WO2015163520A1 - Forme concave transversale d'une bande de polymérisation dans la production de particules polymères absorbant l'eau - Google Patents

Forme concave transversale d'une bande de polymérisation dans la production de particules polymères absorbant l'eau Download PDF

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Publication number
WO2015163520A1
WO2015163520A1 PCT/KR2014/003678 KR2014003678W WO2015163520A1 WO 2015163520 A1 WO2015163520 A1 WO 2015163520A1 KR 2014003678 W KR2014003678 W KR 2014003678W WO 2015163520 A1 WO2015163520 A1 WO 2015163520A1
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WIPO (PCT)
Prior art keywords
belt
water
monomer solution
absorbent polymer
polymer gel
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PCT/KR2014/003678
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English (en)
Inventor
Jeong Beom Park
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Songwon Industrial Co., Ltd.
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Application filed by Songwon Industrial Co., Ltd. filed Critical Songwon Industrial Co., Ltd.
Priority to PCT/KR2014/003678 priority Critical patent/WO2015163520A1/fr
Publication of WO2015163520A1 publication Critical patent/WO2015163520A1/fr

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Classifications

    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L15/00—Chemical aspects of, or use of materials for, bandages, dressings or absorbent pads
    • A61L15/16—Bandages, dressings or absorbent pads for physiological fluids such as urine or blood, e.g. sanitary towels, tampons
    • A61L15/22—Bandages, dressings or absorbent pads for physiological fluids such as urine or blood, e.g. sanitary towels, tampons containing macromolecular materials
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L15/00—Chemical aspects of, or use of materials for, bandages, dressings or absorbent pads
    • A61L15/16—Bandages, dressings or absorbent pads for physiological fluids such as urine or blood, e.g. sanitary towels, tampons
    • A61L15/42—Use of materials characterised by their function or physical properties
    • A61L15/60—Liquid-swellable gel-forming materials, e.g. super-absorbents
    • 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
    • C08F2/00—Processes of polymerisation
    • C08F2/01—Processes of polymerisation characterised by special features of the polymerisation apparatus used
    • 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
    • C08F2/00—Processes of polymerisation
    • C08F2/04—Polymerisation in solution
    • C08F2/10—Aqueous solvent
    • 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
    • C08F2/00—Processes of polymerisation
    • C08F2/46—Polymerisation initiated by wave energy or particle radiation
    • C08F2/48—Polymerisation initiated by wave energy or particle radiation by ultraviolet or visible light
    • 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
    • C08F220/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical or a salt, anhydride ester, amide, imide or nitrile thereof
    • C08F220/02—Monocarboxylic acids having less than ten carbon atoms; Derivatives thereof
    • C08F220/04—Acids; Metal salts or ammonium salts thereof
    • C08F220/06—Acrylic acid; Methacrylic acid; Metal salts or ammonium salts thereof
    • 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
    • C08F6/00—Post-polymerisation treatments
    • C08F6/008—Treatment of solid polymer wetted by water or organic solvents, e.g. coagulum, filter cakes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G15/00—Conveyors having endless load-conveying surfaces, i.e. belts and like continuous members, to which tractive effort is transmitted by means other than endless driving elements of similar configuration
    • B65G15/30—Belts or like endless load-carriers
    • B65G15/32—Belts or like endless load-carriers made of rubber or plastics
    • B65G15/40—Belts or like endless load-carriers made of rubber or plastics troughed or tubular; formed with joints facilitating troughing

Definitions

  • the invention relates to a process for the preparation of water- absorbent polymer particles; to a water-absorbent polymer particle obtainable by such a process; to a composite material comprising such a water-absorbent polymer particle; to a process for the production of a composite material, to a composite material obtainable by such a process; to a use of the water-absorbent polymer particle; to a device for the preparation of water-absorbent polymer particles; and to a process for the preparation of water-absorbent polymer particles using such a device.
  • Superabsorbers are water-insoluble, crosslinked polymers which are able to absorb large amounts of aqueous fluids, especially body fluids, more especially urine or blood, with swelling and the formation of hydrogels, and to retain such fluids under a certain pressure.
  • aqueous fluids especially body fluids, more especially urine or blood
  • hydrogels hydrogels
  • such polymers are chiefly used for incorporation into sanitary articles, such as, for example, baby's nappies/diapers, incontinence products or sanitary towels.
  • the preparation of superabsorbers is generally carried out by free-radical polymerization of acid-group-carrying monomers in the presence of crosslinkers, it being possible for poly- mers having different absorber properties to be prepared by the choice of the monomer composition, the crosslinkers and the polymerization conditions and of the processing conditions for the hydrogel obtained after the polymerization (for details see, for example, Modern Superabsorbent Polymer Technology, FL Buchholz, GT Graham, Wiley-VCH, 1998).
  • the polymer gel, also called hydrogel, obtained after the polymerization is usually comminuted, dried and classified in order to obtain a particulate superabsorber with a well defined particles size distribution.
  • these superabsorbent particles are often surface crosslinked in order to improve the absorption behavior.
  • the par- tides are mixed with an aqueous solution containing a surface crosslinking agent and optionally further additives and the thus obtained mixture is heat treated in order to promote the crosslinking reaction.
  • the acid-group-carrying monomers can be polymerized in the presence of the crosslinkers in a batch process or in a continuous process. Both in continuous and in batchwise polymerization, partially neutralized acrylic acid is typically used as the monomer. Suitable neutralization processes are described, for example, in EP 0 372 706 A2, EP 0 574 260 Al, WO 2003/051415 Al , EP 1 470 905 Al, WO 2007/028751 Al , WO 2007/028746 Al and WO 2007/028747 Al .
  • a common polymerization belt reactor comprises a conveyor belt being designed to carry an aqueous monomer solution which comprises the acid-group-carrying monomers during polymerization.
  • a conveyor belt of a polymerization reactor used in a process for the production of water- absorbent polymer particles in the prior art comprises a trough to keep the aqueous mono- mer solution from flowing off the conveyor belt.
  • a transversal shape of said trough is such that a capacity of the trough for keeping monomer solution from flowing off the belt is high.
  • a further object is to provide a process for the preparation of water- absorbent polymer particles using a polymerization belt reactor, characterized by a favorable balance of the criteria: low content of residual monomers in the water-absorbent polymer particles, low content of water-soluble polymer in the water-absorbent polymer particles, high capacity of the polymerization belt reactor for monomer solution.
  • a further object is to provide superabsorbent polymer particles which have been produced by a less expensive process.
  • It is a further object of the present invention to provide a composite material comprising a water-absorbent polymer particle produced by a process having at least one of the above advantages, wherein the composite material shows no reduction of quality.
  • Figure 1 a flow chart diagram depicting the steps of a process according to the invention
  • Figure 2 a flow chart diagram depicting the steps of another process according to the invention.
  • Figure 3 a flow chart diagram depicting the steps of another process according to the invention.
  • Figure 4 a scheme of a belt shape in a longitudinal cross section according to the invention
  • Figure 5 a scheme of a belt shape in a first transversal cross section according to the invention
  • Figure 6 a scheme of another belt shape in a first transversal cross section according to the invention.
  • Figure 7 a scheme of a belt shape in a transversal cross section not according to the invention.
  • Figure 8 a scheme of another belt shape in a transversal cross section not according to the invention.
  • Figure 9 a scheme of a basic setup of a polymerization belt reactor according to the invention.
  • Figure 10 a block diagram of a device for the preparation of water-absorbent polymer particles according to the invention.
  • step (vii) 108 step (viii)
  • a contribution to the solution of at least one of these objects is made by a process for the preparation of water-absorbent polymer particles, comprising the process steps of
  • the belt has a shape of a first concave curve; wherein R is in the range of from 2 to 30, preferably from 2.5 to 25, more preferably from 3 to 25, more preferably from 3.5 to 25, more preferably from 4 to 25, more preferably from 4.5 to 25, more preferably from 5 to 25, more preferably from 5.5 to 25, more preferably from 6 to 20, most preferably from 6.5 to 20; wherein R is a ratio of a horizontal width of the first concave curve to a vertical height of the first concave curve.
  • a concave curve is a curved line comprising a point, wherein going away from that point along the line includes going monotonically upwards. Going monotonically upwards means, going upwards or keeping a constant level of height. Going monotonically upwards excludes any downward movement. This means that the concave curve is curved away from the belt of the polymerization belt reactor.
  • a preferred first transversal cross section of the belt is a transversal cross section of an upper run the belt.
