Polymer Production

8/13/2019 Polymer Production

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Polymer Production Technology

Sulzer Chemtech


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Sulzer Chemtechs value proposition in the productionof polymers

Proven technology and proven componentsfor the production of Your Polymer

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Static mixing know how Piloting & Scale up

Process & Equipment Engineering

Production of polymers

using static mixingtechnology

Sulzer Chemtech is the worlds mostrenowned supplier of equipmentand related solutions in the fieldof static mixing. The combinationof engineering expertise and manyyears of application know-howenables Sulzer Chemtech to pro-vide global solutions for improvedpolymer product quality. All SulzerChemtech products and services

rely on a successful integration ofthree main competencies:

Static mixing know-how

Piloting & scale up

Process & equipment engineering

Creating value for thepolymer industry

The combination of static mixingknow-how, piloting and scale up,and process and equipment en-

gineering enables Sulzer Chemtechto provide customized solutions anda process guarantee. This service isgreatly linked to the availability of apiloting facility for reliable processsolutions. We offer the flexibility ofconducting piloting programs at ourown or directly at a customers site.Individual components for pilotingas well as fixed installed equipmentare at the customers disposal.Whatever the required approachmay be, Sulzer Chemtech is areliable, global partner for optimized

process solutions and relatedequipment.

The road to success

is with the customer

A history of successful projectsclearly indicates that only a teameffort involving both the customerand Sulzer Chemtech creates valuefor both partners. The customerprovides projects with insight intothe chemistry and process details,while Sulzer Chemtech providespilot testing and broad expertisein static mixing. Newly created, in-

novative solutions are protected bysecrecy agreements that safeguardthe interests of both partners andtheir respective contributions.

Global support where

and when you need it

Regardless of your geographic loca-tion or the size of your project, SulzerChemtechs global presence meansyou will have the support you need.We talk your language and under-stand your requirements equallywell for a single static mixer or fora more complex process solution.Sulzer Chemtech always providessolutions with a focus on process ef-

ficiency and the quality of polymer.


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Reaction Technology Devolatilization Technology Upgrading Technology

Sulzer Chemtech technologies

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Equipment

I Sulzer Static Mixer

II Pre-Polimerizer

III Polymerization Re-

actor

IV Condenser

V Post Polymerization

SMR Reactor

VI Mixer - Heat Exch-

Sulzer Chemtech has developedand introduced a new generation ofreactors based on the principle ofstatic mixing and on the continuousbulk polymerization, e.g. mass- andsolution polymerization. This reac-tor is abbreviated as SMR (SulzerMixing Reactor) and is character-

ized by accurate control of heattransfer and mixing effects so thathigh conversion and consistentlyhigh polymer quality are achievedtime after time in order to meet var-ied and stringent requirements.

In polymer production, devolati-lization is an important operationsince the polymerized product stillcontains a certain amount of un-reacted monomers, oligomers, sol-vents, and other impurities. SulzerChemtech has developed equip-ment specifically for the removal of

this residual material. The single ormultiple stage devolatillization proc-ess features a heat exchanger withmixer inserts, stripping agent dos-ing mixer, and uniquely designeddegassing chambers containingspecial polymer distributors. Thisequipment, with its versatile proc-ess design, does not interfere withthe polymer properties achievedduring the polymerization. It doesremove the residuals effectively inorder to meet industry and legisla-

tive requirements.

After devolatillization, additives canbe mixed into the polymer in orderto upgrade the final product. Sulzerhas years of experience in provid-ing successful upgrading solutionsfor improved product quality andprofitability. Our extensive refer-ence list includes examples of

complex applications with regard todifferences in viscosity, mixing ratioand homogeneity aspects.


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Reaction Technology

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1. Static mixing expertise . . .

