Methods for manufacturing chemical substances

Abstract

This invention provides a manufacturing method that can shorten the manufacturing time of chemical substances. [Solution] This manufacturing method involves producing a chemical substance in a reaction vessel, wherein an analytical device is installed in a flush valve to discharge the chemical substance from the reaction vessel, and the chemical substance in the reaction vessel is analyzed using the analytical device.

Description

Technical Field

[0001] This specification discloses a technology related to a method for producing a chemical substance. In particular, it discloses a technology for producing a liquid chemical substance using a reaction vessel.

Background Art

[0002] A technology of stirring a liquid in a reaction vessel to produce a liquid chemical substance is known. When producing a chemical substance, it is necessary to adjust the state of the raw material in the reaction vessel (for example, the solution concentration) to a predetermined value. In Patent Document 1, the solution in the reaction vessel is sampled, and the solution is analyzed using an analytical instrument provided outside the reaction vessel. The analytical instrument measures the concentration of the sampled solution. In Patent Document 1, the solution concentration in the reaction vessel is automatically adjusted to a predetermined value based on the measurement result of the analytical instrument.

Prior Art Documents

Non-Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In Patent Document 1, the solution in the reaction vessel is sampled, and the solution is analyzed using an analytical instrument provided outside the reaction vessel. Therefore, depending on the operating conditions in the reaction vessel, it may be necessary to change the conditions in the reaction vessel during sampling. For example, when the pressure in the reaction vessel during the production of the chemical substance is high, it may be necessary to reduce the pressure in the reaction vessel during sampling. That is, during sampling, it may be necessary to substantially interrupt the production of the chemical substance. As a result, the production time of the chemical substance is prolonged, and the production cost of the chemical substance increases. The present specification aims to provide a production method that can shorten the production time of a chemical substance.

Means for Solving the Problems

[0005] The first technique disclosed herein is a method for producing a chemical substance in a reaction vessel, wherein an analytical device may be provided in a flush valve for discharging the chemical substance from the reaction vessel, and the chemical substance in the reaction vessel may be analyzed using the analytical device.

[0006] The second technology disclosed herein is a method for producing the first technology described above, wherein the reaction conditions in the reaction vessel may be adjusted based on the results of chemical analysis using an analytical instrument.

[0007] The third technology disclosed herein is a method for producing the second technology described above, wherein the operating conditions of the reaction vessel may be automatically determined based on the analysis results, and the reaction conditions inside the reaction vessel may be automatically adjusted.

[0008] The fourth technology disclosed herein is a manufacturing method of any of the first to third technologies described above, wherein if the analysis indicates that the production of the chemical substance is complete, the flush valve may be automatically opened to discharge the chemical substance to the outside of the reaction vessel.

[0009] The fifth technology disclosed herein is a method for producing any of the first to fourth technologies described above, wherein an analytical device may analyze at least one of the particle size, viscosity, and degree of polymerization of the chemical substance.

[0010] The sixth technology disclosed herein is a manufacturing method of any of the first to fifth technologies described above, wherein the reactor operating conditions may be adjusted in consideration of the analytical results of the analytical instrument and other conditions.

[0011] The seventh technology disclosed herein is a method for producing any of the first to sixth technologies described above, wherein the chemical substance may be an electrical material or a pharmaceutical product. [Brief explanation of the drawing]

[0012] [Figure 1] A cross-sectional view of the main part of the reaction vessel is shown. [Figure 2] A cross-sectional view of the flush valve is shown. [Figure 3]A block diagram illustrating the manufacturing method is shown. [Modes for carrying out the invention]

[0013] In the method for producing chemical substances disclosed herein, an analytical device is installed in a flush valve, and the chemical substances in the reaction vessel are analyzed using the analytical device. The flush valve is attached to a reaction vessel that stirs and mixes a solution to produce a chemical substance. The flush valve is closed while the chemical substance is being produced, and opens when the production of the chemical substance is complete, discharging the chemical substance to the outside of the reaction vessel. The chemical substance discharged from the reaction vessel is moved to the next process or to a storage container. Examples of chemical substances include electrical materials such as resists and pharmaceuticals such as water for injection.

