Description:TECHNICAL FIELD
The present disclosure relates to polymer chemistry. The present disclosure particularly relates to simple, efficient, and economical process for removing rubber mass from surfaces of equipment. The disclosure also relates to kit for removing rubber mass from surfaces of equipment.

BACKGROUND OF THE DISCLOSURE
During the manufacture of polymers by solution and/or emulsion polymerization, monomer and/or finished polymers gradually builds up over a period of time on the surfaces of the process equipment, thereby reducing the efficiency of reactions and ultimately requiring removing of equipment from operation for removal of deposits on the surfaces of the equipment.

Particularly, it is noted that elastomers including styrene butadiene rubber, polybutadiene rubber, butyl rubber, bromo butyl rubber and ethylene propylene diene monomer (EPDM) rubber deposits on the wall of stripper in manufacturing plant over a period of time. Such deposits are generally removed via physical process which is apparently time consuming and requires high pressure water jet. This known process for removal of deposits on the surfaces of the equipment is unsafe and takes several days to clean up the surfaces of the equipment, for e.g., stripper wall and reaction lines of the reactor. The cleaning is also carried out in open environment which causes the exposure of unreacted monomers to the environment. Additionally, the known process utilizes about 1 to 1.5 lakhs kg of water for removal of deposits from the surfaces of the equipment, which is not economical and environmentally friendly.

Thus, there is a need for efficient and simple technique for removal of deposits of monomer or polymer rubber masses from the surfaces of equipment. The present disclosure, in order to address the problem associated with removal of deposits/rubber mass from the surfaces of equipment, describes an efficient and simple process for removal of deposits/rubber mass from the surfaces of the equipment.

STATEMENT OF THE DISCLOSURE
Accordingly, the present disclosure relates to simple, economical, sustainable, efficient and environmentally friendly process for removal of rubber mass deposited on the surfaces of equipment.

The process of removal of rubber mass from the surfaces of equipment comprises- contacting the rubber mass with solvent and alkali agent, followed by adding emulsifier to obtain a mixture; and heating the mixture to dissolve the rubber mass, thereby removing the rubber mass from the surfaces of the equipment.

The present disclosure further relates to a kit for removing rubber mass from surfaces of equipment, said kit comprises- i. at least one container comprising solvent; ii. at least one container comprising alkali agent; iii. at least one container comprising emulsifier; and iv. instructions for carrying out the process for removing rubber mass from surfaces of equipment.

BRIEF DESCRIPTION OF THE ACCOMPANYING FIGURES
In order that the present disclosure may be readily understood and put into practical effect, reference will now be made to exemplary embodiments as illustrated with reference to the accompanying figure. The figure together with detailed description below, are incorporated in and form part of the specification, and serve to further illustrate the embodiments and explain various principles and advantages, where:

FIGURE 1 provides pictorial representation of reduction in size of rubber mass in acidic condition and basic condition.

FIGURE 2 Provides pictorial representation of reduction in size of rubber mass from initial size.

FIGURE 3 Provides pictorial representation of reduction in size of rubber mass from initial size.

FIGURE 4 Provides pictorial representation of reduction in size of rubber mass from initial size.
FIGURE 5 Provides pictorial representation of reduction in size of rubber mass from initial size.

DETAILED DESCRIPTION OF THE DISCLOSURE
Unless otherwise defined, all terms used in the disclosure, including technical and scientific terms, have meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. By means of further guidance, term definitions are included for better understanding of the present disclosure.
As used herein, the singular forms ‘a’, ‘an’ and ‘the’ include both singular and plural referents unless the context clearly dictates otherwise.

The term ‘comprising’, ‘comprises’ or ‘comprised of’ as used herein are synonymous with ‘including’, ‘includes’, ‘containing’ or ‘contains’ and are inclusive or open-ended and do not exclude additional, non-recited members, elements or method steps.

The recitation of numerical ranges by endpoints includes all numbers and fractions subsumed within the respective ranges, as well as the recited endpoints.

