Classifications

• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G65/00—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule
  • C08G65/34—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule from hydroxy compounds or their metallic derivatives
  • C08G65/38—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule from hydroxy compounds or their metallic derivatives derived from phenols
  • C08G65/40—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule from hydroxy compounds or their metallic derivatives derived from phenols from phenols (I) and other compounds (II), e.g. OH-Ar-OH + X-Ar-X, where X is halogen atom, i.e. leaving group
  • C08G65/4093—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule from hydroxy compounds or their metallic derivatives derived from phenols from phenols (I) and other compounds (II), e.g. OH-Ar-OH + X-Ar-X, where X is halogen atom, i.e. leaving group characterised by the process or apparatus used
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G61/00—Macromolecular compounds obtained by reactions forming a carbon-to-carbon link in the main chain of the macromolecule
  • C08G61/12—Macromolecular compounds containing atoms other than carbon in the main chain of the macromolecule
  • C08G61/127—Macromolecular compounds containing atoms other than carbon in the main chain of the macromolecule derived from carbon dioxide, carbonyl halide, carboxylic acids or their derivatives
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G65/00—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule
  • C08G65/34—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule from hydroxy compounds or their metallic derivatives
  • C08G65/38—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule from hydroxy compounds or their metallic derivatives derived from phenols
  • C08G65/40—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule from hydroxy compounds or their metallic derivatives derived from phenols from phenols (I) and other compounds (II), e.g. OH-Ar-OH + X-Ar-X, where X is halogen atom, i.e. leaving group
  • C08G65/4012—Other compound (II) containing a ketone group, e.g. X-Ar-C(=O)-Ar-X for polyetherketones
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G65/00—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule
  • C08G65/34—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule from hydroxy compounds or their metallic derivatives
  • C08G65/46—Post-polymerisation treatment, e.g. recovery, purification, drying
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G75/00—Macromolecular compounds obtained by reactions forming a linkage containing sulfur with or without nitrogen, oxygen, or carbon in the main chain of the macromolecule
  • C08G75/20—Polysulfones
  • C08G75/23—Polyethersulfones
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G2261/00—Macromolecular compounds obtained by reactions forming a carbon-to-carbon link in the main chain of the macromolecule
  • C08G2261/30—Monomer units or repeat units incorporating structural elements in the main chain
  • C08G2261/34—Monomer units or repeat units incorporating structural elements in the main chain incorporating partially-aromatic structural elements in the main chain
  • C08G2261/344—Monomer units or repeat units incorporating structural elements in the main chain incorporating partially-aromatic structural elements in the main chain containing heteroatoms
  • C08G2261/3442—Polyetherketones
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
  • C08G2650/00—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule
  • C08G2650/28—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule characterised by the polymer type
  • C08G2650/38—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule characterised by the polymer type containing oxygen in addition to the ether group
  • C08G2650/40—Macromolecular compounds obtained by reactions forming an ether link in the main chain of the macromolecule characterised by the polymer type containing oxygen in addition to the ether group containing ketone groups, e.g. polyarylethylketones, PEEK or PEK

Definitions

• the present invention relates to a method for manufacturing polyether ketone ketone polymers by electrophilic substitution.
• Polyether ketone ketone (PEKK) polymers have a number of properties which make them useful for applications involving exposure to high temperature or to high mechanical or chemical stress. They are for instance useful in the aerospace industry, in off-shore drilling and in medical devices.
• the process may in particular rely on diphenylether (as described in U.S. Pat. No. 4,816,556), or on 1,4-bis(4-phenoxybenzoylbenzene) as a starting material. Both paths lead to poly ether ketone ketone.
• the process may more specifically rely on 1,4-bis(4-phenoxybenzoylbenzene) as a starting material.
• This compound can be prepared by reacting terephthaloyl chloride and diphenyl ether in the presence of a Lewis acid such as aluminum trichloride (AlCl 3 ).
• the crude polymer most often forms as a sponge-like gel with a large liquid content, typically more than 50% by weight.
• the present invention provides a method for manufacturing polyether ketone ketone with a high purity and a high yield, and more specifically, a method that may be implemented at the industrial scale in an economically realistic manner.
• the solid/liquid separation step comprises a step of centrifugal filtration. Indeed, it has been found that centrifugal filtration is particularly efficient and quick for performing the solid/liquid separation of a crude PEKK polymer suspension.