[0014] The analyzer is rod-shaped, with an analysis section at its tip. The analyzer passes through the valve body of the flush valve and is fixed to the valve stem. The analysis section is located inside the reaction vessel and can directly contact the chemical substance. The analyzer can analyze the reaction state of the chemical substance, for example, measuring its temperature, pH, particle size, viscosity, degree of polymerization, atomic absorption, etc. Because the analyzer is in direct contact with the chemical substance, it can analyze the reaction state of the chemical substance at any point during its manufacturing process.

[0015] In this manufacturing method, the conditions of the reaction vessel are adjusted based on the results of chemical analysis using an analytical instrument. Alternatively, the operating conditions of the reaction vessel may be automatically determined and adjusted based on the analysis results. Specifically, if the analysis results indicate that the reaction (production of chemical substances) is complete, the operation (stirring) of the reaction vessel may be automatically stopped, the flush valve may be automatically opened, and the finished product (chemical substance) may be discharged outside the reaction vessel. If the analysis results indicate that the reaction is in progress and proceeding as planned, the operation of the reaction vessel may be continued. Alternatively, if the analysis results indicate that the reaction is in progress and proceeding as planned (the reaction is progressing slowly or excessively), the conditions inside the reaction vessel may be adjusted and the operation inside the reaction vessel may be continued. When adjusting the conditions inside the reaction vessel, the operating conditions of the reaction vessel may be adjusted considering the analysis results and conditions such as the pressure inside the reaction vessel, solution temperature, solution concentration, solution pH, and stirring speed.

[0016] In this manufacturing method, the results (analysis data) from the analytical instrument may be saved to a server. Furthermore, saving the data to the server from the analytical instrument may be done automatically. In addition, in this manufacturing method, the operation of the analytical instrument and the adjustment of the operating conditions of the reaction vessel may be controlled by a control device. The control device may operate the analytical instrument at a pre-set analysis time, or it may determine the next analysis time based on the results of the chemical substance analysis. [Examples]

[0017] Referring to Figure 1, the reaction vessel 100 used in this manufacturing method will be described. The reaction vessel 100 comprises a tank 2, a raw material inlet 8, a motor 6, a stirring blade 10, a baffle plate 4, and a flush valve 20. Raw materials for manufacturing the chemical substance are supplied into the tank 2 from the raw material inlet 8. The motor 6 is fixed to the tank 2 and rotates the stirring blade 10. The baffle plate 4 extends inward into the tank 2 and is fixed to the tank 2 so as not to interfere with the stirring blade 10. The tank 2 is glass-lined. Glass lining is a composite of metal and glass and is characterized by its excellent corrosion resistance.

[0018] The reaction tank 100 is used for mixing liquid raw materials to produce liquid chemical substances. The raw materials are supplied from the raw material inlet 8 to the tank interior 12. The supply of raw materials to the raw material inlet 8 is automatically performed by a control device 84 which will be described later. The raw materials supplied into the tank interior 12 are stirred by the stirring blade 10. The stirring blade 10 is connected to the motor 6, and by driving the motor 6, the stirring blade 10 rotates to stir the raw materials. By stirring the raw materials, the reaction proceeds, and the target chemical substance can be produced. The reaction tank 100 is internally provided with a heater (not shown) for adjusting the temperature of the raw materials, a thermometer (not shown) for measuring the raw material temperature, and the like.

[0019] The baffle plate 4 disturbs the flow of the liquid (raw material) in the tank interior 12 to generate turbulent flow in the tank interior 12. By generating turbulent flow in the tank interior 12, the reaction of the raw materials is accelerated, and the distribution of the raw materials in the tank interior 12 can be made uniform. The produced chemical substance is discharged from the flush valve 20. The opening and closing of the flush valve 20 is also automatically performed.

[0020] The flush valve 20 will be described with reference to FIG. 2. The flush valve 20 is mounted below the tank 2. The flush valve 20 includes a main body portion 50 through which liquid flows, a valve main body 40, and an analysis device 30. The main body portion 50 includes a first opening 52 to which liquid is supplied from the tank 2, a second opening 54 for discharging the liquid to the outside, and a third opening 56 provided at a position facing the first opening 52. A hollow sealing member 68 is disposed between the first opening 52 and the tank 2.

[0021] The valve main body 40 includes a valve stem 42 and a valve element 44. The valve stem 42 passes through the first opening 52 and the third opening 56. A part of the valve stem 42 is located inside the tank 2. The valve element 44 is provided at the tip of the valve stem 42. The end face of the sealing member 68 functions as a seating surface of the valve element 44. The valve main body 40 (valve stem 42) can reciprocate up and down (in the direction of the arrow in the drawing) by the air cylinder 62.