The term ‘about’ as used herein when referring to a measurable value such as a parameter, an amount, a temporal duration, and the like, is meant to encompass variations of ±10% or less, preferably ±5% or less, more preferably ±1% or less and still more preferably ±0.1% or less of and from the specified value, insofar such variations are appropriate to perform the present disclosure. It is to be understood that the value to which the modifier ‘about’ refers is itself also specifically, and preferably disclosed.

Reference throughout this specification to ‘some embodiments’, ‘one embodiment’ or ‘an embodiment’ means that a particular feature, structure or characteristic described in connection with the embodiment may be included in at least one embodiment of the present disclosure. thus, the appearances of the phrases ‘in some embodiments’, ‘in one embodiment’ or ‘in an embodiment’ in various places throughout this specification may not necessarily all refer to the same embodiment. It is appreciated that certain features of the disclosure, which are for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the disclosure, which are, for brevity described in the context of a single embodiment, may also be provided separately or in any suitable sub-combination.

As used herein, ‘rubber mass’ refers to agglomeration of small crumbs of polymers. Rubber mass contains unreacted monomers, uncoagulated latex impurities and agglomeration of polymer crumbs of styrene butadiene, butyl, bromo butyl, ethylene propylene diene monomer, polybutadiene, acrylonitrile butadiene, polyisoprene, isoprene isobutylene, and any combinations thereof, which are deposited or lodged on the surfaces of the equipment.

The present disclosure relates to simple, efficient, economical, and environmentally friendly process for removal of rubber mass from surfaces of equipment.

In some embodiments of the present disclosure, the process does not involve washing the surfaces of the equipment with water for removal of rubber mass. The inventors have particularly designed the process in such a manner that there is no requirement of washing the surface of the equipment with water.

In some embodiments of the present disclosure, the process of removing rubber mass from surfaces of equipment comprises-
- contacting the rubber mass with solvent and alkali agent, followed by adding emulsifier to obtain a mixture; and
- heating the mixture to dissolve the rubber mass, thereby removing the rubber mass from the surfaces of the equipment.

In some embodiments of the present disclosure, the process of removing rubber mass from surfaces of equipment additionally comprises washing the surfaces of the equipment with the solvent after removing the rubber mass to further remove remnant rubber mass.

In some embodiments of the present disclosure, the process of removing rubber mass from surfaces of equipment comprises-
- contacting the rubber mass with solvent and alkali agent, followed by adding emulsifier to obtain a mixture;
- heating the mixture to dissolve the rubber mass, thereby removing the rubber mass from the surfaces of the equipment; and
- washing the surfaces of the equipment with the solvent to remove remnant rubber mass.

The inventors have particularly identified that combination of solvent and alkali agent dissolves the rubber mass. The alkali agent aids in swelling of the rubber mass in the solvent, thus dissolving the rubber mass completely. The inventors have also identified that addition of emulsifier helps in cleaning and complete removal of the dissolved rubber mass from the surfaces of the equipment.

In some embodiments of the present disclosure, the solvent is selected from a group comprising toluene, benzene, tetrahydrofuran, chloroform, N-methyl-2-pyrrolidone (NMP), hexane, methanol, styrene, and any combinations thereof.

In some embodiments of the present disclosure, the solvent is selected from a group comprising mixture of toluene and methanol, mixture of toluene and N-methyl-2-pyrrolidone (NMP), mixture of toluene and styrene, mixture of toluene and hexane, mixture of toluene, methanol and hexane, any combinations thereof.

In some embodiments of the present disclosure, the solvent is in an amount ranging from about 50% to 98%, including all the values in the range, for instance, 51%, 52%, 53%, 54% and so on and so forth.

In some embodiments of the present disclosure, the alkali agent is selected from a group comprising sodium hydroxide, potassium hydroxide, sodium carbonate, sodium bicarbonate, ammonium hydroxide, ethylene diamine, hydrazine, cyclohexylamine, and any combinations thereof.

In some embodiments of the present disclosure, the alkali agent is in an amount ranging from about 2% to 15%, including all the values in the range, for instance, 2.1%, 2.2%, 2.3%, 2.4% and so on and so forth.

