EP1996632A2 - Système de réacteurs pour la production de polystyrène choc - Google Patents

Système de réacteurs pour la production de polystyrène choc

Info

Publication number
EP1996632A2
EP1996632A2 EP07753329A EP07753329A EP1996632A2 EP 1996632 A2 EP1996632 A2 EP 1996632A2 EP 07753329 A EP07753329 A EP 07753329A EP 07753329 A EP07753329 A EP 07753329A EP 1996632 A2 EP1996632 A2 EP 1996632A2
Authority
EP
European Patent Office
Prior art keywords
reactor
flow reactor
high impact
linear flow
impact polystyrene
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.)
Withdrawn
Application number
EP07753329A
Other languages
German (de)
English (en)
Other versions
EP1996632A4 (fr
Inventor
Doug Berti
Jay Reimers
Thanh Nguyen
Aron Griffith
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Fina Technology Inc
Original Assignee
Fina Technology Inc
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Priority claimed from US11/384,737 external-priority patent/US7488774B2/en
Application filed by Fina Technology Inc filed Critical Fina Technology Inc
Publication of EP1996632A2 publication Critical patent/EP1996632A2/fr
Publication of EP1996632A4 publication Critical patent/EP1996632A4/fr
Withdrawn legal-status Critical Current

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F279/00—Macromolecular compounds obtained by polymerising monomers on to polymers of monomers having two or more carbon-to-carbon double bonds as defined in group C08F36/00
    • C08F279/02—Macromolecular compounds obtained by polymerising monomers on to polymers of monomers having two or more carbon-to-carbon double bonds as defined in group C08F36/00 on to polymers of conjugated dienes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J19/24—Stationary reactors without moving elements inside
    • B01J19/2415—Tubular reactors
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L51/00—Compositions of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers
    • C08L51/04—Compositions of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers grafted on to rubbers

