Brominated Polybutadiene Particle Formation via Seed Bed Spraying
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Solution Overview
Problem
Existing methods for forming devolatilized particles of brominated polybutadiene polymer are inefficient, often requiring high temperatures that lead to thermal degradation and increased capital and operating costs, and result in the formation of impurities and agglomerates.
Innovation Solution
A process involving forming a solution of brominated butadiene polymer into droplets that are contacted with a heated, mechanically agitated bed of seed particles, allowing solvent vaporization and polymer solidification without agglomeration, using moderate temperatures below the polymer's glass transition temperature to minimize degradation and impurities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If ordinary devolatilization processes are used to remove solvent from brominated polymer solution, then solvent removal is achieved, but the polymer is exposed to high temperatures for long residence times causing thermal degradation and impurity formation
Solution Approach 1:
The continuous devolatilization process is segmented into multiple flash chambers, allowing the solvent removal to occur in stages at progressively lower temperatures, reducing thermal exposure time and preventing polymer degradation while achieving complete solvent removal
Solution Approach 2:
The process uses flash evaporation to rapidly remove solvent in a short time period, skipping through the dangerous high-temperature zone quickly and preventing thermal degradation before it can occur
2Ease of manufacture
If the brominated polymer solution is sprayed to form droplets and heated for solvent removal, then particles are formed, but large volumes of fluids must be handled and recovered leading to higher capital and operating costs
Solution Approach 1:
The process extracts only the essential function of particle formation without requiring large volumes of nonsolvent liquid. The spray-drying approach forms particles directly from the polymer solution without needing a separate washing and drying stage using large amounts of additional fluids
Solution Approach 2:
The heated chamber serves multiple functions simultaneously: it acts as both the solvent removal zone and the particle formation zone, eliminating the need for separate washing and drying equipment that would require large fluid volumes
3Productivity
If high temperatures are used to remove solvent and form particles, then solvent removal is accelerated, but the brominated butadiene polymer degrades and develops impurities
Solution Approach 1:
The process changes the temperature parameter progressively through multiple stages, starting with higher temperatures for rapid solvent removal then reducing temperature in subsequent chambers to prevent degradation, thus maintaining both productivity and polymer purity
Solution Approach 2:
The process performs preliminary solvent removal at higher temperatures in early chambers when the polymer concentration is still low and degradation risk is minimal, then transitions to lower temperatures for final particle formation, preserving polymer purity
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 process efficiently removes solvent and forms non-agglomerated particles with a solid external layer of brominated polybutadiene polymer, reducing thermal degradation and impurities while maintaining particle size control and minimizing energy consumption.
Implementation Method 1
solvent volatilizes from the coated seed particles
Implementation Method 2
contacting the droplets with a heated, mechanically agitated bed of seed particles
Data Source
AI summary
Brominated butadiene polymers are recovered from solution and formed into particles by spraying the solution onto a heated, mechanically agitated bed of seed particles. The droplets contact the seed particles in the bed and form a polymer layer on the outside of the seed particles, thereby enlarging them. The solvent is removed from the droplets after they make contact with seed particles in the bed. The process allows for the simultaneous removal of solvent and formation of somewhat large particles. The process forms at most small amounts of agglomerates and fines.