  • the process according to the present invention is preferably a continuous process in which the aqueous monomer solution is continuously provided and is continuously fed into the polymerization belt reactor, preferably onto the belt of the polymerization belt reactor.
  • the polymer gel obtained is continuously discharged out of the polymerization belt reactor and is continuously optionally comminuted, dried, grinded and sized in the subsequent process steps.
  • This continuous process may, however, be interrupted in order to, for example, to substitute certain parts of the process equipment, like the belt material of the polymerization belt reactor,
  • Water-absorbent polymer particles which are preferred according to the invention are parti- cles that have an average particle size in accordance with WSP 220.2 (test method of "Word Strategic Partners " ED ANA and INDA) in the range of from 10 to 3,000 ⁇ , preferably 20 to 2,000 ⁇ and particularly preferably 150 to 850 ⁇ .
  • WSP 220.2 test method of "Word Strategic Partners " ED ANA and INDA”
  • the content of water-absorbent polymer particles having a particle size in a range of from 300 to 600 ⁇ to be at least 30 wt.-%, particularly preferably at least 40 wt- % and most preferably at least 50 wt.-%, based on the total weight of the water-absorbent polymer particles.
  • an aqueous monomer solution containing at least one partially neutralized, monoethylenically unsaturated mono- mer bearing carboxylic acid groups (al) and at least one crosslinker (a3) is prepared.
  • Preferred monoethylenically unsaturated monomers bearing carboxylic acid groups (al) are those cited in DE 102 23 060 Al as preferred monomers (al), whereby acrylic acid is particularly preferred.
  • the water-absorbent polymer produced by the process according to the invention comprises monomers bearing carboxylic acid groups to at least 50 wt.-%, preferably to at least 70 wt.-% and further preferably to at least 90 wt.-%, based on the dry weight. It is particularly preferred according to the invention, that the water-absorbent polymer produced by the process according to the invention is formed from at least 50 wt.-%, preferably at least 70 wt.-% of acrylic acid, which is preferably neutralized to at least 20 mol-%, particularly preferably to at least 50 mol-%.
  • the concentration of the partially neutralized, monoethylenically unsaturated monomers bearing carboxylic acid groups (al) in the aqueous monomer solution that is provided in process step (i) is preferably in the range between 10 to 60 wt.-%, preferably 30 to 55 wt.-% and most preferably between 40 to 50 wt.-%, based on the total weight of the aqueous monomer solution.
  • the aqueous monomer solution may also comprise monoethylenically unsaturated mono- mers (a2) which are copolymerizable with (al).
  • Preferred monomers (a2) are those monomers which are cited in DE 102 23 060 Al as preferred monomers (a2), whereby acryla- mide is particularly preferred.
  • a crosslinking of the polymer is achieved by radical polymerization of the ethylenically unsaturated groups of the crosslinker molecules with the monoethylenically unsaturated monomers (otl) or (a2), while with the compounds of crosslinker class II and the polyvalent metal cations of crosslinker class IV a crosslinking of the polymer is achieved respectively via condensation reaction of the functional groups (crosslinker class II) or via electrostatic interaction of the polyvalent metal cation (crosslinker class IV) with the functional groups of the monomer (al) or (a2).
  • cross-linker class III a cross-linking of the polymers is achieved corre- spondingly by radical polymerization of the ethylenically unsaturated groups as well as by condensation reaction between the functional groups of the cross-linkers and the functional groups of the monomers (al) or (a2).
  • Preferred crosslinkers (a3) are all those compounds which are cited in DE 102 23 060 Al as crosslinkers (a3) of the crosslinker classes I, II, III and IV, whereby as compounds of crosslinker class I, N, N ' -methylene bisacrylamide, polyethylene- glycol di(meth)acrylates, triallylmethylammonium chloride, tetraallylammonium chloride and allylnonaethyleneglycol acrylate produced with 9 mol ethylene oxide per mol acrylic acid are particularly preferred, wherein N, N ' -methylene bisacrylamide is even more preferred, and as compounds of crosslinker class IV, Al 2 (S0 4 ) 3 and its hydrates are particularly preferred.
  • Preferred water-absorbent polymers produced by the process according to the invention are polymers which are crosslinked by crosslinkers of the following crosslinker classes or by crosslinkers of the following combinations of crosslinker classes respectively: I, II, III, IV, I II, I III, I IV, I II III, I II IV, I III IV, II III IV, II IV or III IV.
  • water-absorbent polymers produced by the process according to the invention are polymers which are crosslinked by any of the crosslinkers disclosed in DE 102 23 060 Al as crosslinkers of crosslinker classes I, whereby ⁇ , ⁇ ' -methylene bis- acrylamide, polyethyleneglycol " di(meth)acrylates, triallyl-methylammonium chloride, tetraallylammonium chloride and allylnonaethylene-glycol acrylate produced from 9 mol ethylene oxide per mol acrylic acid are particularly preferred as crosslinkers of crosslinker class I, wherein N, 1ST -methylene bisacrylamide is even more preferred.
  • the aqueous monomer solution may further comprise water-soluble polymers (a4).
  • Preferred water-soluble polymers (cx4) include partly or completely saponified polyvinyl alco- hoi, polyvinylpyrrolidone, starch or starch derivatives, polyglycols or polyacrylic acid. The molecular weight of these polymers is not critical, as long as they are water-soluble.
  • Preferred water-soluble polymers (a4) are starch or starch derivatives or polyvinyl alcohol.
  • the water-soluble polymers ( 4), preferably synthetic, such as polyvinyl alcohol, can not only serve as a graft base for the monomers to be polymerized. It is also conceivable for these water-soluble polymers to be mixed with the polymer gel or the already dried, water- absorbent polymer.
  • the aqueous monomer solution can furthermore also comprise auxiliary substances (cc5), these auxiliary substances including, in particular, complexing agents, such as, for example, EDTA.
  • auxiliary substances including, in particular, complexing agents, such as, for example, EDTA.
  • the relative amount of monomers (al) and (a2) and of crosslinking agents (a3) and water- soluble polymers (a4) and auxiliary substances (a5) in the aqueous monomer solution is preferably chosen such that the water-absorbent polymer structure obtained after drying the optionally comminuted polymer gel is based to the extent of 20 to 99.999 wt.-%, preferably to the extent of 55 to 98.99 wt.-% and particularly preferably to the extent of 70 to 98.79 wt.-% on monomers (al), to the extent of 0 to 80 wt.-%, preferably to the extent of 0 to 44.99 wt.-% and par- ticularly preferably to the extent of 0.1 to 44.89 wt.-% on the monomers (a2), to the extent of 0 to 5 wt.-%, preferably to the extent of 0.001 to 3 wt.-% and particularly preferably to the extent of 0.01 to 2.5 wt.-%
  • Optimum values for the concentration in particular of the monomers, crosslinking agents and water-soluble polymers in the monomer solution can be determined by simple preliminary experiments or from the prior art, in particular from the publications US 4,286,082, DE 27 06 135 Al, US 4,076,663, DE 35 03 458 Al, DE 40 20 780 CI, DE 42 44 548 Al , DE 43 33 056 Al and DE 44 18 818 Al .
  • fine particles of a water-absorbent polymer may optionally be added to the aqueous monomer solution.
  • fine water-absorbent poly- mer particles may be added to the aqueous monomer solution at one selected from the group consisting of after step (iii), after step (iv), and before step (v), or a combination of at least two thereof.
  • Water-absorbent fine particles are preferably water-absorbent polymer particles the compo- sition of which corresponds to the composition of the above described water-absorbent polymer particles, wherein it is preferred that at least 90 wt.-% of the water-absorbent fine particles, preferably at least 95 wt.-% of the water-absorbent fine particles and most preferred at least 99 wt.-% of the water-absorbent fine particles have a particle size of less than 200 ⁇ , preferably less than 150 ⁇ and particular preferably less than 100 ⁇ .
  • the water- absorbent fine particles which may optionally be added to the aqueous monomer solution in process step (ii) are water-absorbent fine particles which are obtained in process step (x) of the process according to the present invention and which are thus recycled.
  • the fine particles can be added to the aqueous monomer solution by means of any mixing device the person skilled of the art would consider as appropriate for this purpose.
  • the fine particles are added to the aqueous mono- mer solution in a mixing device in which a first stream of the fine particles and a second stream of the aqueous monomer solution are directed continuously, but from different directions, onto a rotating mixing device.
  • a mixing device in which a first stream of the fine particles and a second stream of the aqueous monomer solution are directed continuously, but from different directions, onto a rotating mixing device.
