Agitator-Mounted Latex Distribution for Particulate Polymer Coagulation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing emulsion polymerization processes face issues with foam and chunk formation during coagulation, leading to uncontrolled particle size distribution and inefficiencies in producing particulate polymers.
Innovation Solution
A method and system utilizing a coagulator equipped with an agitator, distribution and redistribution members, and a coagulant spray ring, along with steam jets, to evenly distribute polymer latex and coagulant, promoting high shear mixing and controlled agglomeration, resulting in a narrower particle size distribution and reduced foam/chunk formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional coagulation processes are used to isolate polymeric particles from polymer latex, then particle isolation is achieved, but foam and chunk formation occurs and particle size distribution is uncontrolled
Solution Approach 1:
The coagulation process is segmented into multiple zones: a first coagulation zone where coagulant is added to initiate particle aggregation, and a second coagulation zone where further coagulation occurs. This segmentation allows controlled particle size development and prevents uncontrolled foam and chunk formation by distributing the coagulation action across different spatial regions.
Solution Approach 2:
Different regions of the coagulator are provided with different local conditions: the first coagulation zone has specific mixing intensity and coagulant concentration, while the second coagulation zone has different conditions optimized for final particle formation. The agitator creates localized high-shear regions that control aggregation patterns, preventing bulk foam formation while achieving desired particle size distribution.
2Productivity
If coagulant is added to break polymer latex, then polymeric particles are isolated, but foam formation and uncontrolled agglomeration occur
Solution Approach 1:
The coagulation process operates continuously with steady feed of polymer latex and coagulant through the two-zone coagulator system. This continuous operation maintains stable particle size distribution by ensuring consistent mixing and coagulation conditions throughout the process, preventing the formation of foam and chunks that would disrupt production efficiency.
Solution Approach 2:
The two-zone coagulation system provides inherent feedback control: the first zone establishes initial particle aggregation, and the second zone completes the coagulation process. This staged approach allows the system to self-regulate particle size distribution, preventing runaway agglomeration and foam formation while maintaining high productivity through continuous operation.
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
The process achieves a controlled particle size distribution with reduced moisture content and residual acid in the particulate polymer, enhancing production efficiency and quality.
Implementation Method 1
the distribution member is mounted on the agitator shaft and extending upwardly into the vessel through a bottom wall of the vessel, the distribution member having an open top in the vessel and an opposite open bottom facing the coagulator
Implementation Method 2
a coagulator equipped with an agitator having an agitator shaft
Implementation Method 3
mixing the polymer latex, the coagulant, and the steam to break the polymer latex forming the particulate polymer
Implementation Method 4
the polymeric particles that are present in the polymer latex need to be isolated. This can be achieved by the addition of a coagulant to break the polymer latex. During this coagulation process, the original particles in the latex are agglomerated to form bigger particles
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A method of manufacturing a particulate polymer includes introducing a polymer latex into a vessel; distributing the polymer latex in the vessel to a coagulator via a distribution member and a redistribution member; introducing a coagulant and steam into the coagulator; breaking the polymer latex; and separating the particulate polymer. The distribution member and the redistribution member are mounted on an agitator shaft of the coagulator, and are configured such that the polymer latex in the vessel enters the open top and exits the open bottom of the distribution member and flows into the redistribution member. The polymer latex in the redistribution member then overflows into the coagulator.