SYSTEMS AND METHODS FOR PRODUCING SUPERABSORBENT POLYMERS

• US 20190106532A1
• Filed: 03/21/2017
• Published: 04/11/2019
• Est. Priority Date: 03/21/2016
• Status: Active Grant

• Current Assignee: Novomer, Inc (Danimer Scientific, Inc.)
• Original Assignee: Novomer, Inc (Danimer Scientific, Inc.)
• Inventors: SOOKRAJ, Sadesh H.
• Granted Patent: US 10,711,095 B2
• Time in Patent Office: Days
• CPC Class Codes: B01D 3/009 in combination with chemical reactions
• CPC Class Codes: B01D 61/027 Nanofiltration
• CPC Class Codes: B01J 19/246 internally, i.e. the mixture circulating inside the vessel such that the upward stream is separated physically from the downward stream(s)
• CPC Class Codes: B01J 19/248 Reactors comprising multiple separated flow channels
• CPC Class Codes: C08F 220/06 Acrylic acid; Methacrylic acid; Metal salts or ammonium salts thereof
• CPC Class Codes: C08G 63/08 Lactones or lactides
• CPC Class Codes: C08G 63/78 Preparation processes
• CPC Class Codes: C08G 63/785 characterised by the apparatus used
• CPC Class Codes: C08K 3/22 of metals
• CPC Class Codes: C08K 5/0025 Crosslinking or vulcanising agents; including accelerators
• CPC Class Codes: C08K 5/098 Metal salts of carboxylic acids
• CPC Class Codes: Y02P 20/10 Process efficiency

Abstract

Provided herein are systems, and methods of using such systems, for producing superabsorbent polymers from ethylene oxide and carbon monoxide. The production systems have various unit operations, including, for example, a β-propiolactone production system configured to produce β-propiolactone from ethylene oxide and carbon monoxide and a superabsorbent polymer production system configured to produce superabsorbent polymers from β-propio lactone and/or acrylic acid.

Claims

1. A production system for superabsorbent polymers from ethylene oxide and carbon monoxide, comprising:

a β

-propiolactone production system, comprising;

a first reactor comprising;

at least one inlet to receive carbon monoxide, ethylene oxide, carbonylation catalyst, and solvent; and

at least one outlet for a first β

-propiolactone stream comprising β

-propiolactone, solvent, and carbonylation catalyst;

a carbonylation catalyst recycling system configured to separate at least a portion of the carbonylation catalyst from the first β

-propiolactone stream to produce a second β

-propiolactone stream; and

a superabsorbent polymer production system, comprising;

a second reactor comprising;

at least one inlet to receive the second β

-propiolactone stream, a crosslinking agent, and a sodium-containing component; and

at least one outlet for a superabsorbent polymer stream comprising superabsorbent polymer.

2. The production system of claim 1, wherein the second reactor comprises at least one selected from the group of a distillation reactor, a loop reactor, or a continuous stirred-tank reactor.

3. The production system of claim 1, wherein the at least one inlet of the second reactor is further configured to receive a chelating agent.

4. The production system of claim 1, wherein the at least one inlet of the second reactor is further configured to receive a gelling agent.

5. The production system of claim 1, wherein the sodium-containing component comprises sodium hydroxide, sodium acrylate, or sodium methacrylate, or any combinations thereof.

6. The production system of claim 1, further comprising a β

-propiolactone purification system between the carbonylation catalyst recycling system and the superabsorbent polymer production system configured to separate at least a portion of the solvent from the second β

-propiolactone stream to produce a third β

-propiolactone stream which is received by the at least one inlet of the second reactor instead of the second β

-propiolactone stream.

7. A production system for superabsorbent polymers, comprising:

a distillation reactor comprising;

at least one inlet to receive β

-propiolactone, a crosslinking agent, and a sodium-containing component; and

at least one outlet for a superabsorbent polymer stream comprising superabsorbent polymer.

8. The production system of claim 7, wherein the at least one inlet of the distillation reactor is further configured to receive a chelating agent.

9. The production system of claim 7, wherein the at least one inlet of the distillation reactor is further configured to receive a gelling agent.

10. The production system of claim 7, wherein the sodium-containing component comprises sodium hydroxide, sodium acrylate, or sodium methacrylate, or any combinations thereof.

11. The production system of claim 7, wherein the β

-propiolactone comprises solvent.

12. The production system of claim 7, wherein the β

-propiolactone and the sodium-containing component are combined prior to entering the distillation reactor.

13. The production system of claim 7, wherein the crosslinking agent and the sodium-containing component are combined prior to entering the distillation reactor.

14. The production system of claim 7, wherein the distillation reactor further comprises a catalytic material.

15. The production system of claim 7, wherein the distillation reactor comprises a separate inlet to receive the β

-propiolactone, the crosslinking agent, and the sodium-containing component.

16. A production system for superabsorbent polymers, comprising:

a distillation reactor comprising;

at least one inlet to receive acrylic acid, a crosslinking agent, and a sodium-containing component; and

at least one outlet for a superabsorbent polymer stream comprising superabsorbent polymer.

17. The production system of claim 16, wherein the at least one inlet of the distillation reactor is further configured to receive a chelating agent.

18. The production system of claim 16, wherein the at least one inlet of the distillation reactor is further configured to receive a gelling agent.

19. The production system of claim 16, wherein the sodium-containing component comprises sodium hydroxide, sodium acrylate, or sodium methacrylate, or any combinations thereof.

