Sulzer Chemtech

Polymer Production Technology

 Polymer Production Technology

Sulzer Chemtech’s value proposition in the production

of polymers
Production of polymers The road to success Global support – where
using static mixing is with the customer and when you need it
technology
Sulzer Chemtech is the world‘s most A history of successful projects Regardless of your geographic loca-
renowned supplier of equipment clearly indicates that only a team tion or the size of your project, Sulzer
and related solutions in the field effort involving both the customer Chemtech‘s global presence means
of static mixing. The combination and Sulzer Chemtech creates value you will have the support you need.
of engineering expertise and many for both partners. The customer We talk your language and under-
years of application know-how provides projects with insight into stand your requirements equally
enables Sulzer Chemtech to pro- the chemistry and process details, well for a single static mixer or for
vide global solutions for improved while Sulzer Chemtech provides a more complex process solution.
polymer product quality. All Sulzer pilot testing and broad expertise Sulzer Chemtech always provides
Chemtech products and services in static mixing. Newly created, in- solutions with a focus on process ef-
rely on a successful integration of novative solutions are protected by ficiency and the quality of polymer.
three main competencies: secrecy agreements that safeguard
• Static mixing know-how the interests of both partners and
their respective contributions.
• Piloting & scale up
• Process & equipment engineering

Creating value for the Proven technology and proven components

polymer industry for the production of Your Polymer
The combination of static mixing
know-how, piloting and scale up,
and process and equipment en-
gineering enables Sulzer Chemtech
to provide customized solutions and
a process guarantee. This service is
greatly linked to the availability of a
piloting facility for reliable process
solutions. We offer the flexibility of
conducting piloting programs at our
own or directly at a customer‘s site.
Individual components for piloting
as well as fixed installed equipment
are at the customer‘s disposal.
Whatever the required approach
may be, Sulzer Chemtech is a 0692 2742 0682 2026-1
reliable, global partner for optimized
Static mixing know how Piloting & Scale up
process solutions and related
equipment.

Process & Equipment Engineering

2
 Polymer Production Technology

Sulzer Chemtech technologies

Reaction Technology Devolatilization Technology Upgrading Technology
Equipment
I Sulzer Static Mixer
II Pre-Polymerizer
III Polymerization Reactor
IV Post Polymerization SMR Reactor
V Mixer-Heat Exchanger
6 6
VI Devolatilization Vessel
VII Sulzer Distributor
IV IV VIII Granulation / Pelletizer
1
IX Packaging

2 Stream
VII 1 Monomer (fresh or recycle)
I 5 5 2 Catalyst / Additive
3 Additive / Catalyst / Monomer
V VI VI 4 Killing Agent
5 Heat Transfer Medium (HTM)
III 5 I 6 Overhead condensing system
5 5 7 Stripping Agent
II 8 Low Viscous Additive / Masterbatch
9 Polymer Pellets
VIII
I I I
7 9
3 4 8 IX

Sulzer Chemtech has developed In polymer production, devolati- After devolatillization, additives can
and introduced a new generation of lization is an important operation be mixed into the polymer in order
reactors based on the principle of since the polymerized product still to upgrade the final product. Sulzer
static mixing and on the continuous contains a certain amount of un- has years of experience in provid-
bulk polymerization, e.g. mass- and reacted monomers, oligomers, sol- ing successful upgrading solutions
solution polymerization. This reac- vents, and other impurities. Sulzer for improved product quality and
tor is abbreviated as SMR (Sulzer Chemtech has developed equip- profitability. Our extensive refer-
Mixing Reactor) and is character- ment specifically for the removal of ence list includes examples of
ized by accurate control of heat this residual material. The single or complex applications with regard to
transfer and mixing effects so that multiple stage devolatillization proc- differences in viscosity, mixing ratio
high conversion and consistently ess features a heat exchanger with and homogeneity aspects.
high polymer quality are achieved mixer inserts, stripping agent dos-
time after time in order to meet var- ing mixer, and uniquely designed
ied and stringent requirements. degassing chambers containing
special polymer distributors. This
equipment, with its versatile proc-
ess design, does not interfere with
the polymer properties achieved
during the polymerization. It does
remove the residuals effectively in
order to meet industry and legisla-
tive requirements.

