Abstract
This contribution presents a process conversion from discontinuous binder emulsion production at macro scale to microcontinuous operation. The high viscosity of the organic phase represented a challenging product property. With the batch process as a reference, a specification benchmark to be matched by continuously manufactured product was determined. Based on these criteria and despite the high pressure drop, a feasible continuous production process using microstructured devices was developed and industrially implemented. Process development focused on energy efficient, automated production which led to energy savings and improved process stability as well as product quality. Longer operation time yielded increases in energy efficiency, which also resulted in a reduced specific waste production. The new continuous process in an automated demonstration plant resulted in savings of more than 49% of the energy input and more than 99% of waste production per kg binder emulsion product.
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