In some embodiments of the present disclosure, the emulsifier is selected from a group comprising rosin soap, fatty soap, synthetic soap and any combinations thereof. In an embodiment, rosin soap includes combination of potassium salt of abietic acid, neoabietic acid, palustric acid or dehydroabietic acid. In an embodiment, the synthetic soap consists of DNMS, sodium lauryl sulphate and sodium n-dodecyl benzene sulphate, for e.g., C8 to C20 sulphonate, sulphates, sulphoxylates or phosphates. In an embodiment the fatty soap includes but it is not limited to C12 to C25 carboxylic acid, C8 to C20 sulphonates, sulphates, sulphoxylates or phosphates.

In some embodiments of the present disclosure, the emulsifier is in an amount ranging from about 0.05% to 0.5%, including all the values in the range, for instance, 0.06%, 0.07%, 0.08%, 0.09% and so on and so forth.

In some embodiments of the present disclosure, the rubber mass is selected from a group comprising styrene butadiene rubber mass, butyl rubber mass, bromo butyl rubber mass, ethylene propylene diene monomer rubber mass, polybutadiene rubber mass, acrylonitrile butadiene rubber mass, polyisoprene rubber mass, isoprene isobutylene rubber mass, and any combinations thereof.

In some embodiments of the present disclosure, the heating is carried out at a temperature ranging from about 30 ? to 120 ?, including all the values in the range, for instance, 31 ?, 32 ?, 33 ?, 34 ? and so on and so forth. In an embodiment, the heating is carried out for a duration ranging from about 5 hours to 14 hours, including all the values in the range, for instance, 5.1 hours, 5.2 hours, 5.3 hours, 5.4 hours and so on and so forth. In an embodiment, the duration of heating is dependent on size of the rubber mass.

In some embodiments of the present disclosure, the solubility of the rubber mass upon heating to a temperature of about 30 ? to 120 ?, for a duration of about 5 hours to 14 hours is 95% to 99.9%. In an embodiment, the solubility of the rubber mass is about 95.1%, about 95.2%, about 95.3%, about 95.4%, about 95.5%, about 95.6%, about 95.7%, about 95.8%, about 95.9%, about 96%, about 96.1%, about 96.2%, about 96.3%, about 96.4%, about 96.5%, about 96.6%, about 96.7%, about 96.8%, about 96.9%, about 97%, about 97.1%, about 97.2%, about 97.3%, about 97.4%, about 97.5%, about 97.6%, about 97.7%, about 97.8%, about 97.9%, about 98%, about 98.1%, about 98.2%, about 98.3%, about 98.4%, about 98.5%, about 98.6%, about 98.7%, about 98.8%, about 98.9%, about 99%, about 99.1%, about 99.2%, about 99.3%, about 99.4%, about 99.5%, about 99.6%, about 99.7%, about 99.8% or about 99.9%.

In some embodiments of the present disclosure, the process of removing rubber mass from surfaces of equipment comprises-
- contacting the rubber mass with the solvent and the alkali agent, followed by adding the emulsifier to obtain a mixture;
- heating the mixture at a temperature of about 30 ? to 120 ?, for a duration ranging from about 5 hours to 14 hours to dissolve the rubber mass, thereby removing the rubber mass from the surfaces of the equipment; and
- optionally, washing the surfaces of the equipment with the solvent to remove remnant rubber mass.

In some embodiments of the present disclosure, the rubber mass is removed from the surfaces of the equipment in a duration ranging from about 4 hours to 12 hours, including all the values in the range, for instance, 4.1 hours, 4.2 hours, 4.3 hours, 4.4 hours and so on and so forth. In embodiment, the duration of removal of the rubber mass from the surfaces of the equipment is dependent on size of the rubber mass deposited on the surfaces of the equipment.

In some embodiments of the present disclosure, the solvent employed in the said process of removing the rubber mass from the surfaces of the equipment is recovered. In an embodiment, about 80% to 95% of the solvent employed in the process is recovered. The recovered solvent is employed in the subsequent process of recovering rubber mass from the surfaces of the equipment. Thus, the process of the present disclosure is sustainable, green and economical. In an embodiment, about 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89%, 90%, 91%, 92%, 93%, 94% or 95% of the solvent is recovered.