3
 Reaction Technology

Sulzer Chemtech has developed a new generation of accurate control of heat transfer and mixing effects
reactors based on the principle of static mixing and so that high conversion and consistently high polymer
on the continuous bulk polymerization, e.g. mass- and quality are achieved reproducibly in order to meet var-
solution polymerization. This reactor is abbreviated as ied and stringent requirements.
SMR (Sulzer Mixing Reactor) and is characterized by

1. Static mixing expertise . . .

. . . for plug flow reactors stein Numbers of 50/m, equivalent
A typical polymerization post-reac- to ≥ 25 ideal stirred vessels, have
tor consists of a set of SMR mod- been measured at full scale condi-
ules built in series so that several tions.
individual temperature and mixing
zones are available to meet the . . . for loop reactor
varying process needs. As the po- Individual SMR reactors can be
lymerization process proceeds, the configured into a loop reactor
conversion increases and the mon- and are used especially for highly
omer concentration decreases. The exothermic reactions. An excellent
SMR reactor secures a close to ide- mixing characteristic of the SMR
al plug flow regime, keeping the di- equipment ensures the optimal ho-
minishing driving force at the maxi- mogenization of local concentration
mum possible level. It also results in and temperature gradients. With
a narrow residence time distribution a densely packed heat exchange
to promote homogeneous polymer surface area, the SMR provides reli-
quality. This advantage is main- able heat removal and temperature
tained throughout the spectrum control of polymer bulk so optimal
of the changing polymer viscosity, process control is maintained. As in
even at high conversion levels. the common loop reactor set-ups,
virgin monomer is continuously
. . . for adiabatic reactors introduced to the loop while the
Efficient radial mixing effects in the semi finished polymer is drained
SMX plug flow reactor lead to con- and conveyed to the downstream
tinuous equalization of concentra- post-reactor system.
tion, temperature, and velocity so
that the end result is comparable
to plug flow behavior. The Boden- 0604 2701

0605 2715

4
 Reaction Technology

2. Process & equipment engineering HTM

The Sulzer Mixer Reactor (SMR) is a of laminar layers. This effect com-
development based on many years bines well with an extraordinarily
of testing and experience with high surface area per unit volume
smaller mixers used in a variety of of equipment, and makes the
viscous applications. The intersec- SMR one of the highest performing
ting bars encountered in static mix- reactor/heaters in the industry.
ers are suitably replaced by tubular Product
bundles which are adapted to the A performance comparison is
HTM
specific process and mechanical shown in the table below. 0698 2722

requirements of each application. Cutaway of the Sulzer SMR reactor

This layout of tubes, similar to a
1 Sulzer SMR 103
static mixer, induces a product flow 2 Monotube with static mixer
on the shell side that continuously 3 Empty pipe 102

transpositions the liquid layers in 4 Stirred tank

˙ / V∆ T (kW/m3 ˚C)
5 Extruder
a regular and repeatable pattern
10
➀

and suppresses the development The heat transfer capacity of the Sulzer SMR ➄
100
reactor is practically independent of the volume
➁
of the equipment.

Q
➂
10-1
➃
Q˙ = Heat flow (kW)
T   = Temperature difference (˚C) 10-2
V  = Volume (m³) 10-4 10-3 10-2 10-1
V (m3)
100 10 102 103

0691 2738
3. Piloting & scale up Heat transfer capacity of various type of
reactors for laminar flow
In most cases data like physical Typical examples are:
properties, phase behavior and • The effect of liquid viscosity on
operating problems are not read- mixing, heat transfer and reac-
ily available for reliable process tor performance
and equipment design. Sulzer
• The hydraulic behaviour of chem-
Chemtech maintains world class fa-
icals and products in mixing and
cilities for testing of mixing effects,
reaction equipment
heat transfer, polymerization reac-
tions and devolatilization in order • The reaction kinetics
to secure reliable equipment design • Devolatilization
and desired process performance. • High pressure dosing
Individual key equipment and pilot
plant subsystems make it possible
to tailor pilot configurations to very
specific requirements.
0695 2716
Pilot skit

Typical applications for SMR

4. Advantages at a glance and SMX reactors
Improved Product Quality: • the capability of processing fluids • Polystyrene, GPPS, HIPS
• Plug flow profile results in narrow with a wide range of viscosities • Styrenics copolymers,
residence time temperature distri- ABS/SAN
bution with positive impact on Lower Operating Cost due to:
• Polymethylmethacrylate PMMA
the molecular weight distribution • reduced consumption of raw
material (high conversion rate) • Polyethylene, PE
• No channelling / no maldistribu-
tion and dead zones • prevention of large quantity of • Silicon polymers
off-spec product during product • Polypropylene PP chain regula-
High Flexibility in Production grade switch tion
A variety of polymer grades can be • reduced energy requirements • Polyamide 6 PA6
produced in one single line due to (minimum hydraulic pressure loss, • Terpene resins
• exact and independent process lack of agitator) • Polyoxymethylene POM and
temperature adjustment of • fast self cleaning and start-up • Biodegradable polymers
respective reactor zones procedure

