COUNTERCURRENT WASHING TOWER AND COUNTERCURRENT WASHING METHOD USING SAME

Abstract: A countercurrent washing tower including a slurry-­ charging nozzle provided in an upper part of the tower, a slurry-dispersing member disposed underneath the slurry-­ feeding nozzle and a plurality of washing liquid feeding nozzles provided in a lower part of the tower, thereby conducting the countercurrent washing of the slurry while maintaining each of the flows of the slurry and washing liquid in a stable and macroscopically-laminar state within the tower. A slurry of a synthetic resin can be washed countercurrently with good washing efficiency and percen­ tage recovery of the synthetic resin by using the above washing tower and charging the slurry of the synthetic resin through the slurry-charging nozzle at a flow velocity of 0.5 m/sec. or slower as measured at the opening of the slurry-charging nozzle and, at the same time, feeding the washing liquid from the washing liquid feeding nozzles, preferably at a flow velocity of 0.2 m/sec. or slower as measured at the openings of the washing liquid feeding nozzles.

Description: Background of the Invention: 1. Field of the Invention: This invention relates to a countercurrent washing tower for washing a slurry, and particularly to a countercurrent washing tower for washing a great deal of slurry efficiently with a liquid without need for any mixing means. This invention also relates to a method for washing a slurry of a synthetic resin by using the above countercurrent washing tower. 2. Description of the Prior Art: When washing a solid with a liquid, the washing efficiency may generally be improved by mixing the solid and liquid vigorously. However, the mixing operation in such a solid-liquid washing work involves many technical problems or inconveniences in addition to the requirement for a mixing apparatus having a complex structure, including (1) the consumption of a large amount of power for mixing a liquid, especially a slurry; (2) the need for liquid-tight and gas-tight sealing when providing a washing tower with a mixing apparatus; and (3) the absolute necessity for such liquid-tight and gas-tight sealing for safety reasons where a combustible substance is handled. There has accordingly been a longstanding desire for the development of a technique which permits washing a large amount of slurry stably, with high efficiency by means of a relatively simple apparatus without any mixing means. Countercurrent washing towers equipped with no mixing means per se have already been known, as disclosed, for example, in Japanese Patent Publication No. 42379/1972. Such washing towers were able to conduct highly efficient washing and/or purification provided that their horizontal cross-sectional areas were relatively small. However, it was very difficult to achieve a washing and/or purification operation stably and with high efficiency where such washing towers were large in dimension. This big difference in effect between such large countercurrent washing towers and small countercurrent washing towers may perhaps be attributed to the following reasons: In a countercurrent washing tower, a solid which has been introduced into the tower for washing moves downward from an upper part of the tower to a lower part thereof while brought into countercurrent contact with a washing liquid introduced from the lower part of the tower. This permits washing or extracting the solid with the washing liquid so that the thus-washed or extracted solid can be removed from the bottom of the tower. When the size of the countercurrent washing tower becomes greater, the slurry introduced from the upper part of the tower tends to become uneven and the washing liquid, which has been introduced upward from the lower part of the tower, is susceptible of flowing as a turbulent flow, thereby causing the solid and liquid to move up and down. As a result, a large portion of the solid is discharged together with a portion of the extracting or washing liquid from the lower part of the tower and the remaining portion of the extracting or washing liquid is discharged together with the remaining portion of the solid from the upper part of the tower, leading to a reduction in washing or extracting efficiency. Summary of the Invention: An object of this invention is to provide an improved countercurrent washing tower useful for washing a slurry. Another object of this invention is to provide a countercurrent washing tower which can wash a large volume of slurry efficiently without need for any mixing means. A further object of this invention is to provide a method for washing a large volume of slurry of a synthetic resin with high efficiency by using such a washing tower. In one aspect of this invention, there is thus provided a countercurrent washing tower which comprises: a slurry-charging nozzle opening in an upper part of the tower; a slurry-dispersing member disposed underneath the