I. Kufunika kwa Kuyeza Kukhuthala kwa Mphira pa Kupanga kwa SBR
Kupanga bwino kwa Styrene Butadiene Rubber (SBR) kumadalira kuwongolera molondola ndi kuyang'anira mphamvu zake za rheological. Kukhuthala, komwe kumayesa kukana kwa chinthu ku kuyenda, kumakhala ngati gawo lofunikira kwambiri la physicochemical lomwe limayang'anira momwe zinthu zapakati za rabara zimagwirira ntchito komanso chizindikiro chomaliza cha khalidwe la zinthu zomalizidwa.
Murabala yopangidwanjira yopangira, kukhuthala kumapereka njira yodziwikiratu komanso yoyezeka ya kapangidwe ka polima, makamaka kulemera kwake kwa molekyulu (MW) ndi kugawa kwake kwa molekyulu (MWD).muyeso wa kukhuthala kwa rabalazimasokoneza mwachindunji kasamalidwe ka zinthu ndi magwiridwe antchito omalizidwa a chinthucho. Mwachitsanzo, mankhwala omwe ali ndi kukhuthala kwakukulu kwambiri amaletsa kwambiri ntchito zomwe zikuchitika pansi pa madzi monga kutulutsa kapena kuyika zinthu pa kalendala, zomwe zimapangitsa kuti mphamvu zigwiritsidwe ntchito kwambiri, kupsinjika kwakukulu kwa ntchito, komanso kulephera kwa zida. Mosiyana ndi zimenezi, mankhwala omwe ali ndi kukhuthala kochepa kwambiri akhoza kusowa mphamvu yosungunuka yofunikira kuti asunge umphumphu panthawi yopanga kapena gawo lomaliza la kuuma.
Mphira wa Styrene-Butadiene (SBR)
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Kupatula kungogwira ntchito ndi makina, kuwongolera kukhuthala ndikofunikira kuti pakhale kufalikira kofanana kwa zowonjezera zofunika kwambiri, monga kaboni wakuda ndi silica. Kufanana kwa kufalikira kumeneku kumatsimikizira mawonekedwe a makina omaliza, kuphatikiza zoyezera zofunika monga mphamvu yolimba, kukana kukwawa, ndi machitidwe ovuta a mphamvu omwe amawonetsedwa pambuyo pa kufalikira.njira yopangira mphira wopukutira.
II. Zoyambira za Styrene Butadiene Rubber (SBR)
Kodi Styrene Butadiene Rubber ndi chiyani??
Mphira wa Styrene Butadiene (SBR) ndi elastomer yopangidwa mosiyanasiyana, yomwe imagwiritsidwa ntchito kwambiri chifukwa cha chiŵerengero chake chabwino kwambiri cha mtengo-ku-ntchito komanso kupezeka kwake kwakukulu. SBR imapangidwa ngati copolymer yochokera makamaka ku 1,3-butadiene (pafupifupi 75%) ndi styrene monomers (pafupifupi 25%). Ma monomers awa amaphatikizidwa kudzera mu njira ya mankhwala yotchedwa copolymerization, kupanga maunyolo atali a polymer ambiri. SBR idapangidwa makamaka kuti igwiritsidwe ntchito pofuna kulimba kwambiri komanso kukana kukwawa kwapadera, zomwe zimapangitsa kuti ikhale chisankho chabwino kwambiri cha matayala.
Njira Yopangira Mphira Yopangira
Kupanga kwa SBR kumachitika kudzera m'njira ziwiri zosiyana za polymerization ya mafakitale, zomwe zimapangitsa kuti zipangizo zikhale ndi makhalidwe osiyanasiyana ndipo zimafuna kuwongolera kwapadera kwa viscosity panthawi yamadzimadzi.
Kupopera kwa Emulsion (E-SBR):Mu njira yakale iyi, ma monomers amamwazikana kapena kusungunuka mu madzi pogwiritsa ntchito sopo wonga surfactant. Kuchitapo kanthu kumeneku kumayambitsidwa ndi ma free radical oyambitsa ndipo kumafuna zokhazikika kuti zinthu zisawonongeke. E-SBR ikhoza kupangidwa pogwiritsa ntchito kutentha kwa kutentha kapena kuzizira; makamaka E-SBR yozizira imadziwika kuti ndi yolimba kwambiri pakukana kukwawa, mphamvu yokoka, komanso kulimba pang'ono.
Kukonza Polima (S-SBR):Njira yapamwambayi imaphatikizapo polymerization ya anionic, nthawi zambiri imagwiritsa ntchito alkyl lithium initiator (monga butyllithium) mkati mwa hydrocarbon solvent, yomwe nthawi zambiri imakhala hexane kapena cyclohexane. Magulu a S-SBR nthawi zambiri amakhala ndi kulemera kwakukulu kwa mamolekyulu komanso kufalikira kochepa, zomwe zimapangitsa kuti zinthu zikhale bwino monga kusinthasintha bwino, mphamvu yayikulu yogwira, komanso kukana kugwedezeka kwambiri m'matayala, zomwe zimapangitsa S-SBR kukhala chinthu chamtengo wapatali komanso chokwera mtengo.
Chofunika kwambiri, m'njira zonse ziwiri, polymerization reaction iyenera kuthetsedwa bwino poika choletsa unyolo kapena choletsa choyimitsa pang'ono mu madzi otuluka mu reactor. Izi zimalamulira kutalika kwa unyolo womaliza, sitepe yomwe imakhazikitsa mwachindunji kulemera koyambirira kwa mamolekyulu, motero, maziko.kukhuthala kwa rabalamusanapange zinthu zosakaniza.
Katundu wa Styrene Butadiene Rubber
SBR imayesedwa chifukwa cha mawonekedwe ake olimba a zinthu zakuthupi ndi zamakanika:
Magwiridwe antchito a makina:Mphamvu zazikulu zimaphatikizapo mphamvu yokoka kwambiri, yomwe nthawi zambiri imakhala pakati pa 500 ndi 3,000 PSI, kuphatikiza kukana kwabwino kwambiri kwa kukwawa. SBR imasonyezanso kukana bwino ku kupsinjika komanso kukana kwakukulu. Kuphatikiza apo, zinthuzo sizimathyoka, zomwe ndi khalidwe lofunika kwambiri lomwe limalola kuti zinthu zambiri zolimbitsa thupi zigwiritsidwe ntchito, monga kaboni wakuda, kuti ziwonjezere mphamvu ndi kukana kwa UV.
