In December 2024, after-sales engineers from Greatwall Mixers traveled to Shandong to provide on-site installation and commissioning services for a rubber project. The core equipment of the project is a coagulation tank used for the production of polybutadiene rubber.

     About Polybutadiene Rubber

     Polybutadiene rubber plays a crucial role in many fields due to its excellent wear resistance, elasticity, low-temperature resistance, and good processing performance.

     Main applications include:

     Tire Manufacturing: Polybutadiene rubber is one of the most important raw materials in the tire industry. Its excellent wear resistance and elasticity allow tires to provide good grip and durability. It is especially widely used in high-performance tires and low rolling resistance tires.

     Automotive Parts: Used in the production of automotive seals, gaskets, oil seals, etc. Polybutadiene rubber¡¯s aging resistance, low-temperature performance, and wear resistance make it widely used in automotive parts.

     Footwear Materials: Due to its softness and wear resistance, polybutadiene rubber is often used in the production of shoe soles and sports shoes. It provides comfort and durability.

     Rubber Hoses and Belts: Polybutadiene rubber is used in the production of various types of hoses and belts, especially in environments requiring wear resistance, aging resistance, and tolerance to extreme temperatures.

     Cables: Polybutadiene rubber is also used for outer protection in cables, as it effectively prevents cables from being damaged by external environments such as high temperatures, moisture, and chemicals.

    Sports Equipment and Toys: Polybutadiene rubber¡¯s elasticity and durability make it suitable for certain sports equipment (such as jump ropes, exercise bands, etc.) and children¡¯s toys (such as rubber balls).

     Industry Pain Points: Coagulation Tank Process Challenges

     In the production process of polybutadiene rubber, the coagulation tank, as the core equipment, faces significant process challenges. These include an increase in viscosity as the reaction proceeds, leading to decreased fluidity of the slurry and reduced mixing efficiency; solid particles tend to accumulate at the bottom of the tank, forming dead zones that affect equipment stability and reaction rate; uneven liquid-solid dispersion leads to local variations in reaction conditions, which affect the uniformity and quality consistency of the final product; and the viscous slurry results in low mass and heat transfer efficiency, which limits the efficiency and stability of the reaction process. These challenges have become key bottlenecks in improving the production efficiency and quality of polybutadiene rubber.

     Selection and Combination

     To address the process challenges of the polybutadiene rubber coagulation tank, a four-layer impeller combination was adopted, demonstrating exceptional process optimization capabilities. The first layer, a three-narrow-blade impeller with auxiliary blades, drives powerful axial flow to initiate full-tank liquid circulation, preventing stratification and ensuring uniform dispersion of the liquid-solid phase. The middle two layers of three-narrow-blade impellers further enhance the up-and-down fluid circulation, optimizing the mixing effect under varying viscosity conditions and minimizing dead zones. The bottom layer uses a parabolic blade disc turbine impeller, which exerts high shear forces to clean the bottom sediment and enhances local turbulent mixing, improving mass and heat transfer efficiency.

     This combined solution not only achieves uniform mixing, sediment removal, and energy-efficient utilization but also ensures stable reaction conditions, comprehensively improving the process performance and product quality in polybutadiene rubber production.

     The four-layer impeller combination design for the polybutadiene rubber coagulation tank effectively resolves multiple pain points in traditional production, significantly improving reaction efficiency and product quality. It has set a high-efficiency and reliable production benchmark for the industry. With its profound technical expertise and innovative capabilities, Greatwall Mixers will continue to provide advanced mixing solutions for the rubber and related polymer materials sectors, helping customers achieve more efficient and sustainable development goals.