Continuous Aqueous Organic Peroxide Emulsion Production
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Solution Overview
Problem
Current methods for producing aqueous organic peroxide emulsions with low self-accelerating decomposition temperatures (SADT) are limited to batch processes due to safety concerns, as continuous processes pose a risk of rapid decomposition and explosion.
Innovation Solution
A continuous process involving an in-line emulsifier and a downstream heat exchanger is used to produce aqueous organic peroxide emulsions. The process starts with a pre-emulsion mixture cooled to a temperature at least 12°C lower than the SADT of the organic peroxide, which is then fed into the in-line emulsifier and further cooled by the heat exchanger to maintain safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If batch processes are used to produce aqueous organic peroxide emulsions with low SADT, then safety is improved, but productivity is reduced and equipment footprint is increased
Solution Approach 1:
The patent implements continuous emulsification using an in-line emulsifier where the organic peroxide mixture continuously flows through the system at controlled low temperatures. This continuous operation maintains safety through precise temperature control while achieving industrial-scale productivity, resolving the contradiction between batch safety and continuous productivity.
Solution Approach 2:
The patent introduces an intermediary cooling system with heat exchangers and cooling jackets that maintain the organic peroxide mixture at temperatures at least 12°C below SADT throughout the continuous emulsification process. This intermediary cooling mechanism enables continuous operation while preserving the safety margins traditionally associated with batch processes.
2Productivity
If continuous emulsification is attempted for organic peroxides with low SADT, then productivity is improved, but safety deteriorates due to risk of rapid decomposition and explosion
Solution Approach 1:
The patent applies preliminary cooling to the organic peroxide mixture before it enters the in-line emulsifier, ensuring the mixture is already at a safe temperature (at least 12°C below SADT) before emulsification begins. This preliminary temperature control prevents decomposition risks during the continuous emulsification process.
Solution Approach 2:
The patent implements temperature monitoring and control systems that continuously monitor the temperature of the organic peroxide mixture during emulsification and adjust cooling as needed. This feedback control ensures the mixture remains at safe temperatures throughout continuous operation, preventing decomposition while maintaining productivity.
3Ease of operation
If conventional mechanical stirrers or homogenizers are used for emulsification, then ease of operation is maintained, but the process must be batch-based which reduces productivity
Solution Approach 1:
The patent replaces conventional batch mechanical stirrers and homogenizers with an in-line emulsifier that uses high-shear mixing technology. This substitution enables continuous operation while maintaining ease of operation through automated flow control, resolving the contradiction between simple batch operation and continuous productivity.
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 allows for the safe and scalable continuous production of aqueous organic peroxide emulsions, overcoming the limitations of batch processes and enhancing productivity while minimizing equipment footprint and safety risks.
Implementation Method 1
transferring an aqueous organic peroxide emulsion from an outlet of the in-line emulsifier to a heat exchanger downstream of the outlet of the in-line emulsifier, wherein the heat exchanger reduces the temperature of the aqueous organic peroxide emulsion to a temperature of at least 12° C. lower than the SADT of the organic peroxide
Data Source
AI summary
A continuous process produces aqueous organic peroxide emulsions comprising organic peroxides that have a low self-accelerating decomposition temperature. An associated system can perform the continuous process.