Bulk Polymerization
LIST Kneader Reactor technology reacts liquid monomer with catalyst into a polymer under solvent free conditions with conversions of 95% and higher.
Efficient and economic polymerization of monomers or pre-polymers delivers high conversion rates with little or no use of solvents. The ability to operate below the glass transition temperature yields a granular, stable and free-flowing polymer in a single step.
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Dry processing allows for chemical
processes to occur with little or no
use of solvents or diluents. LIST
technology is especially suited for
this type of processing. The LIST
Kneader Reactor is a unique
solution for processing in the
concentrated phase with little or
no solvents.
- A Clever Alternative
- Saying Goodbye to Solvents
- Prediction of Mass Transport of Solvent / Polymer Systems
- Solutions for Polymer Industries
- Additional Articles and Downloads
Solution, Emulsion and Suspension Polymerization
LIST’s experience has shown that many producers can replace solution, emulsion and suspension polymerization with bulk polymerization to simplify the process, cut raw materials costs and save energy. The technology is suitable for solvent-free living and free-radical polymerization.
The LIST Kneader Reactor Solution for Polymerization
To remain competitive, process oriented companies are constantly looking to increase efficiency and optimize their manufacturing processes. LIST Kneader Reactor technology helps clients do both.
Unlike most traditional processors that rely on high shear to achieve good mixing, the LIST Kneader Reactor is designed with shaft geometry that provides a gentle kneading action to ensure excellent mixing and contact heat transfer, while minimizing shear, even with highly viscous materials.
This proven and unique technology gives polymer manufacturers key competitive advantages: effective mixing, low shear, high conversions, elimination of dead spots, high residence times, and the ability to handle very high viscosities and hard to handle materials. As a result, LIST’s Kneader Reactor solutions deliver improved product quality, lower capital and operating costs, increased safety, and more efficient overall processing. Key benefits when it comes to today’s polymerization.
Solvent-Free Bulk Polymerization
During bulk polymerization involving stirred-tank reactors, the viscosity of the reaction mass of most compounds increases. Conventional processors require diluents or solvents to transfer heat and facilitate mixing of the viscous mass. Because the solvents or diluents must be removed separately, the end polymer conversion rates are relatively low, typically 10-20%. Additionally, the use of solvents is a drain on the operator’s bottom line; creating costly solvent recovery and purification issues; increasing maintenance and operating costs; and heightening environmental concern.
The unique design of LIST Kneader Reactor solutions, however, requires little if any solvents or diluents in order to achieve continuous polymerization - even in highly concentrated masses. The solvent-free or solvent-lean technology eliminates the added costs and concerns of conventional bulk polymerization processes. It is also extremely efficient, yielding end polymer conversion rates of at least 90% and, in some cases, close to 100%; The highly-concentrated polymer mass can be directly devolatilized, to 500–1000 ppm or lower if necessary.
The LIST Kneader Reactor is especially effective in exothermic bulk (co)-polymerization applications. Large heat exchange surfaces and excellent evaporative cooling remove heat caused by reaction and mechanical activity. In addition, the LIST Kneader Reactor provides constant surface renewal that improves heat transfer by reducing stagnant zones and keeps the polymer mass well mixed. Efficient mixing minimizes the diffusion and mass transfer limitations, which can significantly reduce reaction time.
For companies looking for greater efficiency, solvent-free processing creates important competitive advantages. Maximum yield with minimum production costs, higher energy savings, and a cleaner, safer production environment. LIST Kneader Reactor technology makes it possible.
To remain competitive, process oriented companies are constantly looking to increase efficiency and optimize their manufacturing processes. LIST Kneader Reactor technology helps clients do both.
Unlike most traditional processors that rely on high shear to achieve good mixing, the LIST Kneader Reactor is designed with shaft geometry that provides a gentle kneading action to ensure excellent mixing and contact heat transfer, while minimizing shear, even with highly viscous materials.
This proven and unique technology gives polymer manufacturers key competitive advantages: effective mixing, low shear, high conversions, elimination of dead spots, high residence times, and the ability to handle very high viscosities and hard to handle materials. As a result, LIST’s Kneader Reactor solutions deliver improved product quality, lower capital and operating costs, increased safety, and more efficient overall processing. Key benefits when it comes to today’s polymerization.
Solvent-Free Bulk Polymerization
During bulk polymerization involving stirred-tank reactors, the viscosity of the reaction mass of most compounds increases. Conventional processors require diluents or solvents to transfer heat and facilitate mixing of the viscous mass. Because the solvents or diluents must be removed separately, the end polymer conversion rates are relatively low, typically 10-20%. Additionally, the use of solvents is a drain on the operator’s bottom line; creating costly solvent recovery and purification issues; increasing maintenance and operating costs; and heightening environmental concern.
The unique design of LIST Kneader Reactor solutions, however, requires little if any solvents or diluents in order to achieve continuous polymerization - even in highly concentrated masses. The solvent-free or solvent-lean technology eliminates the added costs and concerns of conventional bulk polymerization processes. It is also extremely efficient, yielding end polymer conversion rates of at least 90% and, in some cases, close to 100%; The highly-concentrated polymer mass can be directly devolatilized, to 500–1000 ppm or lower if necessary.
The LIST Kneader Reactor is especially effective in exothermic bulk (co)-polymerization applications. Large heat exchange surfaces and excellent evaporative cooling remove heat caused by reaction and mechanical activity. In addition, the LIST Kneader Reactor provides constant surface renewal that improves heat transfer by reducing stagnant zones and keeps the polymer mass well mixed. Efficient mixing minimizes the diffusion and mass transfer limitations, which can significantly reduce reaction time.
For companies looking for greater efficiency, solvent-free processing creates important competitive advantages. Maximum yield with minimum production costs, higher energy savings, and a cleaner, safer production environment. LIST Kneader Reactor technology makes it possible.