Continuous Polymerization Reactor Segmentation for Linearity
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Solution Overview
Problem
Conventional methods for preparing conjugated diene-based polymers face challenges in achieving high linearity, cis 1,4 bond content, and reducing reactor contamination, which affects productivity and physical properties, particularly in tire rubber applications.
Innovation Solution
A continuous polymerization method using two or more reactors, where the weight ratio of polymer to monomer is adjusted in each reactor, with a catalyst composition including a lanthanide rare earth element compound, to control the polymerization reaction and improve reactor efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If batch polymerization is applied to prepare conjugated diene-based polymer, then molecular weight distribution is narrow and physical properties are improved, but productivity is low and processability is poor
Solution Approach 1:
The patent divides the batch polymerization process into multiple stages with different monomer feed rates. The first stage uses a higher monomer feed rate to build polymer mass quickly, while the second stage reduces the feed rate to control molecular weight distribution. This segmentation allows the process to achieve both high productivity and narrow molecular weight distribution by optimizing each stage independently.
2Productivity
If continuous polymerization is applied to prepare conjugated diene-based polymer, then productivity is excellent and processability is improved, but molecular weight distribution is wide and physical properties are not good
Solution Approach 1:
The patent employs dynamic control of monomer feed rates during continuous polymerization. The monomer feed rate is adjusted in real-time based on conversion ratio thresholds: a first feed rate is used when conversion is below a threshold, and a second, lower feed rate is used when conversion exceeds the threshold. This dynamic adjustment maintains narrow molecular weight distribution while preserving the high productivity of continuous operation.
3Productivity
If continuous operation time is increased to improve productivity, then output increases, but reactor contamination increases and limits further operation
Solution Approach 1:
The patent changes the monomer feed rate parameter based on conversion ratio to prevent reactor contamination during extended continuous operation. When conversion ratio exceeds a predetermined threshold, the feed rate is reduced, which controls polymerization kinetics and prevents excessive heat generation and contaminant formation. This allows the reactor to operate continuously for longer periods without contamination buildup.
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 results in a conjugated diene-based polymer with high linearity, improved cis 1,4 bond content, and reduced reactor contamination, enhancing productivity and physical properties such as viscoelasticity, while maintaining excellent processability.
Implementation Method 1
polymerization in the first reactor and the second reactor is performed in the presence of a catalyst composition in a hydrocarbon solvent
Data Source
AI summary
The present invention relates to a method of preparing a conjugated diene-based polymer by continuous polymerization using two or more reactors, and relates to a method of preparing a conjugated diene-based polymer which is capable of providing a conjugated diene-based polymer having excellent cis 1,4 bond content and linearity, by adjusting the ratio of a polymer and a monomer in each reactor and by adjusting the retention time in a second reactor and resolving the deterioration phenomenon of physical properties, while improving productivity by reducing the contamination of the reactors.