Epdxy resin production
A process comprising: a) contacting a polyhydric phenol and an epihalohydrin in the presence of a catalyst under reaction conditions to form an organic feed comprising a bishalohydrin ether; b) contacting the organic feed and an aqueous feed comprising an inorganic hydroxide with a high shear mixer to produce a first mixed feed; c) contacting the first mixed feed with a phase separator to form a first organic product comprising an epoxy resin and a first aqueous product; and d) recovering the first organic product, is disclosed.
1. A process comprising:
a) contacting a polyhydric phenol and an epihalohydrin in the presence of a catalyst under reaction conditions to form an organic feed comprising a bishalohydrin ether;
b) contacting said organic feed and an aqueous feed comprising an inorganic hydroxide with a high shear mixer to produce a first mixed feed comprising an emulsion;
c) contacting said first mixed feed with a centrifugal separator to form a first organic product comprising an epoxy resin and a first aqueous product; and
d) recovering said first organic product.
2. A process in accordance with claim 1 further comprising:
e) contacting said first organic product and an aqueous feed comprising a hydroxide with a high shear mixer to produce a second mixed feed comprising an emulsion;
f) contacting said second mixed feed with a centrifugal separator to form a second organic product comprising an epoxy resin and a second aqueous product; and
g) recovering said second organic product.
3. A process in accordance with claim 1 wherein said first mixed feed is contacted with a reactor prior to said contacting with a centrifugal separator of step (c).
4. A process in accordance with claim 2 wherein said second mixed feed is contacted with a reactor prior to said contacting with a centrifugal separator of step (f).
5. A process in accordance with claim 1 wherein said phenol is selected from the group consisting of bisphenol-A, bisphenol-F, phenol-formaldehyde novolacs, cresol-formaldehyde novolacs, bisphenol-A-formaldehyde novolacs, trisphenols, biphenols, diphenols, hydroquinone and combinations thereof and said epihalohydrin is selected from the group consisting of epichlorohydrin, epibromohydrin, methylepichlorohydrin and combinations thereof.
6. A process in accordance with claim 1 wherein said catalyst of step a) is selected from the group consisting of sodium hydroxide, potassium hydroxide, calcium hydroxide, and combinations thereof.
7. A process in accordance with claim 1 wherein said inorganic hydroxide of step b) is selected from the group consisting of sodium hydroxide, potassium hydroxide, calcium hydroxide, and combinations thereof.
8. A process in accordance with claims 1 wherein steps a) and b) and are conducted in the presence of a cosolvent selected from the group consisting of isopropanol, 1-methoxy-2-propanol, and combinations thereof.
9. A process in accordance with claim 2 wherein step e) is conducted in the presence of a cosolvent selected from the group consisting of isopropanol, 1-methoxy-2-propanol, and combinations thereof.
10. A process in accordance with claim 1 wherein said reaction conditions in step a) comprise a first reaction temperature in the range of from 20° C. to 80° C.
11. A process in accordance with claim 1 wherein the molar ratio of said epihalohydrin to said phenol in step a) is in the range of about 1:1 to about 50:1.