  • a so called "Rotor Stator Mixer” which comprises in its mixing area a preferably cylindrically shaped, non-rotating stator, in the centre of which a likewise preferably cylindrically shaped rotor is rotating.
  • the walls of the rotor as well as the walls of the stator are usually provided with notches, for example notches in the form of slots, through which the mixture of fine particles and aqueous monomer solution can be sucked through and thus can be subjected to hi gl shear forces.
  • the first stream of the fine particles and the second stream of the aqueous monomer solution form an angle ⁇ in the range from 60 to 120°, more preferred in the range from 75 to 105°, even more preferably in the range from 85 to 95° and most preferred form an angle of about 90°.
  • the stream of the mixture of fine particles and aqueous monomer solution that leaves the mixer and the first stream of fine particles that enters the mixer form an angle ⁇ in the range from 60 to 120°, preferably in the range from 75 to 105°, even more preferred in the range from 85 to 95° and most preferred form an angle of about 90°.
  • Such a kind of mixing set up can, for example, be realized by means of mixing devices which are disclosed in DE-A-25 20 788 and DE-A-26 17 612, the content of which is incor- porated herein by reference.
  • Concrete examples of mixing devices which can be used to add the fine particles to the aqueous monomer solution in process step (ii) of the present invention are the mixing devices which can be obtained by the IKA ® Maschinene GmbH & Co. KG, Staufen, Germany, under designations MHD 2000/4, MHD 2000/05, MHD 2000/10, MDH 2000/20, MHD 2000/30 und MHD 2000/50, wherein the mixing device MHD 2000/20 is particularly preferred.
  • Further mixing devices which can be used are those offered by ystral GmbH, Ballrechten-Dottingen, Germany, for example under designation “Conti TDS", or by Kinematika AG, Luttau, Switzerland, for example under the trademark Megatron ® .
  • the amount of fine particles that may be added to the aqueous monomer solution in process step (ii) is preferably in the range from 0.1 to 15 wt.-%, even more preferred in the range from 0.5 to 10 wt.-% and most preferred in the range from 3 to 8 wt.-%, based on the weight of the aqueous monomer solution.
  • a polymerization initiator or at least one component of a polymerization initiator system that comprises two or more components is added to the aqueous monomer solution.
  • polymerization initiators for initiation of the polymerization all initiators forming radicals under the polymerization conditions can be used, which are commonly used in the production of superabsorbers. Among these belong thermal catalysts, redox catalysts and photo-initiators, whose activation occurs by energetic irradiation.
  • the polymerization initiators may be dissolved or dispersed in the aqueous monomer solution. The use of water- soluble catalysts is preferred.
  • thermal initiators may be used all compounds known to the person skilled in the art that decompose under the effect of an increased temperature to form radicals. Particularly preferred are thermal polymerisation initiators with a half life of less than 10 seconds, more preferably less than 5 seconds at less than 180°C, more preferably at less than 140°C. Peroxides, hydroperoxides, hydrogen peroxide, persulfates and azo compounds are particularly preferred thermal polymerization initiators. In some cases it is advantageous to use mixtures of various thermal polymerization initiators. Among such mixtures, those consisting of hydrogen peroxide and sodium or potassium peroxodisulfate are preferred, which may be used in any desired quantitative ratio.
  • Suitable organic peroxides are preferably acetylacetone peroxide, methyl ethyl ketone peroxide, benzoyl peroxide, lauroyl peroxide, acetyl peroxide, capryl peroxide, isopropyl peroxidicarbonate,2-ethylhexyle peroxidicarbonate, tert.-butyl hydroperoxide, cumene hydroperoxide, and peroxides of tert- amyl perpivalate, tert.-butyl perpivalate, tert.-butyl peraeohexonate, tert.-butyl isobutyrate, tert.-butyl per-2-ethylhexenoate, .
  • tert.-butyl perisononanoate tert.-butyl permaleate
  • tert.- butyl perbenzoate tert.-butyl-3,5,5-trimethylhexanoate and amyl perneodecanoate.
  • thermal polymerisation initiators are preferred: azo compounds such as azo-bis-isobutyronitril, azo-bis-dimethylvaleronitril, azo-bis-ami-dinopropane dihydrochloride, 2,2'-azobis-(N,N-dimethylene)isobutyramidine di-hydrochloride, 2- (carbamoylazo)isobutyronitrile and 4,4'-azobis-(4-cyano-valeric acid).
  • azo compounds such as azo-bis-isobutyronitril, azo-bis-dimethylvaleronitril, azo-bis-ami-dinopropane dihydrochloride, 2,2'-azobis-(N,N-dimethylene)isobutyramidine di-hydrochloride, 2- (carbamoylazo)isobutyronitrile and 4,4'-azobis-(4-cyano-valeric acid).
  • the aforementioned compounds are used in conventional amounts,
  • Redox catalysts comprise two or more components, usually one or more of the peroxo compounds listed above, and at least one reducing component, preferably ascorbic acid, glucose, sorbose, mannose, ammonium or alkali metal hydrogen sulfite, sulfate, thiosulfate, hyposulfite or sulfide, metal salts such as iron II ions or silver ions or sodium hydroxymethyl sulfoxylate.
  • reducing component preferably ascorbic acid, glucose, sorbose, mannose, ammonium or alkali metal hydrogen sulfite, sulfate, thiosulfate, hyposulfite or sulfide, metal salts such as iron II ions or silver ions or sodium hydroxymethyl sulfoxylate.
  • ascorbic acid or sodium pyrosulfite is used as reducing component of the redox catalyst.
  • 1 ⁇ 10 "5 to 1 mol-% of the reducing component of the redox catalyst and 1 ⁇ 10 "5 to 5 mol-% of the oxidizing component of the redox catalyst are used, in each case referred to the amount of monomers used in the polymerization.
  • the oxidizing component of the redox catalyst or as a complement thereto, one or more, preferably water-soluble azo compounds may be used.
  • the polymerization is preferably initiated by action of energetic radiation, so-called photo- initiators are generally used as initiator. These can comprise for example so-called a- splitters, H-abstracting systems or also azides.
  • initiators examples include benzophe- none derivatives such as Michlers ketone, phenanthrene derivatives, fluorine derivatives, anthraquinone derivatives, thioxanthone derivatives, cumarin derivatives, benzoinether and derivatives thereof, azo compounds such as the above-mentioned radical formers, substituted hexaarylbisimidazoles or acylphosphine oxides.
  • azides are: 2-(N,N- dimethylamino)ethyl-4-azidocinnamate, 2-(N,N-dimethylamino)ethyl-4- azidonaphthylketone, 2-(N,N-di-methylamino)ethyl-4-azidobenzoate, 5-azido- 1 -naphthyl- 2'-(N,N-dimethylami-no)ethylsulfone, N-(4-sulfonylazidophenyl)maleinimide, N-acetyl-4- sulfonyl-azidoaniline, 4-sulfonylazidoaniline, 4-azidoaniline, 4-azidophenacyl bromide, p- azidobenzoic acid, 2,6-bis(p-azidobenzylidene)cyclohexanone and 2,6-bis(p- azido
  • a further group of photo-initiators are di- alkoxy ketales such as 2,2-dimethoxy-l,2-diphenylethan-l-one.
  • the photo-initiators when used, are generally employed in quantities from 0.0001 to 5 wt.-% based on the monomers to be polymerized.
  • the initiator comprises the following components
  • iiib an organic initiator molecule comprising at least three oxygen atoms or at least three nitrogen atoms;
  • the initiator comprises the peroxodisulfate and the organic initiator molecule in a molar ratio in the range of from 20:1 to 50: 1.
  • concentration of the initiator component iiia. is in the range from 0.05 to 2 wt.-%, based on the amount of monomers to be polymerized.
  • organic initiator molecule is selected from the group con ⁇ sisting of 2,2-dimethoxy-l ,2-diphenylethan-l-one, 2,2-azobis-(2- amidinopropane)dihydrochloride, 2,2-azobis-(cyano valeric acid) or a combination of at least two thereof.
  • the peroxodisul- fate is of the general formula M 2 S 2 0 8 , with M being selected from the group consisting of NH 4 , Li, Na, Ka or at least two thereof.
  • M being selected from the group consisting of NH 4 , Li, Na, Ka or at least two thereof.
  • the above described components are in particular suitable for UV initiation of the polymerization in step (vi) of the process of the present invention.
  • Employing this composition further yields low residual monomer and reduced yellowing in the water-absorbent polymer particle, obtainable by the process according to the present invention.
