Melhoria do processo de produção de resina fenólica
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Citações na Scopus
Tipo de produção
Trabalho de Conclusão de Curso
Data
2023-06-15
Autores
Muniz, Camila Santos
Costa, Kauê Manoel da
Silva, Mateus Rocha da
Costa, Kauê Manoel da
Silva, Mateus Rocha da
Orientador
Novazzi, Luis Fernando
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Texto completo (DOI)
Palavras-chave
resina,fenol,modelagem,resin,phenol,modeling
Resumo
A resina fenólica é um material polimérico sintético com considerável relevância para o cenário econômico mundial por conta de suas características particulares. Com a crescente procura do mercado, é imprescindível a realização de estudos que possibilitem a melhoria dos processos de produção desse produto. Esse material que é formado pela copolimerização de fenóis com aldeídos, que através da catálise em meio básico se origina a resina do tipo resol e catálise em meio ácido gera a resina do tipo novolaca. No presente estudo, é proposta a melhoria no processo de produção da resina fenólica do tipo resol com base nas etapas do processo real de uma indústria localizada no Brasil, onde o processo é operado em semi-batelada durante a primeira hora devido a adição de formaldeído que ocorre lentamente para evitar a excessiva liberação de calor provocado pela reação, e após a adição completa, o processo prossegue em modo batelada. Para isso, a cinética da reação foi tomada diretamente da literatura e foram descritos os balanços molares e de energia para ambas as fases de operação. O modelo cinético foi adaptado da literatura, ajustando-se as constantes cinéticas com dados de conversão obtidos na planta. Esse ajuste foi realizado programando o Excel para minimizar a somatória entre os dados de fração mássica retirados da literatura e os previstos pelo modelo. Após isso, utilizou-se o software MatLab® para simular os modelos fenomenológicos correspondentes ao processo de formação dos precursores da resina fenólica. Assim, foi possível adequar os valores das constantes cinéticas da reação de adição ao processo produtivo. O estudo do balanço de energia foi norteado pelo ajuste do coeficiente global de troca térmica com a utilização da função Fminsearch do MatLab® para minimizar a somatória do erro quadrático entre os dados de temperatura da indústria e os obtidos pelo modelo matemático. Dessa forma, obtém-se o perfil de temperatura que mais se adequa ao processo produtivo em estudo. Dessa maneira, foi possível analisar as condições operacionais e realizar a melhoria do processo avaliando a influência da razão molar (formaldeído / fenol) e do tempo de adição do formaldeído no perfil de temperatura e na conversão do fenol. Com os resultados obtidos foi possível a melhoria do processo mantendo o tempo de adição de formaldeído em 1:00 hora e aumentando a razão molar da resina de 2,19 para 3,0. Assim, o trabalho contribuiu para a geração de resultados positivos ao processo, permitindo ganhos de produtividade com maior conversão de fenol e controle de temperatura.
Phenolic resin is a synthetic polymeric material with considerable relevance to the world economic scenario due to its particular characteristics. With the growing market demand, it is essential to conduct studies to improve the production processes of this product. This material is formed by the copolymerization of phenols with aldehydes, which through catalysis in basic medium originates the resol type resin and catalysis in acid medium generates the novolaca type resin. In the present study, it is proposed to improve the production process of the resol type phenolic resin based on the actual process steps of an industry located in Brazil, where the process is operated in semi-batch mode during the first hour due to the addition of formaldehyde that occurs slowly to avoid excessive heat release caused by the reaction, and after the complete addition, the process continues in batch mode. For this, the kinetics of the reaction was taken directly from the literature and the molar and energy balances for both phases of operation were described. The kinetic model was adapted from the literature by fitting the kinetic constants with conversion data obtained in the plant. This adjustment was performed by programming Excel to minimize the sum between the mass fraction data taken from the literature and those predicted by the model. After that, the MatLab® software was used to simulate the phenomenological models corresponding to the formation process of phenolic resin precursors. Thus, it was possible to adjust the values of the kinetic constants of the addition reaction to the production process. The study of the energy balance was guided by the adjustment of the global heat exchange coefficient using the function Fminsearch of MatLab® to minimize the sum of the quadratic error between the temperature data from the industry and those obtained by the mathematical model. Thus, the tem perature profile that best suits the production process under study is obtained. Thus, it was possible to analyze the operating conditions and improve the process by evaluating the influence of the molar ratio (formaldehyde/phenol) and the formaldehyde addition time on the temperature profile and phenol conversion. With the results obtained it was possible to improve the process by keeping the formaldehyde addition time at 1:00 hour and increasing the resin molar ratio from 2.19 to 3.0. Thus, the work contributed to generate positive results to the process, allowing productivity gains with higher phenol conversion and temperature control.
Phenolic resin is a synthetic polymeric material with considerable relevance to the world economic scenario due to its particular characteristics. With the growing market demand, it is essential to conduct studies to improve the production processes of this product. This material is formed by the copolymerization of phenols with aldehydes, which through catalysis in basic medium originates the resol type resin and catalysis in acid medium generates the novolaca type resin. In the present study, it is proposed to improve the production process of the resol type phenolic resin based on the actual process steps of an industry located in Brazil, where the process is operated in semi-batch mode during the first hour due to the addition of formaldehyde that occurs slowly to avoid excessive heat release caused by the reaction, and after the complete addition, the process continues in batch mode. For this, the kinetics of the reaction was taken directly from the literature and the molar and energy balances for both phases of operation were described. The kinetic model was adapted from the literature by fitting the kinetic constants with conversion data obtained in the plant. This adjustment was performed by programming Excel to minimize the sum between the mass fraction data taken from the literature and those predicted by the model. After that, the MatLab® software was used to simulate the phenomenological models corresponding to the formation process of phenolic resin precursors. Thus, it was possible to adjust the values of the kinetic constants of the addition reaction to the production process. The study of the energy balance was guided by the adjustment of the global heat exchange coefficient using the function Fminsearch of MatLab® to minimize the sum of the quadratic error between the temperature data from the industry and those obtained by the mathematical model. Thus, the tem perature profile that best suits the production process under study is obtained. Thus, it was possible to analyze the operating conditions and improve the process by evaluating the influence of the molar ratio (formaldehyde/phenol) and the formaldehyde addition time on the temperature profile and phenol conversion. With the results obtained it was possible to improve the process by keeping the formaldehyde addition time at 1:00 hour and increasing the resin molar ratio from 2.19 to 3.0. Thus, the work contributed to generate positive results to the process, allowing productivity gains with higher phenol conversion and temperature control.