Typical Process

The general procedure to produce a batch consists of several steps  

Bring the raw materials to starting temperature (MDI may need to be melted). 

Turn on the reactor heating and bring to the starting temperature. 

If temperature rises too rapidly, slow down or stop polyol addition. 

If temperature goes above 85°C, stop polyol addition and start external cooling. 

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Once prepared in S q witli well defined energy E, donor molecules will begin to collide witli batli molecules B at a rate detennined by tire batli-gas pressure. A typical process of tliis type is tire collision between a CgFg molecule witli approximately 5 eV (40 000 cm or 460 kJ mor ) of internal vibrational energy and a CO2 molecule in its ground vibrationless state 00 0 to produce CO2 in tire first asymmetric stretch vibrational level 00 1 [11,12 and 13]. This collision results in tire loss of approximately AE= 2349 cnA of internal energy from tire CgFg,... 

In the first step cumene is oxidized to cumene hydroperoxide with atmospheric air or air enriched with oxygen ia one or a series of oxidizers. The temperature is generally between 80 and 130°C and pressure and promoters, such as sodium hydroxide, may be used (17). A typical process iavolves the use of three or four oxidation reactors ia series. Feed to the first reactor is fresh cumene and cumene recycled from the concentrator and other reactors. Each reactor is partitioned. At the bottom there may be a layer of fresh 2—3% sodium hydroxide if a promoter (stabilizer) is used. Cumene enters the side of the reactor, overflows the partition to the other side, and then goes on to the next reactor. The air (oxygen) is bubbled ia at the bottom and leaves at the top of each reactor. 

Fig. 1. A typical process flowsheet for acrolein manufacture. A, Fixed-bed or fluid-bed reactor B, quench cooler C, absorber D, stripper E and F,...

A typical process for the preparation of a 94.8% ethyl acrylate—5.2% acryUc acid copolymer as an approximately 39% solution in ethyl acetate is given... 

Numerous recipes have been pubUshed, primarily ia the patent Hterature, that describe the preparation of acrylate and methacrylate homopolymer and copolymer dispersions (107,108). A typical process for the preparation of a 50% methyl methacrylate, 49% butyl acrylate, and 1% methacrylic acid terpolymer as an approximately 45% dispersion ia water begias with the foUowiag charges ... 

PVDE is not hazardous under typical processing conditions. If the polymer is accidentaky exposed to temperatures exceeding 350°C, thermal decomposition occurs with evolution of toxic hydrogen fluoride (HE). 

The large excess of water from the hydrolysis is removed in a series of multiple-effect evaporators (8), and the ethylene glycol is refined by vacuum distillation. Figure 3 depicts a typical process flow diagram. 

Decision Process. In many cases, the decision regarding the need for exposure reduction measures is obvious and no formal statistical procedure is necessary. However, as exposure criteria are lowered, and control becomes more difficult, close calls become more common, and a logical decision-making process is needed. A typical process is shown in Eigure 2. Even when decision making is easy it is useful to remember the process and the assumptions involved. Based on an evaluation, decisions are made regarding control. The evaluation and decision steps caimot be separated because the conduct of the evaluation, the strategy, measurement method, and data collection are all a part of the decision process. 

The dehydrogenation of 2-butanol is conducted in a multitube vapor-phase reactor over a zinc oxide (20—23), copper (24—27), or brass (28) catalyst, at temperatures of 250—400°C, and pressures slightly above atmospheric. The reaction is endothermic and heat is suppHed from a heat-transfer fluid on the shell side of the reactor. A typical process flow sheet is shown in Figure 1 (29). Catalyst life is three to five years operating in three to six month cycles between oxidative reactivations (30). Catalyst life is impaired by exposure to water, butene oligomers, and di-j -butyl ether (27). 

Electrochemical deburring is a fast process. Typical process times are 5 to 30 s for smoothing the surfaces of manufactured components. Owing to its speed and simplicity of operation, electrochemical deburring can often be performed using a fixed, stationary cathode tool. The process is used in many apphcations, and is particularly attractive for the deburring of the intersectional region of cross-drilled holes. 