  • step (iii), adding the polymerization initiator may be realized before step (iv), simultaneously to step (iv), or overlapping in time with step (iv), i.e. when the oxygen content of the aqueous monomer solution is decreased.
  • a polymerization initiator system is used that comprises two or more components, one or more of the components of such a polymerization initiator system may, for example, be added before process step (iv), whereas the remaining component or the remaining components which are necessary to complete the activity of the polymerisation initiator system, are added after process step (iv), perhaps even after process step (v).
  • decreasing the oxygen content of the aqueous monomer solution may also be performed before process step (iii) according to the invention.
  • the oxygen content of the aqueous monomer solution is optionally decreased.
  • decreasing the oxygen content of the aqueous monomer solution may also be performed before, during or after process step (ii) according to the invention.
  • the oxygen content of the aqueous monomer solution is decreased after the fine particles have been added in process step (ii).
  • the oxygen content of the aqueous monomer solution is decreased, this may be realized by bringing the aqueous monomer solution into contact with an inert gas, such as nitrogen.
  • the phase of the inert gas being in contact with the aqueous monomer solution is free of oxygen and is thus characterized by a very low oxygen partial pressure.
  • oxygen converts from the aqueous monomer solution into the phase of the inert gas until the oxygen partial pressures in the phase of the inert gas and the aqueous monomer solution are equal.
  • Bringing the aqueous monomer phase into contact with a phase of an inert gas can be accomplished, for example, by introducing bubbles of the inert gas into the monomer solution in co-current, countercurrent or intermediate angles of entry. Good mix- ing can be achieved, for example, with nozzles, static or dynamic mixers or bubble columns.
  • the oxygen content of the monomer solution before the polymerization is preferably lowered to less than 1 ppm by weight, more preferably to less than 0.5 ppm by weight, based on the monomer solution.
  • process step (v) of the process according to the present invention the aqueous monomer solution is charged onto the belt of the polymerization belt reactor.
  • the aqueous monomer solution is charged onto the belt at an upstream position of the belt.
  • a preferred belt is a conveyor belt.
  • any conveyor belt can be used which the person skilled in the art considers to be useful as a support material onto which the above described aqueous monomer solution can be charged and subsequently polymerized to form a hydrogel.
  • the polymerization belt reactor usually comprises an endless moving conveyor belt passing over supporting elements and at least two guide rollers, of which at least one is driven and one is configured so as to be adjustable.
  • a winding and feed system for a release sheet that may be used in sections on the upper surface of the conveyor belt is provided.
  • the system includes a supply and metering system for the reaction components, and optional irradiating means arranged in the direction of movement of the conveyor belt after the supply and metering system, together with cooling and heating devices, and a removal sys- tern for the polymer gel that is arranged in the vicinity of the guide roller for the return run of the conveyor belt.
  • the conveyor belt is supported in the vicinity of the supply system for the reaction components by a plurality of trough-shaped supporting and bearing elements that form a deep trough-like or dish-like configuration for the reaction components that are introduced.
  • each supporting element is preferably formed by a cylindrical or spherical roller that is rotatable about its longitudinal axis.
  • the belt can be made of various materials, although these preferably have to meet the requirements of good tensile strength and flexibility, good fatigue strength under repeating bending stresses, good deformability and chemical resistance to the individual reaction components under the conditions of the polymerization. These demands are usually not met by a single material. Therefore, a multi-layer material is commonly used as belt of the present invention.
  • the mechanical requirements can be satisfied by a carcass of, for example, fabric inserts of natural and/or synthetic fibers or glass fibers or steel cords.
  • the chemical resistance can be achieved by a cover of, for example, polyethylene, polypropylene, polyisobutylene, halogenated polyolefines such as polyvinyl chloride or polytetrafluorethylene, polyamides, natural or synthetic rubbers, polyester resins or epoxy resins.
  • the preferred cover material is silicone rubber.
  • the polymer gel that is obtained on the belt is discharged from the belt.
  • the polymer gel is removed from the belt as a continuous strand that is of a soft semi-solid consistency and is then passed on for further processing optionally comprising comminuting. By comminuting the polymer gel polymer gel particles are obtained.
  • Comminution of the polymer gel is preferably performed in at least three steps: in a first step, a cutting unit, preferably a knife, for example a knife as disclosed in WO-A-96/36464, is used for cutting the polymer gel into flat gel strips, preferably with a length within the range of from 5 to 500 mm, preferably from 10 to 300 mm and particularly preferably from 100 to 200 mm, a height within the range of from 1 to 30 mm, preferably from 5 to 25 mm and particularly preferably from 10 to 20 mm as well as a width within the range of from 1 to 500 mm, preferably from 5 to 250 mm and particularly preferably from 10 to 200 mm; in a second step, a shredding unit, preferably a breaker, is used for shredding the gel strips into gel pieces, preferably with a length within the range of 3 to 100 mm, preferably from 5 to 50 mm, a height within the range from 1 to 25 mm, preferably from 3 to 20 mm as well as a
  • the polymer gel is dried.
  • the drying of the polymer gel can be effected in any dryer or oven the person skilled in the art considers as appropriate for drying the polymer gel or the above described gel particles.
  • Rotary tube furnaces, fluidized bed dryers, plate dryers, paddle dryers and infrared dryers may be mentioned by way of example.
  • belt dryers are a convective system of drying, for the particularly gentle treatment of through-airable products.
  • the product to be dried is placed onto an endless conveyor belt which lets gas through, and is subjected to the flow of a heated gas stream, preferably air.
  • the drying gas is recirculated in order that it may become very highly saturated in the course of repeated passage through the product layer.
  • a certain fraction of the drying gas preferably not less than 10 %, more preferably not less than 15 % and most preferably not less than 20 % and preferably up to 50 %, more preferably up to 40 % and most preferably up to 30 % of the gas quantity per pass, leaves the dryer as a highly saturated vapor and carries off the water quantity evaporated from the product.
  • the temperature of the heated gas stream is preferably not less than 50°C, more preferably not less than 100°C and most preferably not less than 150°C and preferably up to 250°C, more preferably up to 220°C and most preferably up to 200°C.
  • a belt dryer can be embodied as a single-belt, multi-belt, mul- ti-stage or multistory system.
  • the present invention is preferably practiced using a belt dryer having at least one belt.
  • One-belt dryers are very particularly preferred.
  • the drying properties of the water- absorbent polymers are individually determined as a function of the processing parameters chosen.
  • the hole size and mesh size of the belt is conformed to the product.
  • cer- tain surface enhancements such as electropolishing or Teflonizing, are possible.
  • the polymer gel to be dried is preferably applied to the belt of the belt dryer by means of a swivel belt.
  • the feed height i.e. the vertical distance between the swivel belt and the belt of the belt dryer, is preferably not less than 10 cm, more preferably not less than 20 cm and most preferably not less than 30 cm and preferably up to 200 cm, more preferably up to 120 cm and most preferably up to 40 cm.
  • the thickness on the belt dryer of the polymer gel to be dried is preferably not less than 2 cm, more preferably not less than 5 cm and most preferably not less than 8 cm and preferably not more than 20 cm, more preferably not more than 15 cm and most preferably not more than 12 cm.
  • the belt speed of the belt dryer is preferably not less than 0.005 m/s, more preferably not less than 0.01 m/s and most preferably not less than 0.015 m/s and preferably up to 0.05 m/s, more preferably up to 0.03 m/s and most preferably up to 0.025 m/s.
  • the polymer gel is dried to a water content in the range of from 0.5 to 25 wt.-%, preferably from 1 to 10 wt.-% and par- ticularly preferably from 3 to 7 wt.-%, based on the dried polymer gel.
  • the dried polymer gel is ground thereby obtaining water-absorbent polymer particles.
  • any device can be used the person skilled in the art considers as appropriate for grinding the dried polymer gel or the above described dried polymer gel.
  • a suitable grinding device a single- or multistage roll mill, preferably a two- or three-stage roll mill, a pin mill, a hammer mill or a vibratory mill may be mentioned.
  • the ground water- absorbent polymer particles are sized, preferably using appropriate sieves.
  • the content of polymer particles having a particle size of less than 150 ⁇ is less than 10 wt.-%, pref- erably less than 8 wt.-% and particularly preferably less than 6 wt.-% and that the content of polymer particles having a particle size of more than 850 ⁇ is also less than 10 wt.-%, preferably less than 8 wt.-% and particularly preferably less than 6 wt.-%, each based on the total weight of the water-absorbent polymer particles.