• Compaction stress is a parameter that allows to evaluate the directional force applied to the polymer granules during the separation step. Centrifugal filtration allows to apply a notable compaction stress and therefore allows a better extraction of the liquid from within the polymer granules through its pores. The compaction stress is proportional to the acceleration rate in a centrifuge and it can thus be varied easily.
• the washing step may be carried out without resuspending the solid in the solvent used for washing. Indeed, it has surprisingly been found that effective washing can be performed in this manner, despite a fairly low contact time. This finding is thought to be connected to the efficient extraction of the Lewis acid from the granules by applying a notable compaction stress.
• the method of the invention allows the preparation of PEKK with a low residual humidity. Accordingly, the time and energy required for drying can be reduced.
• PEKK polyether ketone ketone
• the at least one difunctional aromatic acyl chloride is selected from terephtalic acid chloride, isophtalic acid chloride and the mixtures thereof.
• the reaction solvent is ortho-dichlorobenzene.
• the Lewis acid is aluminum trichloride.
• the protic solvent used in step (ii) is an aqueous solution, which preferably has a pH of not more than 5, more preferably not more than 3 and most preferably not more than 2.
• the method of the invention comprises after step (iii) further one or more steps of washing the crude PEKK in a protic solvent, preferably an alcoholic aqueous solution, and subjecting the resulting mixture to a further solid/liquid separation, preferably comprising a step of centrifugal filtration.
• a protic solvent preferably an alcoholic aqueous solution
• the method of the invention comprises after step (iii) further one or more steps of washing the crude PEKK in a protic solvent, preferably water, and subjecting the resulting mixture to a further solid/liquid separation, preferably comprising centrifugal filtration.
• a protic solvent preferably water
• the method of the invention comprises after step (iii):
• step (iii) and each subsequent washing step is performed in a centrifugal filtration device, without removing the crude PEKK between subsequent steps.
• step of centrifugal filtration in step (iii) is performed at an acceleration rate of at least 500 g.
• step (iii) and each subsequent washing step is performed for a duration of one hour or less, preferably 30 minutes or less and in particular 15 minutes or less.
• the method of the invention further comprises a subsequent step of drying the purified PEKK.
• the crude PEKK is purified without using a complexing agent.
• the purified PEKK contains less than 1000, preferably 500, and in particular 250 ppm of aluminum, as measured using inductively coupled plasma/optical emission spectrometry (ICP/OES, model ICP Vista-Pro sold by Varian, wavelength: 396.15 nm for aluminum element) on a solution prepared according to the following procedure:
• the effluent containing Lewis acid is recycled, notably as a flocculation agent for water treatment.
• polyaryl ether ketones also known as PAEK
• PAEK polyaryl ether ketones
• Ar and Ar 1 each denote a divalent aromatic radical;
• Ar and Ar 1 may be chosen, preferably, from 1,3-phenylene, 1,4-phenylene, 4,4′-biphenylene, 1,4-naphthylene, 1,5-naphthylene and 2,6-naphthylene;
• the polyether ketone ketone (PEKK) comprises units of the following formulas:
• Ar and Ar 1 represent each a divalent aromatic radical and are preferably selected among 1,3-phenylene and 1,4-phenylene;
• X represents an electron-withdrawing group which is preferably a carbonyl group
• Y represents an oxygen atom
• polyether ketone ketone comprises moieties of formula II A, of formula II B or a mixture thereof:
• the polyether ketone ketone may consist of said moieties of formula IIA and/or IIB.
• the polyether ketone ketone consists of, or essentially consists of moieties of formula IIA and IIB.
• these polymers are especially preferred polyether ketone ketones that have a molar ratio of moieties of formula IIA : moieties of formula IIB (also called T:I ratio) that is comprised between 50:50 and 99:1, and in some embodiments from 55:45 to 85:15, in particular from 60:40 to 80:20.
• polyether ketone ketone may comprise other aromatic moieties of the formula I above, notably moieties where Ar and Ar 1 may also be selected from bicyclic aromatic radicals such as 4,4′-diphenylene or divalent fused aromatic radicals such as 1,4-naphtylene, 1,5-naphtylene and 2,6-naphtylene.
