Continuous Reactor for Anionic Polymerization Initiator Synthesis

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Solution Overview

Problem

The existing methods for preparing anionic polymerization initiators, particularly for styrene-butadiene rubber (SSBR), face issues with instability, inactivation due to storage, and the production of by-products, leading to inconsistent quality and reduced conversion rates, which affects the physical properties of SSBR.

Innovation Solution

A method involving the continuous reactor process where an amine compound and an organometallic compound are introduced and reacted, minimizing the need for storage and reducing by-products, using a device with a mixer and separate inflow lines for these compounds, and optionally a conjugated diene, to enhance the stability and reactivity of the initiator.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If batch-wise preparation method is used for anionic polymerization initiator, then the initiator can be synthesized and stored, but the initiator becomes unstable and inactive over time due to storage

Engineering Contradiction:

Improveinitiator synthesis capabilityVSAvoidinitiator stability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent implements a continuous flow reaction system where the anionic polymerization initiator is synthesized continuously and directly fed into the polymerization reactor without interruption or storage. This eliminates the storage step that causes initiator degradation, maintaining both manufacturing capability and initiator stability throughout the process.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The patent performs the initiator synthesis action in advance within the continuous flow system, generating the active initiator species immediately before they are consumed in the polymerization reaction. This preliminary action ensures the initiator remains in its active state throughout the entire process without exposure to storage conditions.

Inventive Principle:

Principle #10Preliminary action

2Ease of manufacture

If batch-wise preparation method is used for anionic polymerization initiator, then the initiator can be synthesized, but by-products are produced and conversion rate is lowered

Engineering Contradiction:

Improveinitiator synthesis capabilityVSAvoidpolymerization yield

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The continuous flow reaction system maintains steady-state conditions throughout the initiator synthesis and polymerization process, ensuring complete conversion of reactants and minimizing by-product formation. The continuous nature of the process eliminates the start-stop conditions inherent in batch processing that lead to incomplete reactions and reduced yield.

Inventive Principle:

Principle #20Continuity of useful action

3Ease of operation

If storage step is added for batch-prepared initiator, then the initiator can be used later, but the physical properties of SSBR are lowered due to initiator inactivation

Engineering Contradiction:

Improveprocess flexibilityVSAvoidSSBR physical properties consistency

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The patent creates a continuous process where initiator synthesis and polymerization are seamlessly connected without storage interruptions. This continuous action ensures the initiator maintains its activity and the SSBR physical properties remain consistent, while the process can still be operated flexibly by adjusting flow rates and reaction conditions.

Inventive Principle:

Principle #20Continuity of useful action

4Reliability

If simultaneous preparation in one pot is used, then storage problem is solved, but it is difficult to confirm proper initiator synthesis and physical properties are deteriorated

Engineering Contradiction:

Improveinitiator activityVSAvoidinitiator synthesis verification

Core Design Contradiction:

ReliabilityVSDifficulty of detecting and measuring

Solution Approach 1:

The patent divides the process into distinct but continuous segments: initiator synthesis in one reactor zone, followed by immediate polymerization in the next zone. This segmentation allows for verification of initiator formation through online monitoring while maintaining continuous flow, solving both the verification difficulty and the reliability issues.

Inventive Principle:

Principle #1Segmentation

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 approach prevents instability and inactivation of the polymerization initiator, improves the conversion rate, and ensures a stable and consistent quality of SSBR by minimizing by-products and unreacted products, while also reducing the preparation time and enhancing economic efficiency.

Implementation Method 1

introducing at least one amine compound selected from compounds of Formulas 1 and 2 below and an organometallic compound into a continuous reactor and reacting them

Methodology Applied

Scientific EffectChemical reaction: Chemical Bonding

Data Source

PatentEP3351567B1Production method and production device for anionic polymerization initiator, and anionic polymerization initiator produced therefrom

Publication Date: 2023.06.14 LG CHEM LTD

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AI summary

A method for preparing an anionic polymerization initiator, a device for manufacturing the same, and an anionic polymerization initiator prepared therefrom is provided. And the method for preparing an anionic polymerization initiator according to the present invention is characterized in that in a continuous reactor an amine compound of Formula 1 and/or Formula 2; an organometallic compound; and/or a conjugated diene compound are introduced in the form of a solution and reacted.