  • water-absorbent polymer particles after sizing the water-absorbent polymer particles at least 30 wt.-%, more preferred at least 40 wt.-% and most preferred at least 50 wt.-% of the water-absorbent polymer particles have a particle size in a range of from 300 to 600 ⁇ .
  • the surface of the ground and sized water-absorbent polymer particles are optionally treated.
  • any measure can be used the person skilled in the art considers as appropriate for such a purpose.
  • surface treatments include, for example, surface crosslinking, the treatment of the surface with water- soluble salts, such as aluminium sulfate or aluminium lactate, the treatment of the surface with inorganic particles, such as silicon dioxide, and the like.
  • the components used to treat the surface of the polymer particles are added in the form of aqueous solutions to the water-absorbent polymer particles. After the particles have been mixed with the aqueous solutions, they are heated to a temperature in the range of from 150 to 230°C, preferably 160 to 200°C in order to promote the surface- crosslinking reaction.
  • the polymerizing in step (vi) is initiated by an irradiation, preferably of the aqueous monomer solution, with UV radiation.
  • UV radiation is electromagnetic radiation having a wavelength in the range of from 100 to 380 nm.
  • a longitudinal position of the first transversal cross section can be every longitudinal position within a first longitudinally extending portion of the belt; wherein the first longitudinally extending portion of the belt extends longitudinally over 25 to 40 %, preferably over 25 to 38 %, more preferably over 25 to 36 %, more pref- erably over 25 to 34 %, more preferably over 25 to 32 %, more preferably over 25 to 30 %, most preferably over 25 to 28 %, of a longitudinal extension of the belt.
  • the longitudinally extending portion is a longitudinally connected portion.
  • the first concave curve comprises a horizontally aligned portion; wherein the horizontally aligned portion extends over at least 70 %, preferably at least 75 %, more preferably at least 80 %, more preferably at least 85 %, most preferably at least 90 %, of the horizontal width of the first concave curve.
  • the tangent is a tangent on an endpoint of the first concave curve.
  • a preferred first curve angle is an external angle with respect to the first concave curve.
  • the belt downstream to the first longitudinally extending portion of the belt the belt comprises a further longitudinally extending portion; wherein in a further transversal cross section of the belt the belt has a shape of a further concave curve; wherein a longitudinal position of the further transversal cross section can be every longitudinal position within the further longitudinally extending portion of the belt; wherein a tangent on any position of the further concave curve inclines a further curve angle with a horizontal line in the further transversal cross section; wherein a maximum of the further curve angle is in the range of from 0 to 45°, preferably from 0 to 40°, more preferably from 0 to 35°, more preferably from 0 to 30°, more preferably from 0 to 25°, more preferably from 0 to 20°, more preferably from 0 to 15°, most preferably from 0 to 10°.
  • a preferred further longi- tudinally extending portion follows the first longitudinally extending portion directly in a downstream direction.
  • a preferred further curve angle is an external angle with respect to the further concave curve.
  • a preferred further transversal cross section of the belt is a transversal cross section of an upper run the belt.
  • the further longitudinally extending portion of the belt extends longitudinally over 30 % or less, preferably over 25 % or less, more preferably over 20 % or less, most preferably over 15 % or less, of the longitudinal extension of the belt.
  • the first concave curve forms a trough section; wherein the trough section has a trough section area; wherein the trough section area is trapezoidally shaped.
  • the trough section is preferably formed by the belt, preferably by a horizontally aligned portion of the belt and by sidewalls.
  • a preferred trapezoidal shape com- prises rounded corners.
  • a trough section is a longitudinally limited part of a trough.
  • the first concave curve forms a trough section; wherein the trough section has a trough section area; wherein the trough section area has an area of in the range of from 1,000 to 3,000 cm 2 , preferably from 1 ,200 to 2,800 cm 2 , more prefera- bly from 1 ,500 to 2,500 cm 2 .
  • the first concave curve has a vertical height of 500 mm or less, preferably of 450 mm or less, more preferably of 400 mm or less, more preferably of 350 mm or less, more preferably of 300 mm or less, more preferably 250 mm or less, more preferably 200 mm or less, most preferably of 150 mm or less.
  • the polymer gel being discharged in process step (vii) comprises water in the range of from 40 to 60 wt.-%, preferably from 50 to 60 wt.-%, more preferably from 53 to 56 wt.-%, based on the polymer gel.
  • the polymer gel being discharged in process step (vii) is a polymer gel sheet; wherein the polymer gel sheet is characterized by a thickness in the range of from 10 to 200 mm, preferably from 10 to 100 mm, more preferably from 15 to 75 mm, most preferably from 15 to 50 mm.
  • the polymer gel being discharged in process step (vii) is a polymer gel sheet; wherein the polymer gel sheet is characterized by a width in the range of from 30 to 300 cm, preferably from 50 to 250 cm, more preferably from 60 to 200 cm, most preferably from 80 to 100 cm.
  • the polymerization in step (vi) is performed in presence of a blowing agent.
  • the blowing agent may be added to the aqueous monomer solution in one selected from the group consisting of step (i), step (ii), step (iii),.step (iv), step (v), and step (vi), or in a combination of at least two thereof.
  • the blowing agent is added to the monomer solution in step (i).
  • the blowing agent should be added prior or immediately after the polymerization in step (vi) is initiated.
  • the blowing agent is added to the monomer solution after or simultaneously to adding the initiator or a component of an initiator system.
  • the blowing agent is added to the monomer solution in an amount in the range of from 500 to 4000 ppm by weight, preferably from 1000 to 3500 ppm by weight, more preferably from 1500 to 3200 ppm by weight, most preferably from 2000 to 3000 ppm by weight, based on the total weight of the monomer solution.
  • a blowing agent is a substance which is capable of producing a cellular structure or pores or both via a foaming process during polymerization of the monomers.
  • the foaming process is preferably endo thermic.
  • a preferred endothermic foaming process is started by heat from an exothermic polymerisation or crosslinking or both reaction.
  • a preferred blowing agent is a physical blowing agent or a chemical blowing agent or both.
  • a preferred physical blowing agent is one selected from the group consisting of a CFC, a HCFC, a hydrocarbon, and C0 2 , or a combination of at least two thereof.
  • a preferred C0 2 is liquid C0 2 .
  • a preferred hydro- carbon is one selected from the group consisting of pentane, isopentane, and cyclopentane, or a combination of at least two thereof.
  • a preferred chemical blowing agent is one selected from the group consisting of a carbonate blowing agent, a nitrite, a peroxide, calcined soda, an oxalic acid derivative, an aromatic azo compound, a hydrazine, an azide, a ⁇ , ⁇ '- Dinitro- soamide, and an organic blowing agent, or a combination of at least two thereof.
  • a very particularly preferred blowing agent is a carbonate blowing agent.
  • Carbonate blowing agents which may be used according to the invention are disclosed in US 5, 1 18, 719 A, and are incorporated herein by reference.
  • a preferred carbonate blowing agent is a carbonate containing salt, or a bicarbonate containing salt, or both.
  • Another preferred carbonate blowing agent comprises one selected from the group consisting of CO? as a gas, C0 2 as a solid, ethylene carbonate, sodium carbonate, potassium carbonate, ammonium carbonate, magnesium carbonate, or magnesium hydroxic carbonate, calcium carbonate, barium carbonate, a bicarbonate, a hydrate of these, other cations, and naturally occurring carbonates, or a combination of at least two thereof.
  • a preferred naturally occurring carbonate is dolomite.
  • the above mentioned carbonate blowing agents release C0 2 when being heated while dissolved or dispersed in the monomer solution.
  • a particularly preferred carbonate blowing agent is MgC0 3 , which may also be represented by the formula (MgC0 3 ) 4 -Mg(OH) 2 -5-H 2 0.
  • Another preferred carbonate blowing agent is agent is (NH 4 ) 2 C0 3 .
  • the MgC0 3 and (NH 4 ) 2 C0 3 may also be used in mixtures.
  • Preferred carbonate blowing agents are carbonate salts of multivalent cations, such as Mg, Ca, Zn, and the like.
  • Examples of such carbonate blowing agents are Na 2 C0 3 , K 2 C0 3 , (NH 4 ) 2 C0 3 , MgC0 3 , CaC0 3 , NaHC0 3 , KHC0 3 , NH 4 HC0 3 , Mg(HC0 3 ) 2 , Ca(HC0 3 ) 2 , ZnC0 3 , and BaC0 3 .
