CA2374889A1 - Process and apparatus for preparing a composition using a slurry feed - Google Patents
Process and apparatus for preparing a composition using a slurry feed Download PDFInfo
- Publication number
- CA2374889A1 CA2374889A1 CA002374889A CA2374889A CA2374889A1 CA 2374889 A1 CA2374889 A1 CA 2374889A1 CA 002374889 A CA002374889 A CA 002374889A CA 2374889 A CA2374889 A CA 2374889A CA 2374889 A1 CA2374889 A1 CA 2374889A1
- Authority
- CA
- Canada
- Prior art keywords
- reactor
- composition
- reactive
- slurry
- substance
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 239000002002 slurry Substances 0.000 title claims abstract description 58
- 239000000203 mixture Substances 0.000 title claims abstract description 53
- 238000000034 method Methods 0.000 title claims abstract description 40
- 239000012260 resinous material Substances 0.000 claims abstract description 37
- 239000000178 monomer Substances 0.000 claims abstract description 21
- 238000004519 manufacturing process Methods 0.000 claims abstract description 6
- 239000007787 solid Substances 0.000 claims description 38
- 239000007788 liquid Substances 0.000 claims description 22
- 239000003822 epoxy resin Substances 0.000 claims description 20
- 229920000647 polyepoxide Polymers 0.000 claims description 20
- 229920000642 polymer Polymers 0.000 claims description 19
- 239000000126 substance Substances 0.000 claims description 18
- 239000000376 reactant Substances 0.000 claims description 12
- IISBACLAFKSPIT-UHFFFAOYSA-N bisphenol A Chemical compound C=1C=C(O)C=CC=1C(C)(C)C1=CC=C(O)C=C1 IISBACLAFKSPIT-UHFFFAOYSA-N 0.000 claims description 8
- 229920000728 polyester Polymers 0.000 claims description 7
- 150000001875 compounds Chemical class 0.000 claims description 5
- 239000000945 filler Substances 0.000 claims description 4
- 239000000049 pigment Substances 0.000 claims description 4
- 239000003381 stabilizer Substances 0.000 claims description 4
- 239000008199 coating composition Substances 0.000 claims 2
- 125000003700 epoxy group Chemical group 0.000 claims 2
- 239000004615 ingredient Substances 0.000 abstract description 9
- 238000002156 mixing Methods 0.000 abstract description 7
- 238000006243 chemical reaction Methods 0.000 description 11
- 239000000654 additive Substances 0.000 description 9
- 238000006116 polymerization reaction Methods 0.000 description 7
- 239000003054 catalyst Substances 0.000 description 6
- LNEPOXFFQSENCJ-UHFFFAOYSA-N haloperidol Chemical compound C1CC(O)(C=2C=CC(Cl)=CC=2)CCN1CCCC(=O)C1=CC=C(F)C=C1 LNEPOXFFQSENCJ-UHFFFAOYSA-N 0.000 description 6
- 238000010924 continuous production Methods 0.000 description 3
- 239000004850 liquid epoxy resins (LERs) Substances 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- 238000002360 preparation method Methods 0.000 description 3
- 239000000047 product Substances 0.000 description 3
- 230000000996 additive effect Effects 0.000 description 2
- 238000013461 design Methods 0.000 description 2
- 239000011344 liquid material Substances 0.000 description 2
- 239000000523 sample Substances 0.000 description 2
- 238000003860 storage Methods 0.000 description 2
- 238000012935 Averaging Methods 0.000 description 1
- 229930185605 Bisphenol Natural products 0.000 description 1
- 239000004593 Epoxy Substances 0.000 description 1
- 238000001069 Raman spectroscopy Methods 0.000 description 1
- 229920006397 acrylic thermoplastic Polymers 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
- 239000007795 chemical reaction product Substances 0.000 description 1
- 238000013329 compounding Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 229920001577 copolymer Polymers 0.000 description 1
- 238000006731 degradation reaction Methods 0.000 description 1
- QGBSISYHAICWAH-UHFFFAOYSA-N dicyandiamide Chemical compound NC(N)=NC#N QGBSISYHAICWAH-UHFFFAOYSA-N 0.000 description 1
- 239000003989 dielectric material Substances 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 150000002118 epoxides Chemical class 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 238000012840 feeding operation Methods 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 230000009477 glass transition Effects 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 239000011261 inert gas Substances 0.000 description 1
- 239000006193 liquid solution Substances 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 239000011268 mixed slurry Substances 0.000 description 1
- 239000013618 particulate matter Substances 0.000 description 1
- 239000008188 pellet Substances 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 239000006069 physical mixture Substances 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 229920003229 poly(methyl methacrylate) Polymers 0.000 description 1
- 239000004848 polyfunctional curative Substances 0.000 description 1
- 230000000379 polymerizing effect Effects 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 239000011541 reaction mixture Substances 0.000 description 1
- 238000009751 slip forming Methods 0.000 description 1
- 239000011343 solid material Substances 0.000 description 1
- 230000003068 static effect Effects 0.000 description 1
- ISXSCDLOGDJUNJ-UHFFFAOYSA-N tert-butyl prop-2-enoate Chemical compound CC(C)(C)OC(=O)C=C ISXSCDLOGDJUNJ-UHFFFAOYSA-N 0.000 description 1
- 150000003673 urethanes Chemical class 0.000 description 1
Classifications
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- B01J8/18—Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes with fluidised particles
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- C08G59/40—Macromolecules obtained by polymerising compounds containing more than one epoxy group per molecule using curing agents or catalysts which react with the epoxy groups ; e.g. general methods of curing characterised by the curing agents used
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- G01N2291/02—Indexing codes associated with the analysed material
- G01N2291/028—Material parameters
- G01N2291/02836—Flow rate, liquid level
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2291/00—Indexing codes associated with group G01N29/00
- G01N2291/10—Number of transducers
- G01N2291/102—Number of transducers one emitter, one receiver
Abstract
A process and apparatus for preparing compositions including one or more resinous materials and/or other ingredients using a continuous reactor (20) combined with a slurry vessel (10) for feeding a slurry feed stream (15) to the reactor. More specifically, the process and apparatus prepares a composition by feeding a reactive slurry of one or more monomers and/or oligomers into a continuous reactor extruder (20) to manufacture one or more resinous materials. Optionally, the resinous material may be continuously conveying to a mixer for continuously mixing the resinous material with other ingredients to form a blended composition.
