system of the reactor ensures the stability of the reaction, and the product performance is optimal when the temperature is controlled at 70°C.

[0192] Example 3: Solvent recovery efficiency test

[0193] Experimental purpose: To verify the recovery efficiency of solvent volatiles by condenser and adsorption device.

[0194] Experimental conditions:

[0195] Reaction system: same as Example 1;

[0196] Volatile solvent: isopropyl alcohol;

[0197] Condensation temperature: 10℃;

[0198] Adsorption material: activated carbon;

[0199] Recovery time: 30 minutes;

[0200] Experimental data:

[0201] Original volatile amount: 1200g;

[0202] Condensation recovery amount: 1100g;

[0203] Adsorption recovery: 85g;

[0204] Total recovery efficiency: 98.1%;

[0205] Conclusion: The combination of condenser and adsorption device can effectively recover volatile solvents and significantly reduce environmental pollution.

[0206] Example 4: Dehydration treatment efficiency test

[0207] Experimental purpose: To verify the effect of vacuum dryer and centrifugal separation device on improving dehydration efficiency.

[0208] Experimental conditions:

[0209] Initial moisture content: 45%;

[0210] Vacuum drying temperature: 50°C;

[0211] Centrifugal separation speed: 3000RPM;

[0212] Processing time: 60 minutes;

[0213] Experimental data:

[0214] Initial sample weight: 1000 g;

[0215] Sample weight after drying: 550 g;

[0216] The moisture content is reduced to: ≤5%;

[0217] Conclusion: The vacuum dryer and centrifugal separation device effectively reduced the moisture in the product and ensured the dry quality of the final product.

[0218] Example 5: Finished product quality and application performance testing

[0219] Purpose of the experiment: To verify the quality indicators and application performance of the final product.

[0220] Experimental conditions:

[0221] The formula is the same as in Example 1;

[0222] Product form: gel and powder;

[0223] Application test: Test the thickening performance and stability of carbomer under different pH conditions;

[0224] Experimental data:

[0225] Gel transparency: 99%;

[0226] Powder fineness: 120 mesh;

[0227] Thickening performance (solution viscosity):

[0228] pH = 6.0: 27000 mPa·s;

[0229] pH = 7.0: 31000 mPa·s;

[0230] Conclusion: The finished carbomer has high transparency, excellent thickening performance and stability, which meets the needs of industrial applications.

[0231] Comprehensive Conclusion The above experimental results fully prove the beneficial effects of the invention:

[0232] 1. The efficient mixing mechanism ensures material uniformity and mixing efficiency.

[0233] 2. Precise temperature control and stirring control technology stabilizes the polymerization reaction and improves product quality.

[0234] 3. The solvent recovery system greatly reduces the waste of volatile solvents and environmental pollution.

[0235] 4. Product dehydration technology optimizes drying efficiency and finished product quality.

[0236] 5. Through standardized processes, the prepared carbomer products have excellent performance and can adapt to different industrial application scenarios.

[0237] Example 6

[0238] A production process of carbomer, the material ratio is as follows: acrylic acid: 100 parts, cross-linking agent (ethylene glycol diacrylate): 0.5 parts; initiator (ammonium persulfate): 0.2 parts; solvent (ethanol): 120 parts; water: 80 parts; pH regulator (triethanolamine): appropriate amount

[0239] The process steps are as follows

[0240] 1. Raw material preparation: Weigh the above raw materials in proportion, and place acrylic acid, cross-linking agent, initiator, and solvent in storage tanks respectively.

[0241] 2. Solution mixing: Add 80 parts of water into the reactor and start the stirring device. Slowly add acrylic acid and crosslinking agent, keeping the stirring speed at 150 rpm.

[0242] 3. Polymerization reaction: raise the temperature to 70°C, add initiator solution, control the reaction time to 3 hours, and observe the formation of transparent gel.

[0243] 4. Post-treatment: The reaction product was transferred to a vacuum drying device, the temperature was controlled at 50°C, dried for 8 hours, and the pH was adjusted to 6.5.

[0244] 5. Packaging: Process the dried Carbomer through a grinder, sieve it, weigh it according to specifications and seal it.

[0245] The experimental data are as follows: gel transparency: 96%, viscosity (1% aqueous solution, 25°C): 32000 mPa·s, pH stability: maintained stability within the pH range of 6.0-7.0 for 48 hours without change.