In some embodiments of the present disclosure, the rubber mass is recovered from the solution after its removal from the surfaces of the equipment. In an embodiment, the rubber mass is recovered through technique including but it is not limited to vacuum distillation, followed by drying.

In an exemplary embodiment of the present disclosure, the process is concerned with removal of rubber mass, such as elastomer including but it is not limited to styrene butadiene rubber, polybutadiene rubber, butyl rubber, bromo butyl rubber and ethylene propylene diene Monomer (EPDM) rubber, from surfaces of equipment, the process comprises-
- contacting the elastomer with the solvent and the alkali agent, followed by adding the emulsifier to obtain a mixture; and
- heating the mixture at a temperature of about 30 ? to 120 ?, for a duration ranging from about 5 hours to 14 hours to dissolve the elastomer, thereby removing the elastomer from the surfaces of the equipment;

In an exemplary embodiment of the present disclosure, the process is concerned with removal of rubber mass, such as elastomer including but it is not limited to styrene butadiene rubber, polybutadiene rubber, butyl rubber, bromo butyl rubber and ethylene propylene diene Monomer (EPDM) rubber, from surfaces of equipment, the process comprises-
- contacting the elastomer with the solvent and the alkali agent, followed by adding the emulsifier to obtain a mixture;
- heating the mixture at a temperature of about 30 ? to 120 ?, for a duration ranging from about 5 hours to 14 hours to dissolve the elastomer, thereby removing the elastomer from the surfaces of the equipment; and
- washing the surfaces of the equipment with the solvent to remove remnant of the elastomer.

In an exemplary embodiment of the present disclosure, the elastomer in the solution is recovered through technique including but it is not limited to vacuum distillation, followed by drying.

In some embodiments of the present disclosure, the equipment from which the rubber mass is removed includes but it is not limited to stripper wall, polymerization line of reactor, latex storage tank, latex transfer lines, finishing line, tray deposit, pressure flash vessel, vacuum flash vessel, pump, motors, reactors and any combinations thereof. In an embodiment, the equipment is any equipment involved in polymerization of rubber.

The process of the present disclosure provides for following advantages-
- The process is highly efficient in removing rubber mass from the surfaces of the equipment as it reduces the cleaning time from several days to few hours, for e.g., 5 hours to 14 hours.
- The solvent employed in the process is recycled. About 80% to 95% of the solvent is recovered and reused in the subsequent process. Thus, the process is sustainable, green and economically viable.
- The process does not employ water for the removal of rubber mass unlike the conventionally known processes.
- The process can be carried under in closed system, thus avoids direct contact with unreacted monomers in the equipment. In other words, the process of the present disclosure is carried out in reactor vessels by closing them completely and circulating solvent, alkali agent and emulsifier under heating condition without exposing to external environment (including human beings) until the vessel is cleaned, i.e., until the rubber mass is removed, and solvent is recycled. Thus, direct contact of the components employed in the process to the external environment (including human beings) is negligible. Unlike the conventional physical method, the process of the present disclosure reduces the cleaning time from several days to few hours.
- The process is non-hazardous as it is carried under closed condition with minimal or non-exposure to human body.

The present disclosure further relates to a kit for removal of rubber mass from the surfaces of the equipment.

In some embodiments of the present disclosure, the kit comprises-
- at least one container comprising solvent selected from a group comprising toluene, benzene, tetrahydrofuran, chloroform, N-Methyl-2-pyrrolidone (NMP), hexane, methanol, styrene, and any combinations thereof;
- at least one container comprising alkali agent selected from a sodium hydroxide, potassium hydroxide, sodium carbonate, sodium bicarbonate, ammonium hydroxide, ethylene diamine, hydrazine, cyclohexylamine and a combination thereof;
- at least one container comprising emulsifier selected from a group comprising rosin soap, fatty soap, synthetic soap and combination thereof; and
- instructions for removing rubber mass from surfaces of equipment.

