Solvent Purification Segmentation for Conjugated Diene Polymerization
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Solution Overview
Problem
Conventional purification processes for synthetic rubber production using solution polymerization result in solvent loss and decreased catalyst activity due to impurities, leading to increased costs and operational complexity, especially when manufacturing rubber products vulnerable to impurities.
Innovation Solution
A method and apparatus for preparing conjugated diene-based polymers that involve separate polymerization and purification steps for solvents from each polymer solution, allowing for the recovery and reuse of high-purity solvents, thereby reducing solvent loss and improving reactivity and productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional distillation column purification process is used to remove impurities from solvent, then unreacted monomers, water, and butenes are removed from the upper portion, but solvent loss increases and catalyst activity decreases due to remaining impurities
Solution Approach 1:
The purification process is divided into two separate distillation columns: a first distillation column that removes light impurities (unreacted monomers, water, butenes) from the upper portion, and a second distillation column that removes heavy impurities from the lower portion. This segmentation allows each column to be optimized for specific impurity removal, improving overall solvent purity while reducing solvent loss compared to a single-column system.
Solution Approach 2:
The invention extracts and removes specific impurity components (unreacted monomers, water, butenes, and heavies) from the solvent through targeted distillation processes. By taking out these harmful impurities in separate stages, the solvent purity is significantly improved, which directly addresses the catalyst activity problem while minimizing solvent loss.
2Manufacturing precision
If a conventional distillation column purification process is used, then light impurities are removed from the upper portion, but additional columns are needed for complete purification, increasing investment cost and process complexity
Solution Approach 1:
The purification system is segmented into two functional columns: the first column handles light impurity removal (unreacted monomers, water, butenes) from the upper portion, and the second column handles heavy impurity removal from the lower portion. This segmentation achieves complete purification while keeping each column's design and operation relatively simple and specialized.
Solution Approach 2:
The process discards light impurities from the upper portion of the first column and recovers pure solvent from the lower portion. Meanwhile, heavy impurities are discarded from the second column while recovering additional pure solvent. This selective discarding and recovering approach achieves high solvent purity without requiring overly complex additional equipment.
3Manufacturing precision
If solvent is removed from the upper portion of the first column to reduce butenes and moisture, then light impurities are removed, but solvent loss increases and operator fatigue increases due to process variables
Solution Approach 1:
The purification process is segmented into two columns with clearly defined functions: the first column removes light impurities (unreacted monomers, water, butenes) from the upper portion, and the second column removes heavy impurities from the lower portion. This segmentation creates a straightforward, easy-to-manage process flow that reduces operator fatigue by eliminating complex decision-making about which impurities to remove where.
Solution Approach 2:
The process systematically discards light impurities from the first column's upper portion and recovers pure solvent from its lower portion. The second column similarly discards heavy impurities and recovers solvent. This systematic approach to discarding and recovering impurities simplifies process management and reduces operator fatigue while achieving high solvent purity.
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 prevents side effects in the reaction process, reduces gel production, and enhances productivity by utilizing high-purity solvents, minimizing solvent loss and operational costs.
Implementation Method 1
a distillation column is used, and in a first column, an unreacted monomer, water and butenes forming an azeotrope are removed from the upper portion
Implementation Method 2
the solvent recovered from the lower portion is input to a second column to remove heavies
Data Source
AI summary
A method of preparing a conjugated diene-based polymer is provided including: a step of polymerizing a first conjugated diene-based monomer in solution in a first polymerization reactor to prepare a first polymer solution including a first conjugated diene-based polymer; a step of polymerizing a second conjugated diene-based monomer in solution in a second polymerization reactor to prepare a second polymer solution including a second conjugated diene-based polymer; a step of supplying a first fluid separated from the first polymer solution to a first purification unit and purifying the first fluid; and a step of supplying a second fluid separated from the second polymer solution to a second purification unit and purifying the second fluid. An apparatus for preparing a conjugated diene-based polymer is also provided.