. . . for plug flow reactors

A typical polymerization post-reac-tor consists of a set of SMR mod-ules built in series so that severalindividual temperature and mixingzones are available to meet thevarying process needs. As the po-lymerization process proceeds, theconversion increases and the mon-

omer concentration decreases. TheSMR reactor secures a close to ide-al plug flow regime, keeping the di-minishing driving force at the maxi-mum possible level. It also results ina narrow residence time distributionto promote homogeneous polymerquality. This advantage is main-tained throughout the spectrumof the changing polymer viscosity,even at high conversion levels.

. . . for adiabatic reactors

Efficient radial mixing effects in theSMX plug flow reactor lead to con-tinuous equalization of concentra-tion, temperature, and velocity sothat the end result is comparableto plug flow behavior. The Boden- 0604 2701

stein Numbers of 50/m, equivalentto 25 ideal stirred vessels, havebeen measured at full scale condi-tions.

. . . for loop reactor

Individual SMR reactors can beconfigured into a loop reactorand are used especially for highly

exothermic reactions. An excellentmixing characteristic of the SMRequipment ensures the optimal ho-mogenization of local concentrationand temperature gradients. Witha densely packed heat exchangesurface area, the SMR provides reli-able heat removal and temperaturecontrol of polymer bulk so optimalprocess control is maintained. As inthe common loop reactor set-ups,virgin monomer is continuouslyintroduced to the loop while thesemi finished polymer is drained

and conveyed to the downstreampost-reactor system.

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Sulzer Chemtech has developed a new generation ofreactors based on the principle of static mixing andon the continuous bulk polymerization, e.g. mass- andsolution polymerization. This reactor is abbreviated asSMR (Sulzer Mixing Reactor) and is characterized by

accurate control of heat transfer and mixing effectsso that high conversion and consistently high polymerquality are achieved reproducibly in order to meet var-ied and stringent requirements.


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Reaction Technology

2. Process & equipment engineering

Typical examples are:

The effect of liquid viscosity onmixing, heat transfer and reac-tor performance

The hydraulic behaviour of chem-icals and products in mixing andreaction equipment

The reaction kinetics

Devolatilization

High pressure dosing

4. Advantages at a glance

Improved Product Quality: Plug ow prole results in narrow

residence time temperature distri-bution with positive impact onthe molecular weight distribution

No channelling / no maldistribu-tion and dead zones

High Flexibility in Production

A variety of polymer grades can beproduced in one single line due to

exact and independent processtemperature adjustment of

respective reactor zones

the capability of processing uidswith a wide range of viscosities

Lower Operating Cost due to:

reduced consumption of rawmaterial (high conversion rate)

prevention of large quantity ofoff-spec product during productgrade switch

reduced energy requirements(minimum hydraulic pressure loss,lack of agitator)

fast self cleaning and start-upprocedure

Typical applications for SMRand SMX reactors

Polystyrene, GPPS, HIPS Styrenics copolymers,

ABS/SAN

Polymethylmethacrylate PMMA

Polyethylene, PE

Silicon polymers

Polypropylene PP chain regula-tion

Polyamide 6 PA6

Terpene resins

Polyoxymethylene POM and

Biodegradable polymers

HTM

HTM

Product

Pilot skit

Heat transfer capacity of various type ofreactors for laminar flow

Cutaway of the Sulzer SMR reactor

1 Sulzer SMR2 Monotube with static mixer3 Empty pipe

4 Stirred tank5 Extruder

The heat transfer capacity of the Sulzer SMRreactor is practically independent of the volume

of the equipment.Q = Heat flow (kW)T = Temperature difference (C)V = Volume (m)

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(kW/m3

C)

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The Sulzer Mixer Reactor (SMR) is adevelopment based on many yearsof testing and experience with

smaller mixers used in a variety ofviscous applications. The intersec-ting bars encountered in static mix-ers are suitably replaced by tubularbundles which are adapted to thespecific process and mechanicalrequirements of each application.This layout of tubes, similar to astatic mixer, induces a product flowon the shell side that continuouslytranspositions the liquid layers ina regular and repeatable patternand suppresses the development

of laminar layers. This effect com-bines well with an extraordinarilyhigh surface area per unit volume

of equipment, and makes theSMR one of the highest performingreactor/heaters in the industry.