In some embodiments of the present disclosure, the kit is packaged to comprise containers comprising the solvent, the alkali agent and the emulsifier, individually along with instructions on how to perform the process of removing rubber mass from the surfaces of the equipment.

In an embodiment, the kit is packaged to comprise multiple containers comprising each of the solvent or its mixtures individually.

In an embodiment, the kit is packaged to comprise multiple containers comprising each of the alkali agent individually.

In an embodiment, the kit is packaged to comprise multiple containers comprising each of the emulsifier individually or its mixture.

In some embodiments of the present disclosure, in the container, the solvent is in an amount ranging from about 50% to 98%, including all the values in the range, for instance, 51%, 52%, 53%, 54% and so on and so forth.

In some embodiments of the present disclosure, in the container, the alkali agent is in an amount ranging from about 2% to 15%, including all the values in the range, for instance, 2.1%, 2.2%, 2.3%, 2.4% and so on and so forth.

In some embodiments of the present disclosure, in the container, the emulsifier is in an amount ranging from about 0.05% to 0.5%, including all the values in the range, for instance, 0.06%, 0.07%, 0.08%, 0.09% and so on and so forth.

Descriptions of well-known/conventional methods/steps and techniques are omitted so as to not unnecessarily obscure the embodiments herein. Further, the disclosure herein provides for examples illustrating the above-described embodiments, and in order to illustrate the embodiments of the present disclosure, certain aspects have been employed. The examples used herein for such illustration are intended merely to facilitate an understanding of ways in which the embodiments may be practiced and to further enable those of skill in the art to practice the embodiments. Accordingly, following examples should not be construed as limiting the scope of the embodiments herein.

EXAMPLES
Example 1: Dissolving rubber mass
About 5 g of rubber stripper sample having size of about 3 by 2 cm was taken. To the rubber sample, about 58 g of toluene and about 3 g of 10% KOH was added, subsequently about 0.5 g of emulsifier as mixture of rosin soap, fatty soap and synthetic soap was added to obtain a mixture. The mixture was heated at a temperature of about 90 ? for about 9 hours. The size of the rubber sample was reduced to about 2 mm in about 6 hours time. The size of the sample was reduced to less than 1 mm at about 9 hours. Solubility of the sample was found to be more than 98%.

Example 2: Dissolving rubber mass
About 50 g of rubber stripper sample having size of about 10 by 5 cm was taken. To the rubber sample, about 580 g of toluene and about 10 g of 10% KOH was added, subsequently about 2.5 g of emulsifier as mixture of rosin soap, fatty soap and synthetic soap was added to obtain a mixture. The mixture was heated at a temperature of about 90 ? for about 9 hours. The size of the rubber sample was reduced to about 2 cm in about 5 hours time. The size of the sample was reduced to less than 1 mm at about 9 hours. Solubility of the sample was found to be more than 98%.
Figure 2 illustrates the reduction in the size of the rubber, i.e., solubility of the rubber sample

Example 3: Dissolving rubber mass
About 100 g of rubber stripper sample having size of about 14 by 6.5 cm was taken. To the rubber sample, about 1160 g of toluene and about 15 g of 10% KOH was added, subsequently about 5 g of emulsifier as mixture of rosin soap, fatty soap and synthetic soap was added to obtain a mixture. The mixture was heated at a temperature of about 90 ? for about 10.5 hours. The size of the rubber sample was reduced to about 4 cm in about 5.5 hours time. The size of the sample was reduced to less than 1 mm at about 10 hours. Solubility of the sample was found to be more than 98%.
Figure 3 illustrates the reduction in the size of the rubber, i.e., solubility of the rubber sample

Example 4: Dissolving rubber mass
About 300 g of rubber stripper sample having size of about 16 by 10 cm was taken. To the rubber sample, about 1740 g of toluene and about 45 g of 10% KOH was added, subsequently about 15 g of emulsifier as mixture of rosin soap, fatty soap and synthetic soap was added to obtain a mixture. The mixture was heated at a temperature of about 90 ? for about 12 hours. The size of the rubber sample was reduced to about 2 cm in about 6 hours time. The size of the sample was reduced to less than 1 mm at about 12 hours. Solubility of the sample was found to be more than 98%.
Figure 4 illustrates the reduction in the size of the rubber, i.e., solubility of the rubber sample