Mbiri ya Mankhwala ndi Kutentha:Ngakhale kuti nthawi zambiri imakana madzi, mowa, ma ketone, ndi ma organic acid ena, SBR imakhala ndi zofooka zodziwika bwino. Ili ndi kukana kochepa kwa mafuta ochokera ku mafuta, mafuta a hydrocarbon onunkhira, ozone, ndi zinthu zosungunulira za halogenated. Pa kutentha, SBR imasunga kusinthasintha pamitundu yosiyanasiyana, ndi kugwiritsa ntchito kosalekeza kwa pafupifupi 225°F ndi kusinthasintha kochepa kwa kutentha mpaka -60℉.
Kukhuthala monga Chizindikiro Chachikulu cha Kulemera kwa Maselo ndi Kapangidwe ka Unyolo
Makhalidwe a rheological a polima wosaphika amatsimikiziridwa makamaka ndi kapangidwe ka molekyulu—kutalika ndi kuchuluka kwa nthambi za unyolo wa polima—zomwe zimakhazikitsidwa panthawi ya polymerization. Kulemera kwakukulu kwa molekyulu nthawi zambiri kumatanthauza kukhuthala kwakukulu komanso kuchepa kwa kuchuluka kwa madzi osungunuka (MFR/MVR). Chifukwa chake, kuyeza kukhuthala kwa mkati (IV) nthawi yomweyo pakutulutsa kwa reactor ndikofanana ndi kuyang'anira mosalekeza kapangidwe ka mamolekyulu omwe akufuna.
III. Mfundo Zachikhalidwe Zokhudza Kukonza kwa SBR
Mfundo za rheological, kudalira kuchuluka kwa kugunda kwa mtima, kutentha/kupanikizika.
Rheology, kuphunzira momwe zinthu zimasinthira ndi kuyenda, kumapereka njira yasayansi yomvetsetsera khalidwe la SBR pansi pa mikhalidwe yopangira mafakitale. SBR imadziwika kuti ndi chinthu chovuta cha viscoelastic, kutanthauza kuti imawonetsa mawonekedwe osakaniza ma viscous (osatha, oyenda ngati madzi) ndi mayankho otanuka (otha kubwezeretsedwa, osinthika ngati olimba). Kulamulira kwa makhalidwe amenewa kumadalira kwambiri liwiro ndi nthawi ya katundu wogwiritsidwa ntchito.
Ma compound a SBR kwenikweni si a Newtonian fluids. Izi zikutanthauza kuti amaoneka ngati a Newtonian fluids.kukhuthala kwa rabalasi mtengo wokhazikika koma umasonyeza kufunika kofunikirakudalira kuchuluka kwa kumeta; kukhuthala kumachepa kwambiri pamene kuchuluka kwa kumeta kumawonjezera chinthu chodziwika kuti kumeta pang'ono. Khalidwe losakhala la Newtonian ili ndi tanthauzo lalikulu pakuwongolera khalidwe. Ma viscosity omwe amapezeka pamlingo wotsika wa kumeta, monga omwe amayesedwa mu mayeso achikhalidwe a Mooney viscometer, angapereke chiwonetsero chosakwanira cha momwe zinthuzo zimakhalira pansi pa kuchuluka kwa kumeta komwe kumachitika pakusakaniza, kukanda, kapena kutulutsa. Kupatula kumeta pang'ono, kukhuthala kumakhudzanso kutentha; kutentha kwa njira kumachepetsa kukhuthala, komwe kumathandiza kuyenda. Ngakhale kupanikizika kumakhudzanso kukhuthala, kusunga kutentha kokhazikika ndi mbiri yometa pang'ono ndikofunikira kwambiri, chifukwa kukhuthala kumatha kusintha mosiyanasiyana ndi kumeta pang'ono, kupanikizika, ndi nthawi yokonza.
Zotsatira za Mapulasitiki, Zodzaza, ndi Zothandizira Pokonza pa Kukhuthala kwa SBR
Thekukonza rabalaGawo lotchedwa compounding, lomwe limadziwika kuti compounding, limaphatikizapo kuphatikiza zowonjezera zambiri zomwe zimasintha kwambiri rheology ya polymer ya SBR:
Zopangira pulasitiki:Mafuta opangira ndi ofunikira kwambiri pakukweza kusinthasintha ndi kuthekera kwa SBR kugwira ntchito bwino. Amagwira ntchito pochepetsa kukhuthala kwa composite ya composite, zomwe nthawi imodzi zimathandiza kufalikira kwa fillers mofanana ndikufewetsa polymer matrix.
Zodzaza:Zinthu zolimbitsa thupi, makamaka kaboni wakuda ndi silica, zimawonjezera kwambiri kukhuthala kwa zinthuzo, zomwe zimapangitsa kuti zinthuzo zikhale zovuta kwambiri chifukwa cha kuyanjana kwa filler-filler ndi filler-polymer. Kupeza kufalikira kwabwino kwambiri ndi koyenera; zinthu monga glycerol zingagwiritsidwe ntchito kufewetsa lignosulfonate fillers, kusintha kukhuthala kwa filler pafupi ndi kukhuthala kwa SBR matrix, potero kuchepetsa mapangidwe a agglomerate ndikuwonjezera homogeneity.
Othandizira Owononga:Mankhwalawa, kuphatikizapo sulfure ndi ma accelerator, amachititsa kusintha kwakukulu pa rheology ya mankhwala osachiritsidwa. Amakhudza zinthu monga chitetezo cha kutentha (kukana kulumikizana msanga). Zowonjezera zina zapadera, monga fumed silica, zingagwiritsidwe ntchito mwanzeru ngati zinthu zokulitsa kukhuthala kuti zikwaniritse zolinga zinazake za rheological, monga kupanga mafilimu okhuthala popanda kusintha kuchuluka kwa zinthu zolimba.