Definitions

  • the present invention relates generally to polymer synthesis and more particularly to the synthesis of high impact polystyrene using a combination of continuously stirred tank reactors and plug flow reactors.
  • Elastomer-reinforced polymers of monovinylidene aromatic compounds such as styrene, alpha-methylstyrene and ring-substituted styrene have found widespread commercial use.
  • elastomer-reinforced styrene polymers having discrete elastomer particles such as cross-linked rubber dispersed throughout the styrene polymer matrix can be useful for a range of applications including food packaging, office supplies, point-of-purchase signs and displays, housewares and consumer goods, building insulation and cosmetics packaging.
  • HIPS high impact polystyrene
  • Methods for the production of polymers typically employ polymerization using a continuous flow process.
  • Continuous flow processes may involve a plurality of serially arranged reaction vessels wherein the degree of polymerization increases from one vessel to the next.
  • Factors such as the arrangement of the reaction vessels and the reaction conditions influence the characteristics of HIPS produced.
  • Different grades of HIPS may have differing elastomer content and extents of polymerization within each reactor resulting in differing mechanical and/or optical properties.
  • a continuous process for producing high impact polystyrene comprising feeding at least one vinyl aromatic monomer, an elastomer, and a free radical initiator to a first linear flow reactor to form a reaction mixture, polymerizing the reaction mixture in said linear flow reactor to at least the phase inversion point of the mixture, and feeding the reaction mixture from the first linear flow reactor to a second reactor for post-inversion polymerization of the mixture.
  • a method of producing a elastomer-reinforced polymer comprising inverting a reaction mixture comprising at least one vinyl aromatic monomer, an elastomer, and a free radical initiator in a plug flow reactor.
  • a high impact polystyrene reactor system comprising a linear flow reactor having an inlet for receiving at least one vinyl aromatic monomer, an elastomer, and a free radical initiator and an outlet for conveying a reactor effluent, and a continuously stirred tank reactor having an inlet in fluid communication with the linear flow reactor outlet and receiving the effluent from the linear flow reactor.
  • Figure 1 is a schematic representation of an apparatus for HIPS production.
  • Figure 2a is a diagram of a linear flow reactor.
  • Figure 2b is a cross-sectional view of an internal reactor cooling component.
  • FIG. 1 A schematic representation of a reactor system 100 for the continuous production of a elastomer-reinforced polymer is given in Figure 1.
  • reactor system 100 is useful for a continuous HIPS production process.
  • a reaction mixture comprising styrene, an elastomer such as polybutadiene rubber, and a free radical initiator may be fed to a polymerization reactor 10, through a feed line generally indicated at 5.
  • the reaction mixture comprises styrene, an elastomer such as polybutadiene rubber, a chain transfer agent and additional components such as those known in the art for the production of HIPS.
  • the reaction mixture comprises styrene, an elastomer such as polybutadiene rubber, a combination of a free radical initiator and chain transfer agent and additional components such as those known in the art for the production of HIPS.
  • a free radical initiator and chain transfer agent and additional components such as those known in the art for the production of HIPS.
  • the nature and amount of free radical initiator, chain transfer agent and additional components for the production of HIPS may be included as known to one of ordinary skill in the art.
  • Such a feed line may allow for introduction of the reaction mixture through the bottom of the reactor, as shown in Figure 1, alternatively such a feed line may allow for introduction of the reaction mixture through the top of the reactor, alternatively through any position along the reactor vessel that is compatible with the reaction mixture and the reactor equipment.
  • a reaction mixture for introduction to the PFR may comprise from about 75% to about 99% styrene, from about 1% to about 15% polybutadiene, from about 0.001% to about 0.2% free radical initiator and additional components as needed to impart the desired physical properties.
  • the percent values given are percentages by weight of the total composition.
  • styrene includes a variety of substituted styrenes (e.g., alpha-methyl styrene), ring- substituted styrenes such as p-methylstyrene as well as unsubstituted styrenes.
  • the polymerization reactor 10 may be a linear-flow reactor, such as a plug flow reactor (PFR) shown in more detail in Figure 2a.
  • PFR plug flow reactor
  • the polymerization reactor 10 is arranged vertically as shown in Figure 1.
  • the polymerization reactor 10 is arranged horizontally in the apparatus.
  • Polymerization reactor 10 may be operated under conditions that allow the polymerization reaction to proceed to at least the point of phase inversion before the reaction mixture is introduced to any additional polymerization reactors.
  • PFIR plug flow inversion reactor
  • the reactants in polymerization reactor 10 undergo phase inversion prior to exiting the reactor, referred to here after as PFIR 10.
  • Phase inversion refers to a morphological transformation that occurs during the preparation of HIPS.
  • HIPS preparation involves the dissolution of polybutadiene rubber in styrene that is subsequently polymerized.
  • a phase separation based on the immiscibility of polystyrene and polybutadiene occurs in two stages. Initially, a mixture of styrene and polybutadiene forms the major or continuous phase with a mixture of polystyrene and styrene dispersed therein.
  • the PFIR 10 may contain agitators 14 driven by a motor 12. Such agitators may promote radial dispersion of the reactants but are not intended to provide axial mixing so as to minimize backmixing in the reactor.
  • agitators 14 driven by a motor 12. Such agitators may promote radial dispersion of the reactants but are not intended to provide axial mixing so as to minimize backmixing in the reactor.
  • a similar linear flow reactor design has been disclosed in U.S. Patent Application Serial No. 11/384,596 [Arty. Docket No. COS-1038 (4176-00901)] filed concurrently herewith entitled "Horizontal Boiling Plug Flow Reactor," which is incorporated by reference herein.
  • FIG. 2a As polymerization reactions are highly exothermic, means are required to control the temperature in the reaction vessel as the polymerization proceeds.
  • heat is removed through internal cooling coils in the PFDR.
  • Figure 2b is a cross-sectional view of an internal cooling coil taken along line A-A in Figure 2a.
  • arrow 1 indicates the reaction process flow in the PFIR, which is an upward flow of reactants in a vertical reactor, as shown in Figure 1, but with the further understanding that reactor orientation and flow direction can vary as discussed previously.
  • the PFER 10 may be a dual wall reactor having an inner wall 101 and outer wall 102.
  • Outer flow channels 105 are disposed between the inner and outer walls such that a coolant, such as thermal oil, may be introduced to the PFER 10 at inlet ports to the internal cooling coils shown as 3, 7 and 9. The coolant may then circulate throughout the reactor cooling coils and exit the system through the outlet ports 11, 13 and 17. Inner flow channels 106 of the cooling coil may traverse the breadth of the reactor and connect the outer flow channels 105. Coolant flowing through the internal cooling coils functions as a heat exchanger that enables the removal of excess heat from the polymerization reaction. [0022] Referring again to Figure 1, the apparatus may further comprise an additional polymerization reactor, 20, located downstream of polymerization reactor 10. Output from polymerization reactor 10 may be fed to polymerization reactor 20 via line 15.