Example 5: Dissolving rubber mass
About 500 g of rubber stripper sample having size of about 20 by 18 cm was taken. To the rubber sample, about 2900 g of toluene and about 75 g of 10% KOH was added, subsequently about 50 g of emulsifier as mixture of rosin soap, fatty soap and synthetic soap was added to obtain a mixture. The mixture was heated at a temperature of about 90 ? for about 12 hours. The size of the rubber sample was reduced to about 5 cm in about 5 hours time. The size of the sample was reduced to less than 2 mm at about 12 hours. solubility of the sample was found to be more than 98%.
Figure 5 illustrates the reduction in the size of the rubber, i.e., solubility of the rubber sample

Example 6:
About 2 g of the rubber stripper sample was taken and solubility of the rubber stripper sample was assessed with different solvent mixture. Table 1 describes the condition and solubility of the rubber sample. Alkali agent employed was 10% aqueous KOH and emulsifier employed was mixture of rosin soap, fatty soap and synthetic soap.
Sl No. Rubber sample size Solvent Heating Solubility
1 2 g Toluene (90%)+NMP (2%) 50 ?, 3 hours 93%
2 2 g Toluene (90%)+ methanol (2%) 50 ?, 3 hours 95%
3 2 g Toluene (45%)+ hexane (45%)+ methanol (2%) 65 ?, 4 hours 90%
Table 1:

Example 7:
About 5 g of the rubber stripper sample was taken and solubility of the rubber stripper sample was assessed with different solvent mixture. Table 2 describes the condition and solubility of the rubber sample. Alkali agent employed was 10% aqueous KOH and emulsifier employed was mixture of rosin soap, fatty soap and synthetic soap.

Sl No. Rubber sample size Solvent Heating Solubility
1 5 g Toluene (90%)+NMP (10%) 90 ?, 6 hours 97%
2 5 g Toluene (50%)+ styrene (50%) 90 ?, 6 hours 91%
3 5 g Toluene (45%)+ styrene (50%) 90 ?, 6 hours 92%
Table 2:

Example 8: Comparative Example
The process described under Example 1 was carried out in acidic condition, i.e., in place of alkali agent, 3 g of 10% citric acid was added. The rubber sample employed was about 5 g having size of about 3 cm.
Figure 1 demonstrates that the rubber sample size was reduced to about 3 mm in acidic condition. However, it can be noted that under basic condition (using alkali agent), the size of the rubber sample was reduced to about 1mm.

Example 9: Removal of rubber mass from one litre SS reactor surface
About 50 g of rubber mass adhered/deposited to the surface of one litre SS reactor equipment. To remove the adhered rubber mass from the reactor surface, about 580 g of toluene and about 10 g of 10% KOH was added, subsequently about 2.5 g of emulsifier as mixture of rosin soap, fatty soap and synthetic soap was added to obtain a mixture. The SS reactor surface was heated at a temperature of about 90 ? for about 6 hours via oil circulating heating cooling system with gentle stirring. The rubber mass was reduced and dissolved completely from reactor surface in the toluene. The solubility of the rubber mass was found to be more than 98%.

Example 10: Removal of rubber mass from 0.75 litre SS reactor surface
About 25 g of rubber mass deposited to the surface of 0.75 litre SS reactor equipment. To remove the adhered rubber mass from the reactor surface, about 290 g of toluene and about 5 g of 10% KOH was added, subsequently about 1.25 g of emulsifier as mixture of rosin soap, fatty soap and synthetic soap was added to obtain a mixture. The SS reactor surface was heated at a temperature of about 90 ? for about 6 hours via oil circulating heating cooling system. The rubber mass was reduced and dissolved completely from reactor surface in the toluene. The solubility of the rubber mass was found to be more than 99%.

