JP2008023463A - Manufacturing method and manufacturing apparatus of mixed liquid - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method and an apparatus for rapidly manufacturing a stable quality mixed liquid which decrease contamination in a mixing process system, a residual liquid and the loss of a first run liquid and are capable of responding a various production scale. <P>SOLUTION: The process, employed for manufacturing a mixed liquid for executing a plurality of batch treatments by introducing not less than two raw materials into at least one first mixing part 5, comprises the manufacture of a new mixed liquid by (1) storing a predetermined amount of the first run liquid of an initial step of manufacturing in a sub tank 8, and (2) the introduction of a part or all of the mixed liquid manufactured in the first mixing part 5 and a predetermined amount of the first run in the sub tank 8 into a second mixing part 10 to stir and mix in the process of manufacturing a next batch of the mixed liquid after manufacturing the mixed liquid consisting of the same or similar constituents. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a mixed liquid manufacturing method and manufacturing apparatus, and more specifically, to a mixed liquid manufacturing method and manufacturing apparatus such as a urethane stock solution for manufacturing a polyurethane foam.

  For example, in the production process of a mixed liquid such as a urethane stock solution for producing a polyurethane foam, two or more of the same kind of raw materials (for example, a combination of different polyol compounds or a combination of different component polyol compounds) are mixed to prepare a mixed liquid. The quality of the polyurethane foam, which is the final product, may be produced by mixing two or more different raw materials (for example, a combination of a polyol compound and a foam stabilizer, a catalyst or a flame retardant). Therefore, it is required to produce a well-blended mixed solution. In the conventional method for producing a mixed liquid, a large synthesis tank or the like is usually used as a mixing means, and a circulation channel is formed for part or all of the raw material liquid or the mixed liquid to stabilize the mixed liquid. A manufacturing method or a manufacturing apparatus has been used.

However, the conventional method and apparatus for producing such a mixed solution have the following problems.
(1) In a system using a large synthetic tank, material remains in the circulation line and the shipping line, resulting in a loss.
(2) On the other hand, from the viewpoint of productivity and process control, the one-way method is preferable, and a one-way method capable of sufficient blending has been studied.
(3) By adopting a one-way system, we were able to implement contamination countermeasures up to the mixing device, but for each batch, materials from the previous production remain in the mixing device and piping for shipment to drums, etc. Sometimes.
(4) Normally, the allowable amount of contamination is often within 1% on condition that the prescription is the same system, but there is a demand for a product managed with higher accuracy.

  The object of the present invention is to solve these problems, reduce contamination in the mixed processing system, reduce residual liquid, and reduce loss of the first stream, and can be used for various production scales. It is in providing the manufacturing method and manufacturing apparatus of a liquid mixture.

  As a result of intensive studies, the present inventors have found that the above object can be achieved by a mixed liquid production method and production apparatus described below, and have completed the present invention.

That is, the present invention is a method for producing a mixed solution, which is a step of introducing two or more raw materials into at least one first mixing unit to produce a mixed solution for performing a plurality of batch processes, and includes the same component After preparing one batch of the mixed solution of the above or a mixture of similar components, in the preparation process of the mixed solution of the next batch,
(1) The initial flow liquid in the initial production stage is stored in a predetermined amount in the sub tank,
(2) In the subsequent second stage, a part or all of the liquid mixture prepared in the first mixing unit is introduced into the second mixing unit, and a predetermined amount of the initial liquid in the sub tank is introduced into the second mixing unit. And a new mixed solution is prepared by stirring and mixing.

  The material used for various applications such as polyurethane foam is preferably batch production from the viewpoint of efficient production, but the occurrence of initial flow liquid may not be negligible when switching batch production. In the production process of a mixed liquid such as a urethane stock solution, the present invention can store a first-stage liquid in a sub-tank to reduce loss, and process it while ensuring stable quality of the product in its production batch. It proposes a possible method. In other words, on the condition that the previous production was a mixed solution of the same component or a similar component, a predetermined amount of the initial flow liquid in the sub tank is introduced into the second mixing unit, and a new mixing is performed by stirring and mixing. By preparing the liquid, it is possible to provide a method for producing a mixed liquid that can cope with various production scales by reducing the contamination and residual liquid in the mixed treatment system and reducing the loss of the initial flow liquid. became.

  The “mixed liquid of the same component or a mixed liquid of similar components” as used herein means (1) the material system of the product produced last time and the product produced in the future are the same, and (2 ) A liquid mixture that can ensure the condition that it does not affect the quality of newly produced products. The “initial flow liquid” is not only the first mixed liquid introduced from the main tank in the new batch and stirred and mixed in the first mixing section, but also produced in the previous batch, and the first mixing section The liquid containing the liquid mixture which exists in the subsequent flow paths is said.

