Water Absorbent Resin Solvent Separation via Pressure Compression
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Solution Overview
Problem
Conventional reverse phase suspension polymerization methods for producing water-absorbent resins face inefficiencies in solvent separation, leading to high costs, odor issues, and decreased physical properties due to residual organic solvents and surfactants, with filtration methods being inefficient and prone to clogging.
Innovation Solution
A method involving a polymerization step followed by a separation step where a pressure of at least 0.1 MPa is applied to transfer, compress, and discharge the hydrous gel crosslinked polymer using a discharge device with a pressure adjustment mechanism, effectively separating the polymer from the organic solvent and reducing residual liquid ratios.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If reverse phase suspension polymerization is used to produce water-absorbent resin, then the resin can be produced with good water absorption properties, but a large amount of organic solvent is required which causes separation difficulties, high costs, and odor problems
Solution Approach 1:
The patent extracts and removes the organic solvent from the polymerization system by using a continuous filtration device that separates the polymer particles from the solvent during the polymerization process, thereby eliminating solvent residue and odor while maintaining production efficiency
Solution Approach 2:
The patent introduces a filtration device as an intermediary component between the polymerization reaction and the final product, which acts as a mediator to separate and remove the organic solvent without affecting the polymerization reaction or the water absorption properties of the resin
2Ease of manufacture
If conventional filtration methods are used to separate organic solvent from polymer, then separation can be achieved, but the filtration process is inefficient and prone to clogging
Solution Approach 1:
The patent implements a continuous filtration process where the polymerization reaction and solvent separation occur simultaneously in a continuous flow system, eliminating the need for batch filtration and preventing clogging by maintaining constant flow and pressure conditions
Solution Approach 2:
The patent replaces conventional mechanical filtration systems with a continuous flow separation system that uses pressure-driven flow and specialized filter media to achieve efficient solvent removal without the clogging problems associated with traditional filtration
3Stability of the object's composition
If surfactant and dispersing agent are used to disperse monomer aqueous solution, then good dispersion is achieved, but these additives remain in the final product causing decreased surface tension and water absorption speed
Solution Approach 1:
The patent extracts and removes surfactant and dispersing agent residues from the final product through the continuous filtration and washing process, thereby eliminating the negative effects on surface tension and water absorption speed while maintaining dispersion quality during production
4Object-generated harmful factors
If evaporation method is used to remove organic solvent, then solvent removal can be achieved, but the process is troublesome and adds cost
Solution Approach 1:
The patent replaces the thermal evaporation process with a mechanical separation system using continuous filtration and pressure-driven flow, thereby removing the need for complex evaporation equipment and energy-intensive heating processes while achieving effective solvent removal
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 enhances production efficiency, reduces residual solvent and surfactant amounts, improves surface tension, and minimizes clogging and energy consumption, resulting in a water-absorbent resin with improved properties and reduced odor.
Implementation Method 1
a pressure of not less than 0.1 MPa is applied to the hydrous gel crosslinked polymer
Implementation Method 2
a centrifugal filtration type, and a centrifugal sedimentation type have been proposed
Data Source
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AI summary
[Object] To provide a method for producing a water-absorbent resin in powder form or particle form, which has excellent physical properties such as water absorption performance and the like, at high productivity. [Solution] A method for producing a water-absorbent resin includes: a polymerization step of polymerizing a monomer, which is a raw material of the water-absorbent resin, to obtain a hydrous gel crosslinked polymer dispersed in an organic solvent; and a separation step of separating the organic solvent and the hydrous gel crosslinked polymer. The separation step includes transfer, compression, and discharge of the hydrous gel crosslinked polymer.