[0022] When the air cylinder 62 moves the valve main body 40 upward, the valve element 44 separates from the sealing member 68, and the flush valve 20 opens. When the flush valve 20 opens, the liquid (chemical substance) in the tank 2 is discharged from the second opening 54. When the air cylinder 62 moves the valve main body 40 downward, the valve element 44 seats on the sealing member 68, and the flush valve 20 closes. The upper limit and lower limit of the vertical movement of the valve main body 40 are controlled by the limiter switch 64 and the limit switch lever 66. In addition, the valve main body 40 (the valve rod 42 and the valve element 44) has a through hole, and the analyzer 30 passes through the inside of the through hole.

[0023] The analyzer 30 includes an analysis section 32, an intermediate section 34, and a terminal section 36. The analyzer 30 is rod-shaped, the analysis section 32 is provided at one end of the intermediate section 34, and the terminal section 36 is provided at the other end of the intermediate section 34. The analysis section 32 is located inside the tank 2. That is, the analysis section 32 is in direct contact with the chemical substance in the tank 2. The analysis section 32 and the intermediate section 34 pass through the valve main body 40 and are fixed to the valve rod 42. Therefore, when the valve main body 40 moves vertically, the analyzer 30 moves vertically together with the valve main body 40. Note that the intermediate section 34 also passes through the air cylinder 62. The terminal section 36 is located outside the valve main body 40 and the air cylinder 62. The terminal section 36 is connected to an external electronic device (not shown).

[0024] A sealing member 70 is provided between the analysis section 32 and the valve element 44. More specifically, a ring-shaped sealing member 70 is fitted onto the analysis section 32, and the opening portion of the valve element 44 is closed by the sealing member 70. Therefore, leakage of the solution in the tank 2 into the valve main body 40 through the gap between the analyzer 30 (the analysis section 32) and the valve element 44 is suppressed. Further, by removing the sealing member 70, the analyzer 30 can be detached from the valve main body 40. A liquid receiver 60 is provided at the lower portion of the valve main body 40. The liquid receiver 60 suppresses the dripping liquid that falls downward from the second opening 54 from adhering to the air cylinder 62 and the like.

[0025] In the reaction vessel 100, by using a flush valve 20 equipped with an analytical device 30, chemical substances can be analyzed within tank 2 without sampling the chemical substances inside tank 2. Therefore, chemical substance analysis can be performed at any time without changing the reaction conditions inside tank 2.

[0026] Referring to Figure 3, the method for producing the chemical substance will be explained. As described above, the flush valve 20 is equipped with an analyzer 30. When the chemical substance is being produced in the tank 2, the control device 84 drives the analyzer 30 at a predetermined timing to analyze the characteristics of the chemical substance in the tank 2. The analysis results from the analyzer 30 are input to the analysis result determination device 80. The analysis results input to the analysis result determination device 80 are also stored in the server 82 along with the lot number, sampling time, etc.

[0027] The analysis result determination device 80 determines the reaction state (progress of the reaction) of the raw materials in tank 2 based on one or more analysis results. The determination result is input to the control device 84. The control device 84 adjusts the reaction conditions in tank 2 based on the determination result of the analysis result determination device 80. That is, it automatically determines the operating conditions in tank 2 and adjusts the reaction conditions in tank 2 based on the determination result of the analysis result determination device 80. If the analysis result determination device 80 determines that the production of the chemical substance has ended, the control device 84 opens the flush valve 20 and discharges the chemical substance outside tank 2. That is, it automatically opens the flush valve 20 and discharges the chemical substance outside tank 2 based on the determination result of the analysis result determination device 80.

[0028] If the analysis result determination device 80 determines that the chemical reaction is proceeding as planned, the control device 84 continues the production of the chemical while maintaining the operating conditions in tank 2. On the other hand, if the analysis result determination device 80 determines that the chemical reaction is not proceeding as planned, the control device 84 changes the operating conditions in tank 2 and continues the production of the chemical. In this case, the control device 84 adjusts the operating conditions in tank 2 considering the analysis results from the analysis device 30 and other conditions. For example, if the analysis device 30 measures the particle size of the chemical, the control device 84 adjusts the rotation speed of the stirring blade 10 considering the measured particle size and the temperature and pressure in tank 2. Note that "the chemical reaction is not proceeding as planned" includes not only cases where the chemical reaction is behind schedule, but also cases where the chemical reaction is progressing faster than planned.

