Skip to main content

Hitachi

Equipment supply

Our product lineup includes the horizontal dual-axle Spectacle-shaped blade polymerizer, the lattice blade type polymerizer and the horizontal single-axle hybrid blade polymerizer. The horizontal dual-axle polymerizer offer ideal extrusion flow, self-cleaning functions, and stable operation. Our newly developed hybrid blade polymerizer covers as a single machine viscosity regions that previously required multiple polymerization vessels, so now fewer pieces of equipment are needed.

(in-house comparison)

Case Introduction: Spectacle-shaped blade polymerizer, Lattice blade type polymerizer

Photograph: Spectacle-shaped blade polymerizer (external view)
Spectacle-shaped blade polymerizer (external view)

Photograph: spectacle Blade
Spectacle-shaped blade

Photograph: Lattice blade type polymerizer (external view)
Lattice blade type polymerizer (external view)

Photograph: Lattice blade
Lattice blade

Photograph: hybrid blade polymerizer (external view)
hybrid blade polymerizer (external view)

Photograph: hybrid blade
hybrid blade

What is a High-viscous material processor?

Polymerization is the process of taking fluids containing low-molecular-weight materials and agitating them to cause reactions that force molecules to combine, forming polymers. To produce high-quality polymers, the flow state through the agitator must be good, and it is vital to keep the processed fluid from standing still. As polymerization progresses, the viscosity of the fluid rises, so the proper conditions of high dispersion, temperature and residence time must be strictly controlled. Our special blades make several key functions of high-efficiency polymerization possible: self-cleaning, good mix flow and extreme reduction in dead space. We enable our customers to produce high-quality products with stable, continuous operation.

Scope of supply

We offer our customers total support from engineering through delivery and installation to commissioning and maintenance.

The polymerization process involves complicated questions concerning the state of low-molecule materials and solvent in the processed fluid (material properties, heat stability, viscosity, shape, etc.), and the processing volume and degree of polymerization at entry/exit. We choose specifications based on processed fluid data from our customers. We verify functionality in our test facilities; we use simulators to predict functionality, and guarantee the ability to achieve the performance. We offer installation, commissioning and maintenance for high viscous material processor on their own, as well as turnkey EPC projects covering the entire polymerization plant, including engineering, procurement, construction, and commissioning.

(in-house comparison)

Fields of application

General

  • Production of high-vicous materials (polymers)
  • Elimination of remaining monomers in polymers
  • Gas-removal equipment, to remove solvents
  • Continuous processing

Breakdown by product

  • Polybutylene terephthalate (PBT)
  • Polyethylene terephthalate (PET)
  • Biodegradable polymers (PLA, polylactic acid)
  • Polycarbonate (PC)
  • Polyacetal
  • Nylon 66
  • Nylon 12
  • Polystyrene (PS)
  • Liquid crystal polymer
  • Polyethylene naphthalate (PEN)

Technology

Spectacle-shaped blade polymerizer

We have provided many of these machines, earning a solid reputation.
The spectacle-shaped blades achieve outstanding agitation.

Piston flow is ideal, with no reverse mixing.

The number of effective complete mixing vessel stages per 1 Spectacle-shaped blade is 11/16 for viscousities of 400 Pa·s Therefore, by comparison with the 9/16 stages with a circular disc blade, this results in favorable piston flow for the flow of the processing fluid. Stagnation of processed fluid can be prevented.

Image: Tracer response diagram
Enlarge image (opens in new window)

With a large fluid surface, rapid evaporation is possible.

A large fluid surface is formed, making it possible for the blades to pull between each other, and for the fluid to descend freely. Evaporation speed close to 30 times that of a standing type agitation tank can be obtained.

(in-house comparison)

Photograph: Liquid surface formed by an spectacle blade
Enlarge image (opens in new window)

Self-cleaning makes complete mixing possible.

The agitator blades themselves are formed in a way that makes self-cleaning possible, making dead space within the vessel virtually impossible. Consequently, mixing in the radial direction is complete.

Image: polyester polymer degree of polymerization distribution diagram
Enlarge image (opens in new window)

This design has high mechanical reliability.

For the shaft seal, a mechanical seal manufactured to the company's unique design that takes into consideration extreme operating conditions is adopted. The highly reliable drive has achieved remarkable results in wide use.

(in-house comparison)

Image: Device specifications

Lattice blade type polymerizer

As the Figure on the right shows, the flow of processed fluid is mostly piston flow, and there is virtually no dead space inside the vessel.

(in-house comparison)

Photograph: Interior structure of pilot can
Inside of experimental installation

Photograph: Flow of processed fluid

This has many advantages.

  1. By forming the agitator blades using linear materials instead of surface area, we can offer continuous processing of High-viscous materials measuring 5,000 Pa·s or higher.
  2. The simple, shaftless structure prevents contamination, allowing production of highly purified, high-performance resins.
  3. Realizing piston flow of virtually 100%. By scraping the inside surface, stagnation of the processed fluid can be prevented.

(in-house comparison)