Reaction Vessel

Acrylic Emulsion in Paints

We have successfully installed numerous acrylic resin plants with capability of manufacturing multitude of acrylic based products. These plants can be supplied as a separate and standalone units with well defined limit of supply. The emulsion is manufactured in the first module. Second module can be added if there is a need for the addition of glass microspheres to sensitize the product. Other solid additives can be added at this point also.

The complete plant set up comes prewired, plumbed and with all product piping in place. Other optional features can be added to either module for additional production capability. Our highly mobile acrylic resin plants are built onto a rigid skid mounted steel frame, rust protected and painted. These modules are pre run at our facility for final approval prior to shipping.

Acrylic Emulsion Production

We can supply acrylic resin plants in various configuration for manufacturing acrylic emulsion with different formulations. The production of acrylic emulsion varies greatly from product to product in these resin manufacturing plants. Highlights of the production process for acrylic emulsions are as follows:

• Raw materials for the emulsion line include monomers, additives, activators, and catalysts in liquid or solid form. For stabilization, some monomers are pre-mixed with inhibitors.
• Catalysts are used for activating the monomers and initiating the desired reactions. Activators activate the catalysts, initiates the reaction, besides overcoming the effects of the inhibitors. Additives used in the mixture include detergents, dispersants, and pH-adjustment ingredients.
• Thereafter, the monomers are pumped from tanker trucks to monomer tanks for storage.
• From the storage tanks, monomers are pumped to holding/premixing tanks, additive, activator, and catalyst holding tanks where mixing occurs.
• The additives, activators, and catalysts can be directly added to the reactors without being mixed with monomers in their respective holding tanks.
• Then, the raw materials are mixed together in one of three temperature- and pressure-regulated reactors where polymers are formed. The desired chemical reactions are initiated by addition of catalysts and are regulated with additives or by pressure and temperature adjustment.
• The resulting acrylic emulsion polymers are pumped to blend tanks. Formalin is added in the blend as a preservative to control bacteria and mold growth and ammonia is added to for pH adjustment. Sodium hydroxide is another pH-adjustment chemical, added in the blend tanks.
• Ingredients such as emulsions, emulsifiers, surfactants, binders and Thickeners are added to modify monomer viscosity, to stabilize the polymers and to hold the polymers in suspension.
• Finally, deionized water is added to lower the solids content. After each polymer batch is processed, the blend tanks are flushed with deionized water which is further pumped to the emulsion plant's wastewater treatment system.
• Wastes generated during different processes include composited absorbed monomers, burnable liquids, and off grade methylolacrylamide / acrylamide. Most of the composited absorbed monomer waste are generated from spillage during loading and unloading of the rail cars or from batch spills and reactor clean-ups.

Solvent Based Resin Plants

Resin

Resins are translucent and viscous film forming material widely used for production of paints and coatings. It binds the pigment particles to the substrate, forming a layer of film on the surface. The quality of the resin used in production of paints and coating decides the durability of the paint. Resins with different compositions are used depending upon the functional properties of the paint.

Functions of Resin

• To provide gloss and elasticity
• For the suspension of pigments
• To provide resistance to water, chemicals and abrasion
• Makes coating adhere to the surface
• Acts as a dispersant
• For drying properties

Alkyd resins from the largest group of synthetic resins are used in paint industry. Most air drying enamels are based on long or medium oil alkyd resins. These resins dry at room temperature and have excellent flow and leveling properties, good exterior durability and can be thinned with mineral turpentine. Oils used for producing alkyd resins are linseed oil, soybean oil and Dehydrated Castor Oil (DCO).

Plant Operation

ABSter's solvent based plant produces paints, coatings, stains, and surface treating products at a rate of about 1.1 million gal/yr. This paint manufacturing plants operations primarily involve blending and mixing of raw materials, product testing and packaging and cleaning of vessels and lines. Color separation of the product is done to befit customer specifications.

Water-based and solvent-based paints are mixed in different tanks from 200- to 1000-gal capacity. The material used in water-based paints include water, latex, resins, extenders, and dispersed pigments. For solvent-based paints, the materials are generally similar in type, but solvent replaces water and latex. Other ingredients used in this base include plasticizers, tints, and thinners.

After batches are made up, they are transferred to the let-down tanks. Additional water (or solvent), resins, preservatives, anti-foaming agents, thinners, and bactericides are added thereafter in the tanks. Batch testing encompasses checking color, viscosity and gloss. The material are then filtered and charged to cans for labeling, packaging, and shipping.