  • a coolant such as thermal oil
  • polymerization reactor 20 is a continuously stirred tank reactor (CSTR) having an agitator 18 driven by a motor 16.
  • CSTR continuously stirred tank reactor
  • the polymerization of styrene to polystyrene may continue with the output from polymerization reactor 20 being fed to additional polymerization reactors, 30 and 40, via lines 25 and 55, respectively.
  • reactors 30 and 40 may be linear-flow reactors, such as a plug flow reactors, that may also be equipped with agitators 22 and 26 driven by motors 24 and 28, respectively.
  • the two linear flow reactors 30 and 40 are horizontally oriented and serially connected to polymerization reactor 20 with increased polymerization occurring in each subsequent reactor.
  • reactor system 100 may comprise any number of additional reactors downstream of reactor 20 (e.g., CSTR 20) as desired by the user.
  • the number, orientation (e.g., horizontal or vertical), and connectivity (e.g., serial or parallel) of the linear flow reactors may be determined by one skilled in the art based on requirements such as production capacity required or extent of product conversion desired.
  • the resultant HIPS polymer and any other remaining compounds may be removed from the final reactor, e.g., reactor 40, via line 75, and thereafter the HIPS polymer may be recovered and optionally further processed, such as pelletized.
  • unreacted styrene monomer and other volatile residual components may exit any of the reactors or downstream processing equipment (not shown) as a recycle stream.
  • a recycle stream may be recovered from any downstream reactor and returned to any one or more suitable upstream reactors.
  • a recycle stream exiting a separation device downstream of reactor 40 may be returned upstream to polymerization reactor 20 at line 45.
  • a recycle stream exiting polymerization reactor 30 may be returned upstream to polymerization reactor 20 via line 35.
  • a recycle stream exiting polymerization reactor 40 may be returned upstream to polymerization reactor 30 via line 65.
  • the recycle stream undergoes recycle treatment designed to increase the purity of the recycle components, e.g., styrene, before being reintroduced to a reactor. Methods, conditions and apparatuses for carrying out recycle treatments are known to one of ordinary skill in the art.
  • the HIPS produced by the disclosed apparatus and process configuration has a reduced rubber (e.g., polybutadiene rubber) content while having similar or enhanced mechanical and/or optical properties when compared to a HIPS produced using a conventional process configuration and apparatus.
  • a conventional process configuration and apparatus may employ two CSTRs (i.e., reactors 10 and 20 in Figure 1) as the first and second polymerization reactors prior to feeding the reaction mixture to some number of linear flow reactors (i.e., reactors 30 and 40 in Figure 1).
  • the rubber content of the HIPS produced by the disclosed apparatus and process configuration is reduced by equal to or greater than about 5%, alternatively about 10%, but has similar or enhanced mechanical and/or optical properties when compared to HIPS produced by a conventional process configuration and apparatus.
  • HIPS having a reduced rubber content will be denoted rHIPS while HIPS produced using a conventional process configuration and apparatus will be denoted nfflPS.
  • the rHIPS may display an impact strength similar to or improved in comparison to nHEPS when using standard tests of impact strength such as the Izod impact and falling dart test. Izod impact is defined as the kinetic energy needed to initiate a fracture in a specimen and continue the fracture until the specimen is broken.
  • Tests of the Izod impact strength determine the resistance of a polymer sample to breakage by flexural shock as indicated by the energy expended from a pendulum type hammer in breaking a standard specimen in a single blow.
  • the specimen is notched which serves to concentrate the stress and promotes a brittle rather than ductile fracture.
  • the Izod Impact test measures the amount of energy lost by the pendulum during the breakage of the test specimen.
  • the energy lost by the pendulum is the sum of the energies required to initiate sample fracture, to propagate the fracture across the specimen, and any other energy loss associated with the measurement system (e.g., friction in the pendulum bearing, pendulum arm vibration, sample toss energy).
  • the rHIPS of this disclosure has an Izod impact strength of 1.5 ft.lb/inch to 3.5 fUb/inch, alternatively, 2 ft.lb/inch to 3 ft.lb/inch, alternatively 2.8 ft.lb/inch.
  • the falling dart impact test is also a standard test of polymer impact resistance. Specifically, it is the energy required to rupture a film. The test is conducted by determining the weight of a dart dropped from a height of 26 inches that causes 50% of the samples to break.
  • the rHIPS of this disclosure has a falling dart impact strength of 4Og to 20Og, alternatively, of greater than 10Og.
  • the rHIPS may also display ductile properties such as bend or elongation similar to or improved in comparison to that of nHIPS.
  • Ductile properties such as bend or elongation indicate the ability of a material to deform elastically until a fracture or break point.
  • the elongation of a polymer sample is typically given as the percent elongation, which refers to the length the polymer sample is after it is stretched (L), divided by the original length of the sample (LO), and then multiplied by 100.
  • the bend of a polymer sample refers to the number of times a specimen constructed of the polymeric material may be bent before it fractures.
  • the rHIPS of this disclosure has a bend of 10 to 150, alternatively, 20 to 90, alternatively, 70 and an elongation of 2% to 80%, alternatively, 40% to 70%, alternatively 70%.
  • a high impact polystyrene was produced using a polymerization reactor configuration as disclosed herein and depicted in Figure 1.
  • the mechanical and optical properties of this high impact polystyrene material produced using the disclosed reactor system of Figure 1 was compared to that of high impact polystyrene material produced by a standard apparatus and process configuration having the first two reactors as CSTRs (e.g., reactor 10 replaced with a CSTR in Figure 1).
  • the high impact polystyrene material produced by a standard apparatus and process configuration has typical properties as set forth in Table IA and is a high impact strength resin that is suitable for applications such as custom sheet extrusion or thermoforming, printing surfaces and packaging.
  • Trial 1 Four experimental trials were conducted using variations in reagents and/or process configurations of the reactor system of Figure 1.
  • a standard HIPS- type reactant feed given in Table IB, was introduced to the PFIR and reacted to produce HIPS.
  • TAKTENE 380/550 are butadiene rubbers commercially available from Lanxess.
  • Trial 2 was similar to Trial lwith the exception that a different free radical initiator was used and the rubber type was all TAKTENE 550. Low rubber conditions, 6% and 5.5%, were also run in this trial.
  • Trial 3 had similar reaction conditions to Trial 1 however the process was configured such that recycling of unreacted styrene and volatile monomers occurred at different reactors than in previous trials.
  • Trial 4 was similar to Trial 3 however DEENE 70 rubber manufactured by Firestone was used in place of TAKTENE rubber and a low rubber condition, 5.5%, was also run in this trial. Table IB
  • Table 3 compares the physical properties of HIPS produced in Trials 2 and 4 under low rubber conditions. Samples from Trial 2 were run using either 5.5% or 6% rubber as indicated. The physical properties were determined in accordance with the appropriate ASTM method given in parentheses. Table 3

