年产1000吨聚丙烯酸钠车间工艺设计

设计总说明

聚丙烯酸钠的应用极为广泛。在涂料、陶瓷、造纸、纺织工业用作颜料分散剂； 在日用化工领域用作清洁剂成份。可用于墙体材料粘结剂、农药防漂散剂，且在生物方面对动植物蛋白的絮凝有特效作用。此外在石油工业的油田化学领域，用作钻井液的增粘剂、降滤失剂、粘土稳定剂等；还可用作酸化液、制药、化妆品等方面的增稠剂等等。

聚丙烯酸钠合成方法主要有本体聚合、水溶液聚合、反相悬浮聚合、反相乳液聚合、微波合成及辐射合成等多种方式。通过查阅大量相关文献，进行网络与市场调研，选定了基于反相悬浮聚合方法来生产聚丙烯酸钠，将中和后的丙烯酸钠水溶液与由分散介质和分散稳定剂配制好的分散液共同放入反应釜中，在引发剂的作用下进行聚合反应至共沸脱水，反应后生成的混合物通过离心机分离分散介质与聚合物，再经热水洗涤除去聚合物表面的一些残留助剂，将分离工序过后的聚合物进行干燥、计量包装等处理后，得到聚丙烯酸钠产品。

根据任务书的要求对生产条件进行了探讨，分散剂种类、单体浓度、聚合温度对分子量的影响，搅拌转速的影响，中和度的确定，后处理工艺中分离方法和干燥方法的选取，确定了以Span-60作为分散剂，抽余油作为分散介质，过硫酸铵作为引发剂，单体丙烯酸钠中和度为100% 来进行聚合反应，离心机分离后，使用气流干燥机进行干燥。

本设计规模为年生产聚丙烯酸钠1000吨，按全年330天，每天2班，一班8小时生产，一班可以生产两批，每批产量为773.04 kg。并以此进行物料衡算、能量衡算和设备选型，并且进行了简单的经济概算，仅在第一年就可以盈利1444.45万元。而后说明了安全生产规范以及环境保护措施。

Illustration

Application of sodium polyacrylate is very extensive,it can be used as pigment dispersant in the paint, ceramics, papermaking, textile industry，a cleaning agent composition in daily chemical industry,and the pesticide of wall materials and bleaching powder binder. Sodium polyacrylate has special effect on protein in Biology. In addition, it is used as tackifier, drilling fluid filtrate reducer, clay stabilizer in the oil field chemistry of petroleum industry,also it can be used for acidizing fluid, pharmaceutical, cosmetics and other aspects of the thickener etc..

Sodium polyacrylate can be synthesized by the bulk polymerization, solution polymerization, inverse suspension polymerization, inverse emulsion polymerization, microwave synthesis and radiation synthesis etc.. Through consulting a number of literature, surfing on the internet and researching market, I use inverse emulsion polymerization to

product sodium polyacrylate. There are Sodium acrylate solution that had been neutralized， dispersion medium and dispersant in the reactor, The polymerization reaction under the effect of initiator will be carry on until azeotropic dehydration, the generated mixture will be separated of the polymer and remnant dispersion medium by the machine. Finally，the polymer transform into the completion by the post processing such as drying, metering and packing.

The design according to the design tasks are assigned the task of the book, the production conditions are discussed. The type of dispersant, monomer concentration, polymerization temperature effect on the molecular weight, the effects of stirring speed, determination the degree of neutralization, the selection of the separating method and drying method in the end ensure that polymerization reaction is implemented through using Span-60 as dispersant, raffinate oil as dispersing medium, ammonium persulfate as initiator, sodium acrylate whose neutralization degree is 100% as monomer. After that, separating by using the centrifuge, drying by airflow dryer.

The scale of the design for the sodium polyacrylate is1000 tons per year，according to 330 days a year，2 shift a day, 8 working hours a shift, they can produce two batches in a shift, the yield of each batch is 773.04kg. Then mentioned safety production standardization and the measure of environmental protection.

Professor XuChunHua, guiding by the director originally, had submitted a lot of valuable and positive suggestions, had helped me to raise the design mass. Here, I express my sincere thanks to them. Throughout the design process, I had a comprehensive understanding of their production process. According to my professional knowledge, combined with the learning experience, flexible application, laid a basis for future work related.

Because of the wide range of knowledge of the design of Polyacrylate sodium process, and my knowledge and experience is limited. So having design errors and anything wrong with that, I urge marking teacher criticism.

目录

1 前言 ................................................................................................................................. 1 2 聚丙烯酸钠的概述 ......................................................................................................... 1 2.1 聚丙烯酸钠性能 ....................................................................................................... 2 2.2 聚丙烯酸钠的分类 ................................................................................................... 2 2.2.1 低分子量聚丙烯酸钠 .......................................................................................... 2 2.2.2 高分子量聚丙烯酸钠 .......................................................................................... 3 2.3 聚丙烯酸钠的应用 ................................................................................................... 3 2.4 聚丙烯酸钠国内外发展状况及发展前景 ............................................................... 4 3 聚丙烯酸钠生产工艺 ..................................................................................................... 6 3.1 聚丙烯酸钠的聚合方法 ........................................................................................... 6 3.1.1 水溶液聚合 .......................................................................................................... 6 3.1.2 反相乳液聚合 ...................................................................................................... 6 3.1.3 微波法 .................................................................................................................. 6 3.1.4 辐射聚合 .............................................................................................................. 7 3.1.5 反相悬浮聚合 ...................................................................................................... 7 4 聚合过程中工艺条件的确定 ......................................................................................... 8 4.1 分散剂及其助分散剂对分子量的影响 ................................................................... 8 4.2 引发体系的选择及其浓度对分子量的影响 ........................................................... 8 4.3 交联剂对分子量的影响 ........................................................................................... 9 4.4 单体浓度对分子量的影响 ....................................................................................... 9 4.5 聚合温度对分子量的影响 ..................................................................................... 10 4.6 聚合升温控制对聚合稳定性的影响 ..................................................................... 10 4.7 搅拌转速的影响 ..................................................................................................... 11 4.8 中和度的选取 ......................................................................................................... 11 4.9 分离方法的选择 ..................................................................................................... 12 4.10 干燥方法的选择 ..................................................................................................... 12 5 聚丙烯酸钠的生产工艺 ............................................................................................... 13 5.1 生产工艺 ................................................................................................................. 13 5.2 生产原料以产品指标 ............................................................................................. 14 6 工艺衡算 ....................................................................................................................... 14 6.1 物料衡算 ................................................................................................................. 14