A performance comparison isshown in the table below.

3. Piloting & scale up

In most cases data like physicalproperties, phase behavior andoperating problems are not read-ily available for reliable processand equipment design. SulzerChemtech maintains world class fa-cilities for testing of mixing effects,heat transfer, polymerization reac-tions and devolatilization in orderto secure reliable equipment designand desired process performance.Individual key equipment and pilotplant subsystems make it possibleto tailor pilot configurations to veryspecific requirements.


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Devolatilization Technology

1. The concept of low residual volatile content

2. Process and equipment design

First stage

The first devolatilization stage consists of the multi-tube heat exchanger with mixer inserts, followed bya specially designed vacuum flash chamber. The heatexchanger secures rapid and controlled heating of thepolymer solution without notable damage to the poly-mer properties. The separation of the residual volatilesfrom the polymer is carried out in the flash vessel. Thede-gassed volatiles are led to a column for the separa-tion of the oligomers. The polymer is discharged fromthe bottom section from the devolatilization chamberby a gear pump with special inlet section design. Fromthere, the polymer is forwarded either to the next devol-atilization stage or to the pelletizing unit.

Why a multitube heat exchanger with mixer inserts?Unlike common multitube heat exchangers, SulzersSMXL mixer inserts induce a hydraulic regime in a pre-vailing laminar application that is close to turbulent. Theparabolic gradients of temperature and liquid velocityacross the tube diameter are successfully prevented.Sulzers heater design is characterized by greatly re-duced temperature differences required for the trans-fer of energy from heating medium to bulk fluid, by auniform residence time distribution, and by an overallshorter residence time.

In the production of polymers devolatilization is an im-portant unit operation since the polymerized productstill contains a certain amount of un-reacted mono-

mers, oligomers, solvents and other impurities. Forthe purpose of removal of residual materials, SulzerChemtech has developed equipment and a processconcept based on its vast experience in static mixing.The single or multiple stage devolatilization process

features a heat exchanger with mixer inserts, a strip-ping agent dosing mixer, and uniquely designed degas-sing chambers containing special polymer distributors.

Combined with a versatile process design, this equip-ment removes the residuals effectively, but does notinterfere with the polymer properties achieved duringthe polymerization.

Devolatilization Technology (First stage)

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Equipment


II Pre-Polimerizer


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Devolatilization Technology

Final stage

Polymer solution, coming either from the polymerizationprocess or from the preceding devolatilization stage, ispassed to the final stage. The special treatment in this

stage involves the use of stripping agent to intensifythe release of remaining volatiles. The stripping agentcould be water, nitrogen, CO2, etc., depending on theapplication. The mixture of the polymer solution andthe chosen stripping agent are flashed in the 2nd stagevacuum chamber, from where the finished polymer isdischarged again by the special gear pump. The re-leased volatiles and the stripping agent are recoveredin a downstream distillation unit.

Typical applications of polymer devolatilization

Polystyrene, GPPS, HIPS

Styrene copolymer, ABS/SAN

Polyethylene, HDPE, LLDPE

Polyvinylacetate, PVAC

Polyethylacrylat

Polyisobutylene

Polycarbonate, PC

Polyetherglycole, PEG

Polyoxymethylene, POM

Polyisobutylene, PIB

Elastomer, EPM, EPDM

Biodegradable polymers

Why devolatilization with a stripping agent?

The static mixer ensures the dispersion of stripping

agent into the polymer solution which turns into afoam-like phase prior to entering the sub-atmosphericdevolatilization chamber. The special effect of this foamis in the reduction of the diffusion path for the volatilesso that the entire process of mass transfer is signifi-cantly intensied. For example. Devolatilization utilizinga stripping agent allows for consistent depletion ofvolatiles from polystyrene melt down to residue contentof 100 200 ppm. Subject to pilot test confirmation, fullprocess guarantees are backing our scope of supply.Sulzer Chemtech can perform devolatilization tests fornew or untested polymers in order to specify the proc-ess and supply the guarantees.