• Ar and Ar 1 may also be selected from bicyclic aromatic radicals such as 4,4′-diphenylene or divalent fused aromatic radicals such as 1,4-naphtylene, 1,5-naphtylene and 2,6-naphtylene.
• the invention is particularly suited for producing PEKK with a molecular weight such as its inherent viscosity in 96% acid sulfuric according to ISO 307 is between 0.5 and 1.5 dL/g, preferably between 0.6 and 1.2 dL/g, more preferably between 0.7 and 1.1 dL/g
• 1,4-bis(4-phenoxybenzoylbenzene) is reacted with at least one difunctional aromatic acyl chloride.
• 1,4-bis(4-phenoxybenzoylbenzene) is the compound of formula III:
• the compound of formula (Ill) may be made by reacting terephthaloyl chloride with diphenyl ether in a solvent and in the presence of a Lewis acid, acting as a Friedel-Crafts catalyst.
• the reaction results in the production of 1,4-bis(4-phenoxybenzoylbenzene) which is predominantly in the form of a complex with the Lewis acid.
• the polyether ketone ketone may be obtained by reaction of said 1,4-bis(4-phenoxybenzoylbenzene) with at least one difunctional aromatic acyl chloride.
• the difunctional aromatic acyl chloride may in particular include terephthaloyl chloride, isophthaloyl chloride and more preferably a mixture of terephthaloyl chloride and isophthaloyl chloride.
• the reaction is preferably implemented in a solvent.
• the solvent is preferably a non-protic solvent, which can in particular be selected from methylene chloride, carbon disulfide, ortho-dichlorobenzene, meta-dichlorobenzene, para-dichlorobenzene, 1,2,4-trichlorobenzene, 1,2,3-trichlorobenzene, ortho-difluorobenzene, 1,2-dichloroethane, 1,1,2,2-tetrachloroethane, tetrachloroethylene, dichloromethane, nitrobenzene and mixtures thereof.
• Ortho-dichlorobenzene is the most preferred solvent.
• the reaction is implemented in the presence of a Lewis acid as a catalyst.
• Lewis acids which may be used include, for example, aluminum trichloride, aluminum tribromide, antimony pentachloride, antimony pentafluoride, indium trichloride, gallium trichloride, boron trichloride, boron trifluoride, zinc chloride, ferric chloride, stannic chloride, titanium tetrachloride, and molybdenum pentachloride.
• Aluminum trichloride, boron trichloride, aluminum tribromide, titanium tetrachloride, antimony pentachloride, ferric chloride, gallium trichloride, and molybdenum pentachloride are preferred.
• Aluminum trichloride is particularly preferred.
• the reaction is further preferably conducted in the presence of a suitable chain stopper.
• a chain stopper is a monofunctional compound added so as to control the chain length of the polyether ketone ketone.
• Suitable chain stoppers in the present reaction are notably benzoic acid chloride or phenoxybenzophenone.
• the polymerization is performed in a reactor.
• the reactor can be for instance a glass reactor, a glass-lined reactor or a PTFE coated reactor.
• the materials introduced into the reactor in the method of the invention consist essentially, or consist, of 1,4-bis(4-phenoxybenzoylbenzene) and the at least one difunctional aromatic acyl chloride, the reaction solvent, the Lewis acid and the chain stopper.
• an initial reactant mixture comprising (and preferably consisting of) terephthaloyl chloride, isophtaloyl chloride, the chain stopper and 1,4-bis(4-phenoxybenzoylbenzene) in the reaction solvent.
• the reactant mixture can be made by mixing the three components together, in any order.
• the dry solvent can be introduced first in the reactor, and then the two reactants can be added to the reactor.
• a first phase of the reaction can be carried out by mixing the reactants at a temperature ranging from e.g. ⁇ 5 to 25° C.
• the Lewis acid is added to the reactant mixture.
• the Lewis acid is added as a solid.
• it can also be added as a suspension or a solution, preferably in the abovementioned solvent.
• the reactant mixture comprises or consists of diphenylether, at least one difunctional aromatic acyl chloride, the reaction solvent, the Lewis acid and the chain stopper.
• Processing aids such as dispersants or antifouling agents may be added to the reaction mixture if required.
• the polymerization can be carried out at a temperature ranging from e.g. 50 to 120° C.
• the conditions and equipment are preferably chosen in such a way that the polymer is obtained in granular form. If necessary, the crude polymer may be granulated using a suitable milling equipment.