Description
PROCESS AND APPARATUS FOR PREPARING
A COMPOSITION USING A SLURRY FEED
This invention relates to a process and an apparatus for preparing a composition using a continuous extruder. More particularly, this invention relates to a process and an apparatus for preparing a composition by feeding a slurry from a slurry vessel into a continuous reactor.
Heretofore, chemical compositions, for example polymers, have been prepared using continuous reactor extruders. For example, U.S. Patent No.
4,612,355 discloses the use of extruders for the manufacture of plastics. More specifically, to U.S. Patent No. 4,612,355 discloses the use of reaction extruders to prepare epoxy resins.
Typically, the feed of reactants to such extruders is carried out as solids and or as a melt prior to feeding the extruder. It is difficult to thoroughly and intimately mix the solids together before or while feeding the solids to an extruder. Some chemicals cannot be fed as solids and must be prepared in a different manner.
15 In addition, feed accuracy demands for continuous processes are high, particularly when the continuous process is plug flow, with minimum backmixing, and a step polymerization. Step polymerizations involving two different di-functional feeds, represented by A-A and B-B, where A reacts with B, are very sensitive to the ratio of A-A
and B-B
regarding final molecular weight and physical properties.
2o Generally, liquid feeds are preferred for step polymerization processes, as a feed accuracy of less than 0.1 percent can be achieved using liquid feeds.
However, in some manufacturing processes, one or more of the feeds must be a solid, because a liquid feed form may not be desirable due to degradation or safety concerns. Thus, a solid feed system, such as a loss-in-weight feeder, is required when a liquid feed can not be used.
2s The accuracy of loss-in-weight feeders can approach 0.25 percent over a one minute interval, but is generally greater than 1 percent over a 5 second interval. It would be advantageous to avoid having to use a solid feed systems in processes which can not accurately handle solids.
It is therefore desired to provide a process and apparatus for preparing a 3o composition using a slurry feed to a reactor such as an extruder. More preferably, it is desired to provide a process and apparatus which allows averaging of the short term accuracy of a solids feeder by holding up several minutes worth of feed in a continuously stirred, backmixed vessel in combination with a liquid feed.
accuracy of a solids feeder by holding up several minutes worth of feed in a continuously stirred, backmixed vessel in combination with a liquid feed.
The present invention pertains to a process and an apparatus for preparing compositions from one or more resinous materials and other ingredients using a continuous reactor combined with a continuous slurry feed apparatus for feeding the slurry feed stream to the reactor.
In one specific embodiment of the present invention, the present process and apparatus prepares a composition by feeding a slurry of one or more monomers and/or oligomers into a continuous reactor to manufacture one or more resinous materials. The Zo resinous materials may optionally be combined with other additives in a mixer or recovered as a flake for further use.
This process integrates a slurry feeding operation with a reactive extrusion operation. The present invention avoids problems associated with raw materials feed rate variation when using a solid additive to a liquid material without having to melt the solids.
15 The present invention advantageously provides accurate feed flow from a solids feeder.
Figure 1 shows a schematic representation of one embodiment of the apparatus of the present invention and in particular, illustrates a slurry feed vessel in combination with a continuous reactor extruder.
The present invention is directed to a process and an apparatus for achieving 2o consistent feed of a solid feed to a continuous process by using continuously formed and mixed slurry of the solid feed or feeds with a liquid feed. Generally, a loss-in-weight feeder is used to feed the solid to the slurry mixing vessel, and an accurate liquid metering system is used to feed each liquid feed used in the slurry.
The level in the slurry process is controlled by the speed of a pump that 2s forwards the slurry to the process. The level should be measured by a means that does not introduce gas into the system, such as a diaphragm level transmitter or ultrasonic level transmitter. Consistent level control is required to provide a steady feed rate to the process and to ensure adequate mixing. The level in the vessel is controlled at a point above the agitator to create a vortex capable of entraining the solids. The loss in weight feeder 3 o discharge should drop the solid feed directly into the vortex.
One embodiment of the present process and apparatus of the present invention involves the preparation of a composition and/or certain resinous materials that are contained within the composition using a reactor extruder in combination with a slurry vessel.
A COMPOSITION USING A SLURRY FEED
This invention relates to a process and an apparatus for preparing a composition using a continuous extruder. More particularly, this invention relates to a process and an apparatus for preparing a composition by feeding a slurry from a slurry vessel into a continuous reactor.
Heretofore, chemical compositions, for example polymers, have been prepared using continuous reactor extruders. For example, U.S. Patent No.
4,612,355 discloses the use of extruders for the manufacture of plastics. More specifically, to U.S. Patent No. 4,612,355 discloses the use of reaction extruders to prepare epoxy resins.
Typically, the feed of reactants to such extruders is carried out as solids and or as a melt prior to feeding the extruder. It is difficult to thoroughly and intimately mix the solids together before or while feeding the solids to an extruder. Some chemicals cannot be fed as solids and must be prepared in a different manner.