3. Piloting & scale-up

Alike in section Reaction Technology data like physicalproperties, phase behavior and operating problems are

not readily available to perform reliable process andequipment design. In Sulzer Chemtechs testing facilityfor mixing effects, heat transfer, polymerization reac-tions and devolatilization, test set-ups can be tailoredto specic requirements. Devolatilization results areincorporated into the design of industrial size applica-tions with related guaranteed performance.


Investment

The capital cost is comparatively moderate due to theunique process concept and equipment without mov-ing parts.

Operating Cost:

reduced electrical power consumption as the resultof the absence of heavy rotating equipment, e.g.extruder etc.

reduced mechanical maintenance

Product Quality

Reduced polymer degradation due to:

the prevention of damage to the polymer morpho- logy by avoiding exposure to high shear forces

the prevention of elevated process temperature byusing efficient heat transfer equipment

very low residue contentLegende zu PFD

Equipment


II Pre-Polimerizer

III Polymerization Re-

Devolatilization Technology (Second stage)

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Upgrading Technology

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1. The static mixer as key to success

After the removal of un-reacted and inert materialsthrough devolatillization, the subsequent upgradingcommonly involves the admixing of additives or dye

to the polymer. Sulzer has many years of experiencein providing complete solutions for improved productquality and profitability for this finishing process. Wemaintain an extensive reference list with examples ofcomplex applications with regard to viscosity, mixingratio and homogeneity aspects.

2. Process and equipment design

Admixing of additives into polymer products is per-formed in various hydraulic regimes ranging fromlaminar to transitional and turbulent. The polymeradditive mixing ratio defines the degree of mixingcomplexity, which ranges from fair to very demanding.Sulzer Chemtechs static mixing technology is basedon equipment with open intersecting channels whichare formed by uniquely arranged corrugated platesand bars. The mixing action itself is achieved by thecontinuous splitting, extension and transposition ofthe component streams. Successive mixing elementsare rotated by 90 to ensure that local homogeneity isequalized over the entire pipe cross section.

3. Piloting and scale-up

In some applications, solubility of additives in the poly-mer may not be known to the extent needed for reliabledesign. Since this property is of utmost importancefor homogeneity and uniform product quality, SulzerChemtech has the capability of performing testing tai-lored to the specific project requirement and customerobjectives.

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Following are some of the most common applicationsfor admixing of low viscous and semi-soluble additivesin polymers where testing has provided reliable designdata:

UV- stabilizers

antistatic agents

antioxidants

mould release agents

mineral oil etc.

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Sulzer Chemtech patented side stream mixing system


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Upgrading Technology


Investment

Compared to dynamic mixing equipment like extruders,Sulzer static mixing solutions are significantly lower incost.

Operating Cost:

Cost related to maintenance of mixer is non-existent

Product Quality

Prevention of polymer degradation due to lowshear force

High and continuous homogeneity of additive enri-ched polymer

Typical applications for Sulzer static mixer

Admixing of additives

UV-stabilizers

Antistatic agents Antioxidants

Mould release agents

Mineral oil etc.

Monomers like AN, SM, AM

Solvents like EB, chlorobenzene, methylene- chlorid

Colorant

Masterbatch

Polymer industries using Sulzer static mixer

Polystyrene, GPPS, HIPS Styrenic copolymers, ABS/SAN

Polymethylmethacrylate PMMA

Polyethylene, PE (LLDPE, LDPE, HDPE)

Silicon polymers and elastomers

Cellulose bre

Polyethylene terephthalate PET

Polyamide PA, PA6

Viscose

Polycarbonate PC

Polypropylene PP

Terpene resins

Polyoxymethylene POM

Biodegradable Polymers

PBTP, PB, PBS, PIB etc.

