Process for continuous production of water-absorbent resin product
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
C08J-003/00
C08J-003/12
C08J-003/24
출원번호
US-0708342
(2007-02-21)
등록번호
US-9382390
(2016-07-05)
우선권정보
JP-2002-355679 (2002-12-06)
발명자
/ 주소
Ishizaki, Kunihiko
Kajikawa, Katsuhiro
출원인 / 주소
Nippon Shokubai Co., Ltd.
대리인 / 주소
Dickinson Wright PLLC
인용정보
피인용 횟수 :
0인용 특허 :
50
초록▼
There is disclosed a process for continuous production of a water-absorbent resin product by which the water-absorbent resin product having high properties can continuously be produced easily and inexpensively with stable constant quality. In addition, there is disclosed a water-absorbent resin prod
There is disclosed a process for continuous production of a water-absorbent resin product by which the water-absorbent resin product having high properties can continuously be produced easily and inexpensively with stable constant quality. In addition, there is disclosed a water-absorbent resin product having high properties and being stable in quality. The process comprises the following steps of: (A) measuring a water-absorbent resin by its predetermined property and/or its predetermined component content, wherein the water-absorbent resin comes being continuously produced via a classification step and/or a surface-modifying step; (B) separating a predetermined amount of water-absorbent resin (a) from the water-absorbent resin that comes being continuously produced, wherein the water-absorbent resin (a) is a water-absorbent resin which displays not less than a definite value and/or a water-absorbent resin which displays not more than a definite value as to the predetermined property and/or the predetermined component content in accordance with results of the aforementioned measurement; and (C) mixing at least a portion of the aforementioned separated predetermined amount of water-absorbent resin (a) into a water-absorbent resin that comes being continuously produced via a classification step and/or a surface-modifying step on the same or another production line.
대표청구항▼
1. A process for continuous production of a particulate water-absorbent resin product in which a water-absorbent resin is continuously produced via a classification step and a surface-modifying step, said process comprising the steps of: surface-modifying a water-absorbent resin obtained from the cl
1. A process for continuous production of a particulate water-absorbent resin product in which a water-absorbent resin is continuously produced via a classification step and a surface-modifying step, said process comprising the steps of: surface-modifying a water-absorbent resin obtained from the classification step and comprising a water-swellable and substantially water-insoluble crosslinked polymer having a water-extractable component content of 0 to 50 mass %;measuring at least one property of the resulting surface-modified water-absorbent resin where the at least one property is selected from the group consisting of absorption capacity without load, absorption capacity under load, liquid permeability, component content and particle diameter; andchanging a production condition in each of a pulverization step, said classification step, and said surface-modifying step in response to the resulting measurement of the at least one property for the resulting surface-modified water-absorbent resin,and to obtain a yield of the water-absorbent resin per line of not less than 20 t (metric tons)/day. 2. A process for continuous production of a water-absorbent resin product according to claim 1, wherein the aforementioned particle diameters of the surface-modified water-absorbent resin are measured continuously by a laser diffraction scattering method. 3. A process for continuous production of a water-absorbent resin product according to claim 1, wherein the particle diameters of the surface-modified water-absorbent resin are measured by a laser diffraction scattering method and have a mass-average particle diameter of 300 to 600 μm and have particles of 850 to 150 μm (according to JIS-standardized sieve) in an amount of 95 to 100 mass %. 4. A process for continuous production of a water-absorbent resin product according to claim 1, wherein the water-absorbent resin contains a carboxyl group, and the surface-modifying step is carried out by a dehydration-reactable crosslinking agent which can react with the carboxyl group by dehydration esterification and/or dehydration amidation. 5. A process for continuous production of a particulate water-absorbent resin product comprising continuously producing a water-absorbent resin via a classification step and a surface-modifying step, andmeasuring the particle diameter of the water-absorbent resin by a laser diffraction scattering method in a dry manner, where the water-absorbent resin has a water-swellable and substantially water-insoluble crosslinked polymer having a water-extractable component content of 0 to 50 mass %, wherein the water-absorbent resin has a mass-average particle diameter of 300 to 600 μm and comprises particles having a particle diameter of 850 to 150 μm when determined by using a JIS-standard sieve in an amount of 95 to 100 mass %;wherein the yield of the water-absorbent resin product per line is not less than 20 t (metric ton)/day. 6. A process for continuous production of a water-absorbent resin product according to claim 5, wherein the water-absorbent resin contains a carboxyl group, and the surface-modifying step is carried out by a dehydration-reactable crosslinking agent which can react with the carboxyl group by dehydration esterification and/or dehydration amidation. 