Properties of Smart‐<scp>S</scp>caled <scp>PTFE</scp>‐<scp>T</scp>ubular Reactors for Continuous Emulsion Polymerization Reactions

Lueth, Fabian; Pauer, Werner; Moritz, Hans‐Ulrich

doi:10.1002/masy.201300086

Cited by 17 publications

(24 citation statements)

References 18 publications

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“…Two alternative techniques to minimize the RTD in tubular microreactors include the creation of Dean vortices or the use of in-line static mixers. 40,41 Dean vortices represent secondary fluid motion in laminar flow resulting from centripetal forces of fluid flowing in tubes arranged with tight curvature. Tracer experiments on both tightly and loosely coiled reactors showed no difference in RTD, suggesting that Dean vortices did not occur in the geometries and reaction conditions explored herein.…”

Section: As Shown Inmentioning

confidence: 99%

The Influence of Residence Time Distribution on Continuous Flow Polymerization

Reis¹,

Varner²,

Leibfarth³

2019

Preprint

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<p>Continuous-flow chemistry is emerging as an enabling technology for the synthesis of precise polymers. Despite recent advances in this rapidly growing field, there remains a need for a fundamental understanding of how fluid dynamics in tubular reactors influence polymerizations. Herein, we report a comprehensive study of how laminar flow influences polymer structure and composition. Tracer experiments coupled with in-line UV-vis spectroscopy demonstrate how viscosity, tubing diameter, and reaction time affect the residence time distribution (RTD) of fluid in reactor geometries relevant for continuous-flow polymerizations. We found that the breadth of the RTD has strong, statistical correlations with reaction conversion, polymer molar mass, and dispersity for polymerizations conducted in continuous flow. These correlations were demonstrated to be general to a variety of different reaction conditions, monomers, and polymerization mechanisms. Additionally, these findings inspired the design of a droplet flow reactor that minimizes the RTD in continuous-flow polymerizations and enables the continuous production of well-defined polymer at a rate of 1.4 kg/day. </p>

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Section: As Shown Inmentioning

confidence: 99%

The Influence of Residence Time Distribution on Continuous Flow Polymerization

Reis¹,

Varner²,

Leibfarth³

2019

Preprint

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“…Micro‐ and milli‐scale reactors offer the key benefit of large surface to volume ratios, thereby enabling a more accurate temperature control and thus safe and efficient operation of highly exothermic reactions . Due to their large specific heat exchange area, tubular smart‐scale processes offer a high potential for specialty production and process intensification .…”

Section: Introductionmentioning

confidence: 99%

“…Due to their large specific heat exchange area, tubular smart‐scale processes offer a high potential for specialty production and process intensification . Herein, a smart‐scale reactor concept for specialty production is used based on a reactor design by Lueth et al and Schmidt . Smart‐scale continuous reactors also offer other advantages, such as short setup times, low personnel cost, constant product quality, and high space time yields .…”

Section: Introductionmentioning

confidence: 99%

“…Herein, a smart‐scale reactor concept for specialty production is used based on a reactor design by Lueth et al and Schmidt . Smart‐scale continuous reactors also offer other advantages, such as short setup times, low personnel cost, constant product quality, and high space time yields . Due to the advantages offered by continuous processes, especially regarding safety and market adaption, it is meaningful to develop new products in continuous operation.…”

Section: Introductionmentioning

confidence: 99%

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Transfer of Emulsion Polymerization of Styrene and n‐Butyl Acrylate from Semi‐Batch to a Continuous Tubular Reactor

Rossow

Bröge

Lüth

et al. 2016

Macro Reaction Engineering

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The transfer of a semi‐batch emulsion copolymerization to a single feed continuous recipe is investigated herein. A single feed continuous tubular reactor is used in the presented study in accordance with the requirement of minimizing the number of dosing streams. The correlation between operating parameters and the product properties are experimentally presented for the semi‐batch as well as for the single feed continuous tubular reactor. It is shown that the transfer from semi‐batch to continuous smart‐scale tubular reactor needs to be direct as opposed to via a batch reactor. The particle sizes and molecular masses obtained in the tubular reactor are similar to those of the semi‐batch process. However, the adjustment of the polymer composition is challenging. Using monomer addition as a means to influence chemical composition is not applicable. Thus, in the tubular reactor the chemical composition of the resulting copolymer depends on the initial monomer composition and reaction temperature. Nevertheless, the mass transfer of the emulsion polymerization damps the copolymer composition distribution (CCD) drift for higher initial monomer contents compared to bulk polymerization. It is shown that transfer of a semi‐batch product to a continuous recipe is possible in early stages of process development.

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“…The continuously increasing awareness that a sustainable development is a primary requirement of a mature and modern economy is pushing chemical industries to implement the “green principles” into their manufacturing processes. Process intensification, use of environmentally benign solvents and of renewable feedstocks are some of the approaches being pursued. Within this frame, fossil‐based commodity polymers such as PET and PS are being replaced by polymers produced from renewable resources.…”

Section: Introductionmentioning

confidence: 99%

From Laboratory to Industrial Continuous Production of Polylactic Acid with Low Residual Monomer

Costa

Tancini

Hofmann

et al. 2016

Macromolecular Symposia

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Summary: Polylactic acid (PLA) is a 100 % bio-based polyester with strong market growth potential in commodity applications as a substitute of fossil-based polymers such as PET, PE and PS. The successful commercialization of this material relies on the possibility to devolatilize efficiently the unreacted monomer, which, in turn, requires an effective quenching of the polymerization catalyst. In this contribution we report an experimental screening of potential catalyst deactivators performed in small scale batch reactions. The best performing deactivator was then tested on a continuous PLA production plant of 1 kta to prove the reliability of the experimental approach. The plant data confirmed that the use of the selected deactivator improves the efficiency of the devolatilization process and leads to PLA with superior optical properties.

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Properties of Smart‐Scaled PTFE‐Tubular Reactors for Continuous Emulsion Polymerization Reactions

Cited by 17 publications

References 18 publications

The Influence of Residence Time Distribution on Continuous Flow Polymerization

The Influence of Residence Time Distribution on Continuous Flow Polymerization

Transfer of Emulsion Polymerization of Styrene and n‐Butyl Acrylate from Semi‐Batch to a Continuous Tubular Reactor

From Laboratory to Industrial Continuous Production of Polylactic Acid with Low Residual Monomer

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