5
 Devolatilization Technology

1. The concept of low residual volatile content

In the production of polymers devolatilization is an im- features a heat exchanger with mixer inserts, a strip-
portant unit operation since the polymerized product ping agent dosing mixer, and uniquely designed degas-
still contains a certain amount of un-reacted mono- sing chambers containing special polymer distributors.
mers, oligomers, solvents and other impurities. For Combined with a versatile process design, this equip-
the purpose of removal of residual materials, Sulzer ment removes the residuals effectively, but does not
Chemtech has developed equipment and a process interfere with the polymer properties achieved during
concept based on its vast experience in static mixing. the polymerization.
The single or multiple stage devolatilization process

2. Process and equipment design

Devolatilization Technology (First stage)
First stage
Equipment
The first devolatilization stage consists of the multi- I Mixer-Heat Exchanger
2
II Devolatilization Vessel
tube heat exchanger with mixer inserts, followed by
a specially designed vacuum flash chamber. The heat Stream
exchanger secures rapid and controlled heating of the 1 Polymer solution from reactor
2 Overhead condensing system
polymer solution without notable damage to the poly- 3 Polymer melt to final devolatilization
mer properties. The separation of the residual volatiles
from the polymer is carried out in the flash vessel. The
de-gassed volatiles are led to a column for the separa-
tion of the oligomers. The polymer is discharged from II
the bottom section from the devolatilization chamber
by a gear pump with special inlet section design. From I
there, the polymer is forwarded either to the next devol-
atilization stage or to the pelletizing unit.

Why a multitube heat exchanger with mixer inserts?

Unlike common multitube heat exchangers, Sulzer‘s
SMXL mixer inserts induce a hydraulic regime in a pre-
vailing laminar application that is close to turbulent. The
parabolic gradients of temperature and liquid velocity
across the tube diameter are successfully prevented.
Sulzer‘s heater design is characterized by greatly re-
duced temperature differences required for the trans- 3
1
fer of energy from heating medium to bulk fluid, by a
uniform residence time distribution, and by an overall
shorter residence time.

0699 2729-1

6
 Devolatilization Technology

Final stage 3. Piloting & scale-up

Polymer solution, coming either from the polymerization
process or from the preceding devolatilization stage, is Alike in section Reaction Technology data like physical
passed to the final stage. The special treatment in this properties, phase behavior and operating problems are
stage involves the use of stripping agent to intensify not readily available to perform reliable process and
the release of remaining volatiles. The stripping agent equipment design. In Sulzer Chemtech‘s testing facility
could be water, nitrogen, CO2, etc., depending on the for mixing effects, heat transfer, polymerization reac-
application. The mixture of the polymer solution and tions and devolatilization, test set-ups can be tailored
the chosen stripping agent are flashed in the 2nd stage to specific requirements. Devolatilization results are
vacuum chamber, from where the finished polymer is incorporated into the design of industrial size applica-
discharged again by the special gear pump. The re- tions with related guaranteed performance.
leased volatiles and the stripping agent are recovered
in a downstream distillation unit.
4. Advantages at a glance
Why devolatilization with a stripping agent?
Investment
The static mixer ensures the dispersion of stripping
agent into the polymer solution which turns into a The capital cost is comparatively moderate due to the
foam-like phase prior to entering the sub-atmospheric unique process concept and equipment without mov-
devolatilization chamber. The special effect of this foam ing parts.
is in the reduction of the diffusion path for the volatiles
so that the entire process of mass transfer is signifi- Operating Cost:
cantly intensified. For example. Devolatilization utilizing
a stripping agent allows for consistent depletion of • reduced electrical power consumption as the result
volatiles from polystyrene melt down to residue content of the absence of heavy rotating equipment, e.g.
of 100 – 200 ppm. Subject to pilot test confirmation, full extruder etc.
process guarantees are backing our scope of supply. • reduced mechanical maintenance
Sulzer Chemtech can perform devolatilization tests for
new or untested polymers in order to specify the proc- Product Quality
ess and supply the guarantees. Reduced polymer degradation due to:
• the prevention of damage to the polymer morpho-
logy by avoiding exposure to high shear forces
Devolatilization Technology (Second stage)
• the prevention of elevated process temperature by
Equipment using efficient heat transfer equipment
I Sulzer Static Mixer
II Sulzer Distributor 3 • very low residue content
III Devolatilization Vessel