  The present invention is a method for producing the above-mentioned mixed liquid, which is based on the flow rate of the first mixed liquid derived from the first mixing unit, and the amount of the initial flow liquid introduced and stored in the sub tank, and the second mixing It is characterized by controlling and adjusting the flow rates of the initial liquid and the first liquid mixture introduced and mixed in the section.

  As described above, the present invention (2) introduces a predetermined amount of the initial liquid in the sub-tank into the second mixing section under the condition that it does not affect the quality of the newly produced product, and stirs and mixes. One of the features is to prepare a new mixed solution. Specifically, in order to ensure such conditions, the liquid amount of the second liquid mixture that is mixed with the initial flow liquid and taken out as the final product out of the liquid quantity of the liquid mixture taken out as the final product as a predetermined total amount is set. It is preferable to do. That is, based on the flow rate of the first mixed liquid derived from the first mixing unit, (a) the initial storage flow that takes into account the tolerance for the amount of liquid that needs to be processed as the initial flow liquid (planned initial flow volume) Set the amount of liquid (corresponding to the amount of liquid introduced / stored in the sub tank), (b) set the amount of the first mixed liquid to be mixed with this, and (c) first introduce / mix into the second mixing section. It is preferable to set the flow rates of the flowing liquid and the first mixed liquid and to control / adjust the amount of the second mixed liquid. By such control, it is possible to reduce the contamination and residual liquid in the mixing treatment system and the loss of the initial liquid while maintaining the product quality constant.

  The present invention is a method for producing a mixed liquid, characterized in that the flow path of the mixed liquid in the step of preparing the mixed liquid does not have a circulation flow path and is formed in a one-way manner.

  As described above, the one-way method is preferable in the production process of the mixed solution from the viewpoint of productivity and the like, but in such a production process, the generation of the initial flow liquid that can be ignored in the circulation method may not be ignored. In the preparation process of the mixed liquid according to the present invention, a predetermined amount of the initial flow liquid in the sub tank is introduced into the second mixing unit, and stirred and mixed to prepare a new mixed liquid. It has become possible to reduce contamination and residual liquid in the mixed processing system, and to reduce the loss of the initial liquid. In this sense, it can be said that it is preferable to apply the mixed liquid preparation process according to the present invention to the one-way method.

The present invention is a mixed liquid manufacturing apparatus, a main tank for storing two or more raw materials, a pump for supplying raw materials from the main tank, a flow meter for managing the supply amount of the raw materials, An apparatus for producing a mixed solution having at least one first mixing unit for mixing raw materials, and an outlet for the first mixed solution in the outlet channel of the first mixing unit,
At least two branches are provided in the outlet channel of the first mixing unit, and a sub-tank for the first flow liquid, a flow meter and a flow rate adjusting unit are disposed in the bypass channel connected to one branch, and the other one branch The flow meter for the first mixed liquid and the flow rate adjusting unit are disposed in the bypass flow channel connected to the second flow channel, and the second mixing unit is connected to the flow channel to which both bypass flow channels are connected. The passage has an outlet for the second mixed liquid.

  In a mixed liquid manufacturing apparatus including a production batch switching step, the reduction or treatment of the initial liquid plays an important role in stabilizing product quality. In the mixed liquid manufacturing apparatus according to the present invention, the bypass flow path provided on the upstream side of the first mixed liquid outlet flow path is connected to the sub tank so that the initial flow liquid can be stored and provided on the downstream side thereof. A part of the first mixed liquid can be introduced by the bypass flow path, and the initial flow liquid and the first mixed liquid can be stirred and mixed in the second mixing section provided in the flow path connecting both bypass flow paths. By doing so, it is possible to reduce the contamination and residual liquid in the mixing treatment system and reduce the loss of the initial flow liquid, and to provide a high quality mixed liquid manufacturing apparatus that can handle various production scales. became.

  The present invention is the above-described mixed liquid production apparatus, wherein a stirring means is provided in the sub tank, and a vibration mixer is used as a blend mixer in the first mixing section.

  In the first mixing part, since additive materials and / or other raw materials are mixed with one raw material under relatively high temperature conditions, it is important to ensure mixing uniformity in order to obtain a high-quality product stock solution. It becomes. Therefore, it is possible to ensure high mixing uniformity for the first mixed liquid by mixing with the blend mixer in the first mixing unit supplied with the raw materials and further enhancing the mixing function using the vibration mixer as the blend mixer. It becomes possible. Also, the uniformity of the second mixed liquid prepared by mixing a small amount of the initial flow liquid depends on the uniformity of the first mixed liquid, which is the main mixed stock solution, while the initial and final liquids are mixed. If the composition change is large, it may have a non-negligible effect. At this time, if a predetermined volume of a stirring tank is provided to increase the stirring and mixing efficiency of the second mixing unit, the presence of the mixed solution corresponding to the “initial flow liquid” in the second mixing unit cannot be ignored. . In the mixed liquid production apparatus according to the present invention, the agitation means is disposed in the sub tank, and the production batch can be quickly switched by passing through the second mixing section having a small capacity while ensuring the uniformity of the initial flow liquid. This makes it possible to reduce the residual liquid and the loss of the initial liquid.