  • certain of the multivalent transition metal cations may be used, some of them, such as ferric cation, can cause color staining and may be subject to reduction oxidation reactions or hydrolysis equilibria in water. This may lead to difficulties in quality control of the final polymeric product.
  • other multivalent cations such as Ni, Ba, Cd, Hg would be unacceptable because of potential toxic or skin sensitizing effects.
  • a preferred nitrite is ammonium nitrite.
  • a preferred peroxide is hydrogen peroxide.
  • a preferred aromatic azo compound is one selected from the group consisting of a triazene, ary- lazosulfones, arylazotriarylmethanes, a hydrazo compound, a diazoether, and diazoamino- benzene, or a combination of at least two thereof.
  • a prefeixed hydrazine is phenylhydrazine.
  • a preferred azide is a carbonyl azide or a sulfonyl azide or both.
  • a prefeixed ⁇ , ⁇ '- Dinitro- soamide is ' N,N'-dimethyl-N,N'-dinitrosoterephtlialaraide.
  • a contribution to the solution of at least one of the above objects is provided by a device for the preparation of water-absorbent polymer particles in a process stream, comprising
  • a first container designed to take an aqueous monomer solution, comprising at least one partially neutralized, monoethylenically unsaturated monomer bearing carboxylic acid groups (a 1);
  • ii) is designed to comprise the aqueous monomer solution and the at least one crosslinker (a3) during polymerizing the monomers in the aqueous monomer solution, thereby obtaining a polymer gel iii) comprises a belt;
  • the belt has a shape of a first concave curve; wherein R is in the range of from 2 to 30, preferably from 2.5 to 25, more preferably from 3 to 25, more preferably from 3.5 to 25, more preferably from 4 to 25, more preferably from 4.5 to 25, more preferably from 5 to 25, more preferably from 5.5 to 25, more prefera- bly from 6 to 20, most preferably from 6.5 to 20; wherein R is a ratio of a horizontal width of the first concave curve to a vertical height of the first concave curve.
  • preferred components or devices or both of the device for the preparation of water-absorbent polymer particles according to the invention are designed according to the process according to the invention.
  • the device further comprises a radiation source, wherein the radiation source
  • a) is located to irradiate the first transversal cross section with UV radiation, b) provides the UV radiation at a power of at least 0.5 mW, preferably at least 0.8 mW, more preferably at least 1 mW, more preferably at least 1.2 mW, most preferably at least 1.5 mW.
  • a preferred radiation source is a mercury vapour lamp or a metal halide lamp or both.
  • a contribution to the solution of at least one of the above objects is provided by a process for the preparation of water-absorbent polymer particles in the device according to the in- vention.
  • the process comprises the process steps (i) to (xi) according to the invention.
  • a contribution to the solution of at least one of the above objects is provided by a water- absorbent polymer particle, obtainable by the process according to the invention.
  • a contribution to the solution of at least one of the above objects is provided by a composite material comprising a water-absorbent polymer particle according to the invention.
  • the composite material according to the invention com- prises one selected from the group consisting of a foam, a shaped article, a fibre, a foil, a film, a cable, a sealing material, a liquid-absorbing hygiene article, a carrier for plant and fungal growth-regulating agents, a packaging material, a soil additive, and a building material, or a combination of at least two thereof.
  • a preferred cable is a blue water cable.
  • a preferred liquid-absorbing hygiene article is one selected from the group consisting of a diaper, a tampon, and a sanitary towel, or a combination of at least two thereof.
  • a preferred diaper is a baby's diaper or a diaper for incontinent adults or both.
  • a contribution to the solution of at least one of the above objects is provided by a process for the production of a composite material, wherein a water-absorbent polymer particle ac- cording to the invention and a substrate and optionally an auxiliary substance are brought into contact with one another.
  • a contribution to the solution of at least one of the above objects is provided by a composite material obtainable by a process according to the invention.
  • a contribution to the solution of at least one of the above objects is provided by a use of the water-absorbent polymer particle according to the invention in a foam, a shaped article, a fibre, a foil, a film, a cable, a sealing material, a liquid-absorbing hygiene article, a carrier for plant and fungal growth-regulating agents, a packaging material, a soil additive, for con- trolled release of an active compound, or in a building material.
  • test methods are used in the invention.
  • the ISO test method for the feature to be measured being closest to the earliest filing date of the present application applies. If no ISO test method is available, the EDANA test method being closest to the earliest filing date of the present application applies.
  • standard ambient temperature and pressure (SATP) as a temperature of 298.15 K (25 °C, 77 °F) and an absolute pressure of 100 kPa (14.504 psi, 0.986 atm) ap- ply. water content
  • the water content of the water-absorbent polymer particles after drying is determined according to the Karl Fischer method. water-soluble polymer content
  • the water-soluble polymer content of water-absorbent polymer particles is measured according to a standard test method for superabsorbent materials defined by the EDANA. Said test method is described in EDANA, Harmonized Test Methods Nonwovens and Related Industries, 2012 Edition as “Extractables” under the method number WSP 270.2.R3 (12). Therein, the measurement is performed after aging the ' water-absorbent polymer particles. residual monomer content
  • the residual monomer content of the water-ansorbent polymer particles is measured accord- ing to a standard test method for superabsorbent materials defined by the EDANA. Said test method is described in EDANA, Harmonized Test Methods Nonwovens and Related Industries, 2012 Edition as "Residual Monomers” under the method number WSP 210.2.R3 (12).
  • MEHQ mono methyl ether hydroquinone
  • the sodium-acrylate monomer solution is degased with nitrogen.
  • 1 wt.-part of the monomer solution prepared in step A) is mixed with 0.001 wt.-parts of trimethylol propane triacrylate as crosslinker, 0.001 wt.-parts of sodium peroxodisulfate as first initiator component, 0.000034 wt.-parts of 2,2-dimethoxy-l ,2-diphenylethan-l-one (Ciba ® Irgacure ® 651 by Ciba Specialty Chemicals Inc., Basel, Switzerland) as a second initiator component, up to 0.1 wt.-parts of acrylic acid particles (with a particle size of less than 150 ⁇ ) in a container to achieve a mixed solution.
  • sodium carbo- nate is added to the mixed solution in an amount of 0.1 wt.-part based on the total amount of the mixed solution.
  • a sufficient amount of the mixed solution is subjected to further treatment in order to obtain a polymer gel and further downstream water-absorbent polymer particles and further down- stream surface-crosslinked water-absorbent polymer particles as well as further downstream a water-absorbent product which is post treated. Details of the further treatment are given below.
  • the mixed solution is placed on the belt of a conveyer belt reactor and the polymerization is initiated by UV radiation.
  • the UV radiation is provided by mercury vapor lamps which are located above the conveyor belt and irradiate at a power of 1.5 mW.
  • the conveyor belt has a length of at least 20 m and a width of 2 m.
  • the conveyor belt is formed as a trough to keep the solution on the belt prior to and while being polymerized.
  • the trough comprises a longitudinally extending portion over which the parameter R has the value giv- en in table 1 below for the examples and the comparative examples.
  • R is a ratio of a horizontal width of the trough to a vertical height of the trough.
  • Said longitudinally extending portion is about 6 m long.
  • the dimensions of the conveyor belt and the conveying speed of the conveyer belt are selected in a way that a poly-acrylic acid gel is provided at a downstream end of the belt.
  • a water-absorbent polymer gel is achieved.
  • the polymer gel has a water content of about 52 wt.-%, based on the total weight of the polymer gel.
  • the rubbery poly-acrylic acid gel is cut into flat gel strips by a knife.
  • the gel strips have a length in the range of from 10 to 20 cm, a height in the range of from 10 to 20 mm, and a width in the range of from 10 to 200 mm, then
  • a breaker is used to shred the strips into gel pieces having a length in the range from 5 to 50 mm, a height in the range of from 3 to 20 mm, and a width in the range of from 3 to 20 mm, then
  • the gel pieces are extruded through a mixer with a grinder to mince the gel pieces obtain- ing gel pieces having a length in the range of from 3 to 20 mm a height in the range of from 3 to 20 mm and a width in the range of from 3 to less than 20 mm.
  • the comminuted gel is dried in a belt dryer at a temperature of 180 °C to a water content of 5 wt.-% based on the dried polymer gel.
  • the belt of the belt drier provides orifices, where hot air is pressed into the polymer gel via nozzles. Additionally hot air is blown from above the belt onto the gel.