20. The production system of claim 16, wherein the acrylic acid and the sodium-containing component are combined prior to entering the distillation reactor.

21. The production system of claim 16, wherein the crosslinking agent and the sodium-containing component are combined prior to entering the distillation reactor.

22. The production system of claim 16, wherein the at least one inlet of the distillation reactor is further configured to receive a catalytic material.

23. The production system of claim 16, wherein the distillation reactor comprises a separate inlet to receive the acrylic acid, the crosslinking agent, and the sodium-containing component.

24. A production system for superabsorbent polymers, comprising:

a loop reactor comprising;

at least one inlet to receive β

-propiolactone, a crosslinking agent, and a sodium-containing component; and

at least one outlet for a superabsorbent polymer stream comprising superabsorbent polymer.

25. The production system of claim 24, wherein the at least one inlet of the loop reactor is further configured to receive a chelating agent.

26. The production system of claim 24, wherein the at least one inlet of the loop reactor is further configured to receive a gelling agent.

27. The production system of claim 24, wherein the sodium-containing component comprises sodium hydroxide, sodium acrylate, or sodium methacrylate, or any combinations thereof.

28. The production system of claim 24, wherein the β

-propiolactone comprises solvent.

29. The production system of claim 24, wherein the β

-propiolactone and the sodium-containing component are combined prior to entering the loop reactor.

30. The production system of claim 24, wherein the crosslinking agent and the sodium-containing component are combined prior to entering the loop reactor.

31. The production system of claim 24, wherein the at least one inlet of the loop reactor is further configured to receive a catalytic material.

32. The production system of claim 24, wherein the at least one inlet of the loop reactor is further configured to receive a diluent.

33. The production system of claim 24, wherein the loop reactor comprises a separate inlet to receive the β

-propiolactone, the crosslinking agent, and the sodium-containing component.

34. A production system for superabsorbent polymers, comprising:

a loop reactor comprising;

at least one inlet to receive acrylic acid, a crosslinking agent, and a sodium-containing component; and

at least one outlet for a superabsorbent polymer stream comprising superabsorbent polymer.

35. The production system of claim 34, wherein the at least one inlet of the loop reactor is further configured to receive a chelating agent.

36. The production system of claim 34, wherein the at least one inlet of the loop reactor is further configured to receive a gelling agent.

37. The production system of claim 34, wherein the sodium-containing component comprises sodium hydroxide, sodium acrylate, or sodium methacrylate, or any combinations thereof.

38. The production system of claim 34, wherein the acrylic acid and the sodium-containing component are combined prior to entering the loop reactor.

39. The production system of claim 34, wherein the crosslinking agent and the sodium-containing component are combined prior to entering the loop reactor.

40. The production system of claim 34, wherein the at least one inlet of the loop reactor is further configured to receive a catalytic material.

41. The production system of claim 34, wherein the at least one inlet of the loop reactor is further configured to receive a diluent.

42. The production system of claim 34, wherein the loop reactor comprises a separate inlet to receive the acrylic acid, the crosslinking agent, and the sodium-containing component.

43. A production system for superabsorbent polymers from ethylene oxide and carbon monoxide, comprising:

a β

-propiolactone production system, comprising;

a first reactor comprising;

at least one inlet to receive carbon monoxide, ethylene oxide, carbonylation catalyst, and solvent; and

at least one outlet for a first β

-propiolactone stream comprising β

-propiolactone, solvent, and carbonylation catalyst;

a carbonylation catalyst recycling system configured to separate at least a portion of the carbonylation catalyst from the first β

-propiolactone stream to produce a second β

-propiolactone stream;

an acrylic acid production system, comprising;

at least one inlet to receive the second β

-propiolactone stream; and

at least one outlet for an acrylic acid stream comprising acrylic acid; and

a superabsorbent polymer production system, comprising;

a second reactor comprising;

at least one inlet to receive the acrylic acid stream, a crosslinking agent, and a sodium-containing component; and

at least one outlet for a superabsorbent polymer stream comprising superabsorbent polymer.

44. The production system of claim 43, wherein the second reactor comprises at least one selected from the group of a distillation reactor, a loop reactor, or a continuous stirred-tank reactor.

45. The production system of claim 43, wherein the at least one inlet of the second reactor is further configured to receive a chelating agent.

46. The production system of claim 43, wherein the at least one inlet of the second reactor is further configured to receive a gelling agent.

47. The production system of claim 43, wherein the sodium-containing component comprises sodium hydroxide, sodium acrylate, or sodium methacrylate, or any combinations thereof.

48. The production system of claim 47, wherein the sodium-containing component comprises sodium hydroxide.

49. The production system of claim 48, wherein the sodium-containing component further comprises water.

50. The production system of claim 43, further comprising a β

-propiolactone purification system between the carbonylation catalyst recycling system and the acrylic acid production system configured to separate at least a portion of the solvent from the second β

-propiolactone stream to produce a third β

-propiolactone stream which is received by the at least one inlet of the acrylic acid production system instead of the second β

-propiolactone stream.

51. The production system of claim 43, wherein the superabsorbent polymer stream further comprises solvent.

52. The production system of claim 51, further comprising a superabsorbent polymer purification system configured to separate at least a portion of the solvent from the superabsorbent polymer stream to produce a second superabsorbent polymer stream.

53. The production system of claim 43, wherein the superabsorbent polymer stream further comprises water.

54. The production system of claim 53, further comprising a superabsorbent polymer purification system configured to separate at least a portion of the solvent and water from the superabsorbent polymer stream to produce a second superabsorbent polymer stream.