[0246] Example 7

[0247] A production process of carbomer, the material ratio is as follows: acrylic acid: 100 parts, cross-linking agent (pentaerythritol triacrylate): 1 part, initiator (benzoyl peroxide): 0.5 parts; solvent (isopropanol): 100 parts; water: 70 parts, pH regulator (sodium hydroxide): appropriate amount

[0248] The process steps are as follows

[0249] 1. Raw material preparation: Place acrylic acid, cross-linking agent, initiator and solvent in storage tanks respectively, weigh water and add it into the reactor.

[0250] 2. Solution mixing: Slowly add acrylic acid into water, followed by the cross-linking agent, with the stirring speed controlled at 200 rpm.

[0251] 3. Polymerization reaction: Raise the temperature to 75°C, gradually add the initiator solution, maintain the temperature and stir for 2 hours.

[0252] 4. Post-treatment: Drying temperature is 55°C, vacuum drying for 10 hours, and adjusting pH to 6.0.

[0253] 5. Packaging: crush, sieve and then seal.

[0254] The experimental data are as follows: gel transparency: 94%, viscosity (1% aqueous solution, 25°C): 30000mPa·s, water absorption ratio: 1g of product absorbs 250g of water, and the water absorption performance is significant.

[0255] Example 8

[0256] A production process of carbomer, the material ratio is as follows: acrylic acid: 100 parts, cross-linking agent (ethylene glycol diacrylate and pentaerythritol triacrylate, ratio 1:1): 0.75 parts, initiator (ammonium persulfate and benzoyl peroxide, ratio 1:1): 0.4 parts, solvent (ethanol and isopropanol, ratio 1:1): 150 parts, water: 100 parts, pH adjuster (triethanolamine and sodium hydroxide, ratio 1:1): appropriate amount

[0257] The process steps are as follows:

[0258] 1. Raw material preparation: Weigh the raw materials and add them into the storage tank respectively.

[0259] 2. Solution mixing: Add water into the reaction kettle, maintain the stirring speed at 300 rpm, and add acrylic acid, crosslinking agent and initiator in sequence.

[0260] 3. Polymerization reaction: Raise the temperature to 80°C, maintain for 3 hours, and monitor the viscosity change.

[0261] 4. Post-treatment: vacuum drying at 45°C for 12 hours, adjust pH to 7.0, and sieve after drying.

[0262] 5. Packaging: Seal the finished product.

[0263] Experimental data: gel transparency: 98%, viscosity (1% aqueous solution, 25°C): 35000mPa·s, water absorption rate: 1g product absorbs 270g of water, salt resistance: viscosity retention rate in 0.5mol / L sodium chloride solution is 80%.

[0264] Technical effect comparison

[0265]

[0266] It can be seen from the experimental data that different raw material ratios and process conditions can prepare carbomers with excellent performance, among which Example 8 has the best comprehensive performance, especially in terms of viscosity and water absorption rate, showing significant technical advantages, meeting the needs of high-performance carbomer products.

[0267] Although the present invention has been disclosed as above with preferred embodiments, it is not intended to limit the present invention. A person with ordinary knowledge in the technical field to which the present invention belongs may make various changes and modifications without departing from the spirit and scope of the present invention. Therefore, the protection scope of the present invention shall be determined by the definition of the claims.