7. A process for continuous production of a water-absorbent resin product according to claim 5, wherein the obtained water-absorbent resin satisfies the following: (1) a mass-average particle diameter of 300 to 600 μm;(2) a residual monomer content of not higher than 500 ppm;(3) an absorption capacity of not less than 25 g/g without load;(4) an absorption capacity of not less than 20 g/g under a load of 1.9 kPa or 4.9 kPa; and(5) a fine powder (smaller than 150 μm) content of less than 5.0 mass %. 8. A process for continuous production of a water-absorbent resin product according to claim 1, wherein the surface-modifying step comprises surface-crosslinking the water-absorbent resin. 9. A process for continuous production of a water-absorbent resin product according to claim 8, wherein the surface-crosslinking is carried out by mixing the water-absorbent resin with a surface-crosslinking agent, and heating the resulting mixture at 100 to 250° C. 10. A process for continuous production of a water-absorbent resin product according to claim 9, wherein the amount of the surface-crosslinking agent is 0.001 to 10 mass parts per 100 mass parts of the water-absorbent resin. 11. A process for continuous production of a water-absorbent resin product according to claim 8, wherein the surface-crosslinking is carried out by mixing the water-absorbent resin with a surface-crosslinking, water and a hydrophilic organic solvent, and heating the resulting mixture at 100 to 250° C. 12. A process for continuous production of a water-absorbent resin product according to claim 11, wherein the amount of the surface-crosslinking is 0.001 to 10 mass parts, the amount of the water is 0.1 to 10 mass parts, and the amount of the hydrophilic organic solvent is 0 to 10 mass parts, per 100 mass parts of the water-absorbent resin. 13. A process for continuous production of a water-absorbent resin product according to claim 1, wherein the mass-average particle diameter of the water-absorbent resin after the classification or as a final product is 200 to 700 μm. 14. A process for continuous production of a water-absorbent resin product according to claim 1, further comprising the steps of: separating a predetermined amount of the water-absorbent resin from the water-absorbent resin being continuously produced, andmixing the separated water-absorbent resin with a water-absorbent resin which is being continuously produced via the classification step and/or the surface-modifying step on the same or another production line. 15. A process for continuous production of a water-absorbent resin product according to claim 1, wherein the obtained water-absorbent resin satisfies the following: (1) a mass-average particle diameter of 300 to 600 μm;(2) a residual monomer content of not higher than 500 ppm;(3) an absorption capacity of not less than 25 g/g without load;(4) an absorption capacity of not less than 20 g/g under a load of 1.9 kPa or 4.9 kPa; and(5) a fine powder smaller than 150 μm content of less than 5.0 mass %. 16. A process for continuous production of a water-absorbent resin product according to claim 1, wherein transportation of the water-absorbent resin between steps is carried out in a continuous or batch manner. 17. A process for continuous production of a water-absorbent resin product according to claim 1, further comprising a second classification step after the surface-modifying step. 18. A process for continuous production of a water-absorbent resin product according to claim 9, wherein the surface-crosslinking agent is used together with a cationic polymer and/or water-insoluble fine particles. 19. A process for continuous production of a water-absorbent resin product according to claim 18, wherein the amount of the surface-crosslinking agent is 0.01 to 10 mass parts, the amount of the cationic polymer is 0.01 to 10 mass parts, and the amount of water-insoluble fine particles is 0.001 to 5 mass parts, per 100 mass parts of the water-absorbent resin. 20. A process for continuous production of a water-absorbent resin product according to claim 1, wherein the measurement of the property is carried out by the continuous measurement of the property or by measuring the property at predetermined times. 21. A process for continuous production of a water-absorbent resin product according to claim 1, wherein the particulate water-absorbent resin product has (1) a mass-average particle diameter in the range of 300 to 600 μm;(2) a residual monomer content of not higher than 500 ppm;(3) an average value of not less than 25 g/g and a standard deviation of 0 to 0.50 as to an absorption capacity which is measured in a number “n” of analyzed samples=3 without load;(4) an average value of not less than 20 g/g and a standard deviation of 0 to 0.35 as to an absorption capacity which is measured in a number “n” of analyzed samples=3 under a load of 1.9 kPa or 4.9 kPa; and(5) an average value of less than 5.0 mass % and a standard deviation of 0 to 0.50 as to a fine powder smaller than 150 μm content which is measured in a number “n” of analyzed samples=3. 