  As described above, the present invention introduces the initial flow liquid and the first mixed liquid into the second mixing section, and stirs and mixes to produce a new mixed liquid, thereby allowing contamination and remaining in the mixing treatment system. It has become possible to provide a method for producing a mixed liquid and a production apparatus that can cope with various production scales by reducing the liquid and the loss of the initial liquid. In particular, by applying to the one-way method, it has become possible to provide a mixed liquid manufacturing method and a manufacturing apparatus excellent in productivity and the like.

  DESCRIPTION OF EXEMPLARY EMBODIMENTS Hereinafter, a preferred embodiment of a mixed liquid production apparatus (hereinafter referred to as “the present apparatus”) according to the present invention will be described with reference to the drawings. The apparatus includes a main tank that stores two or more raw materials, a pump that supplies the raw materials from the main tank, a flow meter that manages the supply amount of the raw materials, and at least one first mixing unit that mixes the raw materials. And an apparatus for producing a liquid mixture having a first liquid mixture outlet in the outlet channel of the first mixer, wherein the outlet channel of the first mixer is provided with at least two branches. The sub-tank for the first flow liquid, the flow meter, and the flow rate adjusting unit are disposed in the bypass flow channel that is connected, and the flow meter and the flow rate adjusting unit for the first mixed liquid are disposed in the bypass flow channel that is connected to the other one branch. In addition, the second mixing section is connected to the flow path connecting both bypass flow paths, and the outlet of the second mixed liquid is provided in the outlet flow path of the second mixing section.

<Configuration example of this device>
FIG. 1 shows an apparatus for producing a mixed liquid such as a urethane stock solution used for producing a polyurethane foam as one example of the configuration of the apparatus. As the raw material A constituting the urethane stock solution, the main component polyol compound A is supplied from the raw material supply unit 11 to the main tank 1A via the stock solution supply port 12, and at the same time, the stirring blade 13 provided in the main tank 1A. The mixture is stirred and mixed by and stored in a uniform state. Similarly, other polyol compound B, foam stabilizer C, catalyst D and flame retardant E are also stored in a uniform state in main tanks 1B, 1C, 1D and 1E (abbreviated as “1B to 1E”). (In FIG. 1, 1B to 1E are omitted). A predetermined amount of the stored polyol compound A is pumped by the pump 2A during preparation of the urethane stock solution, and the supply flow rate is managed by the flow meter 3A, and is introduced into the first mixing unit 5 via the coupling unit 4A. Similarly, other predetermined amounts of other polyol compound B, foam stabilizer C, catalyst D and flame retardant E are also pumped by pumps 2B to 2E, the supply flow rate is controlled by flow meters 3B to 3E, and the coupling parts 4B to 4E. Is introduced into the first mixing section 5. The first mixed solution obtained by stirring and mixing the raw materials A to E in the first mixing unit 5 is led out to the lead-out flow path L1 through the coupling part 5a, and the switching valve 6, the flow path L2, and the flow path L3. Then, it is introduced into the take-out can 7b through the take-out port 7a and carried out.

  A flow path L4 is connected to the lead-out flow path L1 via a switching valve 6, a sub tank 8 is connected to the other end via a coupling portion 8a, and a coupling connected to the flow path L5 at the lower part of the sub tank 8 A part 8b is provided, and is connected to the second mixing part 10 via a flow rate adjusting part 9a and a flow meter 3f provided in the flow path L5. On the other hand, a flow path L6 is connected to the flow path L2 so as to be branched from the flow path L3, and is connected to the second mixing unit 10 via a flow rate adjusting unit 9b and a flow meter 3g provided in the flow path L6. The second mixing unit 10 is connected to a lead-out flow path L7, and is connected to a take-out can 7d through a take-out port 7b provided in the lead-out flow path L7. When the initial flow liquid is generated at the initial stage of preparation of the mixed liquid, the switching valve 6 is switched, and the initial flow liquid from the outlet flow path L1 is introduced into the flow path L4 and stored in the sub tank 8. In the second stage of preparing the mixed liquid, a predetermined amount of the initial flow liquid stored in the sub tank 8 is introduced into the second mixing section 10 via the flow rate adjusting section 9a and the flow meter 3f, and at the same time, the outlet flow path L1. A predetermined amount of the first mixed liquid from is introduced into the flow path L6 and introduced into the second mixing unit 10 via the flow rate adjusting unit 9b and the flow meter 3g. In the 2nd mixing part 10, both are stirred and mixed, a 2nd liquid mixture is produced, and it introduce | transduces into the extraction can 7d through the extraction outlet 7c from the outlet flow path L7, and is carried out.