In typical processes, the gaseous effluent from the second-stage oxidation is cooled and fed to an absorber to isolate the MAA as a 20—40% aqueous solution. The MAA may then be concentrated by extraction into a suitable organic solvent such as butyl acetate, toluene, or dibutyl ketone. Azeotropic dehydration and solvent recovery, followed by fractional distillation, is used to obtain the pure product. Water, solvent, and low boiling by-products are removed in a first-stage column. The column bottoms are then fed to a second column where MAA is taken overhead. Esterification to MMA or other esters is readily achieved using acid catalysis. 

A typical process for the preparation of an acryUc solution terpolymer of composition 27.5% 2-ethyIhexyl acrylate—41.3% methyl methacrylate—31.2% hydroxyethyl methacrylate begins with the following charges ... 

A typical process for the preparation of a poly(methyl methacrylate) suspension polymer involves charging a mixture of 24.64 parts of methyl methacrylate and 0.25 parts of benzoyl peroxide to a rapidly stirred, 30°C solution of 0.42 parts of disodium phosphate, 0.02 parts of monosodium phosphate, and 0.74 parts of Cyanomer A-370 (polyacrylamide resin) in 73.93 parts of distilled water. The reaction mixture is heated under nitrogen to 75°C and is maintained at this temperature for three hours. After being cooled to room temperature, the polymer beads are isolated by filtration, washed, and dried (69). 

The three chemical reactions in the toluene—benzoic acid process are oxidation of toluene to form benzoic acid, oxidation of benzoic acid to form phenyl benzoate, and hydrolysis of phenyl benzoate to form phenol. A typical process consists of two continuous steps (13,14). In the first step, the oxidation of toluene to benzoic acid is achieved with air and cobalt salt catalyst at a temperature between 121 and 177°C. The reactor is operated at 206 kPa gauge (2.1 kg/cm g uge) and the catalyst concentration is between 0.1 and 0.3%. The reactor effluent is distilled and the purified benzoic acid is collected. The overall yield of this process is beheved to be about 68 mol % of toluene. 

In other designs, a diffused siUcon sensor is mounted in a meter body that is designed to permit caUbration, convenient installation in pressure systems and electrical circuits, protection against overload, protection from weather, isolation from corrosive or conductive process fluids, and in some cases to meet standards requirements, eg, of Factory Mutual. A typical process pressure meter body is shown in Figure 10. Pressure measurement from 0—746 Pa (0—3 in. H2O) to 0—69 MPa (0—10,000 psi) is available for process temperatures in the range —40 to 125°C. Differential pressure- and absolute pressure-measuring meter bodies are also available. As transmitters, the output of these devices is typically 4—20 m A dc with 25-V-dc supply voltage. 

A typical process scheme for the direct hydration of propylene is shown ia Figure 2. Turnkey plants based on this technology are available (71,81). The principal difference between the direct and iadirect processes is the much higher pressures needed to react propylene direcdy with water. Products and by-products are also similar, and refining systems are essentially the same. Under some conditions, the high pressures of the direct process can increase the production of propylene polymers. 

Any sihcate that forms thermally and chemically stable residual compounds as its oxygen content is reduced provides a suitable source of siUcon for this reaction. A typical process consists of alternating aluminum, siUca, and graphite plates separated by 2—4-cm thick graphite spacers stacked in a graphite-lined alumina tube and heated to 1400°C for 12 h in a nitrogen atmosphere. After cooling for approximately 6 h the fibers are removed. 

The success of a reverse osmosis process hinges direcdy on the pretreatment of the feed stream. If typical process streams, without pretreatment to remove partially some of the constituents Hsted, were contacted with membranes, membrane life and performance would be unacceptable. There is no single pretreatment for all types of foulants. Pretreatment methods range from pH control, adsorption (qv), to filtration (qv), depending on the chemistry of the particular foulant. Some of the pretreatment methods for each type of foulant are as foUow (43—45) ... 

Ma.nufa.cture. In a typical process, a solution of sodium carbonate is allowed to percolate downward through a series of absorption towers through which sulfur dioxide is passed countercurrently. The solution leaving the towers is chiefly sodium bisulfite of typically 27 wt % combined sulfur dioxide content. The solution is then mn into a stirred vessel where aqueous sodium carbonate or sodium hydroxide is added to the point where the bisulfite is fully converted to sulfite. The solution may be filtered if necessary to attain the required product grade. A pure grade of anhydrous sodium sulfite can then be crystallized above 40°C because the solubiUty decreases with increasing temperature. 

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