Super Absorbent Polymer Preparation Reducing Fine Powder
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Solution Overview
Problem
The conventional method of preparing super absorbent polymers generates a large amount of fine powder during the drying and pulverization process, which deteriorates the physical properties of the final product and increases energy consumption.
Innovation Solution
A preparation method for a super absorbent polymer composition that involves cross-linking polymerization of a water-soluble ethylene-based unsaturated monomer, followed by mixing with a carboxylic acid-based additive and pulverization to produce hydrous super absorbent polymer particles without agglomeration, significantly reducing fine powder generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the hydrogel polymer is dried and then pulverized to prepare super absorbent polymer particles, then the polymer particles can be obtained with desired particle size, but a large amount of fine powder is generated which deteriorates physical properties
Solution Approach 1:
The patent introduces a specific additive as an intermediary substance during the pulverization process. This additive prevents direct contact and adhesion between polymer particles, thereby suppressing fine powder generation while maintaining effective particle size control. The additive acts as a mediator that facilitates the pulverization process without causing the harmful fine powder effect.
Solution Approach 2:
The patent modifies the pulverization process by changing physical parameters such as adding substances that alter the surface properties of the polymer particles. By changing the surface characteristics through additive incorporation, the pulverization process generates significantly less fine powder while still achieving the desired particle size distribution.
2Loss of substance
If fine powder is reused by mixing with water to agglomerate, followed by drying and pulverization, then the fine powder can be recovered, but energy consumption increases and device load increases
Solution Approach 1:
The patent extracts the fine powder generation problem from the conventional process by introducing an additive that prevents fine powder formation in the first place. Instead of recovering fine powder through additional processing steps, the invention eliminates the root cause, thereby avoiding the energy-intensive drying and re-pulverization steps required for fine powder recovery.
Solution Approach 2:
The additive incorporated in the pulverization process provides self-service by automatically preventing fine powder generation during the process. This eliminates the need for separate fine powder recovery systems and their associated energy consumption, making the process self-sufficient in preventing the problem.
3Loss of substance
If fine powder is reused by mixing with water to agglomerate, then the fine powder can be recovered, but the load on the device increases and productivity decreases
Solution Approach 1:
The additive serves as an intermediary that prevents fine powder generation during pulverization, thereby eliminating the need for downstream fine powder recovery operations. This reduces device load and maintains continuous high-speed production without the productivity losses associated with additional processing steps.
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 method effectively produces super absorbent polymer particles with desired particle sizes without agglomeration, significantly reducing fine powder generation and improving the physical properties and productivity of the super absorbent polymer composition.
Implementation Method 1
a step of mixing the hydrogel polymer with a carboxylic acid-based additive, followed by pulverization to prepare a pulverized product containing hydrous super absorbent polymer particles and the additive
Implementation Method 2
a step of forming a hydrogel polymer by cross-linking polymerization of a water-soluble ethylene-based unsaturated monomer having at least partially neutralized acidic groups in the presence of an internal cross-linking agent and a polymerization initiator
Implementation Method 3
A super absorbent polymer (SAP) is a type of synthetic polymeric material capable of absorbing 500 to 1000 times its own weight of moisture
Data Source
AI summary
The present disclosure relates to a preparation method of a super absorbent polymer composition. More specifically, it relates to a preparation method of a super absorbent polymer composition capable of pulverizing the hydrogel polymer to a normal particle size without agglomeration between particles by adding an additive having a specific structure, and significantly reducing the amount of fine powder generated during the process.