• the reactants mixture is designated as the product mixture.
• the method of the invention comprises steps for purifying polyether ketone ketone from the product mixture, and in particular from the solvent, catalyst and unreacted reactants as well as by-products.
• said purification comprises the step of contacting the product mixture with a protic solvent, so as to recover a first phase containing the Lewis acid and a second phase containing polyether ketone ketone.
• the relative weight ratio of protic solvent and product mixture contacted is preferably from 5 to 100, more preferably from 15 to 50.
• the protic solvent can be an aqueous solution.
• the aqueous solution can be simply water. Alternatively, it can be an acidic solution, such as a solution of hydrochloric acid.
• a preferred aqueous solution is water acidified by addition of up to 10 wt. %, preferably up to 0.4 wt. % of suitable acid, for instance concentrated hydrochloric acid.
• the pH of the aqueous solution is not more than 7, preferably not more than 6, or not more than 5, or not more than 4, or not more than 3, or not more than 2. The dissociation of the polyether ketone ketone-Lewis acid complex is more efficient when an acidic solution is used.
• aqueous-organic solvent e.g. an aqueous solution mixed with methanol, ethanol, isopropanol or acetic acid.
• the proportions of the alcohol in the mixture should be sufficient to allow for good elimination of the aluminum but however limited so as to avoid side reactions.
• a good compromise is a mixture of aqueous solution and alcohol comprising 95 to 60 wt. %, preferably 80 to 95 wt. % of alcohol.
• a first possibility for contacting the polyether ketone ketone-Lewis acid complex with the protic solvent is to add the protic solvent to the product mixture, for example directly in the reactor.
• the addition is preferably performed progressively, over a period of time which can advantageously range from 10 to 180 minutes, preferably from 30 to 90 minutes at a temperature >50° C., preferably between 60 and 160° C.
• a second possibility is to provide the protic solvent in a separate vessel and to subsequently add the product mixture to the protic solvent.
• the addition is preferably performed progressively, over a period of time which can advantageously range from 10 to 180 minutes, preferably from 30 to 90 minutes at a temperature >50° C., preferably between 60 and 160° C.
• the mixture of protic solvent and product mixture is preferably agitated, using e.g. an agitation device such a mechanical stirrer (which may comprise one or more impellers) or a recirculation loop with a pump.
• an agitation device such as a mechanical stirrer (which may comprise one or more impellers) or a recirculation loop with a pump.
• the mixture of both can be maintained, preferably with agitation, for a period of time of e.g. from 10 to 240 minutes, preferably from 30 to 120 minutes at a temperature >75° C., preferably between 80 and 160° C.
• Temperature may optionally be controlled at this stage, and for instance the mixture may be cooled.
• the temperature is not controlled at this stage, and it thus rises, possibly up to the boiling point of one or more of the solvents (including e.g. water) present in the mixture, and even above 100° C. if the reaction is carried out under pressure.
• the steam thus generated can be collected and then treated and/or recycled or disposed of.
• the mixture can optionally cool down (or be actively cooled down) after this exothermic surge. Temperature control and cooling devices as already mentioned above may be used to this end.
• a first phase (containing protic solvent) and a second phase (containing reaction solvent) may be obtained.
• the first phase is an aqueous phase and the second phase is an organic phase.
• Polyether ketone ketone is mostly present in the second phase, while the Lewis acid is mostly present in the first phase.
• the aqueous phase if present, may be separated from the product mixture before or after the centrifugal filtration described below, e.g. by decantation.
• polyether ketone ketones tend to form after dissociation of the complex a gel containing high amounts of liquid.
• the polymer may be granulated if it is not obtained in this form.
• the crude polymer granules obtained are porous and contain high amounts of liquid, and therefore are difficult to separate by conventional filtration.
• the solid/liquid separation step to recover polyether ketone ketone from the mixture thus comprises a step of centrifugal filtration, in a centrifugal filtration device.
• the centrifugal filtration device may be in particular a vertical centrifuge, a horizontal centrifuge or a decanter centrifuge.
• a horizontal centrifuge is preferred within the present process.
• the compaction stress in a centrifuge is proportional to the acceleration rate. Accordingly, it is preferred that the final step of solid/liquid separation after mothers-liquors filtration and washing is carried out under an acceleration rate that corresponds to a compaction stress of at least 0.5 bar during at least 5 minutes and more preferably 15 minutes.