  The outlet channel L1 and the outlet channel L7 are provided with sampling ports 20a and 20b for sampling a part of the first mixed solution and the second mixed solution as measurement samples, respectively, and the composition and properties are inspected by the measuring means 20. It is preferable. The stirring state in the first mixing unit 5 and the second mixing unit 10 and the presence or absence of the influence of the residual liquid in each flow path are analyzed by the composition of the first mixed solution and the second mixed solution, and in particular, the second mixing unit 10 By controlling / adjusting the flow rate of the initial flow liquid introduced into the liquid, it is possible to ensure a certain quality of the extracted liquid. In addition, when the composition and property stability of the first mixed liquid and the second mixed liquid can be ensured, the measurement can be performed in the process after being introduced into the take-out can 7d.

  Next, details of the present apparatus will be described based on the configuration diagram of FIG. Here, it is preferable that the flow path of the mixed liquid is formed in a one-way manner without having a circulation flow path. That is, in this apparatus, when taking one example of the polyol compound A, which is one of the raw materials, it is supplied from the raw material supply unit 11 and is supplied from the main tank 1A → pump 2A → flow meter 3A → first mixer 5 → flow path L1 → By being transferred in a one-way manner from the flow path L2, the flow path L3, the take-out port 7a, and the take-out can 7b, it is possible to ensure high work efficiency and high productivity.

  In the main tanks 1A to 1E, the raw materials A to E are stored, and the reduced amount accompanying the production of the polyurethane foam is replenished from the raw solution supply port 12 (the same applies to the raw materials B to E). The main tanks 1A to 1E are provided with stirring blades 13 for stirring the raw materials A to E, and the stirring blades 13 are rotationally driven by a driving device. The raw materials A to E in the main tanks 1A to 1E are in a liquid state, and the raw materials having a high viscosity at normal temperature are adjusted to a desired viscosity by heating to achieve a uniform temperature distribution. In order to manage the state inside the main tanks 1A to 1E, it is preferable to provide a level gauge for detecting the liquid level of each raw material and a tank pressure gauge for detecting the internal pressure. Furthermore, a safety valve is provided in order to ensure safety, and it is also preferable to supply back pressure air or nitrogen gas for purging the inner air layer portions of the main tanks 1A to 1E and for pressure-feeding the urethane stock solution.

  As the pumps 2A to 2E, cylinder linear pumps, gear pumps, and the like that have high pressure and flow rate stability, can ensure quantitativeness, and are easy to control from the outside are preferable. This is also preferable in that the generation of residual liquid in the pumps 2A to 2E is small. Thereby, the stability of the composition of the first mixed liquid and the constant flow rate can be ensured. In particular, the function can be utilized by controlling the flow rate as a system combined with the flow meters 3A to 3E provided in the subsequent stage. At this time, it is possible to use a mass flow meter having a flow control function such as a mass flow controller in place of the normal flow meters 3A to 3E. Further, the flow meters 3A to 3E can be omitted by using the pumps 2A to 2E as metering pumps. Thereby, it is possible to reduce the internal volume of the flow path and further reduce the generation of residual liquid. Furthermore, the shorter the pipes from the pumps 2A to 2E to the first mixing unit 5, the more the internal volume of the flow path can be reduced.

  In the 1st mixing part 5, it is preferable to use a vibration type mixer as a blend mixer. By utilizing the high mixing function of the vibration mixer, it is possible to ensure high mixing uniformity for the first mixed liquid and minimize the initial flow liquid from the structure in which the mixed liquid hardly remains. And the timing of prescription switching for each batch can be clarified.

  Specifically, a Vibro mixer (manufactured by Chilling Industries Co., Ltd.) 5 as exemplified in FIG. 2 can be mentioned. In FIG. 2, the spiral body 52 disposed in the main shaft portion 51 at the center of the vibrator mixer 5 has a plurality of holes 53, and the main shaft portion 51 moves in the vertical direction as shown by arrows. Here, the main flows of the materials A to E introduced from the lower introduction ports 4A to 4E move upward along the pressure feed and the spiral body 52 of the main shaft portion 51 over a relatively long time. At the same time, a large stirring force can be generated by the liquid flow from the plurality of holes 53 generated by the vertical movement of the main shaft portion 51 to further enhance the mixing function. That is, the materials A to E introduced through the introduction ports 4A to 4E become a first mixed liquid having high uniformity and are led out through the coupling part 5a by the strong stirring force of the vibro mixer 5. It becomes possible. Further, as shown in FIG. 2, the vibro mixer 5 has a structure in which almost all of the liquid mixture inside can be derived when the supply of the materials A to E is stopped at the time of batch prescription switching. Can be minimized.