Kulumikiza Rheology ndi Vulcanization ya njira ya rabara ndi Final Cross-Link Density
Kukhazikika kwa rheological komwe kumachitika panthawi yophatikizana ndi kupanga kumalumikizidwa mwachindunji ndi magwiridwe antchito omaliza a chinthu chopangidwa ndi vulcan.
Kufanana ndi Kufalikira:Ma profiles osasinthasintha a viscosity panthawi yosakaniza—nthawi zambiri ogwirizana ndi mphamvu yolowera yosakwanira—amachititsa kuti pakhale kufalikira kosakwanira komanso kufalikira kosafanana kwa phukusi lolumikizirana (sulfure ndi ma accelerator).
Njira Yopangira Vulcanization ya Rabara:Njira yosinthirayi ya mankhwala imaphatikizapo kutentha kwa SBR compound, nthawi zambiri ndi sulfure, kuti apange maulalo okhazikika pakati pa unyolo wa polima, zomwe zimapangitsa kuti mphira ukhale wolimba, wotanuka, komanso wokhalitsa. Njirayi imaphatikizapo magawo atatu: gawo loyambitsa (kutentha) komwe kumayamba kupangika; gawo lolumikiza kapena kuchiritsa (kuyankha mwachangu pa 250 ℉ mpaka 400 ℉; ndi momwe zinthu zilili bwino.
Kuchuluka kwa Cross-Link:Makhalidwe abwino kwambiri a makina amalamulidwa ndi kuchuluka kwa ma cross-link komwe kwapezeka.cMakhalidwe abwino amalepheretsa kuyenda kwa unyolo wa mamolekyulu, kukweza modulus yosungira ndikukhudza yankho losakhala la mzere wa viscoelastic la chinthucho (lomwe limadziwika kuti Payne effect). Chifukwa chake, kuwongolera kolondola kwa rheological m'magawo osachiritsidwa, okonzedwa ndikofunikira kuti zitsimikizire kuti ma precursors a mamolekyulu akonzedwa bwino kuti azitha kuchira pambuyo pake.
IV. Mavuto Omwe Alipo Pakuyeza Kukhuthala kwa Madzi
Zoletsa za Mayeso Achikhalidwe Opanda Paintaneti
Kudalira kwambiri njira zodziwika bwino, zosapitirira, komanso zogwiritsa ntchito mphamvu zambiri zowongolera khalidwe kumaika zoletsa zazikulu pa ntchito yopanga SBR mosalekeza, zomwe zimalepheretsa kukonza njira mwachangu.
Kuneneratu ndi Kuchedwa kwa Mooney Viscosity:Chizindikiro cha khalidwe lapakati, Mooney viscosity, nthawi zambiri chimayesedwa popanda kugwiritsa ntchito intaneti. Chifukwa cha zovuta zakuthupi komanso kukhuthala kwakukulu kwa mafakitale.njira yopangira rabala, sizingayesedwe mwachindunji munthawi yeniyeni mkati mwa chosakaniza chamkati. Kuphatikiza apo, kulosera molondola phindu ili pogwiritsa ntchito zitsanzo zachikhalidwe ndizovuta, makamaka pazinthu zomwe zimaphatikizapo zodzaza. Kuchedwa kwa nthawi komwe kumagwirizanitsidwa ndi mayeso a labotale kumachedwetsa zochita zokonzanso, zomwe zimawonjezera chiopsezo chandalama chopanga zinthu zambiri zosakhala zofunikira.
Mbiri Yosinthidwa ya Makina:Kuyeza kwa magazi m'mitsempha ya capillary, ngakhale kuti kumatha kuzindikira momwe kayendedwe ka madzi kakuyendera, kumafuna kukonzekera kwakukulu kwa zitsanzo. Zinthuzo ziyenera kupangidwanso kukhala miyeso yeniyeni yozungulira musanayese, njira yomwe imasintha mbiri ya makina a chinthucho. Chifukwa chake, kukhuthala komwe kumayesedwa sikungasonyeze bwino momwe chinthucho chilili panthawi ya ntchito.kukonza rabala.
Deta Yosakwanira ya Pointi Imodzi:Mayeso a Standard Melt flow rate (MFR) kapena Melt Volume Rate (MVR) amapereka flow index imodzi yokha pamikhalidwe yokhazikika. Izi sizokwanira pa SBR yosakhala ya Newtonian. Magulu awiri osiyana akhoza kuwonetsa ma MVR ofanana koma ali ndi kukhuthala kosiyana kwambiri pamitengo yayikulu yochepetsera yomwe ikugwirizana ndi extrusion. Kusiyana kumeneku kungayambitse kulephera kwa kukonza kosayembekezereka.
Mtengo ndi Katundu Wokhudza Kukonza Zinthu:Kudalira kusanthula kwa labotale komwe sikuli pamalopo kumabweretsa ndalama zambiri zoyendetsera zinthu komanso kuchedwa kwa nthawi. Kuwunika kosalekeza kumapereka phindu lazachuma pochepetsa kwambiri chiwerengero cha zitsanzo zomwe zimafunikira kusanthula kwakunja.
Vuto Loyesa Ma Composites a SBR Okhala ndi Kukhuthala Kwambiri ndi Magawo Ambiri
Kugwiritsa ntchito mankhwala a rabara m'mafakitale kumaphatikizapo zipangizo zomwe zimaonetsa kukhuthala kwakukulu komanso mawonekedwe ovuta a viscoelastic, zomwe zimapangitsa kuti pakhale zovuta zapadera pakuyeza mwachindunji.
Kutsetsereka ndi Kusweka:Zipangizo za rabara zokhuthala kwambiri komanso zokhuthala zimakhala ndi mavuto monga kutsetsereka kwa khoma ndi kusweka kwa chitsanzo komwe kumachitika chifukwa cha kusinthasintha kwa kutentha zikayesedwa mu ma rheometers achikhalidwe otseguka. Zipangizo zapadera, monga oscillating die rheometer yokhala ndi mawonekedwe otsekeka komanso otsekedwa, ndizofunikira kuti zithetse vutoli, makamaka m'zipangizo zodzazidwa kumene kuyanjana kwa polymer-filler kumachitika.
