Continuous Polyvinylamide Cellulose Adduct Process
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Solution Overview
Problem
Current methods for preparing cellulose reactive adducts of polyvinylamide are inefficient and require batch processes that are costly due to the need for recalibration with temperature changes in water supply, leading to productivity losses and increased costs.
Innovation Solution
A continuous process for preparing cellulose reactive functionalized polyvinylamide adducts by reacting a vinylamide polymer with a cellulose reactive agent at controlled temperature and pH, using a mathematical equation to maintain a constant reaction rate, allowing for instantaneously varying quantities without buffering storage tanks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If batch processes are used for preparing cellulose reactive adducts, then product quality can be maintained through recalibration, but productivity decreases and costs increase due to frequent recalibration with temperature changes
Solution Approach 1:
The patent implements a continuous process where vinylamide polymer and cellulose reactive agent are continuously reacted in a reactor system, eliminating the need for batch processing and recalibration. The continuous flow allows constant production without interruption, maintaining product quality through steady-state operation rather than repeated batch cycles with recalibration steps.
Solution Approach 2:
The patent pre-determines the optimal pH set point as a function of reaction temperature using the equation pH = 14.9 - 0.047T. This preliminary establishment of the pH-temperature relationship allows the system to automatically maintain optimal reaction conditions without requiring recalibration when temperature changes occur, as the pH adjustment is predictable and pre-calculated.
2Manufacturing precision
If batch processes with recalibration are used, then product quality can be maintained, but manufacturing costs increase due to productivity losses
Solution Approach 1:
The continuous reaction process eliminates the need to shut down and recalibrate between batches, allowing uninterrupted production. This continuity reduces manufacturing costs by eliminating the productivity losses associated with recalibration while maintaining product quality through consistent process parameters.
Solution Approach 2:
The system uses the measured reaction temperature to automatically determine the required pH set point through the pre-established equation pH = 14.9 - 0.047T. This self-adjusting mechanism eliminates the need for manual recalibration operations, reducing both labor costs and productivity losses while maintaining consistent product quality.
3Productivity
If continuous process is used with automatic pH adjustment, then productivity increases and costs reduce, but process complexity increases due to temperature measurement and pH control requirements
Solution Approach 1:
The system continuously measures the reaction temperature and uses this feedback to automatically adjust the pH set point according to the equation pH = 14.9 - 0.047T. This closed-loop feedback control maintains optimal reaction conditions without requiring complex manual intervention, achieving both high productivity and cost reduction while managing complexity through automated control.
Solution Approach 2:
The system changes the pH parameter based on the measured temperature parameter using a predetermined mathematical relationship. This parameter change strategy simplifies the control system compared to complex multi-variable control, as it relies on a single straightforward equation to determine the optimal pH set point for any given temperature, thereby increasing productivity without excessive complexity.
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 method produces a consistent final product with improved efficiency and reduced costs by automatically adjusting reaction parameters, avoiding the need for batch process recalibrations and maintaining product quality across varying ambient conditions.
Implementation Method 1
reacting a substantially aqueous reaction mixture of a vinylamide polymer and a cellulose reactive agent
Data Source
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AI summary
The present disclosure is directed to a continuous process for preparing cellulose reactive adducts of polyvinylamide.