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SAP production line

The Full set production line equipment and process of the SAP 1. Background of the production line At present the application of the polyacrylate and polyacrylamide have become more and more widely. SAP (Super-absorbent polymers) is a new...


The Full set production line equipment and process of the SAP
1. Background of the production line
At present, the application of the polyacrylate and polyacrylamide have
become more and more widely.
SAP (Super-absorbent polymers) is a new type of the high polymer material. In
1975, The United States grain processing company developed starch grafted
acrylonitrile copolymerization soap  hydrolysis to get superabsorbent resin, and
applied to agricultural soil improver. Recently, a new type of the SAP (Super-
absorbent polymers) has been developed. It widely used for the application to
the personal consumer goods, for example: nappy、women's sanitary napkins、
agricultural soil improver、electric line and  cable water proof tape、cold pad
etc, especially the requirement of the disposable baby diapers increased the
fastest among them.
World developed countries have developed high molecular weight、good
function in the polymers、copolymers and ramification of the polyacrylamide.
It widely applied for the oil、papermaking,metallurgy etc. As one of the three
most efficient oil displacement agent, polyacrylamide has been widely used in
the world oil industry. With the development of oil industry in our country, the
Eastern oil zone has turned into the late-middle period of the oil extraction.
Higher demand to the production and quality of the polyacrylamide are needed.
Since national investment in the west development, the treatment to the natural
environment, planting trees in the arid area, the requirement to the water-
retaining agent in seeding has became more and more increasing.
Our company mainly focused on the development and research on the
domestic and overseas’ treatment to the process and way of the polyacrylate
SAP colloid materials, and many years’ experience so that can develop a full set
of the treatment process.
Nowadays , our company has started to produce 、 sales SAP full set
production line. The production line is automatic continual produce, lower labor
source, higher- quality product.
2. SAP production line flow
The whole process flow includes several stage, many of them are hard to
operate. To produce high quality products in a complete pipeline way, strict
control in every step during the process is needed.
The process flow involves: equipment of the raw material、gel
polymerization 、gel broken、drying、surface treatment、second drying、
screening、product packing.
3. Description to the equipment
(1) Equipment of the material(preparation process)
The equipment which the process involves:Acrylic acid storage tank
diluted 、NAOH Configuration kettle、Acid &alkali neutralization kettle.
During the process of the material configuration and acid-base neutralization,
we must make sure that the enough cooling to the material and control the
material temperature strictly.
(2) Gel polymerization
This process is one of the key step to produce the SAP, by many years’
research and practice, it has achieve the high automatic and production, high
quality and uniform in products.(3) Slitting、Granulating
The development of this process is for drying. Due to the material shape is
massive after the gel polymerization, and it is hard to dry directly. We choose to
slit the material into stick, then by squeezing and granulating to make the
material granulous.
(3) Drying
After SAP wet colloid granulating, the drying method can adopt the box-type、
Continuous belt、rotary kiln、XIR extreme infrared、microwave and so on. As
the drying time and temperature are the important factors to affect the molecular
weight, box-type drying need specialized colloidal particle container, it’s not
applied to the continuous produce and the drying process is from outside into the
inside, the surface turned into harder, the inner moisture isn’t easy to evaporate,
the drying speed and production efficiency is low, using the fuel such as coal
may result in environment problems such as the flue gas emission. While the
heating efficiency of electricity drying is low and the floor space of the rotary
kiln is big, it needs the fuel such as coal may also bring about the environment
pollution problems such as flue gas emission. As the SAP colloidal particle has
stickiness, it’s not suitable to adopt this way of drying. The infrared ray and
microwave are the advanced method of drying. Microwave drying has fast
drying speed, but it may existing some problems such as the temperature is hard
to control, the product functions is destroyed, the shape of drying material needs
uniformity, investment and maintenance cost is high. Its application was limited.
In recent years, the far infrared ray drying method has wide application in food,
subsidiary agricultural products, coal, china, wood, chemical industry. The
fluidization drying method has short drying time and high efficiency, it widelyused for the chemical product (such as silica gel, inorganic salt, polyacrylamide),
but it may not shape the fluidization when aimed to gel material. The reason is
the material can adhere so that cannot reach to drying.
This process is the main procedure in producing SAP, by many years practical
experiences, our company developed a producing stable, high quality product,
product quality stable dryer.
(5) Crushing
This process plays a key role in whole production line. Owing to the high
standard to the product granularity, the finished product became the key factor.
In the previous crushing, the rate of finished product is only about 60% and
result in the waste. By many years’ practice and research, our company
improved in the crushing equipment and by a large margin to improve the yield.
So far, the rate can mainly reach above90%.
(6) Surface treatment (mixer)
This process is also a necessary part in whole process. It needs the formula
(liquid form) mixed with the crushed granule evenly. We adopt the way of
mixing, meanwhile the formula spray into the material and stirring fully.
(7) Drying after surface treatment
After surface treatment, we dried the material. Adopt the most common drying
oven can do it.
(8) Sifting (vibration screen)
Civil case of SAP: child diaper: 30-40x, women sanitary articles: 60x.
(9) Assorting packing
4、Lucubrate and discuss
Concerning about our company’s imagination and lucubrate to the SAP: We
found that the smaller granule, the faster of the water absorbing rate, but the
toughness and intensity became smaller. Civil SAP has requirements to the
water absorbing rate, so our company imagined that crush the SAP into a small
granule, then looking for a high adhesive by granulator unit to become the mesh
count which specified. The small granule is hard for moisture to fast absorb, but
we have overcome the crusher in avoiding the moisture absorption, it is also
granulating. The main question is how to find an adhesive and meanwhile it
cannot affect the water absorption to keep the toughness and intensity of SAP,
not separate.

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