Artificial Latex Solvent Removal Process
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Solution Overview
Problem
Current processes for producing artificial latex face challenges in solvent removal, leading to material loss, equipment fouling, reduced throughput, and increased energy consumption, with instability and residual solvent issues.
Innovation Solution
A two-stage solvent reduction process using a continuously stirred vessel with a reboiling loop, where the first stage involves heating the latex to above the solvent's boiling point for evaporation and the second stage occurs under elevated temperature and decreasing pressure, utilizing a foam control agent to minimize fouling and residual solvent levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If solvent is removed by heating the emulsion to above solvent boiling point, then solvent evaporation is enhanced, but material loss and equipment fouling increase
Solution Approach 1:
The solvent removal process is divided into two distinct stages: first stage removes bulk solvent through heating above boiling point, second stage removes residual solvent under reduced pressure. This segmentation allows optimized conditions for each stage, preventing material loss while maintaining high evaporation efficiency.
Solution Approach 2:
The process changes temperature and pressure parameters dynamically: first stage uses high temperature (above solvent boiling point) for rapid evaporation, second stage switches to reduced pressure conditions to remove residual solvent. This parameter change strategy maximizes solvent removal efficiency while minimizing material degradation and loss.
2Loss of energy
If solvent is removed by heating the emulsion to above solvent boiling point, then solvent evaporation is enhanced, but equipment fouling increases
Solution Approach 1:
By segmenting the solvent removal into two stages with different conditions, the process prevents excessive fouling that would occur with single-stage high-temperature processing. The second stage under reduced pressure completes solvent removal without causing additional fouling.
Solution Approach 2:
The reduced pressure condition in the second stage acts as an intermediary that enables complete solvent removal without requiring excessive temperature increases that would cause fouling. This intermediate condition allows gentle removal of residual solvent.
3Productivity
If conventional solvent removal process is used, then throughput is reduced, but material loss and fouling increase
Solution Approach 1:
The two-stage solvent removal process maintains continuous productive action without interruption. The first stage continuously removes bulk solvent, and the second stage continuously removes residual solvent under reduced pressure, maximizing throughput while minimizing material loss through optimized process control.
4Loss of energy
If conventional solvent removal process is used, then energy consumption increases, but material loss and fouling increase
Solution Approach 1:
The process optimizes energy consumption by changing parameters between stages: first stage uses high temperature for efficient bulk solvent evaporation, second stage uses reduced pressure for energy-efficient residual solvent removal. This parameter optimization reduces overall energy consumption while preventing material loss.
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 significantly reduces material loss and fouling, enhances throughput, and lowers energy consumption while achieving low residual solvent and foam control agent levels in the final artificial latex product.
Implementation Method 1
heating the latex to above the solvent's boiling point for evaporation
Implementation Method 2
heating the latex to above the solvent's boiling point
Implementation Method 3
heating the latex to above the solvent's boiling point
Implementation Method 4
utilizing a foam control agent to minimize fouling and residual solvent levels
Data Source
Figure 1
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AI summary
Accordingly, the invention provides a process for the preparation of an artificial latex, comprising the steps: (a) emulsif ication of a cement comprising a rubber dissolved in a suitable organic solvent, together with an aqueous surfactant solution, thus forming an oil-in-water emulsion; (b) step-wise reduction of the solvent content of the oil-in-water emulsion in two or more stages resulting in an artificial latex. In addition, the invention provides a continuous stirred vessel for removing an organic solvent from an oil-in-water emulsion comprising rubber dissolved in an organic solvent.