• the acceleration used corresponds to a compaction stress that is comprised between 0.5 and 30 bars, and even more preferably between 2 and 15 bars.
• the acceleration rate of the centrifuge during the solid/liquid separation step can be constant or variable. According to a preferred embodiment, the acceleration rate is variable. In particular, the acceleration rate may be increased at the end of the solid/liquid separation step.
• the acceleration rate considered for a variable acceleration rate embodiment is the maximum acceleration rate.
• the acceleration rate for the solid/liquid separation is preferably at least 300 g, even more preferred at least 500 g, in particular at least 800 g and particularly preferred at least 1000 g.
• the acceleration rate may be advantageously increased.
• the acceleration rate can be raised during the last quarter, preferably the last 20%, the last 15% or the last 10% of the entire duration of the centrifugal filtration.
• the increased acceleration rate is preferably at least 500 g and more preferably at least 800 and in particular at least 1200 g.
• the solid/liquid separation step is advantageously performed at a temperature that ranges from 5° C. to 90° C.
• a separation temperature of at least 20° C. is preferred, in particular if an aqueous solution is used as a protic solvent.
• the duration of the centrifugal filtration is generally between 15 to 60 minutes, preferably 30 minutes or less and in particular 15 minutes or less.
• the centrifugal filtration be carried out in one batch.
• the dry solid matter content of the crude polyether ketone ketone product at the end of the solid/liquid separation step comprising a centrifugal filtration is preferably from 10 wt. % to 90 wt. %, preferably from 20 to 80 wt. % and in particular from 30 to 60 wt. %.
• the liquid effluents, containing the first phase and the second phase may optionally be separated so as to be recovered separately, preferably by decantation.
• a surfactant can be added in order to facilitate the phase separation.
• Solid polyether ketone ketone, together with residual impurities, is recovered after the solid/liquid separation step.
• the liquid effluents containing the Lewis acid may be submitted to suitable treatments so as to allow their reuse or recycling into the process.
• the effluents comprising Lewis acid may be recycled, notably as a flocculation agent for water treatment.
• said crude polyether ketone ketone is further purified by washing with one or more protic solvents.
• the protic solvent at this stage is preferably water or an aqueous solution.
• the protic solvent at this stage may be an organic solvent, optionally mixed with water.
• Aliphatic straight or branched alcohols such as methanol, ethanol and isopropanol are particularly preferred organic solvents. These organic solvents may optionally be mixed with another and/or with water.
• the weight ratio of protic solvent used at this stage to crude polyether ketone ketone may be e.g. be from 2 to 30, preferably from 3 to 10.
• the washing step may be performed by mixing the crude polyether ketone ketone recovered at the previous step with the protic solvent in a vessel.
• the duration of such a washing step may be e.g. from 15 min to 240 min, preferably from 15 to 120 min.
• centrifugal filtration device use is made of a centrifugal filtration device, so that washing and solid/liquid separation may be performed concomitantly in this device, without re-suspending the product.
• the acceleration rate of the centrifuge during the washing and subsequent solid/liquid separation step can be constant or variable. According to a preferred embodiment, the acceleration rate is lower during the washing step, so as to increase the contact time. However, the acceleration rate may be increased when starting the subsequent solid/liquid separation step and/or at the end thereof.
• the acceleration rate of the centrifuge for the washing is preferably 500 g or less, even more preferred 300 g or less, in particular 100 g or less.
• the acceleration rate for the subsequent solid/liquid separation is preferably at least 500 g, even more preferred at least 800 g, in particular at least 1000 g.
• the washing step and the subsequent or concomitant solid/liquid separation step are preferably performed at a temperature of at least 20° C.
• Possible temperature ranges for these steps are in particular from 20 to 25° C., from 25 to 30° C., from 30 to 35° C., from 35 to 40° C., from 40 to 45° C., from 45 to 50° C., from 50 to 55° C., and from 55 to 60° C. and even up to 100° C. for water.
• the washing step and the associated solid/liquid separation (preferably including centrifugal centrifugation) step may optionally be repeated one or more times, in exactly the same manner or in a different manner.
• different protic solvents, different washing durations and/or different temperatures may be used in the various washing and solid/liquid separation steps.
• the recovered solid may be dried.