  The sub-tank 8 stores a predetermined amount (hereinafter referred to as “stored initial flow amount”) Vs of the initial flow at the time of batch prescription switching. The sub tank 8 is provided with a stirring blade (corresponding to “stirring means”) 8c for stirring the initial flow liquid, and the stirring blade 8c is driven to rotate by a driving device. At the beginning of the initial flow liquid, a large amount of the remaining liquid of the previous batch is contained, and at the end of the initial flow liquid, the first mixed liquid of the new batch is almost obtained. It is preferable to make the composition uniform as a whole including the initial flow liquid. In addition, when a high-viscosity initial flow liquid is planned at normal temperature, it is adjusted to a desired viscosity by heating to achieve a uniform temperature distribution. In order to manage the internal state of the sub-tank 8, it is preferable to provide a level meter that detects the liquid level of the initial flow liquid and a tank pressure gauge that detects the internal pressure. In addition, a safety valve is provided to ensure safety, and it is also preferable to supply back pressure air for purging the inner air layer portion of the main tanks 1A to 1E and pressure feeding of the urethane stock solution.

  In the 2nd mixing part 10, it is preferable to use a non-drive type mixer as a blend mixer. Since the first mixed liquid, which is the main component of almost the same property, and a small amount of the initial liquid are stirred and mixed, the static mixing function combined with the mixing function allows the extraction can 7d to be generated in a state where there are few bubbles and the like. Can be introduced and removed. Specific examples include a non-driving mixer represented by a motor-driven in-line mixer or a static mixer.

  The measuring means 20 is not particularly limited as long as it is an analyzer capable of inspecting the composition and properties of the first mixed liquid and the second mixed liquid that are urethane stock solutions. An analyzer capable of continuous measurement is preferable in order to control the supply amount of ~ E and to control the flow rates of the first mixed liquid and the initial flow liquid for the second mixed liquid. Specifically, a gas chromatograph (GC), an infrared spectrophotometer (IR), or an ultraviolet spectrophotometer (UV) can be cited as a composition analysis means, and a viscometer or a specific gravity meter can be cited as a property analysis means. Can be mentioned. Or it is most preferable to mix with isocyanate regularly and to confirm with real products, such as reactivity and free foaming density.

  In this apparatus, although the 1st mixing part 5 and the 2nd mixing part 10 are not made into the object of temperature control, both or any one is set as the structure which uses temperature control means, such as a heat-medium circulation type and a jacket type. It is possible. Further, it is possible to provide a heat exchanger (not shown) in order to stabilize the temperatures of the raw materials A to E and the mixed solutions in response to changes in seasons and the installation conditions of the apparatus.

  Here, it is preferable that this apparatus is a mixed liquid of the same component or a mixed liquid of similar components in the production process of a mixed liquid such as a urethane stock solution. Specifically, when (1) the material system of the product produced last time and the product produced from now on is the same, and (2) the quality of the newly produced product is not affected, It is possible to reduce contamination and residual liquid in the mixing treatment system and to reduce loss of the initial flow liquid.

  With the above configuration, contamination and reduction of residual liquid and initial flow loss are reduced in the mixing treatment system, and this device has the following functions to minimize the generation amount of the initial flow liquid. It is preferable.

  (1) It is preferable that the downstream flow path of the main tanks 1 </ b> A to 1 </ b> E or the pumps 2 </ b> A to 2 </ b> E forms a natural falling flow with the upstream as a high place. In the final stage of liquid mixture preparation, each subsequent raw material of the piping system can be effectively taken out and the residual liquid (that is, The initial volume of the batch) can be minimized.

  (2) By setting the flow paths L1 to L7 to the minimum diameter pipe adapted to the flow rate of the mixed liquid and the shortest pipe length, the residual liquid can be minimized even when switching to a new batch. . For example, in the case of a flow rate of 10 to 50 L / min, it is preferable to use a pipe having an inner diameter φ of 25 to 50 mm and form a piping system without accumulation.

