Mixing Kneader and Process for Preparing Poly(Meth)Acrylates Using the Mixing Kneader

Abstract

The invention relates to a mixing kneader comprising at least two shafts ( 2,3 ) configured as hollow shafts, on whose surfaces kneading bars ( 4 ) are disposed on elements ( 5 ). The construction of the shafts is selected in such a way that the resonant frequencies of the shafts have a separation of at least 5% from the excitation frequencies. At least one of the shafts is preferably flowed through by a temperature-control medium, the inlet being disposed on one side and the outlet on the other side of the shaft. The mixing kneader preferably comprises at least one orifice above the shafts which is configured as a dome, the dome being closed by a displacer ( 22 ). In addition, at least one orifice for product withdrawal is provided, whose orifice cross section is adjustable during operation.

1 - 23 . (canceled) 
     
     
         24 . A mixing kneader comprising at least two shafts ( 2 ,  3 ) on whose surfaces are disposed kneading bars ( 4 ) on elements ( 5 ) and which are enclosed by a casing ( 6 ), in which at least one orifice ( 10 ) above the shafts and at least one orifice ( 11 ) for product removal are formed, the shafts ( 2 ,  3 ) being mounted so as to be rotatable at the same or different rates and in the same or opposite sense at both ends and being driven at at least one end, wherein at least one of the following features is ensured:
 (a) the shafts are designed in such a way that flexural resonant frequencies of the shaft have a separation of at least 5% from the excitation frequencies,   (b) at least one shaft is configured as a hollow shaft and is flowed through by a temperature-control medium, an inlet ( 12 ) being disposed on one side and an outlet ( 13 ) on the other side of the shaft,   (c) the at least one orifice is closed above the shafts by a displacer ( 23 ) whose side facing the shafts is configured such that a gap is present between the displacer ( 23 ) and the kneading bars of the shafts and has a maximum gap width which corresponds to the available gap width between kneading bars and casing.   
     
     
         25 . The mixing kneader according to  claim 24 , which has a reactor volume of at least 500 l. 
     
     
         26 . The mixing kneader according to  claim 24 , wherein the orifice above the shafts is formed as a dome ( 20 ) in the casing. 
     
     
         27 . The mixing kneader according to  claim 24 , wherein the orifice for product removal is configured as a weir ( 14 ) in the casing wall. 
     
     
         28 . The mixing kneader according to  claim 24 , wherein the cross section of the orifice ( 11 ) for product removal is adjustable. 
     
     
         29 . The mixing kneader according to  claim 28 , wherein the cross section of the orifice ( 11 ) for product removal is adjusted during operation by a flap ( 15 ) shiftable in the axial direction. 
     
     
         30 . The mixing kneader according to  claim 28 , wherein the cross section of the orifice ( 11 ) for product removal is adjusted during operation by a flap shiftable in the tangential direction. 
     
     
         31 . The mixing kneader according to  claim 27 , wherein a height of the weir ( 14 ) forming the orifice ( 11 ) for product removal is adjustable during operation by tangential shifting of the weir. 
     
     
         32 . The mixing kneader according to  claim 24 , wherein a downcomer is attached to the orifice for product withdrawal and its walls are provided with insulation. 
     
     
         33 . The mixing kneader according to  claim 24 , which includes an additional closeable emptying flap ( 17 ) having an orifice cross section of at least 10,000 mm 2 . 
     
     
         34 . The mixing kneader according to  claim 33 , wherein the emptying flap ( 17 ) is disposed on the product withdrawal side in the casing ( 6 ). 
     
     
         35 . The mixing kneader according to  claim 33 , wherein the emptying flap ( 17 ) is formed in the weir ( 14 ). 
     
     
         36 . The mixing kneader according to  claim 24 , wherein at least one channel ( 25 ,  26 ) for reactant feeding is formed in the displacer ( 23 ). 
     
     
         37 . The mixing kneader according to  claim 36 , wherein a metering apparatus is accommodated in the channel ( 25 ) for reactant feeding. 
     
     
         38 . The mixing kneader according to  claim 36 , wherein the at least one channel ( 25 ,  26 ) has a plastics surface. 
     
     
         39 . The mixing kneader according to  claim 36 , wherein, in the case of at least two channels ( 25 ,  26 ) in the displacer, the orifices, facing the shafts, of the channels are arranged close to one another. 
     
     
         40 . The mixing kneader according to  claim 24 , wherein the shafts, the elements, the kneading bars, the casing, and the displacer are manufactured from ferritic-austenitic duplex material, from a nickel-based alloy, or from titanium. 
     
     
         41 . A process for preparing poly(meth)acrylates using the mixing kneader according to  claim 24 . 
     
     
         42 . The process according to  claim 41 , wherein the mixing kneader is emptied via an emptying flap at or before a shutdown. 
     
     
         43 . The process according to  claim 41 , wherein the mixing kneader is preheated before the reactants are added. 
     
     
         44 . The process according to  claim 41 , wherein monomers are initially added as reactants in the mixing kneader and, at the position at which 99.5% of the monomers have been converted to polymer, further components are added in the form of solid particles. 
     
     
         45 . The process according to  claim 44 , wherein the solid particles have a maximum particle size of 500 μm. 
     
     
         46 . The process according to  claim 41 , wherein the shafts are cooled during operation of the mixing kneader. 
     
     
         47 . The process according to  claim 46 , wherein the shafts are cooled by being flowed through with a temperature-control medium having a temperature of not more than 80° C. 
     
     
         48 . The mixing kneader according to  claim 24 , wherein the shafts are designed in such a way that the flexural resonant frequencies of the shaft have a separation of at least 15% from the excitation frequencies. 
     
     
         49 . The mixing kneader according to  claim 24 , wherein the shafts are designed in such a way that the flexural resonant frequencies of the shaft have a separation of at least 20% from the excitation frequencies.