15 In addition, feed accuracy demands for continuous processes are high, particularly when the continuous process is plug flow, with minimum backmixing, and a step polymerization. Step polymerizations involving two different di-functional feeds, represented by A-A and B-B, where A reacts with B, are very sensitive to the ratio of A-A
and B-B
regarding final molecular weight and physical properties.
2o Generally, liquid feeds are preferred for step polymerization processes, as a feed accuracy of less than 0.1 percent can be achieved using liquid feeds.
However, in some manufacturing processes, one or more of the feeds must be a solid, because a liquid feed form may not be desirable due to degradation or safety concerns. Thus, a solid feed system, such as a loss-in-weight feeder, is required when a liquid feed can not be used.
2s The accuracy of loss-in-weight feeders can approach 0.25 percent over a one minute interval, but is generally greater than 1 percent over a 5 second interval. It would be advantageous to avoid having to use a solid feed systems in processes which can not accurately handle solids.
It is therefore desired to provide a process and apparatus for preparing a 3o composition using a slurry feed to a reactor such as an extruder. More preferably, it is desired to provide a process and apparatus which allows averaging of the short term accuracy of a solids feeder by holding up several minutes worth of feed in a continuously stirred, backmixed vessel in combination with a liquid feed.
accuracy of a solids feeder by holding up several minutes worth of feed in a continuously stirred, backmixed vessel in combination with a liquid feed.
The present invention pertains to a process and an apparatus for preparing compositions from one or more resinous materials and other ingredients using a continuous reactor combined with a continuous slurry feed apparatus for feeding the slurry feed stream to the reactor.
In one specific embodiment of the present invention, the present process and apparatus prepares a composition by feeding a slurry of one or more monomers and/or oligomers into a continuous reactor to manufacture one or more resinous materials. The Zo resinous materials may optionally be combined with other additives in a mixer or recovered as a flake for further use.
This process integrates a slurry feeding operation with a reactive extrusion operation. The present invention avoids problems associated with raw materials feed rate variation when using a solid additive to a liquid material without having to melt the solids.
15 The present invention advantageously provides accurate feed flow from a solids feeder.
Figure 1 shows a schematic representation of one embodiment of the apparatus of the present invention and in particular, illustrates a slurry feed vessel in combination with a continuous reactor extruder.
The present invention is directed to a process and an apparatus for achieving 2o consistent feed of a solid feed to a continuous process by using continuously formed and mixed slurry of the solid feed or feeds with a liquid feed. Generally, a loss-in-weight feeder is used to feed the solid to the slurry mixing vessel, and an accurate liquid metering system is used to feed each liquid feed used in the slurry.
The level in the slurry process is controlled by the speed of a pump that 2s forwards the slurry to the process. The level should be measured by a means that does not introduce gas into the system, such as a diaphragm level transmitter or ultrasonic level transmitter. Consistent level control is required to provide a steady feed rate to the process and to ensure adequate mixing. The level in the vessel is controlled at a point above the agitator to create a vortex capable of entraining the solids. The loss in weight feeder 3 o discharge should drop the solid feed directly into the vortex.
One embodiment of the present process and apparatus of the present invention involves the preparation of a composition and/or certain resinous materials that are contained within the composition using a reactor extruder in combination with a slurry vessel.
The term "slurry" herein means one or more solid materials suspended in a liquid material.
With reference to Figure 1, there is shown a slurry vessel 10 connected to a reactor 20. A liquid monomer stream in conduit 11 from storage vessel (not shown) may be heated by an exchanger (not shown) and rate added to the slurry vessel 10 using a rate addition pump (not shown) or alternately a control valve (not shown). The temperature of the liquid monomer stream 11 is controlled to produce a slurry stream that is pumpable. In some cases, the liquid monomer stream 11 is heated to a temperature required to melt any solid monomers present in the slurry vessel 10.
1o A solid monomer stream in conduit 12 from a solid addition system 13 is rate added to the slurry vessel 10 and a high speed mixer 14 in the slurry vessel 10 combines the solid and liquid monomers to form the reactive slurry stream in conduit 15.
The slurry stream 15 is continuously rate added to the reactor 20 using rate addition pump (not shown).
If required to complete the reaction, the slurry 15 is combined with a catalyst from catalyst s5 addition pump (not shown). The slurry and catalyst may be combined together in the slurry feed line 15 or alternatively in a high speed inline mixer (not shown) located within slurry line 15 and fed into the continuous reactor 20.
The monomers and other additives such as a catalyst added to the continuous reactor 20 are heated to sufficient temperatures required to produce a reaction 2 o within the reactor and ultimately a reaction product stream in conduit 21 exits the reactor 20.
Although not shown, various other embodiments of the present invention, may include for example, where the output of the continuous reactor 20 such as a resinous material is force conveyed through a conduit connecting the continuous reactor 20 with a continuous mixer using a resinous material pump. A liquid additive storage tank and 2s metering flow control pump can also be attached to the system to add any liquid additives or other ingredients to the resinous material before conveying to the mixer. A
preferred process and apparatus useful in the present invention for combining a reactor with a mixer is described in copending U.S. Patent Application, Attorney Docket No. 44646, entitled "Process and Apparatus For Preparing A Composition Using A Continuous Reactor And 3 o Mixer In Series" filed by Keillor et al., of even date herewith.
In addition, the conditions of the resinous material from continuous reactor must be modified before introduction into the continuous mixer. For example, a filter system may be used to remove any particulate matter from the resinous material; or a heat ' exchanger system may be used to reduce the temperature of the resinous material to the required temperatures for proper mixing. Other solid ingredients may be added from a continuous addition system to the mixer and combined with the resinous material feed stream. At the solids discharge end of the continuous mixer, the product may be transferred to a flaker to solidify and form the product into flakes the composition.