• the drying step can be realized in a conventional manner, for instance at a temperature ranging from 100° C. to 280° C., and under atmospheric pressure or, preferably, under reduced pressure, for instance at a pressure of 30 mbar.
• polyether ketone ketone obtained is substantially pure.
• the ash content of the polyether ketone ketone is preferably less than 0.5 wt. %, preferably less than 0.3 wt. % and in particular less than 0.1 wt. %.
• the ash content is measured by determining the residual mass of a PEKK sample of a given weight after calcination in a furnace at 600° C. during 24H and dividing said residual mass by the mass of the PEKK sample before calcination.
• the polyether ketone ketone obtained according to the invention can subsequently be compounded and/or formed into the appropriate shape in view of further transformation and final use.
• a protic solvent aqueous solution of HCl at 3.3 wt.
• the residual humidity was measured using a halogen moisture analyzer (Mettler Toledo HR73) at 200° C. until constant weight.
• the residual aluminum was measured according to the following procedure:
• the resulting crude PEKK sample was analyzed using inductively coupled plasma/optical emission spectrometry (ICP/OES, model ICP Vista-Pro sold by Varian, wavelength: 396.15 nm for aluminum element). A standard was passed before and after each sample to check the base line.
• ICP/OES inductively coupled plasma/optical emission spectrometry
• centrifugal filtration was more efficient than filtration in terms of residual humidity and at least as good in terms of aluminum extraction.
• the crude PEKK slurry was washed immediately following initial solid/liquid separation, once with methanol and twice with water, using a centrifuge.
• the cake obtained was washed with 70 kg of methanol at 500 g, raised to 1000 g for the last 10 minutes of the duration of the centrifuge cycle.
• the washed cake was further washed twice with 30 kg of water, respectively, using the same acceleration scheme.
• the total time required for the solid/liquid separation and the subsequent washing sequence in the centrifuge was approximately 1 hour. Following washing, 7 kg of wet PEKK with a humidity of 55.2 wt. % and 140 ppm of residual aluminum are obtained.
• the methanol washing is divided in 3 sequences including one reslurrying and takes at least 4 hours.
• the washing is operated in 2 reslurrying steps and takes at least 3 hours.
• Example 10A-C Filter Cake Resistance Of Crude PEKK as a Function of Pressure
• the filter specific cake resistance of crude PEKK as obtained after contacting the product mixture with a protic solvent was determined for different pressures.
• the comparative example 1 was repeated as explained above adjusting the nitrogen pressure to 1, 2 and 3 bars, respectively, and the filtration pressure was determined as follows.
• the filter cake specific resistance R s was calculated by plotting the filtration time divided by the filtered volume (t/V) as a function of the filtered volume (V), by measuring the slope of the corresponding graph in the area where the regime is substantially linear, and by referring to the following Kozeny-Carman equation:
• t is the filtration time expressed in s
• R 0 is the specific resistance of the filtering medium expressed in m ⁇ 1 ,
• ⁇ is the viscosity of the filtrate at the filtration temperature in Pa.s
• V is the filtered volume at time t expressed in m 3 .
• A is the filtration surface is m 2 ,
• ⁇ P is the pressure drop across the filter (including the cake and the filtering medium) expressed in Pa
• W is the dry solid concentration of the suspension to be filtered in kg/m 3 and
• R s is the cake specific resistance in m/kg.
• a PEKK with low residual humidity may be obtained by applying a directional force on the granules during filtration.
• An appropriate directional stress may be applied in centrifugal filtration, and may be adjusted readily by changing the acceleration rate.
• a low residual humidity allows for a gain in drying time and energy and furthermore also improves the recuperation of residual Lewis acid.
• centrifugal filtration of the solid/liquid separation step and the subsequent washing steps in the same device so as to improve washing efficiency and to avoid the transfer of the crude product, gain time and improve efficiency.
• the method proposed thus allows the manufacture of polyether ketone ketone with a high purity and a high yield, which can be implemented at the industrial scale in an economically realistic manner.

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• Polyoxymethylene Polymers And Polymers With Carbon-To-Carbon Bonds (AREA)

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• 2017
  • 2017-07-18 EP EP17305956.9A patent/EP3431522B1/fr active Active
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  • 2018-07-16 CN CN201880047708.9A patent/CN110914331B/zh active Active
  • 2018-07-18 US US16/038,678 patent/US10851205B2/en active Active

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