Kukonza ndi Kuyeretsa:Machitidwe oyenda kudzera pa intaneti kapena ma capillary nthawi zambiri amatsekeka chifukwa cha kukhuthala komanso kukhuthala kwa ma polima ndi ma filler. Izi zimafuna njira zoyeretsera zambiri ndipo zimapangitsa kuti pakhale nthawi yokwera mtengo yopuma, vuto lalikulu popanga zinthu mosalekeza.
Kufunika kwa chida cholimba cha kukhuthala kwamkati pa mayankho a polima.
Mu gawo loyamba la yankho kapena slurry, pambuyo pa polymerization, muyeso wofunikira ndi intrinsic viscosity (IV), womwe umagwirizana mwachindunji ndi kulemera kwa mamolekyulu ndi magwiridwe antchito a polima. Njira zachikhalidwe za labu (monga GPC kapena capillaries yagalasi) ndizochedwa kwambiri kuti zisamayendetsedwe nthawi yeniyeni.
Malo opangira mafakitale amafuna makina odziyimira pawokha komanso olimbachida chamkati cha kukhuthalaMayankho amakono, monga IVA Versa, amayendetsa ntchito yonse pogwiritsa ntchito dual-capillary relative viscometer kuti ayesere kukhuthala kwa yankho, kuchepetsa kukhudzana kwa ogwiritsa ntchito ndi zosungunulira ndikupeza kulondola kwakukulu (RSD values pansi pa 1%). Pakugwiritsa ntchito mkati mwa gawo losungunuka, Side Stream Online-Rheometers (SSR) imatha kudziwa mtengo wa IV-Rheo kutengera muyeso wopitilira wa kukhuthala kwa kukhuthala pamlingo wokhazikika wa kukhuthala. Muyeso uwu umakhazikitsa ubale wovomerezeka womwe umalola kuwunika kusintha kwa MW mumtsinje wosungunuka.
V. Magawo Ofunika Kwambiri Oyang'anira Kukhuthala kwa Kukhuthala
Kufunika kwa kuyeza pa intaneti pa kutulutsa kwa polymerization reactor, kusakaniza/kukanda, ndi kupanga pre-extrusion.
Kugwiritsa ntchito muyeso wa viscosity pa intaneti ndikofunikira chifukwa magawo atatu akuluakulu a ndondomekoyi—polymerization, compounding (mixing), ndi final forming (extrusion)—lililonse limapanga makhalidwe enieni, osasinthika a rheological. Kulamulira pa mfundo izi kumaletsa zolakwika za khalidwe kuti zisapitirire pansi.
Kutulutsa kwa Polymerization Reactor: Kuyang'anira kutembenuka, kulemera kwa mamolekyulu.
Cholinga chachikulu pa gawoli ndikuwongolera molondola kuchuluka kwa momwe zinthu zimachitikira nthawi yomweyo komanso kufalikira kwa polima ya SBR komwe kumafika pamlingo womaliza wa molekyulu (MW).
Kudziwa za kulemera kwa mamolekyu komwe kukusintha n'kofunika kwambiri, chifukwa kumatsimikiza makhalidwe otsiriza a thupi; komabe, njira zachikhalidwe nthawi zambiri zimayesa MW pokhapokha ngati reaction yatha. Kuwunika nthawi yeniyeni ya slurry kapena solution viscosity (pafupifupi intrinsic viscosity) kumatsata mwachindunji kutalika kwa unyolo ndi kapangidwe kake.
Pogwiritsa ntchito mayankho a kukhuthala kwa mphamvu nthawi yeniyeni, opanga amatha kukhazikitsa njira yowongolera yogwira ntchito. Izi zimathandiza kusintha molondola kayendedwe ka molecular weight regulator kapena short-stop agent.isanafikeKusintha kwa monomer kumafika pachimake. Mphamvu imeneyi imakweza kuwongolera njira kuyambira pakuwunika khalidwe lochita kusintha (komwe kumaphatikizapo kuchotsa kapena kusakanizanso magulu osafotokozera) kupita ku kayendetsedwe kosalekeza, kodziyimira pawokha ka kapangidwe ka maziko a polima. Mwachitsanzo, kuyang'anira kosalekeza kumaonetsetsa kuti kukhuthala kwa polymer Mooney kukugwirizana ndi zomwe zafotokozedwa pamene kuchuluka kwa kusintha kufika pa 70%. Kugwiritsa ntchito ma probe olimba, okhala ndi torsional resonator, omwe amapangidwira kupirira kutentha kwambiri ndi kupsinjika komwe kumachitika chifukwa cha madzi otuluka mu reactor, ndikofunikira kwambiri pano.
Kusakaniza/Kukanda: Kukonza bwino kufalikira kwa zowonjezera, kulamulira kudulidwa kwa ufa, kugwiritsa ntchito mphamvu.
Cholinga cha gawo losakaniza, lomwe nthawi zambiri limachitidwa mu chosakanizira chamkati, ndikupeza kufalikira kofanana kwa polima, zodzaza zolimbitsa, ndi zothandizira kukonza pamene mukuyang'anira mosamala mbiri ya kutentha ndi kudulidwa kwa mankhwalawo.
Mbiri ya kukhuthala imagwira ntchito ngati chizindikiro chotsimikizika cha kusakaniza bwino. Mphamvu zazikulu zodulidwa zomwe zimapangidwa ndi ma rotor zimaswa rabala ndikufalikira. Mwa kuyang'anira kusintha kwa kukhuthala (nthawi zambiri kumaganiziridwa kuchokera ku torque yeniyeni ndi mphamvu zomwe zimalowetsedwa), zenizenimapetoNjira imeneyi ndi yabwino kwambiri kuposa kudalira nthawi yokhazikika yosakanikirana, yomwe imatha kukhala pakati pa mphindi 15 mpaka 40 ndipo imakonda kusinthasintha kwa ogwiritsa ntchito komanso zinthu zina zakunja.
