Solution polymerization technologies are widely used to manufacture high-performance synthetic rubbers, elastomers and specialty polymers, including SSBR, LCBR, SBS, SIS, SEBS and related materials such as BR (Ned, Co, Ni, Pd) or EPDM.

Depending on the polymerization chemistry, catalysts, initiators and associated reaction residues may remain within the polymer solution after polymerization. Their presence can become relevant to product purity, polymer properties, downstream processing and the ability to manufacture demanding specialty grades. The presence of catalyst and/or initiator residues may lead to polymer yellowness, degradation, and gel formation over time.

Residue elimination should be considered as part of the complete process

The optimum approach cannot necessarily be defined by considering polymerization alone. Polymer concentration, solvent system, reaction chemistry, polymer viscosity, downstream recovery technology and final product requirements all influence how a residue-elimination strategy should be designed and integrated.

INNVENTIK has developed a proprietary Catalyst & Initiator Residues Elimination Module intended for integration into solvent-polymerization processes.

The concept can be engineered and adjusted according to the specific polymer system and plant configuration and considered for both new facilities and existing-plant revamps.

Potential areas of application

The module can be implemented for batch, continuous and swing production configurations, before the and polymer recovery and finishing areas (Steam Stripping or Direct Devolatilization). The approach is particularly relevant to solution-polymerization technologies such as:

• SSBR and functionalized SSBR
• LCBR
• Styrene Block Copolymers (SBCs) such as SBS and SIS
• SEBS, SEPS and other hydrogenated block copolymers
• Other polymers manufactured through solvent-based polymerization processes (i.e EPDM)

An integrated engineering approach

Residue elimination from the polymer solution (cement) should be evaluated together with the surrounding process rather than as an independent operation. INNVENTIK’s approach therefore considers the complete manufacturing chain, including polymerization, solvent management and purification, polymer recovery, finishing, utilities and product-quality requirements. This allows the residue-elimination concept to be incorporated within broader process-improvement and industrialization programs.

Beyond conventional polymerization processes

The technology forms part of INNVENTIK’s broader development of advanced solution-polymerization concepts, including high-solids polymerization, batch-to-continuous processing flexibility, reduced solvent consumption, advanced polymer recovery and process intensification, integrating the most advance process practices for polymer recovery (direct devolatilization).

INNVENTIK supports projects from initial process assessment and feasibility evaluation through Conceptual, Basic and Detail Engineering, implementation, commissioning and start-up.

Companies interested in evaluating catalyst or initiator residue elimination in an existing or new polymerization process are invited to contact INNVENTIK for a confidential technical discussion.