In another variation of the design illustrated in Figure 1, multiple continuous slurry feed streams may be fed to the continuous reactor or one slurry feed stream may be fed to multiple continuous reactors.
In one embodiment of the present invention, the resinous material, which may so be used as a component in the preparation of a composition prepared in the present invention, may be prepared by the process of the present invention in a continuous reactor.
The continuous reactor used for this purpose may be a pipe or tubular reactor, or an extruder. It is preferred to use an extruder. More than one such reactor may be used for the preparation of different resinous materials. Any number of reactors may be used and 15 optionally any or all of the reactors may be connected directly to a mixer in which the composition may also be prepared. A pipe or tubular joint is suitable for use as the means of making such connection.
The resinous material useful in the present invention is prepared by polymerizing one or more monomers and/or oligomers in a continuous polymerization 2o reactor to form the resinous material, more specifically a polymer.
Typically, a catalyst may be added to the polymerization reaction mixture for the purpose of obtaining a specific type of resinous material, or a desired rate of conversion. The monomer(s), oligomer(s), and catalyst when desired, may, each separately or in groups of two or more, be fed to the polymerization reactor in one or more of the following forms: a liquid solution, a slurry, or a 2s dry physical mixture. However, at least one or more of the components is fed into the reactor extruder as a slurry.
The resinous material from which a composition is prepared according to the present invention may be virtually any polymer or copolymer. The resinous material need not have any particular molecular weight to be useful as a component in the composition.
3 o The resinous material may have repeating units ranging from at least two repeating units up to those resinous materials whose size is measured in the hundreds or thousands of repeating units. Particular resinous materials that may be used in the methods of the present invention include for example, epoxy resins, polyesters, urethanes, acrylics and others as set forth in U.S. Patent No. 5,094,806. The most preferred resinous materials useful in the present invention from among those listed above are epoxy resins and polyesters. Epoxy resins useful in the present invention, and materials from which epoxy resins may be prepared, are described in U.S. Patent No. 4,612,156. Polyesters useful in the present invention, and materials from which polyesters may be prepared, are described in Volume 12 of Encyclopedia of Polymer Science and Enaineerina, pages 1 -313.
In the production of a resinous material to be used as a component of a composition of the present invention, various conditions or parameters have an effect on the course of the polymerization reaction. Typical examples of these conditions or parameters Zo are as follows: the rate of feed to the reactor of the monomers) and/or oligomer(s); the temperature at which the reaction occurs; the length of time during which the reaction occurs; and the degree to which the reactants are mixed or agitated during the reaction. The rate of feed of monomers) and/or oligomer(s) can be influenced, for example, by valve adjustment on a pressured line. The temperature at which the reaction occurs can be 15 influenced, for example, by the direct heating or cooling of the monomers) and/or oligomer(s) or to the reactor itself. The length of time during which the reaction occurs can be influenced, for example, by the size of the reactor, such as the length of a pipe, tube or extruder, or the speed at which the reactants move into and out of the reactor, such as may result from the particular speed or design of an extruder screw, or the introduction of a 2o pressurized inert gas into a pipe or tube. The degree to which the reactants are mixed or agitated during the reaction can be influenced, for example, by the size, shape and speed of blades or other mixing elements, by the presence of a static mixing element in a pipe or tube, or the speed of the screw in an extruder.
The quality of the composition prepared by the process and apparatus of the 2 s present invention is improved if the properties of the resinous material to be used as a component in the composition are known and maintained at a desired level.
Typical examples of resinous material properties that may be analyzed for this purpose are viscosity, melt index, melt flow rate, molecular weight, molecular weight distribution, equivalent weight, melting point, glass transition temperature, density, specific gravity, and purity. For example, 3 o when an epoxy resin is used as a resinous material, it is desired that its viscosity be in the range of from 1 to 100,000 centipoise. The analytical techniques that may be used to determine resinous material properties such as the foregoing include ultrasonic wave energy, Raman, infrared, near infrared; and dielectrics energy. A preferred process.and apparatus for measuring properties of the resinous material used in the present invention is described in copending U.S. Patent Application, Attorney Docked No. 44646 2, entitled "Process And Apparatus For Preparing A Composition of Matter Utilizing An Ultrasonic Device", filed by Shawn Maynard, of even date herewith .
Generally, the compositions prepared by the slurry process of the present s invention are prepared by continuously feeding a reactive slurry solution from a slurry vessel to a reactor extruder. Any number of other ingredients may be added to the slurry vessel, to the line feed of the reactor or to the reactor to form a composition. For example, one or more polymers that have not been prepared in a reactor, reactive or inert compounds, or additives such as pigments, filler or stabilizer. Optionally, when the final composition is a to blend of materials, the composition from the reactor extruder may be conveyed from the reactor to a mixer through a connection between the reactor and the mixer to form a composition. If more than one reactor is used, a connection is established between each reactor and the mixer.
The preferred type of mixer to use is an extruder, particularly a twin-screw 15 extruder but other types of mixers such as co-kneaders may be used as well.
In another embodiment of the present invention, a composition may be prepared by compounding the resinous material with other components to prepare a final composition. The remaining components of the final composition includes a number of other ingredients which may also include a resinous material, such as an epoxy or a polyester, or 20 other resinous materials listed above. The remaining components of the composition may also include ingredients such as conventional additives for example hardeners for an epoxy resin (for example, dicyandiamide), fillers, pigments and stabilizers. Other additives as ingredients for the composition prepared by the process and apparatus of the present invention are disclosed in U.S. Patent No. 5,416,148. Such additives may be incorporated as as a liquid into the composition. After mixing the composition in the mixer, the composition is recovered in a form suitable for handling, such as in the form of a flake or pellet.