Example 11: Reduction in the cost demonstrated by the process of the present disclosure when compared to Conventional washing process.
Process of present disclosure and conventional washing process individually were employed for removal of rubber mass from stripper column.
Table 3 describes the cost involved in removing the rubber mass from stripper column employing the process of the present disclosure.
Description for chemical cleaning Values Units

Column Volume 160 M3
Hot Toluene Density 800 kg/M3
Column Volume, Qty 128000 kg

Dirty Toluene Flow Rate 3063 kg/hr
MP Steam Flow Rate, in Toluene Recovery 4200 kg/hr
MP Steam Price 870.9 Rs/Mt

Dirty Toluene Req. 128000 kg
MP Steam Qty 175.5 MT
MP Steam Price 1,52,852 Rs./Batch

Fresh Toluene Flow Rate 19500 kg/hr
LP Steam Flow Rate to Heat Toluene 1540 kg/hr
LP Steam Price 692 Rs/Mt

Fresh Toluene Qty 128000 kg
LP Steam Qty 10.1 MT
LP Steam Price 6,994 Rs. / Batch

Operating Time 41.8 Hours/Column

Tag Description Amp Power (kW)
SBR-II1802 AV-1802 15 9.7
SBR-II1802P P-1802 DIRTY TOLUNE TO STRIPPING 18 11.6
SBR-II1803 AV-1803 18 11.6
SBR-II1803P P-1803 H2O & CRUMBS TO SECOND ST 18 11.6
SBR-II1804 AV-1804 18 11.6
SBR-II1804P P-1804 H2O & CRUMBS TO CRUMB TAN 18 11.6
SBR-II1805 AV-1805 18 11.6
SBR-II1805P P-1805 H2O & CRUMBS TO SHAKER SC 18 11.6
SBR-II1807P P-1807 RECYCLE WATER TO STRIPPER 50 32.3

Total Power (kW) 123.6
Total Power (kWH) 5163.4

Power Price 4.88

Power Cost, Rs/Batch 25,197

Tentative Cost, per 1 Time 1,85,043

Tentative Cost, per 2 Times, 1 Column 3,70,086
Tentative Cost, per 2 Times, 2 Column 7,40,172

Tentative Change overs/Year 12
Tentative Cost/Year 88,82,067

Table 3:

Table 4 describes the cost involved in removing the rubber mass from stripper column employing washing method (conventional process).

Total washings for 2 columns

1 Washing frequency of each Stripper Column (in days) 40
2 No. of stripper columns 2
3 Total no. of washings for both columns (annually) 20

Labour Cost

1 Labor Cost per person (RS) 2500
2 Time for each washing (days) 15
3 Labour for each washing 10
4 Labor cost for each washing: 10 persons x 15 days x 2500 (Rs) 3,75,000
5 Total labour cost annually (for 20 washings) in Rs. 75,00,000

Energy (Electricity Cost)
1 Electricity Cost (per unit) in Rs. 12
2 Total electricity cost per day for high pressure jet (10 kW) = 1 unit cost for every 2 minutes = 30 x 6 h x 12 (in Rs) 2160
3 Total cost for one washing = 2160 x 15 days x 10 labour jet 3,24,000
4 Total energy cost annually (20 stripper washings) 64,80,000
5 Water cost (1.5 lack litre per washing X 20 X 0.5 1500000

Total Cost

Labour Cost + Energy cost (Rs.) + water consumption cost 1,54,80,000
Table 4:

From the data in Tables 3 and 4 it can be noted that the process of the present disclosure is significantly economical (leads to reduced cost) for removal of rubber mass from the surfaces of equipment when compared to conventional washing process.

, Claims:WE CLAIM:
1. A process for removing rubber mass from surfaces of equipment, said method comprises-
- contacting the rubber mass with solvent and alkali agent, followed by adding emulsifier to obtain a mixture; and
- heating the mixture to dissolve the rubber mass, thereby removing the rubber mass from the surfaces of the equipment.