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  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Health & Medical Sciences (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Graft Or Block Polymers (AREA)
  • Polymerisation Methods In General (AREA)

Abstract

L'invention concerne un procédé continu de production de polystyrène choc consistant à charger au moins un monomère vinylaromatique, un élastomère et un initiateur de radicaux libres dans un premier réacteur à écoulement linéaire pour former un mélange réactionnel, à polymériser le mélange réactionnel dans ce réacteur à écoulement linéaire au moins au point d'inversion de phase dudit mélange et à acheminer ce mélange réactionnel du premier réacteur à écoulement linéaire vers un second réacteur pour la polymérisation post-inversion dudit mélange. Un procédé de production d'un polymère renforcé par élastomère consiste à inverser un mélange réactionnel contenant au moins un monomère vinylaromatique, un élastomère et un initiateur de radicaux libres dans un réacteur piston. L'invention concerne également un système de réacteurs pour polystyrène choc qui comprend un réacteur à écoulement linéaire, pourvu d'une entrée et d'une sortie, ainsi qu'un réacteur-cuve agité en continu, pourvu d'une entrée en communication fluidique avec la sortie du réacteur à écoulement linéaire et recevant un effluent du réacteur à écoulement linéaire.
EP07753329A 2006-03-20 2007-03-16 Système de réacteurs pour la production de polystyrène choc Withdrawn EP1996632A4 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US11/384,737 US7488774B2 (en) 2005-12-21 2006-03-20 Reactor system for the production of high impact polystyrene
PCT/US2007/006694 WO2007109167A2 (fr) 2005-12-21 2007-03-16 Système de réacteurs pour la production de polystyrène choc

