Commercial Production and Technology Transfer of Specialty Polymer

Project Objectives

Prepare pilot plant quantities of a series of novel polymer intermediates for customer sampling. Perform scale-up studies and determine which process variables impact product quality.

Client Profile/Project Background

Our client was a large specialty chemicals and polymers company whose novel polymer intermediates are considered to be break-through materials which would have rapid acceptance in the marketplace. They came to Ricerca for preparation of specification materials to meet urgent customer sampling needs. The processing involved the first time scale-up of a novel processing approach.

Results/Status

The process involved a chemical reaction, followed by a short residence time flash distillation which resulted in isolation of the product. We ran the reaction at the 100-gallon scale and performed the isolation by use of a continuous vacuum flash distillation approach. Scale-up problems relating to complete removal of residual material from the isolated product were encountered and resolved through equipment modifications and process variable changes. On-specification products were routinely produced.

The new products were so well received in the marketplace that Ricerca acquired and installed larger equipment to produce about 20,000 lbs of a variety of related polymer intermediates to support our client's market development efforts. Process technology has been transitioned to full commercial scale, and our client has formed a new division based on this technology.