<Control functions and operation method of this device>
In preparing the mixed liquid in this apparatus, it is important to appropriately control the mixed state in the first mixing unit 5 and at the same time appropriately control the mixed state in the second mixing unit 10. As illustrated in FIG. 3, with respect to the former, the pumps 2A to 2E are controlled using the outputs of the flow meters 3A to 3E for raw materials provided in the flow paths from the main tanks 1A to 1E as indexes, and the sampling port 20a The composition and properties are inspected by the measuring means 20 through the first, and a first mixed liquid in which a desired component is blended can be produced. For the latter, the flow rate controller 9a is controlled using the flow rate Rs of the initial liquid stored in the sub-tank 8 as an index and the flow rate Rd of the first mixed liquid introduced into the flow path L6. The flow rate adjusting unit 9b is controlled using the output of 3 g as an index, and the composition and properties are inspected by the measuring means 20 through the sampling port 20b, so that a second mixed liquid containing a desired component can be produced. The control function of this apparatus is provided with a control unit 30 as shown by the one-dot chain line in FIG. 3 and takes in the outputs of the flow meters 3A to 3E, 3f and 3g and the output of the measuring means 20, and the pumps 2A to 2E and the flow rate Control and adjustment of the adjusters 9a and 9b are performed.

  At this time, in order for the present apparatus to operate properly, (a) setting of the amount of the initial flow liquid to be introduced / stored in the sub tank 8 (storage initial flow volume Vs), and (b) the second mixing unit The setting of the liquid volume Vd of the first mixed liquid introduced into 10, and (c) the control / adjustment of the flow rate Rs of the initial liquid to be introduced and mixed into the second mixing unit 10 and the flow rate Rd of the first mixed liquid. It is preferable to perform these, and in particular, it is preferable to perform these based on the flow rate Rt of the first mixed liquid that is led out from the first mixing unit 5 and flows through the outlet flow path L1.

The flow rate Rt of the first mixed liquid derived from the first mixing unit 5 and flowing through the outlet flow path L1 is set from the production amount Vt of one batch and the batch processing time T, and the flow rate for each raw material is set according to this. The control target value is obtained. If the flow rate Rt of the first mixed liquid is controlled under a constant condition, Rt = Vt / T. However, in the actual production process, the flow rate Rt of the first mixed liquid may be changed. It becomes like 1.
Rt (average value) = Vt / T (average value) (Formula 1)

(A) Setting of stored initial flow volume Vs introduced / stored in sub tank 8 (a-1) In consideration of replacement of residual liquid volume in the mixed system, the stored initial flow volume Vs, which is the total amount of the initial flow liquid, is For one, it is preferable to set the liquid volume in consideration of the tolerance to the liquid volume (planned initial liquid volume) that needs to be processed as the initial liquid. Specifically, with reference to the internal volume Va of the flow path after the first mixer 5, the liquid remaining on the inner wall of the first mixing unit 5 or the like when switching to a new batch is included in the first mixed liquid. The liquid volume Vb and the liquid volume Vc are verified in advance until the composition of the liquid mixture generated in the first mixing section 5 is stabilized due to the difference in flow rate of the raw materials introduced into the first mixing section 5 at that time. Alternatively, an estimate is made, these are added, and a storage initial flow amount Vs multiplied by a safety factor α is set (see Formula 2).
Vs = (Va + Vb + Vc) × α (Expression 2)

  (A-2) The stored initial flow amount Vs is calculated in consideration of the capacity S of the second mixing unit 10 (hereinafter referred to as “capacity S”) in addition to the setting method according to (a-1). Is preferably adopted. This equipment is intended to reduce contamination and residual liquid in the mixing treatment system and reduce the loss of the first-stage liquid, and to produce mixed liquids that can respond quickly to various production scales by batch production using the one-way method. Is required. At this time, in order to improve the production efficiency of the mixed liquid, it is preferable to reduce the capacity S, while a capacity for sufficient processing of the initial flow liquid is required. That is, if the volume S is increased, the throughput of the first stream can be increased. On the other hand, it is necessary to increase the flow rate of the first mixture to be mixed therewith, and if the volume S is decreased, the throughput of the first stream is increased. Limited. Specifically, the relationship between the storage initial flow amount Vs and the processing time when the capacity S is constant, and the relationship between the capacity S and the processing time when the storage initial flow amount Vs is constant are illustrated in FIG. It becomes like 4. Therefore, as a result of verifying the liquid volume of the initial flow liquid considering the volume S, when the volume S is constant at 350 mL and the stored initial flow volume Vs is calculated from the intersection of the processing times, it is about 3500 mL, that is, about 10 of the volume S. It has been found that treatment of double volumes of the initial stream is preferred. In the verification under other conditions, substantially the same result is obtained. In setting the stored initial flow volume Vs, it is preferable to treat the initial flow liquid in an amount 5 to 15 times the volume S, and further, the capacity S 8 Treatment of ~ 12 times the initial flow is preferred.