  • the dried polymer gel is ground in three steps. First the dried polymer gel is fed tlirough a Herbold Granu'lator HGM 60/145 (HERBOLD Meckesheim GmbH) and the achieved parts of the dried polymer gel have a size of less than 7 mm and are then kept for 2.5 hours in a container to equalize the humidity content of the polymer gel parts. The dried polymer gel parts are then milled in a roller mill of Bauerffle Type 350.1 x 1800 (3-stage crusher) (Bauermeister Zerklein mecanicstechnik GmbH) to obtain water-absorbent polymer particles having a particle size of less than 1 mm.
  • the water absorbent polymer particles are sieved with a tumbler sieves having several screens.
  • the mesh sizes of the screens change from 20, 30, 40, 50, 60 to 100 U.S. -mesh.
  • At least 50 wt.-% of the obtained water-absorbent polymer particles have a particles size in the range of from 300 to 600 ⁇ .
  • Less than 5 wt.-% of the water-absorbent polymer particles of the examples according to the invention are smaller than 150 ⁇
  • less than 5 wt.-% of the water-absorbent polymer particles of the examples according to the invention are have a particle size of more than 850 ⁇ .
  • the obtained water-absorbent polymer particles are named precursor I.
  • Si0 2 silicon dioxide
  • the silicon dioxide is used in form of Sipernat ® 22 obtainable from Evonik Industries AG, Essen, Germany.
  • the precursor still has a temperature of more than 80 °C to 100 °C, preferably of 100 °C.
  • a precursor II is achieved.
  • wt.-part of the precursor II is mixed with 0.003 wt.-part (+-10 %) of a surface crosslinker, based on the total weight of the mixture of precursor II and crosslinker.
  • the surface crosslinker is composed of 19 wt.-% water, 40 wt.-% ethylene glycol diglycidyl ether, 1 wt.-% Na 2 S0 3 , 40 wt.-% poly ethylene glycol with a molecular weight of 400 g/mol, each based on the total amount of the crosslinker.
  • the ingredients of the crosslinker are mixed in a line static mixer.
  • the crosslinker is mixed in a nnglayer mixer CoriMix ® CM 350 (Gebriider Lodige Mascheninenbau GmbH, Paderborn, Germany) with precursor II.
  • the mixture is heated to a temperature in the range of from 130 to 160 °C.
  • the mixture is then dried in a paddle dryer Andritz Gouda Paddle Dryer, preferably of type GPWD12W120, by Andritz AG, Graz, Austria for 45 minutes at a temperature in the range of from 130 to 160°C.
  • Surface-cross-linked absorbent polymer particles are obtained.
  • the temperature of the surface-cross-linked absorbent polymer particles is decreased to below 60 °C, obtaining cooled surface-cross- linked absorbent polymer particles referred as to precursor III.
  • 1 wt.-part of precursor III is then subjected to mixing with 0.005 wt.-part Ag-zeolite. Subsequently, the mixture is sieved. The sieve is selected to separate agglomerates of the cooled surface-cross-linked absorbent polymer particle having a particle size of more than 850 ⁇ . At least 50 wt.-% of the surface-crosslined absorbent polymer particles have a particles size in the range of from 300 to 600 ⁇ .
  • Less than 5 wt.-% of the surface-crosslinked absorbent polymer particles of the examples according to the invention are smaller than 150 ⁇ , less than 5 wt.-% of the surface-crosslinked absorbent polymer particles of the examples according to the invention are have a particle size of more than 850 ⁇ . Post treated crosslinked water-absorbent polymer particles are obtained.
  • Table 1 Characteristics of example processes for different belt shapes.
  • the parameter R throughout the longitudinally extending portion of the belt described above is 1.
  • R is 4.
  • Com- paring the example 1 to the comparative example 1 it can be seen that an R of 4 means that the trough of the belt can take less of the monomer solution - the polymerisation belt reca- tor capacity for the monomer solution is decreased.
  • the water- soluble polymer content and the residual monomer content of the surface-crosslinked water- absorbent polymer particles produced according to the above description are drastically decreased. Hence, the quality of the surface-crosslinked water-absorbent polymer particles is improved.
  • FIG. 1 shows a flow chart diagram depicting the steps 101 to 1 1 1 of a process 100 for the preparation of water-absorbent polymer particles according to the invention.
  • a first step 101 an aqueous monomer solution comprising at least one partially neutralized, monoethy- lenically unsaturated monomer bearing carboxylic acid groups (al) and at least one cros- slinker (a3) is provided.
  • the aqueous monomer solution is an aqueous solution of partially neutralized acrylic acid, further comprising crosslinkers.
  • fine particles of a water-absorbent polymer may be added to the aqueous monomer solution.
  • a polymerization initiator or at least one component of a polymerization initiator system that comprises two or more components is added to the aqueous monomer solution.
  • the oxygen content of the aqueous monomer solution is decreased by bubbling nitrogen into the aqueous monomer solution.
  • the monomer solution is charged onto a belt 401 of a polymerization belt reactor 400.
  • the belt 401 is an endless conveyor belt.
  • aqueous monomer solution is polymerized to a polymer gel.
  • the polymer gel is discharged from the belt 401. Subsequently, the polymer gel is comminuted, whereby polymer gel particles are obtained.
  • the polymer gel particles are charged onto a belt of a belt dryer and subsequently dried at a temperature of about 120 to 150°C. The dried polymer gel particles are discharged from the belt dryer and subsequently in a ninth step 109 grinded to obtain water-absorbent polymer particles.
  • the water-absorbent polymer particles are sized to obtain water-absorbent polymer particles having a well defined particle size distribution.
  • the surface of the water-absorbent polymer particles is treated in terms of a surface crosslinking.
  • Figure 2 shows a flow chart diagram depicting the steps 101 to 1 1 1 of a process 100 for the preparation of water-absorbent polymer particles according to the invention.
  • the process 100 shown in figure 2 is the same as the process 100 in figure 1, wherein the third process step 103 and the fourth process step 104 overlap in time. While the polymerization initiator is added to the aqueous monomer solution, nitrogen is bubbled into the aqueous monomer solution in order to decrease its oxygen content.
  • Figure 3 shows a flow chart diagram depicting the steps 101 , 103, 105 to 1 10 of a process 100 for the preparation of water-absorbent polymer particles according to the invention. The process 100 shown in figure 3 is the same as the process 100 in figure 1, wherein the second step 102, the fourth step 104, and the eleventh step 1 1 1 are not part of the process 100 ac- cording to figure 3.
  • FIG. 4 shows a scheme of a shape of a belt 401 of a polymerization belt reactor 400 in a longitudinal cross section according to the invention.
  • the polymerization belt reactor 400 comprises the belt 401 , at least two guide rollers 410 and mercury vapor lamps 409.
  • One of the guide rollers 410 drives the belt 401 which is an endless conveyor belt such that an upper run 41 1 of the belt 401 moves in a downstream direction 412. Consequently, a lower run 41 1 of the belt 401 moves in an upstream direction 413.
  • the downstream direction 412 and the upstream direction 413 are longitudinal directions of the belt 401.
  • the upper run 41 1 of the belt 401 comprises a trough 402; wherein the trough 402 longitudinally extends by a longitudinal extension 403 of the trough 402 over about 60 % of a longitudinal extension 404 of the belt 401.
  • the trough 402 comprises a first part 405 and a further part 406.
  • the mercury vapour lamps 409 irradiate a part of the first part 405 of the trough 402 with electromagnetic waves 408 capable of activating the polymerization initiator or the polymerization initiator system or both, wherein the electromagnetic waves 408 comprise UV radiation.
  • the first part 405 is characterized by a first depth 407, wherein the first depth 407 refers to a maximum depth in a transversal direction 904 of the belt 401, at each longitudinal position of the first part 405 of the trough 402.
  • the first depth 407 refers to a maximum depth in a transversal direction 904 of the belt 401, at each longitudinal position of the first part 405 of the trough 402.
  • the further part 406 is characterized by a further depth, wherein the further depth refers to a maximum depth in a transversal direction 904 of the belt 401 , at each longitudinal position of the further part 406 of the trough 402.
  • the first depth 407 is more than the further depth. This means that at each longitudinal position the first part 405 of the trough 402 is deeper than the further part 406 of the trough 402.
  • the first depth 407 is 250 mm throughout the first part 405.
  • the further depth ranges from more than 0 to less than 250 mm.
  • the first part 405 longitudinally extends over 25 %, which are a first longitudinally extending portion of the belt 401 according to the invention, of the longitudinal extension 404 of the belt 401.
  • the further part 406 longitudinally extends over 30 %, which are a further longitudinally extending portion of the belt 401 according to the invention, of the longitudinal extension 404 of the belt 401.
