Research progress of horizontal kneading reactor and its application in polymerization industry

doi:10.11949/0438-1157.20231172

Abstract

Abstract:

The horizontal kneading reactor with large effective reaction volume possesses excellent mixing, surface renewal, heat transfer and self-cleaning performance. Hence, the kneading reactor has broad application prospects in fields such as bulk polymerization, polymerization condensation and polymer devolatilization. This article reviews several types of kneading reactors, research on stirring characteristics and their application in the polymerization industry. The experimental measurement techniques have significant limitations due to the complex geometry and the CFD simulation is the main research method. The kneading reactor with self-cleaning characteristics is the main direction for the development of agitated equipment for polymer. The efficient, intensive, green and environmentally friendly advanced processes and devices are the key to promoting the development of polymer industry.

Key words: kneading reactor, agitating characteristic, computational fluid dynamics, process intensification, bulk polymerization, polymerization condensation, polymer devolatilization

摘要：

卧式捏合反应器具有大的反应体积，优异的混合性能、表面更新性能、传热性能和自清洁性能，因而在本体聚合、缩合聚合和聚合物脱挥等领域具有广阔的应用前景。综述了几种捏合反应器及其搅拌特性研究，以及在聚合工业中的应用研究，指出捏合反应器具有非常复杂的几何结构，实验测量技术具有很大的局限性，计算流体力学（CFD）模拟为主要的研究方法；进一步指出具有自清洁特性的捏合反应器是聚合物搅拌设备开发的主要方向，高效、集约化、绿色、环保的先进工艺与装置是促进我国聚合工业发展的关键。

关键词: 捏合反应器, 搅拌特性, 计算流体力学, 过程强化, 本体聚合, 缩合聚合, 聚合物脱挥

CLC Number:

TQ 320.5

Wenkai CHENG, Jinyu YAN, Jiajun WANG, Lianfang FENG. Research progress of horizontal kneading reactor and its application in polymerization industry[J]. CIESC Journal, 2024, 75(3): 768-781.

成文凯, 颜金钰, 王嘉骏, 冯连芳. 卧式捏合反应器及其在聚合工业中的研究进展[J]. 化工学报, 2024, 75(3): 768-781.

Figures/Tables 20

Fig.1 Comparison of characteristics among different reactors

Table 1 Comparison of characteristics among different reactors

项目	List捏合反应器	螺杆挤出机	薄膜蒸发器	CSTR	转盘反应器
反应器体积	大	小	大	大	大
物料停留时间	灵活调节	短	短	长	长
是否需要溶剂	否	否	是	是	是
物料黏度	中黏至超高黏	中黏至超高黏	低黏	低黏	低黏
操作模式	间歇或连续	连续	连续	间歇或多釜连续	间歇
流动行为	平推流或有返混	平推流	平推流	有返混	有返混
生产操作弹性	很大	较大	很小	较大	很大

Fig.2 Horizontal single-shaft kneading reactor

Table 2 List kneading reactor

反应器类型	体积/L	操作温度/℃	操作压力/bar	最大功率/MW	最大扭矩/(kN·m)	驱动方式	搅拌轴密封
单轴捏合反应器	7~20000	-100~400	0.0001~100	2.5	500	液压马达或电机	机械或填料密封
双轴捏合反应器	3~10000	-100~400	0.001~10	1.5	500	液压马达或电机	机械或填料密封

Fig.3 Horizontal twin-shaft kneading reactor

Fig.4 Novel horizontal twin-shaft kneading reactor

Fig.5 Horizontal three-shaft kneading reactor

Fig.6 Experimental agitated equipment for film formation characteristics

Fig.7 Schematic diagram of mass transfer experiment and agitated equipment

Fig.8 Comparison of different polymerization techniques

Fig.9 Methyl methacrylate bulk polymerization process

Table 3 Comparison of different polymerization equipment for PLA

装置	体积/L	表面积/m²	比表面积/m^-1	物料温度/℃	物料黏度/(Pa∙s)	停留时间/h
CSTR	125000	117	0.936	195	300	3.8
捏合反应器	2900	43	14.828	194(max)	18(max)	1.7

Fig.10 Temperature distribution and conversion of lactide in kneading reactor

Fig.11 Short process for bulk polymerization of PLA

Table 4 Comparison of PEF performance prepared by different reactors

PEF类型	聚合装置	数均分子量	重均分子量	PDI	特性黏度/(dL/g)
PEF-1	三口烧瓶	18177	34751	1.91	0.26
PEF-2	List捏合反应器	22376	41835	1.86	0.36

Fig.12 Comparison of polymer devolatilization for rubber solution by different techniques

Fig.13 Direct devolatilization for BR solution

Table 5 Equipment parameters and operating conditions of used device

反应器类型	功能	体积/L	传热面积/m²	转速/(r/min)	温度/℃	操作压力/mbar
单轴捏合反应器	主蒸发器	100	2.1	50~80	80	300
双轴捏合反应器	脱挥器	200	7	60	80	60

Fig.14 Direct polymer solution devolatilization of styrene thermoplastic elastomer in cyclohexane

Fig.15 Sketch of pilot plant for direct devolatilization of PA6 melt

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