  (A-3) Therefore, in setting the stored initial flow volume Vs, it is possible to quickly and accurately prepare a mixed liquid by setting the conditions so as to overlap the conditions shown in (a1). It becomes.

(B) Setting of the liquid volume Vd of the first mixed liquid introduced into the second mixing unit 10 The allowable amount of contamination in this apparatus that requires high accuracy is preferably within 0.5 to 1%. . That is, the liquid volume Vd of the first liquid mixture introduced into the second mixing unit 10 needs to be 200 to 100 times the stored initial flow liquid volume Vs. However, as shown in the above (a), since the setting of the stored initial flow volume Vs itself has a margin of 2 to several times the contamination, the liquid volume Vd of the first mixed liquid is substantially equal to An amount of 100 to 20 times the stored initial flow amount Vs is sufficient. In this apparatus, it sets as 100 times the storage initial flow liquid volume Vs, and it controls to introduce the equivalent into the 2nd mixing part 10 among the production planned total quantities of a liquid mixture. According to the above example, when the capacity S is 350 mL, the stored initial flow volume Vs is about 3500 mL, and the volume Vd of the first mixed liquid is preferably about 350 L.

(C) Control of flow rate Rs of initial flow liquid and flow rate Rd of first mixed liquid introduced into second mixing unit 10 As described above, appropriate storage initial flow liquid amount Vs and first mixed liquid flow rate in this apparatus are as described above. Since the liquid amount Vd can be set, the flow rate Rs of the initial flow liquid to be introduced and mixed in the second mixing unit 10 and the first mixing are determined based on the flow rate Rt of the first mixed liquid flowing through the outlet flow path L1. The liquid flow rate Rd can be set. Specifically, it can be set as follows. Here, when Vd / Vs = α, Rd / Rs = α.

  (C-1) The total batch processing time Tt in the manufacturing process of one batch is [the storage time Ts of the initial liquid in the sub-tank 8 in the initial stage of preparation of the mixed liquid] and the initial flow in the second stage of preparation of the mixed liquid. It is a time obtained by adding the batch processing time Ta of the liquid to the second mixing unit 10 and the batch processing time Tb for taking out only the first mixed liquid in the third stage of preparing the mixed liquid.

(C-2) At this time, Vs = Rt × Ts = Rs × Ta. That is, the flow rate Rs of the initial liquid and the flow rate Rd of the first mixed liquid can be set by setting the time Ta based on the flow rate Rt by the following equations 3 and 4. Here, the time Ta can be set by the capacity of the second mixing unit 10 or the entire processing time Tt.
Rs = Rt × (Ts / Ta) (Formula 3)
Rd = Rt × α × (Ts / Ta) (Formula 4)

  It is preferable that this apparatus is operated according to the following procedure by effectively utilizing the above functions. In addition, here, in order to show basic operation, the case where the 1st liquid mixture was derived | led-out from the 1st mixing part 5 by the fixed flow volume Rt was set, However, A flow volume can also be changed for every procedure.

(1) First Step of Producing Mixed Liquid First, the switching valve 6 is operated to connect the outlet flow path L1 and the flow path L4, and the flow rate adjusting unit 9a is not operated. Next, in this state, when each raw material is supplied to the first mixing unit 5 at a predetermined flow rate, a first mixed solution mixed and homogenized in the first mixing unit 5 is created, and the derived flow at the flow rate Rt. Derived from the path L1. The first mixed liquid is introduced into the sub tank 8 through the switching valve 6 and the flow path 4 and is introduced for the time Ts, whereby the initial flow liquid is stored in the stored initial flow liquid amount Vs and the sub tank 8.

  At this time, the composition and properties are inspected by the measuring means 20 through the sampling port 20a, the first mixed liquid containing the desired components is prepared, and the composition and properties are stable within the time Ts. It is preferable to confirm that Further, in the sub tank 8, it is preferable to drive the stirring blade 8c to measure the homogenization of the initial flow liquid.

(2) Second stage of production of mixed liquid After the time Ts has elapsed, the switching valve 6 is returned to the original position to connect the outlet flow path L1 and the flow path L2. Thereby, the 1st liquid mixture with which the property was stabilized can be taken out with the flow volume Ra from the extraction port 7a via the flow path L3. At the same time, the flow rate adjusting unit 9b is controlled to introduce the first mixed liquid into the second mixing unit 10 at the flow rate Rd, and the flow rate adjusting unit 9a is controlled to control the initial flow liquid stored in the sub tank 8 at the flow rate Rs. Introduce into the second mixing unit 10. As a result, the uniformly mixed second mixed liquid is led out from the second mixing unit 10, and the second mixed liquid whose properties are stabilized is taken out from the outlet 7b through the outlet flow path L7 by the flow rate [Rd + Rs]. it can. However, since Rd >> Rs, [Rd + Rs] ≈Rd.

