Rubber Precipitation Recycling to Cut Particle Loss and Blockage
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Solution Overview
Problem
Existing processes for producing particulate rubbers result in significant amounts of rubber particles being lost in wastewater due to sieving and filtration, leading to blockages in precipitation and sintering equipment, and inefficient use of precipitation salts.
Innovation Solution
A process involving the recycling of a liquid phase containing finely divided rubber back to the precipitation vessel, subjecting it to thermal stress, which reduces the solids content to less than 25% by weight, thereby minimizing wastewater and reducing the risk of blockages while maintaining product quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If dewatering is performed using filtration or sieving, then rubber particles can be separated from water, but rubber particles are lost in wastewater and blockages occur in precipitation and sintering equipment
Solution Approach 1:
The patent recovers the liquid phase containing finely divided rubber particles and returns it to the precipitation vessel, preventing rubber loss in wastewater and eliminating blockages in equipment. This recovery approach addresses both the loss of substance and reliability issues simultaneously.
Solution Approach 2:
The patent extracts the liquid phase containing rubber particles from the dewatering process and separates it from the solid rubber particles. By taking out the liquid phase for recycling, the system prevents rubber particles from being discarded with wastewater and avoids equipment blockages.
2Loss of substance
If precipitation solution is used to separate rubber from dispersion, then rubber particles can be formed, but precipitation salt is wasted and requires disposal
Solution Approach 1:
The patent recovers the liquid phase containing rubber particles and returns it to the precipitation vessel, which also allows recovery and reuse of the precipitation salt solution. This prevents salt waste and improves rubber yield by ensuring all rubber particles are processed.
Solution Approach 2:
The patent implements a feedback loop where the liquid phase is returned to the precipitation vessel for reprocessing. This feedback mechanism ensures that both rubber particles and precipitation salt are reused, minimizing waste and maximizing productivity.
3Productivity
If high solids content dispersion is used, then space-time yield is maximized, but blockages occur in precipitation and sintering process parts
Solution Approach 1:
The patent recovers the liquid phase containing rubber particles and returns it to the precipitation vessel, which allows the system to operate with lower solids content in the precipitation and sintering equipment. This recovery approach maintains productivity while eliminating blockages.
Solution Approach 2:
The patent segments the processing into two streams: solid rubber particles that proceed to sintering and liquid phase containing fine particles that are recycled to precipitation. This segmentation allows high solids content processing without blocking equipment, as the liquid phase is separated and recycled.
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 increases yield and minimizes the amount of rubber and precipitation salt removed, reducing the risk of blockages and maintaining mechanical properties of the treated rubber products.
Implementation Method 1
supplying the dispersion containing the rubber and a precipitation solution to a precipitation vessel to obtain an aqueous suspension containing rubber particles
Implementation Method 2
the rubber particles present in the aqueous suspension containing rubber particles are optionally sintered to afford larger particles
Implementation Method 3
the aqueous suspension containing rubber particles is mechanically dewatered to afford rubber particles containing residual moisture and a liquid phase containing finely divided rubber
Data Source
AI summary
The invention relates to a method for preparing rubbers from a dispersion (1) containing the rubber, said method comprising: (a) feeding the dispersion (1), that contains the rubber, and a precipitation solution (3) into a precipitation tank (5), an aqueous suspension (9) that contains rubber particles being produced; (b) optionally sintering the rubber particles contained in the aqueous suspension (9) that contains rubber particles to form larger particles; (c) mechanically dewatering the aqueous suspension (9) that contains rubber particles, rubber particles (33) that contain residual moisture and a liquid phase (35) that contains fine-particle rubber being obtained, the liquid phase (35) that contains fine-particle rubber being returned to the precipitation tank (5).