Example 1 Solid epoxy resins were prepared via the reaction of a liquid epoxy resin and bisphenol A. The feeding of molten bisphenol A to a reactor extruder was deemed 3 o unacceptable for this application due to color buildup upon shutdown and startup. Thus, liquid epoxy resin and bisphenol A were fed to a slurry vessel in a continuous manner at desired flow rates as shown in Table 1 below. Slurry from the slurry vessel was then continuously fed to a Krupp Werner & Pfleiderer ZSK-40 reactor extruder using a MoynoT"' =6-progressing cavity pump and "The Probe" ultrasonic level measurement. The epoxide equivalent weight of the product produced in the reactor was measured over time as indicated in Table 1 I. Consistency of the EEW was acceptable, demonstrating the efficacy of the slurry feed system. The following table shows the results of this Example.
Table 1 SAMPLE # TIME LER RATE BISPHENOL RATE EEW
Ib/hr Ib/hr #1 1545 101.716 38.284 688.5 #2 1600 101.716 38.284 675.1 #3 1615 101.716 38.284 678.8 #4 1630 101.716 38.284 685.2 #5 1645 101.716 38.284 680.8 #6 1700 101.716 38.284 691.2 #7 1715 101.716 38.284 683.2 #8 1730 101.716 38.284 690.3 _7_
With reference to Figure 1, there is shown a slurry vessel 10 connected to a reactor 20. A liquid monomer stream in conduit 11 from storage vessel (not shown) may be heated by an exchanger (not shown) and rate added to the slurry vessel 10 using a rate addition pump (not shown) or alternately a control valve (not shown). The temperature of the liquid monomer stream 11 is controlled to produce a slurry stream that is pumpable. In some cases, the liquid monomer stream 11 is heated to a temperature required to melt any solid monomers present in the slurry vessel 10.
1o A solid monomer stream in conduit 12 from a solid addition system 13 is rate added to the slurry vessel 10 and a high speed mixer 14 in the slurry vessel 10 combines the solid and liquid monomers to form the reactive slurry stream in conduit 15.
The slurry stream 15 is continuously rate added to the reactor 20 using rate addition pump (not shown).
If required to complete the reaction, the slurry 15 is combined with a catalyst from catalyst s5 addition pump (not shown). The slurry and catalyst may be combined together in the slurry feed line 15 or alternatively in a high speed inline mixer (not shown) located within slurry line 15 and fed into the continuous reactor 20.
The monomers and other additives such as a catalyst added to the continuous reactor 20 are heated to sufficient temperatures required to produce a reaction 2 o within the reactor and ultimately a reaction product stream in conduit 21 exits the reactor 20.
Although not shown, various other embodiments of the present invention, may include for example, where the output of the continuous reactor 20 such as a resinous material is force conveyed through a conduit connecting the continuous reactor 20 with a continuous mixer using a resinous material pump. A liquid additive storage tank and 2s metering flow control pump can also be attached to the system to add any liquid additives or other ingredients to the resinous material before conveying to the mixer. A
preferred process and apparatus useful in the present invention for combining a reactor with a mixer is described in copending U.S. Patent Application, Attorney Docket No. 44646, entitled "Process and Apparatus For Preparing A Composition Using A Continuous Reactor And 3 o Mixer In Series" filed by Keillor et al., of even date herewith.
In addition, the conditions of the resinous material from continuous reactor must be modified before introduction into the continuous mixer. For example, a filter system may be used to remove any particulate matter from the resinous material; or a heat ' exchanger system may be used to reduce the temperature of the resinous material to the required temperatures for proper mixing. Other solid ingredients may be added from a continuous addition system to the mixer and combined with the resinous material feed stream. At the solids discharge end of the continuous mixer, the product may be transferred to a flaker to solidify and form the product into flakes the composition.
In another variation of the design illustrated in Figure 1, multiple continuous slurry feed streams may be fed to the continuous reactor or one slurry feed stream may be fed to multiple continuous reactors.
In one embodiment of the present invention, the resinous material, which may so be used as a component in the preparation of a composition prepared in the present invention, may be prepared by the process of the present invention in a continuous reactor.
The continuous reactor used for this purpose may be a pipe or tubular reactor, or an extruder. It is preferred to use an extruder. More than one such reactor may be used for the preparation of different resinous materials. Any number of reactors may be used and 15 optionally any or all of the reactors may be connected directly to a mixer in which the composition may also be prepared. A pipe or tubular joint is suitable for use as the means of making such connection.
The resinous material useful in the present invention is prepared by polymerizing one or more monomers and/or oligomers in a continuous polymerization 2o reactor to form the resinous material, more specifically a polymer.
Typically, a catalyst may be added to the polymerization reaction mixture for the purpose of obtaining a specific type of resinous material, or a desired rate of conversion. The monomer(s), oligomer(s), and catalyst when desired, may, each separately or in groups of two or more, be fed to the polymerization reactor in one or more of the following forms: a liquid solution, a slurry, or a 2s dry physical mixture. However, at least one or more of the components is fed into the reactor extruder as a slurry.
The resinous material from which a composition is prepared according to the present invention may be virtually any polymer or copolymer. The resinous material need not have any particular molecular weight to be useful as a component in the composition.
3 o The resinous material may have repeating units ranging from at least two repeating units up to those resinous materials whose size is measured in the hundreds or thousands of repeating units. Particular resinous materials that may be used in the methods of the present invention include for example, epoxy resins, polyesters, urethanes, acrylics and others as set forth in U.S. Patent No. 5,094,806. The most preferred resinous materials useful in the present invention from among those listed above are epoxy resins and polyesters. Epoxy resins useful in the present invention, and materials from which epoxy resins may be prepared, are described in U.S. Patent No. 4,612,156. Polyesters useful in the present invention, and materials from which polyesters may be prepared, are described in Volume 12 of Encyclopedia of Polymer Science and Enaineerina, pages 1 -313.