Kulamulira kukhuthala kwa compound mkati mwa mtundu womwe watchulidwa ndikofunikira kwambiri pa ubwino wa zinthuzo. Kusalamulira kokwanira kumabweretsa kufalikira koyipa komanso zolakwika mu mawonekedwe omaliza a zinthuzo. Pa rabara yokhala ndi kukhuthala kwakukulu, liwiro lokwanira losakaniza ndilofunikira kuti pakhale kufalikira kofunikira. Popeza kuli kovuta kuyika sensa yeniyeni pamalo osokonezeka komanso okhuthala kwambiri a chosakanizira chamkati, kulamulira kwapamwamba kumadaliramasensa ofewaMa model awa oyendetsedwa ndi deta amagwiritsa ntchito ma process variables (liwiro la rotor, kutentha, mphamvu yokoka) kuti alosere mtundu womaliza wa batch, monga kukhuthala kwake kwa Mooney, motero amapereka kuyerekezera kwa nthawi yeniyeni kwa index ya khalidwe.
Kutha kudziwa nthawi yabwino kwambiri yosakaniza kutengera mawonekedwe a viscosity a nthawi yeniyeni kumabweretsa phindu lalikulu la mphamvu ndi mphamvu. Ngati gulu likwaniritsa kukhuthala kwake kofalikira mofulumira kuposa nthawi yokhazikika yokhazikika, kupitiriza njira yosakaniza kumawononga mphamvu ndipo kumawononga unyolo wa polima kudzera mu kusakaniza kwambiri. Kukonza njira yogwiritsira ntchito kutengera mawonekedwe a viscosity kungachepetse nthawi yozungulira ndi 15-28%, zomwe zikutanthauza kuti kugwira ntchito bwino komanso phindu la ndalama.
Kutulutsa/Kupanga Zinthu Patsogolo: Kuonetsetsa kuti kusungunuka kwa madzi kumayenda bwino, komanso kuti zinthuzo zikhale zokhazikika.
Gawoli limaphatikizapo kupukuta pulasitiki ya rabara yolimba ndikuyikakamiza kudutsa mu die kuti ipange mawonekedwe osalekeza, nthawi zambiri imafuna kukanikiza pamodzi.
Kulamulira kukhuthala kwa polima ndikofunikira kwambiri chifukwa kumayang'anira mwachindunji mphamvu ya kusungunuka kwa polima ndi kuyenda kwake. Kutsika kwa kusungunuka (kukhuthala kwakukulu) nthawi zambiri kumakondedwa potulutsa, chifukwa kumapereka mphamvu yayikulu ya kusungunuka, zomwe ndizofunikira poyang'anira mawonekedwe (kukhazikika kwa mawonekedwe) a mbiriyo ndikuchepetsa kutupa kwa die. Kusasunthika kwa kusungunuka kwa madzi (MFR/MVR) kumabweretsa zolakwika pakupanga: kuyenda kwambiri kungayambitse kung'anima, pomwe kuyenda kochepa kungayambitse kudzaza magawo kapena kutseguka kwa madzi.
Kuvuta kwa malamulo okhudza kukhuthala kwa mpweya mu extrusion, komwe kumakhala kosavuta kusokonezeka kwakunja komanso khalidwe losagwirizana ndi mzere wa rheological, kumafuna njira zowongolera zapamwamba. Njira monga Active Disturbance Rejection Control (ADRC) zimagwiritsidwa ntchito poyang'anira kusintha kwa kukhuthala kwa mpweya, zomwe zimapangitsa kuti pakhale magwiridwe antchito abwino posunga kukhuthala komwe kumawonekera poyerekeza ndi olamulira a Proportional-Integral (PI) wamba.
Kukhazikika kwa kukhuthala kwa kusungunuka kwa chinthu pa mutu wa die ndiko kumatsimikizira khalidwe la chinthucho komanso kuvomereza kwake. Kutulutsa chinthu kumawonjezera zotsatira za viscoelastic, ndipo kukhazikika kwa mawonekedwe ake kumakhudzidwa kwambiri ndi kusinthasintha kwa kukhuthala kwa kusungunuka, makamaka pamlingo wapamwamba wa shear. Kuyeza kwa kukhuthala kwa kusungunuka pa intaneti nthawi yomweyo die isanayambe kumalola kusintha mwachangu, kodziyimira payokha kwa magawo a ndondomeko (monga, liwiro la screw kapena mbiri ya kutentha) kuti pakhale kukhuthala kofanana, kuonetsetsa kuti mawonekedwe ake ndi olondola komanso kuchepetsa zinyalala.
Gome Lachiwiri likuwonetsa zofunikira zowunikira mu unyolo wonse wa kupanga wa SBR.
Gome Lachiwiri. Zofunikira pa Kuwunika Kukhuthala kwa Kukhuthala Pamagawo Ogwiritsira Ntchito SBR
| Gawo la Njira | Gawo Lokhuthala | Cholinga cha Parameter | Ukadaulo Woyezera | Kulamulira Komwe Kwayatsidwa |
| Kutulutsa kwa Reactor | Yankho/Slurry | Kukhuthala Kwamkati(Kulemera kwa Mamolekyulu) | Rheometer Yoyenda M'mbali (SSR) kapena Yodziyimira Yokha IV | Sinthani mphamvu yamagetsi yogwira ntchito kapena yowongolera kayendedwe ka madzi. |
| Kusakaniza/Kukanda | Chophatikiza Cholimba Kwambiri | Kukhuthala kwa Mooney (Kulosera kwa Torque Kooneka) | Sensor Yofewa (Kujambula kwa Torque/Energy Input) | Konzani nthawi yosakaniza ndi liwiro la rotor kutengera kukhuthala kwa end-point. |
| Kutulutsa/Kupanga Zinthu Patsogolo | Kusungunuka kwa Polima | Kusungunuka Kowoneka Bwino (MFR/MVR correlation) | Choyezera cha Torsional cha Inline kapena Capillary Viscometer | Sinthani liwiro la screw/tembiricha kuti muwonetsetse kuti pali kukhazikika kwa kukula kwake komanso kutupa kwa die nthawi zonse. |
Dziwani Zambiri Zokhudza Ma Meter Ochulukirachulukira
Mayeso Ena Ogwiritsa Ntchito Paintaneti
VI. Ukadaulo Woyezera Kukhuthala Pa Intaneti
Lonnmeter Liquid Viscosity Meter Inline
Pofuna kuthana ndi zofooka zomwe zimapezeka poyesa labotale, zamakonokukonza rabalaimafuna zida zolimba komanso zodalirika. Ukadaulo wa torsional resonator ukuyimira kupita patsogolo kwakukulu pakuwona kosalekeza, mkati mwa mzere wa rheological, komwe kumatha kugwira ntchito m'malo ovuta opangira SBR.