Claims

1. A carbomer production system, characterized in that: include: A raw material mixing mechanism, the raw material mixing mechanism comprising a plurality of storage tanks (1), a metering pump (2) and a high-efficiency mixer (3), the storage tanks (1) being used to store monomers, crosslinking agents and initiators respectively, each storage tank (1) being provided with a sealing cover and an exhaust port at the top, the bottom of the storage tank (1) being connected to the metering pump via a pipeline, the metering pump (2) being connected to the bottom of the storage tank and being used to deliver the raw materials to the high-efficiency mixer (3) according to a set ratio; the high-efficiency mixer (3) being connected to the metering pump via a delivery pipe (4), the high-efficiency mixer (3) being provided with a multi-blade high-speed stirring blade; A polymerization reactor (5), wherein the polymerization reactor (5) is connected to the outlet of the high-efficiency mixer (3), and the polymerization reactor (5) is equipped with a high-precision temperature control system (6), an agitator (7) and an airtight sealing structure (8); The temperature control system (6) includes a plurality of temperature sensors, a heating unit and a cooling unit, and adjusts the temperature in the kettle through a jacket structure. The stirrer (7) is located in the kettle, and the stirrer (7) is driven by a variable speed motor, and the stirring speed is adjusted according to the reaction viscosity; The sealing structure (8) includes a sealing ring and an exhaust valve, which are arranged on the kettle cover to prevent the solvent from volatilizing; A solvent recovery mechanism, which is connected to the exhaust valve of the polymerization reactor (5) through a pipeline and is used to recover the solvent volatilized during the production process; The solvent recovery mechanism comprises a condenser (9) and an adsorption device (10), wherein the condenser (9) condenses the volatile solvent into a liquid, and the adsorption device (10) is connected to the outlet of the condenser (9) via a pipeline, and the adsorption device (10) has built-in activated carbon or adsorption resin for further absorbing uncondensed solvent; A product dehydration mechanism, the product dehydration mechanism is connected to the discharge port at the bottom of the polymerization reactor (5), and the product dehydration mechanism is used to remove water and solvent from the carbomer reaction product; The product dehydration mechanism comprises a vacuum dryer (11) and a centrifugal separation device (12), wherein the vacuum dryer (11) comprises a heating plate and a vacuum pump and is used to remove the solvent in a low temperature environment, and the centrifugal separation device (12) separates excess liquid and solid by centrifugal force; A packaging mechanism, comprising an automatic weighing device and a sealing device, for packaging the finished product after dehydration, the packaging mechanism comprising an automatic weighing device (13) and a sealing device (14), the automatic weighing device (13) being connected to the outlet of the dehydration device for accurate weighing, the sealing device (14) comprising a sealing machine and a vacuum packaging device for sealing and packaging the finished product.

2. A carbomer production system according to claim 1, characterized in that: The inner wall of the polymerization reactor body (5) is made of corrosion-resistant material, and a jacket heating structure is provided on the outside for heating or cooling the reaction liquid.

3. A carbomer production system according to claim 1, characterized in that: The storage tank (1), metering pump (2) and high-efficiency mixer (3) are connected by a quick-install pipeline; the polymerization reactor (5) is connected to the solvent recovery mechanism by a high-temperature resistant pipeline, and a flow control valve is provided on the pipeline; the polymerization reactor (5) is connected to the product dehydration mechanism by a delivery pump, and a filter screen is provided at the inlet of the delivery pump to prevent solid particles from clogging the pipeline; all equipment are fixed on a standardized base and are uniformly controlled by a central control system (15).

4. A carbomer production system according to claim 1, characterized in that: The polymerization reactor (5) is provided with a temperature sensor and a pressure sensor, which are used to detect reaction conditions; a gas concentration sensor in the solvent recovery mechanism, which is used to monitor the volatilization of the solvent; a humidity sensor in the dehydration mechanism, which is used to determine whether the dehydration process is completed; The polymerization reactor (5) is provided with a pH sensor, a viscometer and a solid content analyzer; The polymerization reactor (5) is provided with a heating unit and a pressure control unit, wherein the heating unit is an electric heater and the pressure control unit is a pressure valve.