By continuing this state for the time Ta, it becomes possible for the entire amount of the initial liquid stored in the sub tank 8 to form a part of the second mixed liquid and to be taken out from the outlet 7b. Here, time Ta shows the relationship of the following Formula 5.
Ta = Vs / Rs = Ts × (Rt / Rs) (Formula 5)

  At this time, the composition and properties are inspected by the measuring means 20 through the sampling port 20b, the second mixed liquid containing the desired components is prepared, and the composition and properties are stable within the time Ts. It is preferable to confirm that

(3) Production of Mixed Liquid Third Stage After Ta has elapsed, the flow rate adjusting sections 9a and 9b can be controlled to finish taking out the second mixed liquid from the outlet 7b. At this time, since only the first mixed liquid can be taken out from the take-out port 7a at the flow rate Rt, the remaining amount of the production amount Vt of one scheduled batch is maintained by maintaining this state for the batch processing time Tb. Can be secured.

  In addition, after Tb has elapsed, in order to minimize the residual liquid of this batch, a processing time for taking out the natural falling flow such as the inner wall of the flow path can be provided, contamination in the mixed processing system, reduction of residual liquid, and initial flow liquid This is effective for reducing the loss of the image.

  In the above embodiment, the production method and production apparatus of a mixed liquid such as a urethane stock solution for producing a polyurethane foam have been exemplified, but the present invention is widely applied to the production method or production apparatus of a mixed liquid of other polymer stock solutions. Is possible. Specifically, it can be applied to various foams such as a phenol resin foam.

Explanatory drawing illustrating the basic configuration of this device Explanatory drawing illustrating the vibratory mixer used in this device Explanatory drawing which illustrates the control function concerning this device Explanatory drawing which illustrates the relationship between the capacity | capacitance S of the 2nd mixing part which concerns on this apparatus, or the storage initial flow volume Vs, and processing time.

Explanation of symbols

1A Main tanks 2A, 2B, 2C, 2D, 2E Pumps 3A, 3B, 3C, 3D, 3E, 3f, 3g Flowmeters 4A, 4B, 4C, 4D, 4E, 5a, 8a, 8b Coupling section 5 First mixing Part 6 Switching valve 7a, 7c Outlet 7b, 7d Outlet 8 Sub tank 8c, 13 Stirrer blades 9a, 9b Flow control part 10 Second mixing part 11 Raw material supply part 12 Raw liquid supply port 20 Measuring means 20a, 20b Sampling port L1, L7 outlet flow path L2 to L6 flow path

Claims (5)

Introducing two or more raw materials into at least one first mixing section to prepare a mixed solution for performing a plurality of batch processes, wherein one batch of a mixed solution of the same component or a mixture of similar components was prepared. Later, in the preparation process of the mixed solution of the next batch,
(1) The initial flow liquid in the initial production stage is stored in a predetermined amount in the sub tank,
(2) In the subsequent second stage, a part or all of the liquid mixture prepared in the first mixing unit is introduced into the second mixing unit, and a predetermined amount of the initial liquid in the sub tank is introduced into the second mixing unit. Then, stir and mix to make a new mixture,
A method for producing a mixed liquid, comprising:   Based on the flow rate of the first mixed liquid derived from the first mixing unit, the amount of the initial flow liquid introduced / stored in the sub tank, and the initial flow liquid and the first mixed liquid introduced / mixed in the second mixing unit The method for producing a mixed liquid according to claim 1, wherein the flow rate of the mixed liquid is controlled and adjusted.   3. The method for producing a mixed liquid according to claim 1, wherein the flow path of the mixed liquid in the step of producing the mixed liquid is formed in a one-way manner without having a circulation flow path. A main tank for storing two or more raw materials, a pump for supplying the raw materials from the main tank, a flow meter for managing the supply amount of the raw materials, and at least one first mixing unit for mixing the raw materials, An apparatus for producing a mixed liquid having a first mixed liquid outlet in the outlet channel of the first mixing section,
At least two branches are provided in the outlet channel of the first mixing unit, and a sub-tank for the first flow liquid, a flow meter and a flow rate adjusting unit are disposed in the bypass channel connected to one branch, and the other one branch The flow meter for the first mixed liquid and the flow rate adjusting unit are disposed in the bypass flow channel connected to the second flow channel, and the second mixing unit is connected to the flow channel to which both bypass flow channels are connected. An apparatus for producing a mixed liquid, wherein the passage has an outlet for the second mixed liquid.   The apparatus for producing a mixed liquid according to claim 4, wherein a stirring unit is provided in the sub tank, and a vibration mixer is used as a blend mixer in the first mixing unit.

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