(Meth)acrylate Process Oxygen Control High Molecular Weight
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Solution Overview
Problem
Existing processes for preparing (meth)acrylates are inadequate for producing high molecular weight polymer dispersions, which are necessary for applications such as flow resistance reduction in mineral oil extraction, as they often result in undesirably low specific viscosities and molecular weights due to insufficient oxygen control during the reaction.
Innovation Solution
A process involving the reaction of (meth)acrylates with alcohols in the presence of a catalyst and phenolic polymerization inhibitors, with controlled oxygen input of less than or equal to 1.0 liters per kilogram of (meth)acrylate, to inhibit polymerization and achieve high molecular weight polymer dispersions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional processes are used for preparing (meth)acrylates, then the production process is simple, but the resulting polymer dispersions have low molecular weight and low specific viscosity
Solution Approach 1:
The patent applies parameter changes by precisely controlling the oxygen concentration in the reaction atmosphere (maintaining oxygen content below 1.0 liter per kilogram of (meth)acrylate) and adjusting reaction parameters such as temperature and catalyst concentration. This controlled parameter approach prevents premature polymerization while maintaining high molecular weight in the resulting polymer dispersions, directly resolving the contradiction between manufacturing precision and process complexity.
Solution Approach 2:
The patent uses phenolic polymerization inhibitors as intermediary substances that mediate between the (meth)acrylate monomers and oxygen, preventing unwanted polymerization reactions. These inhibitors act as intermediaries that control the reaction pathway, allowing the production of high molecular weight polymers without requiring excessively complex process control mechanisms.
2Reliability
If oxygen input is not controlled during (meth)acrylate preparation, then the process is easier to operate, but undesired polymerization occurs resulting in low specific viscosity
Solution Approach 1:
The patent creates an inert reaction environment by strictly controlling oxygen input during the (meth)acrylate preparation process. By maintaining oxygen levels below 1.0 liter per kilogram of product and using nitrogen or other inert gases to displace oxygen, the process prevents undesired polymerization while remaining operationally simple. This inert atmosphere approach directly addresses the contradiction between reliability and ease of operation.
Solution Approach 2:
The patent applies preliminary action by adding phenolic polymerization inhibitors before the polymerization reaction begins and controlling oxygen levels in advance during the reaction process. This preliminary control of reaction conditions prevents undesired polymerization from occurring, ensuring high specific viscosity in the final product without requiring complex real-time monitoring or adjustment mechanisms.
3Productivity
If high molecular weight polymer dispersions are produced, then flow resistance reduction in mineral oil extraction is improved, but the production process requires precise oxygen control
Solution Approach 1:
The patent achieves high quality polymer dispersions suitable for mineral oil extraction by changing and controlling critical reaction parameters, particularly oxygen concentration (maintained below 1.0 liter per kilogram of (meth)acrylate), temperature, and catalyst levels. These parameter changes enable the production of high molecular weight polymers with superior flow resistance reduction properties while using a relatively simple control system that does not require complex equipment.
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 process effectively produces (meth)acrylates suitable for preparing high molecular weight homo- or copolymers with specific viscosities greater than 1000 ml/g, enhancing their suitability for thickening liquids and adjusting flow properties in mineral oil extraction.
Implementation Method 1
the reaction being undertaken with input or introduction into the reaction mixture resulting from the reaction of an amount of oxygen or of an oxygenous gas mixture sufficient to inhibit undesired polymerization
Implementation Method 2
in the presence of an amount of a phenolic polymerization inhibitor or a combination of two or more phenolic polymerization inhibitors which is sufficient to inhibit undesired polymerization
Implementation Method 3
by reacting a (meth)acrylate of the formula II with an alcohol of the formula (III) in the presence of an amount of a suitable catalyst which catalyses the reaction
Data Source
AI summary
Process for preparing (meth)acrylates of the formula (I)CH2═C(R1)—CO—O—R2 (I)in which R1 is hydrogen or methyl andR2 is a saturated or unsaturated, linear or branched, aliphatic or cyclic alkyl radical having 6 to 22 carbon atoms, or a (C6-C14)-aryl-(C1-C8)-alkyl radical;by reacting a (meth)acrylate of the formula IICH2═C(R1)—CO—OR3 (II)with an alcohol of the formula (III)HO—R2 (III)in the presence of an amount of a suitable catalyst which catalyzes the reaction and of an amount of a phenolic polymerization inhibitor or a combination of two or more phenolic polymerization inhibitors which is sufficient to inhibit undesired polymerization;the reaction being undertaken with input or introduction into the reaction mixture resulting from the reaction of an amount of oxygen or of an oxygenous gas mixture sufficient to inhibit undesired polymerization, and the process is characterized in thatthe specific total oxygen input is less than or equal to 1.0 l/kg, measured in liters of oxygen per kilogram of (meth)acrylate of the formula (I), where the volume of oxygen introduced is calculated at a temperature of 25° C. and a pressure of 101 325 pascal.The resulting (meth)acrylates can surprisingly be processed to particularly high molecular weight emulsion polymers which are, for example, outstandingly suitable for use as flow resistance reducers in mineral oil extraction.