5. A carbomer production system according to claim 4, characterized in that: The control system includes a PLC, the temperature sensor, the pressure sensor, the pH sensor, the viscometer stirrer and the electric heater are all connected to the PLC, and the PLC performs the following process to adjust the temperature of the polymerization reaction: Step 1: data collection and preprocessing; The following variables are collected from the sensors: Temperature-T measured (t), pressure P measured (t), viscosity η measured (t), pH measured (t); Denoising, using the sliding average method to smooth the collected raw data and filter out noise: Among them, X(t) is the real-time collection value, and N is the size of the sliding window; Calculate the error. The error calculation formula is as follows: e T (t)=T target -T filtered (t); e P (t)=P target -P filtered (t); e S (t)=η target -or filtered (t); e T (t): temperature error, the temperature error at time t, unit: °C; T target : Target temperature, preset ideal temperature value, unit ℃; T measured (t): the current measured temperature value, in °C; e P (t): pressure error, pressure error at time tt, unit: MPa; P target : Target pressure, preset ideal pressure value, unit: MPa; P measured (t): currently measured pressure value, the pressure obtained by real-time monitoring of the system, unit: MPa; e S (t): stirring speed error, viscosity error at time tt, mPa·s; η target : Target viscosity, preset ideal viscosity value, unit: mPa·s; η measured (t): currently measured viscosity value, the viscosity obtained by real-time monitoring of the system, unit: mPa·s; Step 2: fuzzy control rules; The input error e T 、e P 、e S The membership function is defined by the output adjustment values ​​ΔT, ΔP, and ΔS, using a triangular distribution: a, b, and c are the thresholds of the membership function; If e T is "high", then increase ΔT; if e P is "low", then reduce ΔP; if e S If it is "high", reduce ΔS; Fuzzy control output calculation: ΔT: Temperature adjustment value, adjusts the output of the heating or cooling system; ΔP: pressure adjustment value, adjusts the output of the pressure system; ΔS: stirring speed adjustment value, adjust the speed of the stirrer; w i : The weight value of the ii-th fuzzy rule, indicating the influence of the rule on the final adjustment amount; μ(e T ): Temperature error e T The membership function value of represents the fuzzy membership of temperature error; μ(e P ): Pressure error e P The membership function value of represents the fuzzy membership of the pressure error; μ(e S ): stirring speed error e S The membership function value of represents the fuzzy membership of the stirring speed error; n: the number of fuzzy rules, each rule will give an adjustment value; Step 3: PID controller parameter self-tuning; Each adjustment amount is calculated through PID control, and the formula is as follows: Δu T (t): The adjustment amount of temperature control, that is, adjusting the control output of the heating / cooling system according to the temperature error; K pT : Proportional gain of temperature control, indicating the weight of the proportional control part; K iT : Integral gain of temperature control, indicating the weight of the integral control part; K dT : The differential gain of temperature control, which indicates the weight of the differential control part; e T (t): temperature error, which represents the difference between the target temperature and the current temperature; ∫e T (t): The integral part of the temperature error, indicating the cumulative value of the error; The differential part of the temperature error represents the rate of change of the error; PID controller parameters are dynamically adjusted through fuzzy control: K pT , K iT , K dT is the gain parameter of the PID controller, μ(e T ) is the fuzzy controller output; The same applies to the adjustment of PID control parameters for pressure and stirring speed.

6. A production process of carbomer, characterized in that: The production system of carbomer according to any one of claims 1 to 5 further comprises the following steps: Step 1: Prepare raw materials, including 100 parts of acrylic acid, 0.5-1 parts of cross-linking agent, 0.2-0.5 parts of initiator, 100-150 parts of solvent, appropriate amount of pH adjuster, and 50-100 parts of water. Acrylic acid is used as the main monomer to provide the basic structure of carbomer. Acrylic acid, cross-linking agent, initiator and solvent are weighed in proportion and placed in storage tanks respectively; water is added to the reactor, stirring is started, and a uniform liquid environment is maintained; Step 2: Mix the solutions, slowly add acrylic acid and crosslinking agent into the reaction kettle while stirring; add initiator solution, control the stirring speed at 100-300 rpm to ensure uniform mixing; control the temperature at 25-35°C to avoid too high a reaction rate; Step 3: Polymerization reaction: start the heating system and raise the temperature of the reactor to 65-80°C; when the reaction starts, observe the viscosity change of the system and adjust the stirring speed; the reaction time is 2-4 hours, and a transparent gel polymer will be formed after the reaction is completed; Step 4: Post-treatment: transfer the reaction product to a vacuum drying device, control the temperature below 60°C, remove the solvent and moisture; adjust the pH to a range of 6.0-7.0 to ensure that the carbomer has good application performance; if powdered carbomer is required, it can be further processed by crushing and sieving; Step 5: Packaging: The dried carbomer is transferred to the packaging machine, automatically weighed and sealed according to specifications to prevent moisture absorption.

7. A carbomer production system according to claim 1, characterized in that: The crosslinking agent is one or both of ethylene glycol diacrylate and pentaerythritol triacrylate, and the crosslinking agent imparts a network structure to the carbomer gel.

8. A carbomer production system according to claim 1, characterized in that: The initiator is one or both of ammonium persulfate and benzoyl peroxide, and the initiator is used to initiate the polymerization reaction.

9. A carbomer production system according to claim 1, characterized in that: The solvent is isopropanol or ethanol, and the solvent serves as a dispersion medium to reduce by-products in the reaction process.

10. A carbomer production system according to claim 1, characterized in that: The pH regulator is sodium hydroxide or triethanolamine.

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