Scaling Up Polymer Batch Production

By leveraging innovative engineering solutions and advanced process controls, EPIC Systems successfully transitioned a leading research college’s polymer batch production from lab-scale to industrial-scale manufacturing, solidifying its role as a leader in polymer research and development.

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Hygienic Process System Design

Project

Overview

  • Industry: Specialty Chemicals (Industrial) 
  • Location: USA
  • Customer Use Case: Scale-Up, Batch Mixing

Customer’s

Challenge

A leading research institution developed a polymer batch-making system in their laboratory and sought to scale up production to an X100 capacity. Their goal was to produce large quantities of their specialized polymer while maintaining process integrity, precise temperature control, and operational efficiency. 

The polymer production process required melting at an extremely high temperature of 570°F inside a reactor before being transferred to an underwater pelletizer, where it was cooled and chopped into pellets. Traditional heat tracing, where electrical wires heat the pump, was insufficient for maintaining these extreme temperatures. Instead, a more advanced thermal management solution was required to prevent polymer solidification and system blockages.  

Additionally, the reaction process needed to operate under vacuum conditions to enhance efficiency and reaction speed, necessitating specialized pressure control. 

Epic

Solution

To address these challenges and achieve the necessary scale-up, EPIC Systems engineered a robust and highly controlled polymer batch production system incorporating: 

  • Hot Oil Jacketed Piping: Instead of conventional heat tracing, EPIC implemented a hot oil jacketed piping system to ensure uniform heating of the polymer transfer lines, preventing temperature fluctuations and solidification. 
  • Temperature Control Units (TCUs): Integrated TCUs maintained precise high-temperature conditions throughout the system, ensuring consistent polymer processing. 
  • Specialty Pump & Instrumentation: A specialized pump with heating coils on its flanges was used to prevent polymer from solidifying at critical transfer points. Additionally, custom instrumentation and valves ensured proper flow without low spots where material could accumulate. 
  • Vacuum Pump Integration: The reactor process required vacuum conditions to enhance polymerization and control pressure. EPIC incorporated a vacuum pump system to depressurize the vessel, speeding up the reaction process. 
  • Helical Mixer Design: A custom helical mixer was installed to optimize material movement within the reactor, ensuring uniform temperature distribution and preventing polymer adhesion to the reactor walls. 
  • Cooling & Safety Systems: Chillers and heat exchangers were implemented to cool the polymer mixture to a safe temperature before waste or carryover was removed from the column. This ensured that the material was safe for handling and disposal. 
  • Non-Destructive Testing & Factory Acceptance Testing: EPIC conducted rigorous non-destructive testing (NDT) on welds and performed factory acceptance testing (FAT) to validate system performance before deployment. 

 

Project

Impact

  • 100x Increase in Production Capacity: The upgraded system effectively met the scale-up requirements, enabling high-volume polymer production.
  • Enhanced Thermal Management: The hot oil jacketed piping and TCU systems provided stable, uniform heating, eliminating temperature inconsistencies and process interruptions.
  • Optimized Process Efficiency: The integration of vacuum pressure control and advanced mixing technology improved reaction speed and overall efficiency.
  • Increased Safety & Reliability: With specialized cooling, heating, and pressure control mechanisms, the system ensured safe and consistent polymer processing, reducing risks of overheating or blockages. 
  • Validated System Performance: Through comprehensive testing and validation, EPIC ensured that the scaled-up process met all operational and safety standards. 

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