Fractionator For Separating Solubilized Rubber From A Co-Solvent Based Miscella And Related Processes

A fractionator for separating solubilized rubber from a co-solvent based miscella, the fractionator comprising:

• a primary vessel comprising:
• a feed inlet for feeding a co-solvent based miscella into the primary vessel, wherein the co-solvent based miscella separates to form (i) a non-polar solvent viscous rubber phase in a lower portion of the primary vessel and (ii) a polar solvent solubilized resin phase above the non-polar solvent viscous rubber phase;
• a side outlet for removing the polar solvent solubilized resin phase from the primary vessel;
• and
• a bottom outlet for removing the non-polar solvent viscous rubber phase from the primary vessel.

A fractionator for separating solubilized rubber from a co-solvent based miscella, the fractionator comprising:

• a primary vessel comprising:
• a feed inlet for feeding a co-solvent based miscella into the primary vessel, wherein the co-solvent based miscella separates to form (i) a non-polar solvent viscous rubber phase in a lower portion of the primary vessel and (ii) a polar solvent solubilized resin phase above the non-polar solvent viscous rubber phase;
• a side outlet for removing the polar solvent solubilized resin phase from the primary vessel;
• and
• a bottom outlet for removing the non-polar solvent viscous rubber phase from the primary vessel;
• an overflow vessel having an inlet and an outlet, wherein the overflow vessel inlet is fluidly connected to the side outlet such that the polar solvent solubilized resin phase flows through the side outlet into the overflow vessel and is removed through the overflow vessel outlet;
• and
• at least one additional fractionator connected in series, wherein each additional fractionator has
• a feed inlet that is fluidly connected to the bottom of the preceding fractionator, and
• wherein the primary vessel further comprises an internal weir, wherein the side outlet is bounded by the internal weir such that the polar solvent solubilized resin phase flows over the internal weir to remove the polar solvent solubilized resin phase through the side outlet.

A process for separating solubilized non-Hevea rubber from a co-solvent based miscella, the process comprising:

• (a) providing an initial co-solvent based miscella comprising at least one polar solvent, at least one non-polar solvent, solubilized non-Hevea rubber, and solubilized resin;
• (b) using a fractionation system comprising multiple fractionators in series to separate the initial co-solvent based miscella into at least two phases, wherein the multiple fractionators include a first fractionator, one or more intermediate fractionators, and a final fractionator, and wherein each fractionator comprises a primary vessel having (i) a feed inlet, (ii) a side outlet, (iii) a bottom outlet, and (iv) an internal weir between the interior of the primary vessel and the side outlet or an overflow vessel external to the primary vessel and fluidly connected to the side outlet;
• wherein the initial co-solvent based miscella is fed into the first fractionator primary vessel through the first fractionator primary vessel feed inlet, and the initial co-solvent based miscella separates to form (i) a first non-polar solvent viscous rubber phase in a lower portion of the first fractionator primary vessel and (ii) a first polar solvent solubilized resin phase above the first non-polar solvent viscous rubber phase, and wherein a first vapor blanket is maintained above the first polar solvent solubilized resin phase in an upper portion of the first fractionator primary vessel;
• (c) allowing at least a portion of the first polar solvent solubilized resin phase to flow over the internal weir of the first fractionator or into the overflow vessel of the first fractionator for removal from the first fractionator primary vessel through the side outlet;
• (d) allowing the first non-polar solvent viscous rubber phase to flow out of the bottom outlet of the first fractionator primary vessel and into an intermediate fractionator;
• (e) adding additional polar solvent and optionally additional non-polar solvent to the intermediate fractionator primary vessel to form a co-solvent based miscella mixture with the non-polar solvent viscous rubber phase from the first fractionator primary vessel and allowing for separation of that mixture into (i) an intermediate non-polar solvent viscous rubber phase in a lower portion of the intermediate fractionator primary vessel and (ii) an intermediate polar solvent solubilized resin phase above the intermediate non-polar solvent viscous rubber phase, and wherein an intermediate vapor blanket is maintained above the intermediate polar solvent solubilized resin phase in an upper portion of the intermediate fractionator primary vessel;
• (f) allowing at least a portion of the intermediate polar solvent solubilized resin phase to flow over the internal weir of the intermediate fractionator or into the overflow vessel of the intermediate fractionator for removal from the intermediate fractionator primary vessel through the side outlet;
• (g) allowing the intermediate non-polar solvent viscous rubber phase to flow out of the bottom outlet of the intermediate fractionator primary vessel and into the final fractionator;
• (h) adding additional polar solvent and optionally additional non-polar solvent to the final fractionator primary vessel to form a co-solvent based miscella mixture with the non-polar solvent viscous rubber phase from the intermediate fractionator primary vessel and allowing for separation of that mixture into (i) a final non-polar solvent viscous rubber phase in a lower portion of the final fractionator primary vessel and (ii) a final polar solvent solubilized resin phase above the final non-polar solvent viscous rubber phase, and wherein a final vapor blanket is maintained above the final polar solvent solubilized resin phase in an upper portion of the final fractionator primary vessel;
• (i) allowing at least a portion of the final polar solvent solubilized resin phase to flow over the internal weir of the final fractionator or into the overflow vessel of the final fractionator for removal from the final fractionator primary vessel;
• and
• (j) allowing the final non-polar solvent viscous rubber phase to flow out of the bottom outlet of the final fractionator primary vessel, thereby providing a separated solubilized rubber phase with reduced resin and polar solvent content as compared to the initial co-solvent based miscella.