PUR

Teon

Adhesives

Special polymers as additives for concrete or forother polymers

All kind of polymers in solution or asco-polymers

others

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LIF principle and set-up

Section of pilot plant for polymer production


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Further activity related to polymers and static mixing

Heat exchange

Especially with regard to high viscous

components Sulzer Chemtech acquired

and developed a wide range of expertise

in the field of exchange of thermal energy.Equipment concepts and designs derived

from this expertise are characterised by

short residence time and homogeneous

bulk temperature. All properties ensure

that the medium being subject to heating/

cooling is processed in a careful manner

which in turn means no degradation of

product quality. Heat exchange equipment

from Sulzer Chemtech is successfully installed in the following industries

* Polymer Production

* Polymer Processing

* Production of synthetic fibres

Typical applications:

Heating and Cooling of polymer and polymer- solutions.

Mixing and removing of exothermic heat during

reaction. Melt viscosity adjustement by temperature

variation to obtain optimal process conditions.

Cooling polymer melts before granulation toraise the viscosity.

Cooling polymer melts before lling plants toavoid thermal damage to packing material

Cooling polyester melts between polyconden-sation and spinning step.

Typical applications:

* Heating and Cooling of polymer and poly-mer-solutions.

* Mixing and removing of exothermic heat

during reaction.

* Melt viscosity adjustement by tempera-

ture variation to obtain optimal process

Multitube mixer-heat exchanger with removable SMXL mixingelements

SMR plug flow reactor and heat exchanger

SMXL Static mixer-heat exchanger

The product-conveying inner tubes are filled with staticmixing elements, creating a radial mixing effect. The re-sult is a considerably increased heat transfer and a nar-

row residence time distribution, making is possible toachieve a short residence time. A continuous renewalof the thermal boundary layer on the piping wall pre-vents thermal damage of heat sensitive products.

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Sulzer has developed a unique technology for the production of EPS thatis based on the advantages of static mixing and continuous operation. Inthis versatile path of production blowing agent, e.g. pentane is continu-

ously dosed in a bulk ow of crude polystyrene. Homogeneous mixing andtemperature conditioning is taking place prior to the pelletization of prod-uct. EPS grades manufactured with Sulzer technology can be further proc-essed as with any other commercially available EPS grade.

The fact that Sulzers EPS technology can be applied to a wide range ofpolystyrene grades (HIPS, GPPS), this technology has clearly proven itsindustrial viability and acceptance. Some of the technologys characteris-tics are:

Wide range of polystyrene grades can be converted into EPS pellets

Flexibility in producing specialty grades e.g. colored beads, varyingblowing agents, flame retardants and additives

Virtually zero emissions such as blowing agent and waste water,resulting in high operating safety and low production cost

Technology for expandable polystyrene (EPS)

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Further activity related to polymers and static mixing

EPS production unit


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Distributed by:

Legal Notice: The information contained in this publication is believed to be accurate and reliable but is not to be construed as implying any

The activity program comprises:

Process components such as fractionation trays, structured and ran-

dom packings, liquid and gas distributors, gas-liquid separators, and

internals for separation columns

Engineering services for separation and reaction technology such as

conceptual process design, feasibilities studies, plant optimizations in-

cluding process validation in the test center

Recovery of virtually any solvents used by the pharmaceutical and

chemical industry, or difficult separations requiring the combination of

special technologies, such as thin film/short-path evaporation, distilla-

tion under high vacuum, liquid-liquid extraction, membrane technology

or crystallization.

Complete separation process plants, in particular modular plants

(skids)

Advanced polymerization technology for the production of PLA and

EPS

Tower eld services performing tray and packing installation, tower

maintenance, welding, and plant turnaround projects

Mixing and reaction technology with static mixers

Cartridge-based metering, mixing and dispensing systems, and dis-

posable mixers for reactive multi-component material

Sulzer Chemtech Ltd, a member of the Sulzer Corporation, with headquar-

ters in Winterthur, Switzerland, is active in the field of process engineering

and employs some 4000 persons worldwide.

Sulzer Chemtech is represented in all important industrial countries and

sets standards in the field of mass transfer and static mixing with its ad-

vanced and economical solutions.

www.sulzer.com

Please check for your local contact

Documents

Polymer Production