Zipangizo mongaLonnmeter Liquid Viscosity Meter InlineGwiritsani ntchito resonator yozungulira (chinthu chogwedeza) chomwe chimamizidwa mokwanira mu madzi a process. Chipangizochi chimayesa kukhuthala mwa kuyeza kukhuthala kwa makina komwe resonator imakumana nako chifukwa cha madzi. Kuyeza uku kumachepetsa kukhuthala, nthawi zambiri pamodzi ndi kuwerenga kwa kuchuluka kwa madzi, pogwiritsa ntchito ma algorithms apadera kuti apereke zotsatira zolondola, zobwerezabwereza, komanso zokhazikika za kukhuthala.
Ukadaulo uwu ndi woyenera kwambiri kugwiritsa ntchito SBR chifukwa cha mphamvu zake zazikulu zogwirira ntchito:
Kulimba ndi Chitetezo Choteteza ku Matenda:Masensa nthawi zambiri amakhala ndi kapangidwe ka zitsulo zonse (monga 316L Stainless Steel) ndi zomatira zopangidwa ndi zitsulo kuchokera ku zitsulo kupita ku zitsulo, zomwe zimapangitsa kuti pasakhale kufunika kwa ma elastomer omwe angatukuke kapena kulephera kutentha kwambiri komanso kugwiritsa ntchito mankhwala.
Kugwirizana kwa Ma Range ndi Madzi:Machitidwe awa amatha kuyang'anirakukhuthala kwa rabalaMa compounds osiyanasiyana, kuyambira otsika kwambiri mpaka okwera kwambiri (monga 1 mpaka 1,000,000+ cP). Amathandizanso poyang'anira madzi osakhala a Newtonian, amodzi, komanso ambiri, ofunikira pa SBR slurries ndi ma polymer melts odzazidwa.
Mikhalidwe Yovuta Kwambiri Yogwirira Ntchito:Zipangizozi zili ndi satifiketi yoti zigwiritsidwe ntchito pamavuto ndi kutentha kosiyanasiyana.
Ubwino wa masensa oyesera ma viscosity omwe amapezeka nthawi yeniyeni, pa intaneti, komanso okhala ndi miyeso yambiri (kulimba, kuphatikiza deta)
Kugwiritsa ntchito njira zamakono zowunikira zinthu nthawi yeniyeni, zomwe zimagwira ntchito pa intaneti, kumapereka chidziwitso chokhazikika cha zinthu zomwe zimapangidwira, kusuntha kupanga kuchokera pakuwunika khalidwe pang'onopang'ono kupita ku malamulo okhudza njira zogwirira ntchito.
Kuwunika Kosalekeza:Deta yeniyeni imachepetsa kwambiri kudalira kusanthula kwa labotale kochedwa komanso kokwera mtengo. Imalola kuzindikira mwachangu kusintha kwa njira kapena kusintha kwa magulu azinthu zopangira zomwe zikubwera, zomwe ndizofunikira kwambiri popewa mavuto a khalidwe labwino.
Kusamalira Kochepa:Mapangidwe olimba komanso oyenera a resonator amapangidwira kuti agwiritsidwe ntchito kwa nthawi yayitali popanda kukonza kapena kukonzanso, zomwe zimachepetsa nthawi yogwira ntchito.
Kuphatikiza Deta Mosasokonekera:Masensa amakono amapereka maulumikizidwe amagetsi osavuta kugwiritsa ntchito komanso njira zolumikizirana zomwe zimagwiritsidwa ntchito m'mafakitale, zomwe zimathandiza kuphatikiza mwachindunji kukhuthala ndi deta ya kutentha mu Distributed Control Systems (DCS) kuti zisinthe njira zokha.
Njira Zosankhira Chida Chogwiritsidwa Ntchito Poyesa Kukhuthala M'magawo Osiyanasiyana a SBR.
Kusankha koyenerachida chogwiritsidwa ntchito poyesa kukhuthalazimadalira kwambiri momwe zinthu zilili pa mfundo iliyonsenjira yopangira rabala:
Yankho/Slurry (Reactor):Chofunika ndi kuyeza kukhuthala kwa slurry mkati kapena kooneka bwino. Ukadaulo umaphatikizapo Side Stream Rheometers (SSR) zomwe zimasanthula mosalekeza zitsanzo zosungunuka, kapena ma probe okhala ndi mphamvu yapamwamba yowunikira madzi/slurry.
Chosakaniza Chokhala ndi Kukhuthala Kwambiri (Chosakaniza):Kuyeza mwachindunji mwakuthupi sikungatheke mwaukadaulo. Yankho labwino kwambiri ndikugwiritsa ntchito masensa ofewa oneneratu zomwe zimagwirizanitsa njira zolondola kwambiri zolowera (torque, energy draw, temperature) ya chosakanizira chamkati ndi metric yofunikira, monga Mooney viscosity.
Kusungunuka kwa Polima (Kutulutsidwa Patsogolo):Kutsimikiza komaliza kwa ubwino wa kuyenda kwa madzi kumafuna sensa yothamanga kwambiri mu chitoliro chosungunuka. Izi zitha kuchitika kudzera mu ma probe olimba a torsional resonator kapena ma viscometer apadera a inline capillary (monga VIS), omwe amatha kuyeza kukhuthala kooneka bwino kwa kusungunuka pamlingo wapamwamba wokhudzana ndi kutuluka kwa madzi, nthawi zambiri kumagwirizanitsa deta ndi MFR/MVR.