Stream
1 Polymer from reactor or upstream
devolatilization
2 Stripping Agent
3 Overhead condensing system
4 Polymer melt to upgrading and
pelletizing
II Typical applications of polymer devolatilization
• Polystyrene, GPPS, HIPS
• Styrene copolymer, ABS/SAN
• Polyethylene, HDPE, LLDPE
• Polyvinylacetate, PVAC
III
• Polyethylacrylat
I
• Polyisobutylene
• Polycarbonate, PC
• Polyetherglycole, PEG
• Polyoxymethylene, POM
• Polyisobutylene, PIB
• Elastomer, EPM, EPDM
1 4
2 • Biodegradable polymers

7
 Upgrading Technology

1. The static mixer as key to success

After the removal of un-reacted and inert materials
through devolatillization, the subsequent upgrading
commonly involves the admixing of additives or dye
to the polymer. Sulzer has many years of experience
in providing complete solutions for improved product
quality and profitability for this finishing process. We
maintain an extensive reference list with examples of
complex applications with regard to viscosity, mixing
ratio and homogeneity aspects.

2. Process and equipment design

Admixing of additives into polymer products is per-
formed in various hydraulic regimes ranging from
laminar to transitional and turbulent. The polymer
additive mixing ratio defines the degree of mixing
complexity, which ranges from fair to very demanding.
Sulzer Chemtech‘s static mixing technology is based
on equipment with open intersecting channels which
are formed by uniquely arranged corrugated plates
and bars. The mixing action itself is achieved by the
continuous splitting, extension and transposition of
the component streams. Successive mixing elements
are rotated by 90 º to ensure that local homogeneity is
equalized over the entire pipe cross section.

0694 2717

3. Piloting and scale-up

In some applications, solubility of additives in the poly- Following are some of the most common applications
mer may not be known to the extent needed for reliable for admixing of low viscous and semi-soluble additives
design. Since this property is of utmost importance in polymers where testing has provided reliable design
for homogeneity and uniform product quality, Sulzer data:
Chemtech has the capability of performing testing tai- • UV- stabilizers
lored to the specific project requirement and customer
• antistatic agents
objectives.
• antioxidants
• mould release agents
• mineral oil etc.
Sulzer Chemtech patented side stream mixing system

0697 2710

8
 Upgrading Technology

4. Advantages at a glance
Typical applications for Sulzer static mixer
Investment
• Admixing of additives
Compared to dynamic mixing equipment like extruders, • UV-stabilizers
Sulzer static mixing solutions are significantly lower in
cost. • Antistatic agents
• Antioxidants
Operating Cost: • Mould release agents
• Cost related to maintenance of mixer is non-existent • Mineral oil etc.
• Monomers like AN, SM, AM
Product Quality • Solvents like EB, chlorobenzene, methylene-
• Prevention of polymer degradation due to low chlorid
shear force • Colorant
• High and continuous homogeneity of additive enri- • Masterbatch
ched polymer
Polymer industries using Sulzer static mixer
• Polystyrene, GPPS, HIPS
• Styrenic copolymers, ABS/SAN
• Polymethylmethacrylate PMMA
• Polyethylene, PE (LLDPE, LDPE, HDPE)
• Silicon polymers and elastomers
• Cellulose fibre
• Polyethylene terephthalate PET
• Polyamide PA, PA6
• Viscose
• Polycarbonate PC
• Polypropylene PP
LIF principle and set-up • Terpene resins
• Polyoxymethylene POM
• Biodegradable Polymers
• PBTP, PB, PBS, PIB etc.
• PUR
• Teflon
• Adhesives
• Special polymers as additives for concrete or for
other polymers
• All kind of polymers in solution or as
co-polymers
• others