[0029] Furthermore, the control device 84 can automatically supply raw materials for manufacturing chemical substances into tank 2. For example, if the raw material concentration in tank 2 is low, the control device 84 can automatically supply raw materials into tank 2 without stopping the operation of the reaction vessel 100. Also, if the raw material concentration in tank 2 is low, the control device 84 can automatically supply a diluent into tank 2 without stopping the operation of the reaction vessel 100.

[0030] As described above, in the manufacturing method disclosed herein, the properties of the chemical substance in the tank 2 are analyzed using an analyzer 30 installed in the flush valve 20. The operation of the analyzer 30, the adjustment of the operating conditions in the tank 2, and the opening and closing of the flush valve 20 are all performed by the control device 84. Therefore, the entire chemical substance manufacturing process is controlled by the control device 84, and the chemical substance can be manufactured fully automatically.

[0031] In the above embodiment, an example was described in which the valve body (valve stem) is moved up and down using an air cylinder. However, the valve body (valve stem) may also be moved up and down using a manual handle or the like. In this case, the air cylinder can be omitted, and the cost of the flush valve can be reduced.

[0032] In the above embodiment, an example was described in which the operating conditions in the tank are automatically adjusted based on the analysis results of the analytical device. However, the operating conditions in the tank may also be adjusted manually. The important thing is to install an analytical device on the flush valve to discharge the chemical substances in the reaction vessel (tank) and to use that analytical device to analyze the chemical substances in the reaction vessel.

[0033] In the above embodiment, an example was described in which the flush valve is automatically opened when the production of the chemical substance is completed based on the results of analysis by the analytical instrument. However, if the production of the chemical substance is completed, it is also acceptable to simply stop the operation of the reaction vessel without opening the flush valve. In this case, the flush valve may be opened manually at a predetermined timing.

[0034] In the above embodiment, an example was described in which one control device 84 controls the reaction conditions in the tank 2, opens and closes the flush valve 20, and drives the analyzer 30. However, the control device for adjusting the reaction conditions in the tank 2, the control device for opening and closing the flush valve 20, and the control device for driving the analyzer 30 may each be separate.

[0035] Although specific examples of the present invention have been described in detail above, these are merely illustrative and do not limit the scope of the claims. The technologies described in the claims include various modifications and changes to the specific examples illustrated above. Furthermore, the technical elements described in this specification or drawings exhibit technical usefulness individually or in various combinations, and are not limited to the combinations described in the claims at the time of filing. In addition, the technologies illustrated in this specification or drawings can achieve multiple objectives simultaneously, and achieving even one of these objectives itself constitutes technical usefulness. [Explanation of Symbols]

[0036] 20: Flush bulb 30: Analyzer 100: Reaction can

Claims

1. A method for producing chemical substances in a reaction vessel, An analytical device is installed in the flush valve to discharge the chemical substances inside the reaction vessel. A method for producing a chemical substance, comprising analyzing the chemical substance in a reaction vessel using the aforementioned analytical device.

2. A method for producing a chemical substance according to claim 1, comprising adjusting the reaction conditions in a reaction vessel based on the results of chemical substance analysis using an analytical device.

3. A method for producing a chemical substance according to claim 2, wherein the operating conditions of the reaction vessel are automatically determined based on the analysis results, and the reaction conditions inside the reaction vessel are automatically adjusted.

4. The method for producing a chemical substance according to claim 1, wherein, if the analysis results in the completion of the production of the chemical substance, the flush valve is automatically opened to discharge the chemical substance to the outside of the reaction vessel.

5. A method for producing a chemical substance according to claim 1, wherein the analytical device analyzes at least one of the particle size, viscosity, and degree of polymerization of the chemical substance.

6. A method for producing a chemical substance according to claim 1, comprising adjusting the reactor operating conditions in consideration of the analysis results of an analytical instrument and other conditions.

7. A method for producing a chemical substance according to any one of claims 1 to 6, wherein the chemical substance is an electrical material or a pharmaceutical product.

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