6.2 热量衡算 ................................................................................................................. 18 6.2.1 配碱工序 ............................................................................................................ 19 6.2.2 中和工序 ............................................................................................................ 20 6.2.3 聚合反应工序 .................................................................................................... 21 7 设备选型 ....................................................................................................................... 23 7.1 釜的选择 ................................................................................................................. 23 7.1.1 配碱釜的选择 .................................................................................................... 23 7.1.2 中和反应釜的选择 ............................................................................................ 25 7.1.3 分散介质调配釜的选择 .................................................................................... 26 7.1.4 聚合反应釜的选取 ............................................................................................ 28 7.1.5 釜体夹套尺寸的确定 ........................................................................................ 30 7.2 分离设备 ................................................................................................................. 33 7.3 干燥设备 ................................................................................................................. 33 7.4 泵的选型 ................................................................................................................. 34 8 生产工艺流程图 ........................................................................................................... 35 9 设备一览表 ................................................................................................................... 36 10 车间设计 ....................................................................................................................... 36 10.1 车间设备布置的原则 ............................................................................................. 36 10.2 车间设备平面布置的原则 ..................................................................................... 37 10.3 车间布置图 ............................................................................................................. 37 11 经济概算 ....................................................................................................................... 38 11.1

原料估算 ............................................................................................................... 38 11.1.1 原料用量 ............................................................................................................ 38 11.1.2 原料费用 ............................................................................................................ 39 11.2 11.3

其他费用 ............................................................................................................... 39 利润估算 ............................................................................................................... 40

12 生产安全与环境保护 ................................................................................................... 40 12.1 设计依据 ............................................................................................................... 40 12.2 环保治理措施 ....................................................................................................... 41 12.2.1 预期效果 ............................................................................................................ 41 12.2.2 环保管理及监测 ................................................................................................ 42 12.2.3 绿化概况 ............................................................................................................ 42 12.2.4 劳动安全、工业卫生与消防 ............................................................................ 42 致谢 ................................................................................................... 错误！未定义书签。 参考文献 ............................................................................................................................. 42

年产1000吨聚丙烯酸钠车间工艺设计 1

1 前言

随着我国丙烯酸工业的迅速发展，对丙烯酸下游产品的研究不断深入，应用范围不断扩大。聚丙烯酸钠盐是丙烯酸盐类中最重要、应用最广、最有代表性的产物，聚丙酸钠盐中含有大量亲水基团，它易溶于水，形成的水溶液是一种高分子电解质。

聚丙烯酸钠水溶液具有良好的离解性、较理想的润湿性、保水性和成膜性(浸渍或涂布时)，同时还具有耐温性强、冻融稳定性、机械稳定性、以及经长期贮存后其粘度无明显变化等特点。聚丙烯酸钠的分子量从几百至几千万以上，变化幅度很大，不同分子量的聚丙烯酸钠可以用作各种各样的目的和用途。超低分子量(700以下)的用途还未完全开发出来；低分子量(1000-5000)时，主要起分散作用；中等分子量(104-106)显示有增稠性；高分子量(106-107)的聚丙烯酸钠主要做增稠剂和絮凝剂；超高分子量(107)的聚丙烯酸钠不再溶于水，而是在水中溶胀，生成水凝胶，主要用作吸水剂[1]。水溶性聚丙烯酸钠中又包括高分子量和低分子量两大类。本论文主要涉及水溶性高分子量聚丙烯酸钠生产车间的工艺设计。

2 聚丙烯酸钠概述

聚丙烯酸钠的应用极为广泛，在涂料、陶瓷、造纸、纺织工业用作颜料分散剂；在日用化工领域用作清洁剂成份[2]。可用于墙体材料粘结剂、农药防漂散剂，且在生物方面对动植物蛋白的絮凝有特效作用。此外在石油工业的油田化学领域，用作钻井液的增粘剂、降滤失剂、粘土稳定剂等；还可用作酸化液、制药、化妆品等方面的增稠剂等[3]。

图 2.1 聚丙烯酸钠结构式

聚丙烯酸钠，英文名Sodium polyacrylate，缩写PAAS或简称PAA-Na，结构式为 -[CH2 - CH(COONa)]n-，是一种水溶性高分子化合物。商品形态的聚丙烯酸钠，相对分子质量小到几百，大到几千万，外观为无色或淡黄色液体、粘稠液体、凝胶、树脂或固体粉末，易溶于水；因中和程度不同，水溶液的pH一般在6-9。缓慢溶于水形成极粘稠的透明液体，粘性并非吸水膨润（如CMC，海藻酸钠）产生，而是由于分子内许多阴离子基团的离子现象使分子链增长，其粘度约为CMC、海藻酸钠的15-20倍[4]。加热处理、中性盐类、有机酸类对其粘性影响很小，碱性时则粘性增大。不溶于乙醇、丙酮等有机溶剂。

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