Subcategory 3 Solution Crumb Rubber Production

Solution polymerization is bulk polymerization in which excess monomer serves as the solvent. Solution polymerization, used at approximately 13 plants, is a newer, less conventional process than emulsion polymerization for the commercial production of crumb rubber. Polymerization generally proceeds by ionic mechanisms. This system permits the use of stereospecific catalysts of the Ziegler-Natta or alkyl lithium types which make it possible to polymerize monomers into a cis structure characteristic that is very similar to that of natural rubber. This cis structure yields a rubbery product, as opposed to a trans structure which produces a rigid product similar to plastics.

The production of synthetic rubbers by solution polymerization processes is a stepwise operation very similar in many aspects to production by emulsion polymerization. There are distinct differences in the two technologies, however. For solution polymerization, the monomers must be extremely pure and the solvent should be completely anhydrous. In contrast to emulsion polymerization, where the monomer conversion is taken to approximately 60%, solution polymerization systems are polymerized to conversion levels typically in excess of 90%. The polymerization reaction is also more rapid, usually being completed in 1 to 2 hours.

Fresh monomers often have inhibitors added to them while in storage to prevent premature polymerization. These inhibitors and any water that is present in the raw materials must be removed by caustic scrubbers and fractionating drying columns to provide the solution process with the high purity and anhydrous materials needed. The purified solvent and monomers are then blended into what is termed the "mixed feed," which may be further dried in a desiccant column.

The dried mixed feed is now ready for the polymerization step, and catalysts can be added to the solution (solvent plus monomers) just prior to the polymerization stage or in the lead polymerization reactor.

The blend of solution and catalysts is polymerized in a series of reactors. The reaction is highly exothermic and heat is removed continuously by either an ammonia refrigerant or by chilled brine or glycol solutions. The reactors are similar in both design and operation to those used in emulsion polymerization. The mixture leaves the reactor train as a rubber cement, that is, polymeric rubber solids dissolved in solvent. A short stop solution is added to the cement after the desired conversion is reached.

The rubber cement is then sent to storage tanks where antioxidants and extenders are mixed in. The rubber cement is pumped from the storage tank to the coagulator where the rubber is precipitated with hot water under violent agitation. The solvent and unreacted monomer are first steam stripped overhead and then condensed, decanted, and recycled to the feed stage. The bottom water layer is discharged to the wastewater treatment facility.

The stripped crumb slurry is further washed with water, then dewatered, dried, and baled as final product. Part of the water from this final washing is recycled to the coagulation stage, and the remainder is discharged for treatment.

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