2. The process as claimed in claim 1, wherein the process additionally comprising washing the surfaces of the equipment with solvent after removing the rubber mass to further remove remnant rubber mass.

3. The process as claimed in claim 1, wherein the solvent is selected from a group comprising toluene, benzene, xylene, tetrahydrofuran, chloroform, N-Methyl-2-pyrrolidone (NMP), hexane, heptane, octane, decane, methanol, styrene, and any combinations thereof.

4. The process as claimed in claim 2, wherein the solvent is selected from a group comprising mixture of toluene and methanol, mixture of toluene and N-Methyl-2-pyrrolidone (NMP), mixture of toluene and styrene, mixture of toluene and hexane, mixture of toluene, methanol and hexane, and any combinations thereof.

5. The process as claimed in claim 1, wherein the alkali agent is selected from a group comprising sodium hydroxide, potassium hydroxide, sodium carbonate, sodium bicarbonate, ammonium hydroxide, ethylene diamine, hydrazine, cyclohexylamine and any combinations thereof.

6. The process as claimed in claim 1, wherein the emulsifier is selected from a group comprising rosin soap, fatty soap, synthetic soap and combinations thereof.

7. The process as claimed in claim 1, wherein the solvent is in an amount ranging from about 50% to 98%.

8. The process as claimed in claim 1, wherein the alkali agent is in an amount ranging from about 2% to 15%.

9. The process as claimed in claim 1, wherein the emulsifier is in an amount ranging from about 0.05% to 0.5%.

10. The process as claimed in claim 1, wherein the heating is carried out at a temperature ranging from about 30 ? to 120 ?, for a duration ranging from about 5 hours to 14 hours, wherein the duration of heating is dependent on size of the rubber mass.

11. The process as claimed in claim 1, wherein the rubber mass is removed from the surfaces of the equipment in a duration ranging from about 4 hours to 12 hours, depending on size of the rubber mass.

12. The process as claimed in claim 1, wherein the rubber mass is selected from a group comprising styrene butadiene rubber mass, butyl rubber mass, bromo butyl rubber mass, ethylene propylene diene monomer rubber mass, polybutadiene rubber, acrylonitrile butadiene, polyisoprene rubber, isoprene isobutylene rubber, and any combination thereof.

13. The process as claimed in claim 1, wherein solubility of the rubber mass upon heating is ranging from about 95% to 99.9%.

14. The process as claimed in claim 1, wherein the equipment is selected from a group comprising stripper wall, polymerization line of reactor, latex storage tank, latex transfer lines, finishing line, tray deposit, pressure flash vessel, vacuum flash vessel, pump, motors, reactors and any combinations thereof.

15. The process as claimed in claim 1, wherein the process further comprises recovering the rubber mass from solution, wherein the recovering involves vacuum distillation, followed by drying.

16. The process as claimed in claim 1, wherein the process further comprises recycling of the solvent, wherein about 80% to 95% of the solvent is recovered.

17. A kit for removing rubber mass from surfaces of equipment, said kit comprises:
i. at least one container comprising solvent selected from a group comprising toluene, benzene, tetrahydrofuran, chloroform, N-Methyl-2-pyrrolidone (NMP), hexane, methanol, styrene, and any combinations thereof;
ii. at least one container comprising alkali agent selected from a sodium hydroxide, potassium hydroxide, sodium carbonate, sodium bicarbonate, ammonium hydroxide, ethylene diamine, hydrazine, cyclohexylamine and a combination thereof;
iii. at least one container comprising emulsifier selected from a group comprising rosin soap, fatty soap, synthetic soap and combinations thereof; and
iv. instructions for removing rubber mass from surfaces of equipment.

18. The kit as claimed in claim 17, wherein the solvent is in an amount ranging from about 50% to 98%; the alkali agent is in an amount ranging from about 2% to 15%; and the emulsifier is in an amount ranging from about 0.05% to 0.5%.

Dated this 15th day of September 2022

Signature:
Name: Sridhar R
To, Of K&S Partners, Bangalore
The Controller of Patents Agent for the Applicant
The Patent Office, at Mumbai IN/PA-2598