In the production of a resinous material to be used as a component of a composition of the present invention, various conditions or parameters have an effect on the course of the polymerization reaction. Typical examples of these conditions or parameters Zo are as follows: the rate of feed to the reactor of the monomers) and/or oligomer(s); the temperature at which the reaction occurs; the length of time during which the reaction occurs; and the degree to which the reactants are mixed or agitated during the reaction. The rate of feed of monomers) and/or oligomer(s) can be influenced, for example, by valve adjustment on a pressured line. The temperature at which the reaction occurs can be 15 influenced, for example, by the direct heating or cooling of the monomers) and/or oligomer(s) or to the reactor itself. The length of time during which the reaction occurs can be influenced, for example, by the size of the reactor, such as the length of a pipe, tube or extruder, or the speed at which the reactants move into and out of the reactor, such as may result from the particular speed or design of an extruder screw, or the introduction of a 2o pressurized inert gas into a pipe or tube. The degree to which the reactants are mixed or agitated during the reaction can be influenced, for example, by the size, shape and speed of blades or other mixing elements, by the presence of a static mixing element in a pipe or tube, or the speed of the screw in an extruder.
The quality of the composition prepared by the process and apparatus of the 2 s present invention is improved if the properties of the resinous material to be used as a component in the composition are known and maintained at a desired level.
Typical examples of resinous material properties that may be analyzed for this purpose are viscosity, melt index, melt flow rate, molecular weight, molecular weight distribution, equivalent weight, melting point, glass transition temperature, density, specific gravity, and purity. For example, 3 o when an epoxy resin is used as a resinous material, it is desired that its viscosity be in the range of from 1 to 100,000 centipoise. The analytical techniques that may be used to determine resinous material properties such as the foregoing include ultrasonic wave energy, Raman, infrared, near infrared; and dielectrics energy. A preferred process.and apparatus for measuring properties of the resinous material used in the present invention is described in copending U.S. Patent Application, Attorney Docked No. 44646 2, entitled "Process And Apparatus For Preparing A Composition of Matter Utilizing An Ultrasonic Device", filed by Shawn Maynard, of even date herewith .
Generally, the compositions prepared by the slurry process of the present s invention are prepared by continuously feeding a reactive slurry solution from a slurry vessel to a reactor extruder. Any number of other ingredients may be added to the slurry vessel, to the line feed of the reactor or to the reactor to form a composition. For example, one or more polymers that have not been prepared in a reactor, reactive or inert compounds, or additives such as pigments, filler or stabilizer. Optionally, when the final composition is a to blend of materials, the composition from the reactor extruder may be conveyed from the reactor to a mixer through a connection between the reactor and the mixer to form a composition. If more than one reactor is used, a connection is established between each reactor and the mixer.
The preferred type of mixer to use is an extruder, particularly a twin-screw 15 extruder but other types of mixers such as co-kneaders may be used as well.
In another embodiment of the present invention, a composition may be prepared by compounding the resinous material with other components to prepare a final composition. The remaining components of the final composition includes a number of other ingredients which may also include a resinous material, such as an epoxy or a polyester, or 20 other resinous materials listed above. The remaining components of the composition may also include ingredients such as conventional additives for example hardeners for an epoxy resin (for example, dicyandiamide), fillers, pigments and stabilizers. Other additives as ingredients for the composition prepared by the process and apparatus of the present invention are disclosed in U.S. Patent No. 5,416,148. Such additives may be incorporated as as a liquid into the composition. After mixing the composition in the mixer, the composition is recovered in a form suitable for handling, such as in the form of a flake or pellet.
Example 1 Solid epoxy resins were prepared via the reaction of a liquid epoxy resin and bisphenol A. The feeding of molten bisphenol A to a reactor extruder was deemed 3 o unacceptable for this application due to color buildup upon shutdown and startup. Thus, liquid epoxy resin and bisphenol A were fed to a slurry vessel in a continuous manner at desired flow rates as shown in Table 1 below. Slurry from the slurry vessel was then continuously fed to a Krupp Werner & Pfleiderer ZSK-40 reactor extruder using a MoynoT"' =6-progressing cavity pump and "The Probe" ultrasonic level measurement. The epoxide equivalent weight of the product produced in the reactor was measured over time as indicated in Table 1 I. Consistency of the EEW was acceptable, demonstrating the efficacy of the slurry feed system. The following table shows the results of this Example.
Table 1 SAMPLE # TIME LER RATE BISPHENOL RATE EEW
Ib/hr Ib/hr #1 1545 101.716 38.284 688.5 #2 1600 101.716 38.284 675.1 #3 1615 101.716 38.284 678.8 #4 1630 101.716 38.284 685.2 #5 1645 101.716 38.284 680.8 #6 1700 101.716 38.284 691.2 #7 1715 101.716 38.284 683.2 #8 1730 101.716 38.284 690.3 _7_
Claims (29)
1. A process for preparing a composition of matter comprising the steps of:
(a) providing one or more solids reactant components, (b) providing one or more liquid reactant components, (c) admixing the solids reactant components with the liquid reactant components to form a reactive solids-containing slurry stream, (d) continuously, feeding the reactive solids-containing slurry stream of one or more components of the composition of matter into at least one continuous reactor, (e) continuously reacting the reactive solids-containing slurry stream in the reactor to form the composition of matter in the reactor from said slurry, and (f) recovering said composition of matter from said reactor.