22. A process for continuous production of a water-absorbent resin product according to claim 2, wherein the laser diffraction scattering method is carried out by dry measurement at a temperature of 0 to 100° C. 23. A process for continuous production of a water-absorbent resin product according to claim 5, wherein the surface-modifying step comprises surface-crosslinking the water-absorbent resin. 24. A process for continuous production of a water-absorbent resin product according to claim 23, wherein the surface-crosslinking step comprises mixing the water-absorbent resin with a surface-crosslinking agent, and heating the resulting mixture at 100 to 250° C. 25. A process for continuous production of a water-absorbent resin product according to claim 24, wherein the amount of the surface-crosslinking agent is 0.001 to 10 mass parts per 100 mass parts of the water-absorbent resin. 26. A process for continuous production of a water-absorbent resin product according to claim 23, wherein the surface-crosslinking step comprises mixing the water-absorbent resin with a surface-crosslinking, water and a hydrophilic organic solvent, and heating the resulting mixture at 100 to 250° C. 27. A process for continuous production of a water-absorbent resin product according to claim 26, wherein the amount of the surface-crosslinking is 0.001 to 10 mass parts, the amount of the water is 0.1 to 10 mass parts, and the amount of the hydrophilic organic solvent is 0 to 10 mass parts, per 100 mass parts of the water-absorbent resin. 28. A process for continuous production of a water-absorbent resin product according to claim 23, wherein the mass-average particle diameter of the water-absorbent resin product is 300 to 600 μm, and an average value of fine powder smaller than 150 μm is less than 5.0 mass %. 29. A process for continuous production of a water-absorbent resin product according to claim 5, wherein transportation of the water-absorbent resin is carried out in a continuous or batch manner. 30. A process for continuous production of a water-absorbent resin product according to claim 5, wherein the laser diffraction scattering method is carried out by dry measurement at a temperature of 0 to 100° C. 31. A process for continuous production of a water-absorbent resin product according to claim 5, further comprising a second classification step after the surface-modifying step. 32. A process for continuous production of a water-absorbent resin product according to claim 5, wherein the particulate water-absorbent resin product has (1) a mass-average particle diameter in the range of 300 to 600 μm;(2) a residual monomer content of not higher than 500 ppm;(3) an average value of not less than 25 g/g and a standard deviation of 0 to 0.50 as to an absorption capacity which is measured in a number “n” of analyzed samples=3 without load;(4) an average value of not less than 20 g/g and a standard deviation of 0 to 0.35 as to an absorption capacity which is measured in a number “n” of analyzed samples=3 under a load of 1.9 kPa or 4.9 kPa; and(5) an average value of less than 5.0 mass % and a standard deviation of 0 to 0.50 as to a fine powder smaller than 150 μm content which is measured in a number “n” of analyzed samples=3. 33. The process of claim 1, wherein the process continuously produces said water-absorbent resin having predetermined properties, said process comprising: surface-modifying the water-absorbent resin obtained from the classification step under a predetermined production condition selected from the group consisting of temperature, amount of surface-modifying agent, particle diameter distribution and particle diameter;measuring said at least one property of the resulting surface-modified water-absorbent resin and determining whether said at least one property is outside a predetermined range; andchanging the production condition of said surface-modifying step in response to said measured property outside the predetermined range. 34. The process of claim 33, wherein said water-absorbent resin obtained from said classifying step has a particle diameter, said process comprising measuring the particle diameter of the resulting surface-modified water-absorbent resin, andchanging the particle diameter of the water-absorbent resin in the surface-modifying step in response to the measured particle diameter. 35. The process of claim 33, wherein said measuring step measures the absorption capacity without load, absorption capacity under load, liquid permeability or component content of the surface-modified water-absorbent resin, and changing said temperature, or amount of surface-modifying agent, in the surface-modifying step in response to said measurement. 36. The process of claim 1, further comprising measuring said absorption capacity without load, absorption capacity under load, liquid permeability or component content property of the surface-modified water-absorbent resin, andchanging the temperature, amount of surface modifying agent or particle diameter distribution in said surface-modifying step in response to said measured property.
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