Non-Continuous Screw Reactor for Polymer Latex Resin Powder
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Solution Overview
Problem
Current methods for preparing polymer latex resin powder face inefficiencies in mixing steam, latex, and coagulant, leading to high moisture content and reduced drying efficiency, as well as the need for excessive coagulants, which affect the quality and characteristics of the final powder.
Innovation Solution
An apparatus with a reactor that incorporates a non-continuous screw for coagulation and aging, enhancing mixing efficiency by inducing turbulent flow and reducing moisture content, thereby improving drying efficiency and powder quality with a decreased coagulant amount.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional mixing methods are used in the reactor, then the structure is simple, but the mixing efficiency of steam, latex, and coagulant is low
Solution Approach 1:
The patent applies the dynamics principle by introducing a non-continuous screw that rotates at high speed to create turbulent flow in the reactor. This dynamic mixing mechanism transforms the static mixing process into an active turbulent flow state, significantly enhancing the mixing efficiency of steam, latex, and coagulant while maintaining a relatively simple reactor structure.
Solution Approach 2:
The high-speed rotation of the non-continuous screw generates mechanical vibrations and turbulent flow patterns that intensify the mixing process. This mechanical action creates chaotic flow fields that improve contact between steam, latex, and coagulant, resolving the contradiction between mixing efficiency and structural complexity.
2Reliability
If excessive coagulant is used to ensure coagulation, then coagulation effectiveness is improved, but the amount of coagulant required increases and powder quality deteriorates
Solution Approach 1:
The patent applies preliminary action by pre-mixing the coagulant with the latex before introducing steam for coagulation. This preliminary mixing ensures uniform distribution of the coagulant throughout the latex, maximizing its effectiveness and reducing the total amount of coagulant needed while maintaining reliable coagulation and improving powder quality.
Solution Approach 2:
The patent changes the physical parameters of the mixing process by introducing high-speed turbulent flow through the non-continuous screw. This parameter change enhances the interaction between coagulant and latex, improving coagulation effectiveness and allowing reduction of coagulant dosage while maintaining reliable coagulation results.
3Ease of manufacture
If high moisture content slurry is processed, then the coagulation process is simpler, but drying efficiency is reduced and energy consumption increases
Solution Approach 1:
The patent applies parameter changes by modifying the mixing intensity and steam introduction method to control the moisture content during coagulation. The high-speed turbulent mixing and optimized steam injection create conditions that reduce excess moisture formation, producing slurry with lower moisture content that requires less energy for drying while maintaining process simplicity.
4Speed
If rapid coagulation is performed with excess coagulant, then coagulation speed is improved, but particle size distribution becomes wide and apparent specific gravity is reduced
Solution Approach 1:
The patent applies preliminary action by thoroughly mixing the coagulant with the latex before steam introduction. This pre-mixing ensures uniform coagulant distribution, which enables rapid coagulation while maintaining uniform particle size distribution and apparent specific gravity, avoiding the irregular coagulation that occurs with direct steam addition to unprepared latex.
Solution Approach 2:
The patent changes the coagulation parameters by controlling the mixing intensity and steam addition rate. The high-speed turbulent mixing creates optimal conditions for rapid and uniform coagulation, achieving fast coagulation speed while maintaining narrow particle size distribution and high apparent specific gravity through optimized process parameters.
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 apparatus achieves enhanced mixing efficiency, simplifies post-treatment processes, reduces energy consumption, and improves the color and powder characteristics of the polymer latex resin powder by minimizing moisture content and coagulant usage.
Implementation Method 1
enhancing mixing efficiency by inducing turbulent flow
Implementation Method 2
Coagulation of an emulsion-polymerized polymer latex may be performed by breaking stability of latex particles stabilized by an emulsifying agent added during emulsion polymerization by a chemical method using various coagulants
Implementation Method 3
The coagulated polymer slurry is transferred to the aging bath 3 and then subjected to aging at high temperature for a residence time of 40 to 90 minutes
Implementation Method 4
The resulting slurry is subjected to dehydration and drying
Implementation Method 5
The resulting slurry is subjected to dehydration and drying
Data Source
AI summary
Disclosed are an apparatus for preparing a polymer latex resin powder in which an efficiency of mixing of steam, a latex, and a coagulant is increased by introducing a non-continuous screw into a reactor that performs coagulation and aging and thus a moisture content of a slurry is decreased and, accordingly, drying efficiency may be enhanced, and a polymer latex resin powder with excellent color and powder characteristics may be prepared using a decreased amount of coagulant and a method of preparing a polymer latex resin powder by using the same.