(a) providing one or more solids reactant components, (b) providing one or more liquid reactant components, (c) admixing the solids reactant components with the liquid reactant components to form a reactive solids-containing slurry stream, (d) continuously, feeding the reactive solids-containing slurry stream of one or more components of the composition of matter into at least one continuous reactor, (e) continuously reacting the reactive solids-containing slurry stream in the reactor to form the composition of matter in the reactor from said slurry, and (f) recovering said composition of matter from said reactor.
2. The process of Claim 1 wherein the composition of matter is a resinous material.
3. The process of Claim 2 wherein the resinous material is a polymer.
4. The process of Claim 3 wherein the slurry comprises one or more monomers and/or oligomers.
5. The process for Claim 3 wherein the polymer is an epoxy resin.
6. The process of Claim 1 wherein the reactor is an extruder.
7. The process of Claim 3 including the steps of:
(g) conveying the polymer from the reactor to a mixer through a connection between the reactor and the mixer, and (h) preparing the composition of matter by admixing, in the mixer, the polymer and one or more other components of the composition of matter.
(g) conveying the polymer from the reactor to a mixer through a connection between the reactor and the mixer, and (h) preparing the composition of matter by admixing, in the mixer, the polymer and one or more other components of the composition of matter.
8. The process of Claim 7 wherein the mixer is an extruder.
9. The process of Claim 7 wherein the composition of matter is a coating formulation.
10. The process of Claim 9 wherein the slurry is prepared from (i) a substance containing an average of more than one vicinal epoxy group per molecule, and/or (ii) a substance containing an average, per molecule, of more than one moiety that is reactive with the substance (i).
11. The process of Claim 10 wherein the substance (ii) is a polyhydroxyl compound.
12. The process of Claim 11 wherein the polyhdyroxyl compound is bisphenol-A.
13. The process of Claim 10 wherein, in step (h), the one or more other components admixed with the polymer is at least one member selected from: a substance that is reactive with an epoxy resin, a substance that is not reactive with an epoxy resin, a pigment, a stabilizer and a filler.
14. The process of Claim 13 wherein the substance reactive with an epoxy resin is a polyester.
15. The process of Claim 13 wherein an epoxy resin is prepared in a first reactor, and a substance that is reactive with an epoxy resin is prepared in a second reactor
16. An apparatus for preparing a composition of matter comprising:
(a) a means for providing one or more solids reactant components, (b) a means for providing one or more liquid reactant components, (c) a means for admixing the solids reactant components with the liquid reactant components to form a reactive solids-containing slurry stream, (d) a means for continuously feeding the reactive solids-containing slurry of one or more components of the composition of matter into at least one continuous reactor, (e) a continuous reactor for reacting the reactive solids-containing slurry to form a composition of matter, and (f) a means for recovering said composition of matter from said reactor.
(a) a means for providing one or more solids reactant components, (b) a means for providing one or more liquid reactant components, (c) a means for admixing the solids reactant components with the liquid reactant components to form a reactive solids-containing slurry stream, (d) a means for continuously feeding the reactive solids-containing slurry of one or more components of the composition of matter into at least one continuous reactor, (e) a continuous reactor for reacting the reactive solids-containing slurry to form a composition of matter, and (f) a means for recovering said composition of matter from said reactor.
17. An apparatus for preparing a polymer comprising:
(a) a means for providing one or more, solids monomers and/or oligomers, {b) a means for providing one ore more liquid monomers and/or oligomers, (c) a slurry vessel for continuously admixing the solids monomers and/or oligomers with the liquid monomers and/or oligomers to form a reactive solids-containing slurry stream of one or more monomers and/or oligomers, (d) at least one continuous reactor connected to said slurry vessel, said reactor adapted for continuously preparing one or more polymers by reacting the slurry of one or more monomers and/or oligomers in the reactor, (e) a means for continuously feeding the slurry into the at least one continuous reactor to form a polymer, and (f) a means for recovering said polymer from said reactor.
(a) a means for providing one or more, solids monomers and/or oligomers, {b) a means for providing one ore more liquid monomers and/or oligomers, (c) a slurry vessel for continuously admixing the solids monomers and/or oligomers with the liquid monomers and/or oligomers to form a reactive solids-containing slurry stream of one or more monomers and/or oligomers, (d) at least one continuous reactor connected to said slurry vessel, said reactor adapted for continuously preparing one or more polymers by reacting the slurry of one or more monomers and/or oligomers in the reactor, (e) a means for continuously feeding the slurry into the at least one continuous reactor to form a polymer, and (f) a means for recovering said polymer from said reactor.
18. The apparatus of Claim 17 wherein the reactor is an extruder.
19. The apparatus of Claim 17 including (g) a mixer connected to said reactor, said mixer adapted for preparing the composition of matter by admixing, in the mixer with the polymer(s) prepared in each reactor, one or more other components of the composition, and (h) a means for conveying the polymer(s) from each reactor to a mixer through a connection between each reactor and the mixer.
20. The apparatus of Claim 19 including a means for conveying the polymer(s) from each reactor to the mixer at a controlled rate.
21. The apparatus of Claim 17 wherein the polymer prepared is an epoxy resin.
22. The apparatus of Claim 19 wherein the at least one or more other components admixed with the polymer(s) is at least one member selected from :
a substance that is reactive with an epoxy resin, a substance that is not reactive with an epoxy resin, a pigment, a stabilizer and a filler.
a substance that is reactive with an epoxy resin, a substance that is not reactive with an epoxy resin, a pigment, a stabilizer and a filler.
23. The apparatus of Claim 19 wherein the mixer is an extruder.
24. The apparatus of Claim 19 including a first reactor for preparing an epoxy resin and a second reactor for preparing a substance that is reactive with the epoxy resin.
