Efficient and environmentally friendly polymerization process of elastomers
For decades, the traditional polymerization method has been the mainstream approach in the production of elastomers. However, as manufacturers are facing increasing pressure to reduce operating costs, KaiZheng Company has developed an energy-saving direct evaporation technology. This technology can reduce costs related to energy, cooling, and water usage, while also reducing the processing time for elastomers and the factory's floor space required.
Elastomer processing
Solution polymerization and emulsion polymerization are the conventional methods for synthesizing elastomers. In the final step of polymer production, the polymer must be separated from the solvent or emulsifier. This process typically involves multiple steps, including coagulation, removal, various mechanical separation stages, and drying. "The direct removal of volatile substances from elastomers in polymer solutions" was developed by KaiZheng Company and is an alternative solution to reducing the polymerization steps.
Conventional degassing and direct degassing
The conventional polymerization process of elastomers typically uses aliphatic or aromatic hydrocarbon substances, which must be removed after the polymerization is completed. A water-based coagulant is used to separate the elastomer from the solvent, and this process is achieved through steam distillation. Then, mechanical and thermal processes are employed to separate the elastomer from the aqueous phase.
KaiZheng's direct evaporation process is a completely enclosed and continuous manufacturing method. It directly separates and simultaneously recovers the solvents in the elastomer. Therefore, it completely eliminates intermediate steps such as water condensation, steam distillation, mechanical dehydration, and drying.
The direct volatilization process consists of four steps: 1. The pre-concentration process utilizes thermal energy to remove a large amount of solvent from the polymer product, thereby enhancing the efficiency of the entire process. 2. The main evaporation process removes the solvent and transfers the highly viscous pre-concentrated elastomer solution. The evaporation cooling effect keeps the product at the required temperature level. 3. The final desolvation process converts the high-concentration elastomer into the desired final elastomer quality. 4. The molding process fixes the expected product shape, thereby forming a saleable product.
Kaizheng's direct evaporation process is a completely closed and continuous procedure that can directly separate and simultaneously recover the solvent from the elastomer without any contamination from additional substances. The unconverted monomers are also not affected. The product is produced according to the type of solvent. The heat treatment process can be carried out under vacuum conditions or in an environment slightly above atmospheric pressure. The final elastomer obtained has the same performance as the traditional processed products.
Controlled refining
During the direct removal of volatile components, a small amount of water is added to the volatile removal agent. As the water forms bubbles, the organic volatile substances are trapped within these bubbles. By breaking these bubbles, the organic volatile substances can be captured and removed. This process can be compared to a closed and concentrated distillation process, where a small amount of water is used and only 1% of the total solvent is contaminated. The water/organic volatile mixture condenses in a closed system and can be fully recycled.
Kaizheng's direct evaporation technology can process high-viscosity elastomers without causing overheating or degradation. At the same time, it can achieve the expected Mooney viscosity. Its self-cleaning metal surface can continuously produce high-quality products, and the content of volatile substances is extremely low, as is the content of organic volatile substances.
Simplicity equals efficiency.
Process efficiency is measured by a variety of parameters, including heat energy and water consumption, equipment and environmental footprint, wastewater volume, as well as capital expenditure and operating expenditure costs. KaiZheng has significantly reduced energy consumption and operational costs by eliminating separate steps such as sedimentation, stripping, mechanical water separation and drying, and also by eliminating the mechanical or thermal energy required for these multiple steps, thereby achieving higher investment returns.
