ACRYLIC POLYMER PRODUCTION

INTRODUCTION

Polymers are usually produced by reacting two structures called “mers”. These are the building blocks of the polymer and the final polymer structure varies depending on the starting composition. To create fiber this polymer is usually mixed with a solvent. The resultant material is referred to as “dope”. The dope is processed further whereby the viscosity increases and the volume of air increases. A deaerator and some type of filter are imperative for removing excess air bubbles, solids and agglomerates.

APPLICATION

Our main concern in this application is to monitor for air bubbles in the dope. In normal processing, the volume of air can reach as high as 7%. The Monitek unit however, is intended to monitor for low levels of air (ppm levels) in the spin dope as it leaves the deaerator and/or the storage tank, prior to the fiber line. Solids are also another major concern in the manufacturer’s operation since particles and agglomerates can clog the spinnerets. The polymer manufacturer must have a liquid, free of any bubbles or solids prior to introduction into the spinnerets. Upstream contaminants can result in the clogging of spinnerets, producing thin and weak fibers. This production of material that is not within the manufacturer’s specifications creates large amounts of waste material. In some processes, production must be halted so that the spinneret be disassembled and cleaned. Bubbles also cause a weakness in the fibers due to lack of continuity.

SOLUTION

The Monitek acoustic suspended solids monitor will continuously check the process and will immediately detect if the volume of air and solids exceeds the predetermined ppm limit. The Monitek unit warns the operator of conditions before they reach the fiber line. This enables him to take appropriate action. Because the spinnerets remain cleaner longer, maintenance can be scheduled at non-critical down times.

ADDITIONAL COMMENTS

The current monitoring method in most plants is by random sampling and/or sightglass checks, but large amounts of contaminated material can travel through the process before being detected. Therefore, continuous in-line monitoring is preferred.

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