High Shear Oxidation of Wax and Polymers
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Solution Overview
Problem
Current oxidation processes for polymers and waxes are inefficient and lack economical solutions for modifying molecular weight distribution, viscosity, and drop point, often resulting in undesirable cross-linking and viscosity issues.
Innovation Solution
A high shear oxidation system comprising a shear device, substrate, oxidant, and steam, where the mixture is subjected to controlled shear, temperature, and pressure conditions to reduce viscosity, modify density, and decrease molecular weight, utilizing a recycle loop and temperature/pressure control systems to manage the oxidation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional oxidation processes are used to modify polymer properties, then molecular weight distribution and functionalization can be achieved, but cross-linking occurs and viscosity control is poor
Solution Approach 1:
The patent applies high shear stress (a physical parameter) to the polymer-oxidant mixture to control the oxidation reaction. By varying shear rate, residence time, and temperature parameters, the process achieves precise molecular weight distribution control while preventing cross-linking through controlled chain scission mechanisms
Solution Approach 2:
The continuous circulation system creates periodic exposure of polymer to oxidant through the loop configuration, allowing controlled oxidation events to occur at specific intervals rather than continuous uncontrolled reaction, thereby preventing cross-linking while achieving desired molecular weight modification
2Manufacturing precision
If oxidation is applied to reduce polymer viscosity, then molecular weight can be decreased, but process efficiency is low and economic viability is poor
Solution Approach 1:
The patent replaces conventional thermal or chemical oxidation methods with a mechanically-driven high shear oxidation process. The mechanical shear energy directly drives the oxidation reaction and chain scission, significantly accelerating the viscosity reduction process and improving productivity while maintaining precise control over the modification degree
Solution Approach 2:
The continuous circulation loop enables uninterrupted oxidation reaction, with polymer continuously exposed to oxidant and high shear conditions. This eliminates batch processing interruptions and maximizes productivity while maintaining consistent viscosity modification through sustained useful action
3Manufacturing precision
If high shear oxidation is applied to decrease molecular weight, then viscosity and drop point can be controlled, but system complexity increases
Solution Approach 1:
The high shear oxidation system performs multiple functions simultaneously: it oxidizes the polymer, controls molecular weight distribution, adjusts viscosity, and modifies drop point all within a single integrated circulation loop. This multi-functionality reduces the need for separate processing steps and equipment, thereby managing system complexity while achieving precise control over multiple properties
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 system effectively reduces viscosity, modifies the drop point, and decreases molecular weight of polymers and waxes, avoiding cross-linking while allowing for controlled oxidation, thereby enhancing the properties of the products and improving process efficiency.
Implementation Method 1
applying shear to the mixture to form a product
Implementation Method 2
oxidation of polymers and waxes is able to modify the properties of polymers and waxes
Implementation Method 3
providing steam; mixing the substrate, the oxidant and steam to form a mixture
Data Source
AI summary
In this disclosure, a system is described, comprising a shear device with at least one inlet and at least one outlet and a mixing vessel with at least one inlet and at least one outlet, wherein an inlet of the shear device is in fluid communication with an outlet of the mixing vessel. In certain embodiments, the shear device and the mixing vessel form a loop for fluid communication. Also disclosed herein is a method of high shear oxidation, comprising mixing an oxidant with a substrate to form a substrate-oxidant mixture and applying shear to the substrate-oxidant mixture to form a product. The product includes ethylene oxide, propylene oxide, terephthalic acid, phenol, acrylonitrile, maleic anhydride, phthalic anhydride, nitric acid, caprolactam, oxidized polyethylene, oxidized polypropylene, oxidized polyethylene copolymers, and oxidized polypropylene copolymers. Suitable oxidant includes air, oxygen, ozone, peroxide, organic peroxide, halogen, oxygen-containing gas, and halogen-containing gas.