Njira yodziwira zinthu zosiyanasiyana iyi, yomwe imaphatikiza masensa olimba a hardware komwe kuyenda kwa madzi kumakhala kochepa komanso masensa ofewa odziwikiratu komwe kulowa kwa makina kumakhala kochepa, imapereka njira yowongolera yodalirika kwambiri yofunikira kuti igwire bwino ntchito.kukonza rabalakasamalidwe.
VII. Kukhazikitsa Mwanzeru ndi Kuyeza Mapindu
Njira Zowongolera Paintaneti: Kugwiritsa ntchito njira zobwezera mayankho kuti zisinthe machitidwe okhazikika kutengera kukhuthala kwa nthawi yeniyeni.
Makina owongolera okha amagwiritsa ntchito deta yooneka ngati ya viscosity nthawi yeniyeni kuti apange ma resolution oyankha, kuonetsetsa kuti zinthu zili bwino komanso zokhazikika kuposa momwe anthu angathere.
Mlingo Wodzipangira Wokha:Pophatikiza, makina owongolera amatha kuyang'anira mosalekeza kusinthasintha kwa ma compound ndikuwongolera zokha zigawo zomwe zimakhala ndi kukhuthala kochepa, monga ma plasticizer kapena zosungunulira, mu kuchuluka kolondola nthawi yomweyo. Njira iyi imasunga kugwedezeka kwa ma viscosity mkati mwa kuchuluka kotsimikizika pang'ono, kupewa kusuntha.
Kuwongolera Kwambiri Kukhuthala:Popeza kusungunuka kwa SBR si kwa Newtonian ndipo kumakhala ndi mavuto ambiri pakutuluka kwa zinthu, olamulira a Proportional-Integral-Derivative (PID) nthawi zambiri sakwanira pokonza kusungunuka kwa zinthu. Njira zamakono, monga Active Disturbance Rejection Control (ADRC), ndizofunikira. ADRC imaona kusokonezeka ndi zolakwika za chitsanzo ngati zinthu zogwira ntchito zomwe ziyenera kukanidwa, zomwe zimapereka yankho lolimba losunga kukhuthala kwa zinthu zomwe zili pachiwopsezo ndikuwonetsetsa kuti zinthuzo zili bwino.
Kusintha kwa Kulemera kwa Mamolekyulu Osiyanasiyana:Pa reactor ya polymerization, deta yopitilira kuchokera kuchida choyezera kukhuthala kwamkatiimabwezeretsedwa mu dongosolo lowongolera. Izi zimathandiza kusintha kofanana kwa kuchuluka kwa kayendedwe ka unyolo, zomwe zimathandizira nthawi yomweyo kusintha pang'ono kwa reaction kinetics ndikuwonetsetsa kuti kulemera kwa molekyulu ya polima ya SBR kumakhalabe mkati mwa gulu lopapatiza lofunikira pa kalasi yeniyeni ya SBR.
Kuchita Bwino & Kupeza Mtengo: Kuwerengera kusintha kwa nthawi yozungulira, kuchepetsa kukonzanso, kugwiritsa ntchito mphamvu bwino komanso zinthu.
Ndalama zomwe zayikidwa mu machitidwe a rheology pa intaneti zimabweretsa phindu lachindunji komanso loyezeka lomwe limawonjezera phindu lonse lanjira yopangira rabala.
Nthawi Yoyenera Yoyendera:Pogwiritsa ntchito kuzindikira kwa ma viscosity-based end-point detection mu chosakanizira chamkati, opanga amachotsa chiopsezo cha kusakaniza mopitirira muyeso. Njira yomwe nthawi zambiri imadalira ma cycle okhazikika a mphindi 25-40 ikhoza kukonzedwa bwino kuti ifike pa ma viscosity ofunikira mu mphindi 18-20. Kusinthaku kwa ntchito kungayambitse kuchepa kwa 15-28% mu nthawi ya cycle, zomwe zikutanthauza kuti kuchuluka kwa ma throughput ndi mphamvu popanda ndalama zatsopano zogulira.
Kuchepetsa Kukonzanso ndi Kutaya Zinyalala:Kuyang'anira kosalekeza kumathandiza kukonza nthawi yomweyo zolakwika mu ndondomeko zisanabweretse kuchuluka kwa zinthu zomwe sizikufotokozedwa bwino. Mphamvu imeneyi imachepetsa kwambiri kukonzanso zinthu ndi zinyalala zomwe zimawononga ndalama zambiri, zomwe zimapangitsa kuti zinthuzo zigwiritsidwe ntchito bwino.
Kugwiritsa Ntchito Mphamvu Mwabwino Kwambiri:Mwa kuchepetsa bwino gawo losakaniza kutengera mawonekedwe a kukhuthala kwa nthawi yeniyeni, mphamvu yolowera imakonzedwa kuti ikwaniritse kufalikira koyenera. Izi zimachotsa zinyalala zamphamvu zomwe zimagwirizanitsidwa ndi kusakaniza mopitirira muyeso.
Kugwiritsa Ntchito Zinthu Zofunika Kusinthasintha:Kusintha kwa kukhuthala koyenera ndikofunikira kwambiri pokonza zakudya zosinthika kapena zosagwira ntchito, monga ma polima obwezerezedwanso. Kuyang'anira kosalekeza kumalola kusintha mwachangu magawo okhazikika a njira ndi kusintha kwa kukhuthala koyenera (monga kuwonjezera kapena kuchepetsa kulemera kwa mamolekyu kudzera mu zowonjezera) kuti zikwaniritse bwino zolinga za rheological zomwe mukufuna, ndikuwonjezera kugwiritsa ntchito zipangizo zosiyanasiyana komanso zotsika mtengo.
Zotsatira zake zachuma ndi zazikulu, monga momwe zafotokozedwera mu Table III.
