Self-Cleaning Filter for ABS Polymerization Contaminant Removal
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Solution Overview
Problem
Existing rubber and latex production processes, such as those for polybutadiene and ABS, often result in defects due to over-crosslinking gels, degraded rubber particles, fibrous materials, and other contaminants, leading to fouling, corrosion, and quality degradation in final products, and require extensive cleaning processes like butadiene washing and distillation.
Innovation Solution
A method involving a reactor where petrochemical monomers are polymerized with an activator, followed by passing the polymerized stream through a continuously self-cleaning filter to remove contaminants, and then through a grafting unit with acrylonitrile and styrene to produce acrylonitrile-butadiene-styrene, reducing contaminants and cleaning needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional emulsion polymerization is used to produce ABS, then production efficiency is maintained, but crosslinked gels, rubber particle agglomerates, and other contaminants form leading to product defects
Solution Approach 1:
The patent applies preliminary action by implementing a pre-filtration system that removes contaminants before they can cause defects in the final product. The filter is positioned in the polymerization reactor to intercept and remove crosslinked gels, rubber particle agglomerates, and other contaminants during the polymerization process itself, preventing downstream quality issues without requiring extensive post-processing
Solution Approach 2:
The patent extracts harmful contaminants from the polymerization system by introducing a filter that selectively removes crosslinked gels, rubber particle agglomerates, and other unwanted substances from the reaction mixture. This extraction occurs continuously during polymerization, separating the harmful elements from the desired polymer product while maintaining production efficiency
2Manufacturing precision
If extensive cleaning processes like butadiene washing and distillation are implemented, then contaminant removal is improved, but process complexity and cost increase
Solution Approach 1:
The patent performs contaminant removal in advance by filtering during polymerization rather than requiring extensive post-polymerization cleaning. The pre-filtration approach eliminates the need for complex downstream cleaning processes like butadiene washing and distillation, as contaminants are removed before they can become embedded in the final product
Solution Approach 2:
The patent extracts contaminants directly from the polymerization reaction stream using a filter, removing the need for complex extraction and cleaning processes. By taking out crosslinked gels and agglomerates during polymerization, the system eliminates the requirement for multiple cleaning stages including washing, distillation, and other inert component removal processes
3Manufacturing precision
If filtration is performed to remove contaminants, then product quality improves, but filter fouling and corrosion occur
Solution Approach 1:
The patent implements self-service by designing a filter system that automatically maintains its own performance. The filter is positioned to receive clean monomer feed and polymerization activator, and the continuous flow of fresh reactants helps prevent fouling by constantly flushing the filter surface. The system serves itself by using the polymerization process conditions to maintain filter effectiveness without requiring external intervention
Solution Approach 2:
The patent applies parameter changes by optimizing the filter placement and operating conditions within the polymerization reactor. By positioning the filter to receive freshly mixed monomer and activator solutions, and by maintaining appropriate flow rates and temperature conditions, the system changes the operational parameters to minimize filter fouling while maximizing contaminant removal effectiveness
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method significantly reduces crosslinking gels, coagulates, and agglomerate contaminants, minimizes fouling and corrosion, and decreases the need for cleaning processes, achieving products with less than 25 ppm gel content and improved molecular mobility, resulting in higher-quality articles with reduced defects.
Implementation Method 1
contacting the petrochemical monomer with a polymerization activator within the reactor to produce a polymerized stream comprising rubber, latex, or a combination thereof
Implementation Method 2
passing the polymerized stream through a filter to produce a filtered product stream, wherein the filter is a continuously self-cleaning filter
Implementation Method 3
passing the filtered product stream through a grafting unit comprising acrylonitrile and styrene to produce acrylonitrile-butadiene-styrene
Data Source
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AI summary
A method of forming articles from acrylonitrile-butadiene-styrene, the method comprising: feeding a monomer stream comprising a petrochemical monomer into a reactor; contacting the petrochemical monomer with a polymerization activator within the reactor to produce a polymerized stream comprising rubber, latex, or a combination thereof and withdrawing the polymerized stream from the reactor; passing the polymerized stream through a filter to produce a filtered product stream, wherein the filter is a continuously self-cleaning filter; passing the filtered product stream through a grafting unit comprising acrylonitrile and styrene to produce acrylonitrile-butadiene-styrene; and forming an article from the acrylonitrile- butadiene - styrene, wherein the article is an extruded sheet, a molded part, or a combination thereof.