Upgrades: Late 1990's many items replaced or overhauled
Brief overview: Solutia (Monsanto) designed continuous acrylic polymer facility including co-polymers of acrylonitrile (AN) and vinyl acetate (VA), as well as terpolymers of AN, VA, and vinyl bromide (VBr).
Process Description
The continuous polymer reaction takes place in a water phase in the presence of monomers.
The resulting slurry containing polymer, un-reacted monomers and inorganic salts is filtered and the polymer cake is washed with softened water.
It is then re-slurried with a secondary filter wash and refiltered.
The wet polymer is pelletized and distributed across the apron of a conveyor dryer.
Dried pellets (less than 1% moisture) are pulverized through a hammer mill.
The pulverized product is pneumatically conveyed to storage bins.
Pulverized product is then mixed with solvent and run through a series of mixers and polishing filters until the final dope is sent to the spinning line.
There are (24) fiber spinning lines each made up of either (12) or (24) spinnerettes creating (6) tow bands, which in turn are run through a series of washers, dying rolls, with some stretching ability.
From the end of the spinning line the dried tow is reheated and crimped, then piled into bins for further processing.
Three of the lines can spin pre-dyed dope.
There are (6) annealing chambers that further process the tow.
Major Equipment
Solvent recovery plant polymer preparation plant
Rotary vacuum dryers
(11) 2000 gallon aluminum reactors
(2) 8500 pph Proctor Schwartz conveyor dryers
Dope preparation
(5) polymer bins with Acrison screw feeders
Baker Perkins conical mixers
Micromotion flow controllers
Sperry 36" and 18" aluminum polishing filters
Maag dope pumps
Spinning
(24) fiber spinning lines
(5) annealing chambers
(24) recrimpers
Automated production floor with robot controlled forklift carts baling
Lummus rotary cutters
(3) staple balers
(1) compact tow baler
Pilot plant facilities and finished product quality control equipment
Short and long fiber carding machines
Platt Saco Lowell spinning lines
Seydel stretch break machine
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