US 8,912,364 B2 · Continuous loop flow process for polyether polyol production

Abstract

The present disclosure relates, according to some embodiments, to compositions, apparatus, methods, and systems that may be used to produce polyols, for example, polyether polyols with a narrow range of molecular weights, with little if any unsaturated byproducts, in a sustained and/or continuous reaction, with efficient heat transfer, and/or at high production rates. For example, in some embodiments, teachings of the disclosure may be used to produce polyether polyols in a continuous loop flow process. A continuous loop flow process may be practiced such that heat is effectively transferred and/or product properties (e.g., range of molecular weights) are controllable. For example, a continuous loop flow process may use one or more continuous flow loops comprising a heat exchanger, a means to move material around each loop, inlets for catalyst, monomer, initiator or starter, and an outlet for polyol product.

Claims15

Dependent claims

An alkoxylation process comprising:

continuously contacting a compound comprising at least one active hydrogen, a compound comprising an alkene oxide, and a double metal cyanide catalyst in a continuous flow loop under conditions that permit formation of a polyether polyol at least in part by alkoxylation;
continuously maintaining the spread in flow loop temperature equal to or less than about 5° C.;
and
continuously maintaining the spread in unreacted alkene oxide concentration in the continuous flow loop at no more than about 2 weight percent.

1 more element

A process for producing a polyether polyol, the process comprising:

providing a reactor having a reactor volume equal to or greater than about 1 cubic meter, the reactor comprising
at least one continuous flow loop operable to permit the continuous flow of at least a portion of a reaction stream,
at least one monomer inlet in fluid communication with the at least one flow loop,
at least one initiator inlet in fluid communication with the at least one flow loop,
at least one catalyst inlet in fluid communication with the at least one flow loop,
at least one heat exchanger in fluid communication with the at least one flow loop and operable to remove heat of reaction from the reaction stream, and
at least one product outlet in fluid communication with the at least one flow loop and downstream of the at least one catalyst inlet;
providing a reaction stream flowing in the continuous flow loop;
admitting a monomer into the reaction stream through the at least one monomer inlet;
admitting an initiator into the reaction stream through the at least one initiator inlet;
admitting a double metal cyanide catalyst into the reaction stream through the at least one catalyst inlet under conditions that permit formation of a polyether polyol;
contacting the reaction stream with the heat exchanger under conditions that permit thermal energy to be removed from the reaction stream at a thermal energy removal rate of at least about 400 Btu/hour-cubic foot·° F.;
removing a portion of the reaction stream through the at least one product outlet;
and
recirculating the remaining portion of the reaction stream around the flow loop, wherein the recycle ratio is at least about 10, the spread in monomer concentration may be equal to or less than about 5%, and the spread in flow loop temperature may be equal to or less than about 5° C.

12 more elements

Dependencies are inferred from the claim text.

Continuous loop flow process for polyether polyol production

Life of this patent

Continuous loop flow process for polyether polyol production

Life of this patent

Abstract

Claims15