Gome Lachitatu. Phindu Lachuma ndi Ntchito Lomwe Likuyembekezeka Kuchokera ku Kulamulira Kukhuthala Kwapaintaneti
| Chiyerekezo | Baseline (Kulamulira Kopanda Paintaneti) | Cholinga (Kulamulira Paintaneti) | Phindu/Zotsatira Zoyezera |
| Nthawi Yozungulira Gulu (Kusakaniza) | Mphindi 25–40 (Nthawi Yokhazikika) | Mphindi 18–20 (Mapeto a Kukhuthala) | Kuwonjezeka kwa 15–28% kwa Mphamvu Yogwiritsidwa Ntchito; Kuchepetsa Kugwiritsa Ntchito Mphamvu. |
| Chiŵerengero cha Batch Chosafotokozedwa | 4% (Chiwerengero Cha Makampani Omwe Amagwiritsidwa Ntchito) | <1% (Kukonza Kosalekeza) | Kuchepetsa mpaka 75% kwa ntchito yokonzanso/zochepa; Kuchepetsa kutayika kwa zinthu zopangira. |
| Nthawi Yokhazikika kwa Njira (Zolowetsa Zobwezerezedwanso) | Maola (Kufunika mayeso angapo a labu) | Mphindi (Kusintha Mwachangu kwa IV/Rheo) | Kugwiritsa ntchito bwino zinthu; luso lokonza zinthu zosiyanasiyana. |
| Kukonza Zipangizo (Zosakaniza/Zotulutsa) | Kulephera Kochitapo Kanthu | Kuwunika Zochitika Zolosera | Kuzindikira zolakwika msanga; kuchepetsa nthawi yogwira ntchito yoopsa komanso ndalama zokonzera. |
Kusamalira Mosalekeza: Kugwiritsa ntchito kuwunika kosalekeza kuti mupeze zolakwika koyambirira komanso njira zodzitetezera.
Kusanthula kwa kukhuthala kwa pa intaneti kumapitirira kuwongolera khalidwe mpaka kukhala chida chogwirira ntchito bwino komanso kuyang'anira thanzi la zida.
Kuzindikira Cholakwika:Kusintha kosayembekezereka kwa mawerengedwe opitilira a kukhuthala komwe sikungathe kufotokozedwa ndi kusintha kwa zinthu zakumtunda kumatha kukhala ngati chenjezo loyambirira la kuwonongeka kwa makina mkati mwa makina, monga kuwonongeka kwa zomangira za extruder, kuwonongeka kwa rotor, kapena kutseka zosefera. Izi zimathandiza kukonza mwachangu komanso mwadongosolo, kuchepetsa chiopsezo cha kulephera kwakukulu.
Kutsimikizira kwa Sensor Yofewa:Deta yopitilira muyeso, kuphatikizapo zizindikiro za chipangizo ndi zolowetsa masensa, ingagwiritsidwe ntchito popanga ndikuwongolera zitsanzo zolosera (masensa ofewa) a zoyezera zofunika monga Mooney viscosity. Kuphatikiza apo, njira zopitilira izi zitha kugwiranso ntchito ngati njira yowunikira ndikutsimikizira magwiridwe antchito a zida zina zoyezera zomwe zili mumzerewu.
Kuzindikira Kusinthasintha kwa Zinthu:Kusinthasintha kwa kukhuthala kumapereka chitetezo chofunikira kwambiri ku kusalingana kwa zinthu zopangira zomwe sizimawonedwa ndi macheke oyambira a khalidwe. Kusinthasintha kwa mawonekedwe a kukhuthala kosalekeza kumatha kuwonetsa nthawi yomweyo kusinthasintha kwa kulemera kwa mamolekyu a polima yoyambira kapena kuchuluka kwa chinyezi kapena khalidwe losasinthasintha mu zodzaza.
Kusonkhanitsa kosalekeza kwa deta ya rheological mwatsatanetsatane—kuchokera ku masensa ozungulira ndi masensa ofewa oneneratu—kumapereka maziko a deta kuti akhazikitse chithunzi cha digito cha rabara. Deta yopitilira iyi, yakale, ndi yofunika kwambiri popanga ndi kukonza zitsanzo zapamwamba zoyesera zomwe zimalosera molondola mawonekedwe ovuta a ntchito yomaliza ya chinthu, monga mawonekedwe a viscoelastic kapena kukana kutopa. Mlingo uwu wa ulamuliro wokwanira umakwezachida choyezera kukhuthala kwamkatiKuchokera pa chida chosavuta chapamwamba kupita ku chida chofunikira kwambiri chowongolera kapangidwe kake komanso kulimba kwa njira.
VIII. Mapeto ndi Malangizo
Chidule cha zomwe zapezeka pankhani yoyeza kukhuthala kwa mphira.
Kusanthulaku kukutsimikizira kuti kudalira kwachikhalidwe pa mayeso a rheological osapitilira, osagwiritsidwa ntchito pa intaneti (Mooney viscosity, MFR) kumaika malire ofunikira pakukwaniritsa kulondola kwakukulu ndikukulitsa magwiridwe antchito pakupanga kwamakono kwa SBR kwamphamvu. Mtundu wovuta, wosakhala wa Newtonian, komanso wa viscoelastic wa Styrene Butadiene Rubber umafuna kusintha kwakukulu panjira yowongolera—kuchoka pa single-point, metrics, kupita ku kuwunika kosalekeza, nthawi yeniyeni ya viscosity yooneka komanso mbiri yonse ya rheological.
Kuphatikiza masensa olimba komanso omangidwa ndi cholinga, makamaka omwe amagwiritsa ntchito ukadaulo wa torsional resonator, kuphatikiza njira zapamwamba zowongolera (monga kudziwira zofewa mu zosakaniza ndi ADRC mu zotulutsa), zimathandiza kusintha kokhazikika, kodziyimira pawokha m'magawo onse ofunikira: kuonetsetsa kuti kulemera kwa mamolekyulu kuli kolimba pa polymerization, kukulitsa kufalikira kwa filler panthawi yosakaniza, ndikutsimikizira kukhazikika kwa magawo panthawi yomaliza yosungunuka. Kulungamitsidwa kwachuma kwa kusinthaku kwaukadaulo ndikosangalatsa, kumapereka phindu loyezera mu throughput (kuchepetsa 15-28% mu nthawi yozungulira) komanso kuchepetsa kwakukulu kwa kugwiritsa ntchito zinyalala ndi mphamvu. Lumikizanani ndi gulu logulitsa la RFQ.
