Controlled suspension polymerization process without mechanical agitation
AssigneeNova Chemical Corporation
InventorsKarel Cornelis Bleijenberg, Grazyna Petela
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Abstract
Non-Newtonian fluids, such as partially polymerized monomers or solutions of polymer in monomer may be pressure atomized below the free surface of a continuous liquid phase to produce a dispersed phase. A uniform or customized droplet size distribution can be obtained by imposing a required pressure pulsation on a flowing monomer upstream the atomizer inlet. This initial particle size distribution can be maintained or modified during subsequent polymerization process in a low shear, controlled turbulence flow pattern, created without mechanical agitation within the continuous liquid, by continuously or periodically injecting an inert gas at selected locations within the reactor.
Claims40
A process comprising pressure atomizing from 0.01 to 60 volume % of a non-Newtonian immiscible liquid having a density ±20% of the density of a continuous liquid phase, at a pressure of at least 5 bar, below the free surface of the continuous liquid phase which may be stationary or flowing, contained in a holding tank or a tank, pipe or loop reactor, to produce a dispersion of atomized droplets of the immiscible liquid having at least one controlled average diameter from 0.1 mm to 10 mm and processing/polymerizing the dispersed phase in a low shear flow pattern with a controlled low turbulence level created, without mechanical agitation, by continuously or periodically injecting at gauge pressure up to 15 bar into selected parts of the reactor one or more streams of gas inert to the reactor contents having a density lower than the continuous phase and immiscible with the reactor contents and recovering this gas from the top of reactor, above free surface of the continuous phase.
Dependencies are inferred from the claim text.