0601 2700-1

Section of pilot plant for polymer production

9
 Further activity related to polymers and static mixing

Heat exchange
Typical applications:
Especially with regard to high viscous components, • Heating and Cooling of polymer and polymer-
Sulzer Chemtech has acquired a wide range of exper- solutions.
tise in the field of exchange of thermal energy. Equip- • Mixing and removing of exothermic heat during
ment concepts and designs derived from this expertise reaction.
are characterized by short residence time and homoge- • Melt viscosity adjustement by temperature
neous bulk temperature. All properties ensure that the variation to obtain optimal process conditions.
medium being subjected to the heating/cooling is proc-
• Cooling polymer melts before granulation to
essed in a careful manner, resulting in a quality product.
raise the viscosity.
Heat exchange equipment from Sulzer Chemtech is
successfully installed in the following industries: • Cooling polymer melts before filling plants to
avoid thermal damage to packing material
• Polymer Production
• Cooling polyester melts between polyconden-
• Polymer Processing
sation and spinning step.
• Production of synthetic fibres

Sulzer Chemtech has a great deal of experience designing and fabricating two different types of mixer-heat ex-
changers, each well suited for certain applications, mainly in the laminar field. The SMXL mixer-heat exchanger
divides the main product stream in sub-streams flowing through parallel tubes, whereas the product in a SMR
mixer is not split but is mixed completely over the entire diameter, making it well suited for reactions and mass
transfer where mixing is important.

SMXL Static mixer-heat exchanger SMR Static mixer-heat exchanger

The product-conveying inner tubes are filled with static The SMR equipment is not only suited for applications
mixing elements, creating a radial mixing effect. The re- in which mixing and heat exchange occur, but also in
sult is a considerably increased heat transfer and a nar- mass and/or reaction processes that take place simul-
row residence time distribution, making is possible to taneously. The static mixing elements are made from
achieve a short residence time. A continuous renewal tubes to create a radial mixing of the product flowing
of the thermal boundary layer on the piping wall pre- around the tubes, which the heat transfer fluid flows
vents thermal damage of heat sensitive products. through. Due to the radial mixing over the entire shell
diameter, the SMR is well suited for reactions where
good mixing, high heat transfer, and narrow residence
time distribution is important.

Multitube mixer-heat exchanger with removable SMXL mixing SMR plug flow reactor and heat exchanger
elements

0605 2706-6 0605 2717

10
 Further activity related to polymers and static mixing

Technology for expandable polystyrene (EPS)

Sulzer has developed a unique technology for the production of EPS that
is based on the advantages of static mixing and continuous operation. In
this versatile path of production blowing agent, e.g. pentane is continu-
ously dosed in a bulk flow of crude polystyrene. Homogeneous mixing and
temperature conditioning is taking place prior to the pelletization of prod-
uct. EPS grades manufactured with Sulzer technology can be further proc-
essed as with any other commercially available EPS grade.
The fact that Sulzer‘s EPS technology can be applied to a wide range of
polystyrene grades (HIPS, GPPS), this technology has clearly proven its
industrial viability and acceptance. Some of the technology‘s characteris-
tics are:
• Wide range of polystyrene grades can be converted into EPS pellets
• Flexibility in producing specialty grades e.g. colored beads, varying
blowing agents, flame retardants and additives
• Virtually zero emissions such as blowing agent and waste water,
resulting in high operating safety and low production cost 0698 2720

EPS production unit

0604 2714

11
 www.sulzer.com
Please check for your local contact

Sulzer Chemtech Ltd, a member of the Sulzer Corporation, with headquar- The activity program comprises:
ters in Winterthur, Switzerland, is active in the field of process engineering • Process components such as fractionation trays, structured and ran-
and employs some 4000 persons worldwide. dom packings, liquid and gas distributors, gas-liquid separators, and
Sulzer Chemtech is represented in all important industrial countries and internals for separation columns
sets standards in the field of mass transfer and static mixing with its ad- • Engineering services for separation and reaction technology such as
vanced and economical solutions. conceptual process design, feasibilities studies, plant optimizations in-
cluding process validation in the test center
• Recovery of virtually any solvents used by the pharmaceutical and
chemical industry, or difficult separations requiring the combination of
special technologies, such as thin film/short-path evaporation, distilla-
tion under high vacuum, liquid-liquid extraction, membrane technology
or crystallization.
• Complete separation process plants, in particular modular plants
(skids)
• Advanced polymerization technology for the production of PLA and
EPS
• Tower field services performing tray and packing installation, tower
maintenance, welding, and plant turnaround projects
• Mixing and reaction technology with static mixers
• Cartridge-based metering, mixing and dispensing systems, and dis-
posable mixers for reactive multi-component material

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Legal Notice: The information contained in this publication is believed to be accurate and reliable, but is not to be construed as implying any
23.04.06.40 - III.13 - 10 - Printed in Switzerland warranty or guarantee of performance. Sulzer Chemtech waives any liability and indemnity for effects resulting from its application.