  • the further part 406 directly follows the first part 405 in a downstream longitudinal direction 412 of the belt 401.
  • the belt 401 has a shape of a first concave curve 501.
  • Each transversal cross section of the first part 405 is a first transversal cross section 500 according to the invention.
  • the first concave curve 501 has a hori- zontal width 502 and a vertical height .503 which determine an R of 80. Furtheraiore, the first concave curve 501 comprises a horizontally aligned portion 504 which extends over 90 % of the horizontal width 502 of the first concave curve 501.
  • a tangent 505 on any position of the first concave curve 501 inclines a first curve angle 507 with a horizontal line 506 in the first transversal cross section 500.
  • the maximum first curve angle 507 is 45°.
  • Fur- thermore, the first concave curve 501 forms a trough section having a trough section area 508.
  • the trough section area 508 is trapezoidally shaped.
  • the first concave curve 501 has a vertical height 503 of 250 mm.
  • the further part 406 is a further longitudinally extending portion of the belt 401 according to the invention. Throughout the further part 406, that means in each transversal cross section of the further part 406, the belt 401 has a shape of a further concave curve.
  • transversal cross sections are further transversal cross sections according to the invention.
  • a tangent on any position of the further concave curve inclines a further curve angle 507 with a horizontal line in the further transversal cross section.
  • the maximum further curve angle is in the range of from more than 0 to less than 45°.
  • the polymerization belt reactor 400 may comprise further components which are not shown in the figure, such as support elements, a supply and metering system, cooling and heating devices, and a removal system.
  • FIG. 5 shows a scheme of a shape of a belt of 401 a polymerization belt reactor 400 in a first transversal cross section 500 according to the invention.
  • the first transversal cross sec- tion 500 is a transversal cross section of an upper run 41 1 of the belt 401 which is an end- less conveyor belt.
  • the belt 401 shown has the shape of a first concave curve 501.
  • the first concave curve 501 has a horizontal width 502 and a vertical height 503 which determine an R of 4.
  • the first concave curve 501 comprises a horizontally aligned portion 504 which extends over 70 % of the horizontal width 502 of the first concave curve 501.
  • a tangent 505 on any position of the first concave curve 501 inclines a first curve angle 507 with a horizontal line 506 in the first transversal cross section 500.
  • the maximum first curve angle 507 is 50°.
  • the first concave curve 501 forms a trough section having a trough section area 508.
  • the trough section area 508 is trapezoidally shaped.
  • Figure 6 shows a scheme of another shape of a belt 401 of a polymerization belt reactor 400 in a first transversal cross section 500 according to the invention.
  • the first transversal cross section 500 is a transversal cross section of an upper run 41 1 of the belt 401 which is an endless conveyor belt.
  • the belt 401 shown has the shape of a first concave curve 501.
  • the first concave. curve 501 has a horizontal width 502 and a vertical height 503 which deter- mine an R of 20. Furthermore, the first concave curve 501 comprises a horizontally aligned portion 504 which extends over 90 % of the horizontal width 502 of the first concave curve 501. A tangent 505 on any position of the first concave curve 501 inclines a first curve angle 507 with a horizontal line 506 in the first transversal cross section 500. The maximum first curve angle 507 is 70°.
  • FIG. 7 shows a scheme of a shape of a belt of a polymerization belt reactor in a transversal cross section 700 not according to the invention.
  • the transversal cross section 700 is a transversal cross section of an upper run of the belt which is an endless conveyor belt.
  • the belt shown has the shape of a concave curve 701.
  • the concave curve 701 has a horizontal width 702 and a vertical height 703 which determine an R of 1.5.
  • a tangent 704 on any position of the concave curve 701 inclines a maximum angle 706 with a horizontal line 705 in the transversal cross section 700.
  • the maximum angle 706 is 87°.
  • FIG 8 shows a scheme of another shape of a belt of a polymerization belt reactor in a transversal cross section 700 not according to the invention.
  • the transversal cross section 700 is a transversal cross section of an upper run of the belt which is an endless conveyor belt.
  • the belt shown has the shape of a concave curve 701.
  • the concave curve 701 has a horizontal width 702 and a vertical height 703 which determine an R of 40.
  • a tangent 604 on any position of the concave curve 701 inclines a maximum angle 706 with a horizontal line 705 in the transversal cross section 700.
  • the maximum angle 706 is 87°.
  • FIG 9 shows a scheme of a basic setup of a polymerization belt reactor 400 according to the invention.
  • the polymerization belt reactor 400 comprises a belt 401.
  • the belt 401 is an endless conveyor belt.
  • the belt 401 passes over two guide rollers 410 such that an upper run 41 1 of the belt 401 moves downstream.
  • the downstream movement of the upper run 41 1 of the belt 401 deteraiines the direction of movement 901 of the polymer gel on the belt 401, indicated by an arrow.
  • Another arrow indicates a counter direction 902 to a direction of movement 901 of the polymer gel on the belt 401.
  • Another arrow indicates both longitudinal directions 903 of the belt 401 and yet another arrow the transversal directions 904 of the belt 401.
  • the belt 401 extends in the longitudinal directions 903 over a length which is a longitudinal extension 404 of the belt 401.
  • the polymerization belt reactor 400 may comprise further components which are not shown in the figure, such as support elements, a supply and metering system, irradiating means, cooling and heating devices, and a removal system.
  • FIG. 10 shows a block diagram of a device 1000 for the preparation of water-absorbent polymer particles according to the invention.
  • the arrows show a direction of a process stream 1008 of the preparation of water-absorbent polymer particles.
  • the device 1000 comprises a first container 1001 , a further container 1002, downstream a mixing device 1003, downstream a polymerization belt reactor 400, downstream a comminuting device 1004, downstream a belt dryer 1005, downstream a grinding device 1006, and downstream a sizing device 1007, each according to the invention.

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  • Chemical & Material Sciences (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Engineering & Computer Science (AREA)
  • Hematology (AREA)
  • Epidemiology (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Animal Behavior & Ethology (AREA)
  • General Health & Medical Sciences (AREA)
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  • Veterinary Medicine (AREA)
  • Dispersion Chemistry (AREA)
  • Polymerisation Methods In General (AREA)

Abstract

De manière générale, l'invention concerne un procédé pour la préparation de particules polymères absorbant l'eau, comprenant les étapes de procédé consistant à (i) préparer une solution monomère aqueuse comprenant au moins un monomère à insaturation monoéthylénique partiellement neutralisé, portant des groupes acide carboxylique (alpha 1) et au moins un agent de réticulation (alpha 3) ; (ii) éventuellement ajouter de fines particules d'un polymère absorbant l'eau à la solution monomère aqueuse ; (iii) ajouter à la solution monomère aqueuse un initiateur de polymérisation ou un ou plusieurs composants d'un système initiateur de polymérisation qui comprend deux ou plusieurs composants ; (iv) éventuellement diminuer la teneur en oxygène de la solution monomère aqueuse ; (v) charger la solution monomère aqueuse sur une courroie de réacteur à courroie de polymérisation ; (vi) polymériser les monomères dans la solution monomère aqueuse sur la courroie, ce qui permet d'obtenir un gel polymère ; (vii) décharger le gel polymère à partir de la courroie et éventuellement broyer le gel polymère ; (viii) sécher le gel polymère éventuellement broyé ; (ix) broyer le gel polymère séché, ce qui permet d'obtenir des particules polymères absorbant l'eau ; (x) dimensionner les particules polymères absorbant l'eau broyées ; et (xi) éventuellement traiter la surface des particules polymères absorbant l'eau broyées et calibrées ; caractérisé en ce que, dans une première section transversale de la courroie, cette dernière a la forme d'une première courbe concave ; R est dans la plage de 2 à 30.
PCT/KR2014/003678 2014-04-25 2014-04-25 Forme concave transversale d'une bande de polymérisation dans la production de particules polymères absorbant l'eau WO2015163520A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PCT/KR2014/003678 WO2015163520A1 (fr) 2014-04-25 2014-04-25 Forme concave transversale d'une bande de polymérisation dans la production de particules polymères absorbant l'eau

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PCT/KR2014/003678 WO2015163520A1 (fr) 2014-04-25 2014-04-25 Forme concave transversale d'une bande de polymérisation dans la production de particules polymères absorbant l'eau

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Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20130260988A1 (en) * 2012-03-30 2013-10-03 Basf Se Color-Stable Superabsorbent

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20130260988A1 (en) * 2012-03-30 2013-10-03 Basf Se Color-Stable Superabsorbent

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