Publications (2)

Publication Number Publication Date
EP1996632A2 true EP1996632A2 (fr) 2008-12-03
EP1996632A4 EP1996632A4 (fr) 2010-06-02

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Family Applications (1)

Application Number Title Priority Date Filing Date
EP07753329A Withdrawn EP1996632A4 (fr) 2006-03-20 2007-03-16 Système de réacteurs pour la production de polystyrène choc

Country Status (3)

Country Link
EP (1) EP1996632A4 (fr)
CN (1) CN101405313B (fr)
CA (1) CA2642953A1 (fr)

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN108671867A (zh) * 2018-06-06 2018-10-19 博立尔化工（扬州）有限公司 一种制备固体丙烯酸树脂的设备及其方法
IT201800006303A1 (it) 2018-06-14 2019-12-14 Configurazione di reazione e procedimento per la produzione di polimeri
CN114395067B (zh) * 2022-01-29 2023-12-01 上海希尔吾新材料科技发展有限公司 工业规模级高性能高抗冲聚苯乙烯生产装置及生产工艺

Citations (5)

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Publication number Priority date Publication date Assignee Title
US2727884A (en) * 1953-04-13 1955-12-20 Dow Chemical Co Process of mass polymerization in vertical unmixed strata
WO1997039040A1 (fr) * 1996-04-12 1997-10-23 The Dow Chemical Company Procede bimodal simplifie
WO1998032797A1 (fr) * 1997-01-24 1998-07-30 The Dow Chemical Company Polymeres contenant des caoutchoucs hautement greffes
WO2001094434A1 (fr) * 2000-06-02 2001-12-13 Dow Global Technologies Inc. Polymeres aromatiques de monovinylidene a resistance et rigidite ameliorees et leur procede de preparation
WO2006124297A2 (fr) * 2005-05-13 2006-11-23 Fina Technology, Inc. Reacteur a flux piston et polymeres obtenus avec ce reacteur

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US3903202A (en) * 1973-09-19 1975-09-02 Monsanto Co Continuous mass polymerization process for polyblends
US5747593A (en) * 1993-07-14 1998-05-05 Nippon Steel Chemical Co., Ltd. Process for producing rubber-modified styrene resin
US5414045A (en) * 1993-12-10 1995-05-09 General Electric Company Grafting, phase-inversion and cross-linking controlled multi-stage bulk process for making ABS graft copolymers

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2727884A (en) * 1953-04-13 1955-12-20 Dow Chemical Co Process of mass polymerization in vertical unmixed strata
WO1997039040A1 (fr) * 1996-04-12 1997-10-23 The Dow Chemical Company Procede bimodal simplifie
WO1998032797A1 (fr) * 1997-01-24 1998-07-30 The Dow Chemical Company Polymeres contenant des caoutchoucs hautement greffes
WO2001094434A1 (fr) * 2000-06-02 2001-12-13 Dow Global Technologies Inc. Polymeres aromatiques de monovinylidene a resistance et rigidite ameliorees et leur procede de preparation
WO2006124297A2 (fr) * 2005-05-13 2006-11-23 Fina Technology, Inc. Reacteur a flux piston et polymeres obtenus avec ce reacteur

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
See also references of WO2007109167A2 *

Also Published As

Publication number Publication date
CA2642953A1 (fr) 2007-09-27
CN101405313A (zh) 2009-04-08
EP1996632A4 (fr) 2010-06-02
CN101405313B (zh) 2011-02-09

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