25. The apparatus of Claim 24 wherein the substance reactive with an epoxy resin is a polyester.
26. An apparatus of Claim 17 wherein the composition of matter is a coating formulation.
27. The apparatus of Claim 26 wherein the slurry is a mixture of (i) a substance containing an average of more than one vicinal epoxy group per molecule, and (ii) a substance containing an average, per molecule, of more than one moiety that is reactive with the substance (i).
28. The apparatus of Claim 27 wherein the substance (ii) is a polyhydroxyl compound.
29. The apparatus of Claim 28 wherein the polyhydroxyl compound is bisphenol-A.~
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
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US13928199P | 1999-06-15 | 1999-06-15 | |
US60/139,281 | 1999-06-15 | ||
PCT/US2000/016522 WO2000076736A1 (en) | 1999-06-15 | 2000-06-15 | Process and apparatus for preparing a composition using a slurry feed |
Publications (1)
Publication Number | Publication Date |
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CA2374889A1 true CA2374889A1 (en) | 2000-12-21 |
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ID=22485909
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
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CA002374889A Abandoned CA2374889A1 (en) | 1999-06-15 | 2000-06-15 | Process and apparatus for preparing a composition using a slurry feed |
CA002374324A Abandoned CA2374324A1 (en) | 1999-06-15 | 2000-06-15 | Process and apparatus for preparing a composition of matter utilizing an ultrasonic device |
Family Applications After (1)
Application Number | Title | Priority Date | Filing Date |
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CA002374324A Abandoned CA2374324A1 (en) | 1999-06-15 | 2000-06-15 | Process and apparatus for preparing a composition of matter utilizing an ultrasonic device |
Country Status (12)
Country | Link |
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US (2) | US6436326B1 (en) |
EP (2) | EP1196239B1 (en) |
JP (2) | JP2003502447A (en) |
KR (2) | KR20020010704A (en) |
CN (2) | CN1355738A (en) |
AR (3) | AR024360A1 (en) |
AT (1) | ATE238098T1 (en) |
AU (3) | AU5491000A (en) |
BR (2) | BR0012117A (en) |
CA (2) | CA2374889A1 (en) |
DE (1) | DE60002333T2 (en) |
WO (3) | WO2000076656A1 (en) |
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- 2000-06-14 AR ARP000102942A patent/AR024360A1/en unknown
- 2000-06-14 AR ARP000102944A patent/AR025176A1/en unknown
- 2000-06-14 AR ARP000102943A patent/AR024361A1/en unknown
- 2000-06-15 EP EP00939900A patent/EP1196239B1/en not_active Expired - Lifetime
- 2000-06-15 CA CA002374889A patent/CA2374889A1/en not_active Abandoned
- 2000-06-15 JP JP2001503226A patent/JP2003502447A/en active Pending
- 2000-06-15 KR KR1020017016097A patent/KR20020010704A/en not_active Application Discontinuation
- 2000-06-15 WO PCT/US2000/016521 patent/WO2000076656A1/en not_active Application Discontinuation
- 2000-06-15 AU AU54910/00A patent/AU5491000A/en not_active Abandoned
- 2000-06-15 WO PCT/US2000/016522 patent/WO2000076736A1/en not_active Application Discontinuation
- 2000-06-15 EP EP00939901A patent/EP1196272A1/en not_active Withdrawn
- 2000-06-15 BR BR0012117-7A patent/BR0012117A/en not_active Application Discontinuation
- 2000-06-15 AU AU54909/00A patent/AU5490900A/en not_active Abandoned
- 2000-06-15 KR KR1020017016120A patent/KR20020023957A/en not_active Application Discontinuation
- 2000-06-15 BR BR0012118-5A patent/BR0012118A/en not_active Application Discontinuation
- 2000-06-15 AT AT00939900T patent/ATE238098T1/en not_active IP Right Cessation
- 2000-06-15 CA CA002374324A patent/CA2374324A1/en not_active Abandoned
- 2000-06-15 US US09/595,041 patent/US6436326B1/en not_active Expired - Fee Related
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- 2000-06-15 CN CN00809022A patent/CN1355726A/en active Pending
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2002
- 2002-06-19 US US10/175,729 patent/US20020180099A1/en not_active Abandoned
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CN1355738A (en) | 2002-06-26 |
AR024361A1 (en) | 2002-10-02 |
JP2003502447A (en) | 2003-01-21 |
EP1196239B1 (en) | 2003-04-23 |
ATE238098T1 (en) | 2003-05-15 |
KR20020010704A (en) | 2002-02-04 |
AU5491100A (en) | 2001-01-02 |
WO2000076736A1 (en) | 2000-12-21 |
AR025176A1 (en) | 2002-11-13 |
WO2000076737A1 (en) | 2000-12-21 |
JP2003501254A (en) | 2003-01-14 |
EP1196272A1 (en) | 2002-04-17 |
CN1355726A (en) | 2002-06-26 |
AU5490900A (en) | 2001-01-02 |
BR0012118A (en) | 2002-03-12 |
AU5491000A (en) | 2001-01-02 |
BR0012117A (en) | 2002-03-12 |
CA2374324A1 (en) | 2000-12-21 |
DE60002333D1 (en) | 2003-05-28 |
US20020180099A1 (en) | 2002-12-05 |
WO2000076656A1 (en) | 2000-12-21 |
US6436326B1 (en) | 2002-08-20 |
AR024360A1 (en) | 2002-10-02 |
KR20020023957A (en) | 2002-03-29 |
DE60002333T2 (en) | 2004-02-12 |
EP1196239A1 (en) | 2002-04-17 |
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