slurry-charging nozzle and having a projected top area wider than the area of the opening of the slurry-charging nozzle; a leg section of the washing tower, said leg section being disposed upright below the slurrydispersing member; a plurality of washing liquid feeding nozzles disposed in a lower end part of the leg section, each nozzle having a small opening; a lower discharge opening formed through the wall of the washing tower at a bottom location thereof for removal of washed slurry; and an upper discharge opening formed through the wall of the washing tower at an upper location thereof for withdrawal of spent washing liquid; thereby bringing the slurry from the slurrycharging nozzle into countercurrent contact with the washing liquid from the washing liquid feeding nozzles, both as macroscopically laminar flows, so that the slurry is washed with the washing liquid. In another aspect of this invention, there is also provided a method for washing a slurry of a synthetic resin countercurrently with a washing liquid, which method comprises: charging, into a countercurrent washing tower as described above, the slurry through the slurrycharging nozzle at a flow velocity of 0.5 m/sec. or slower as measured at the opening of the slurrycharging nozzle; and feeding, into the leg section of the countercurrent washing tower, the washing liquid from the washing liquid feeding nozzles at such a flow velocity that formation of turbulence is avoided in the leg section of the washing tower, thereby forming a stable slurry/spent washing liquid interface in an upper part of the washing tower so that the slurry is washing countercurrently with the washing liquid; discharging the washed slurry through a lower discharge opening at a lower location of the washing tower; and discharging the spent washing liquid through an upper discharge opening at an upper location of the washing tower. Brief Description of the Drawings: In the drawings: Figure 1 is a schematic illustration of a countercurrent washing tower according to one embodiment of this invention; Figure 2 is simplified, schematic, plan view showing one example of arrangement of washing liquid feeding nozzles in the countercurrent washing tower according to this invention; Figure 3 is an enlarged, vertical, crosssectional view illustrating one example of the washing liquid feeding nozzle; and Figure 4 is a plan view showing washing liquid feeding nozzles arranged in a ring-like configuration, which were used in Comparative Example 2. Detailed Description of the Invention: The countercurrent washing tower according to this invention (hereinafter called "the tower") will now be described with reference to the accompanying drawings. The tower is closed except for inlets for a material to be treated and a washing liquid and outlets for the treated material and the spent washing liquid. This hermetic sealing of the tower must be ensured particularly carefully where a combustible substance is handled. In Figure 1, a slurry-charging nozzle 4 is provided in an upper part of the tower, for example, in the central upper part of the tower. The nozzle 4 opens for example, downward. The nozzle 4 is provided in the abovedescribed manner in order to charge a slurry into the tower as smoothly as possible with a view toward avoiding development of turbulence. It is desirable for the smooth charging of the slurry into the tower to make the diameter of the nozzle as great as possible. However, an excessively large nozzle diameter impedes the upward flow of the spent washing liquid, thereby causing a turbulent flow to occur and preventing the formation of a stable slurry/spent washing liquid interface and thus making it difficult to bring about the effects of this invention. One slurry-charging nozzle is generally provided but a plurality of slurry-charging nozzles may be provided in the upper part of the tower, preferably by arranging them as a unit in the central upper part of the tower. Underneath the nozzle 4, a slurry-dispersing member 3 is disposed. The slurry-dispersing member 3 is provided in order to hinder the movement of the slurry, which has been charged into the tower through the nozzle 4 and is about to undergo a free downward falling flow, so that the slurry will be dispersed as evenly as possible and allowed to flow downward through the tower. For this purpose, it is necessary to have the dispersing member extended underneath the opening of the nozzle 4 and greater in size than the opening of the nozzle 4. Accordingly, it is required to dispose the dispersing member 3 underneath the nozzle 4 and to make the projected top area of the dispersing member 3 wider than the area of the opening of the nozzle 4. The slurry-dispersing member may be able to attain the object of this invention even if it is formed into a simple plate-like configuration. As can be readily realized from its objective which is to disperse the falling slurry smoothly and evenly in horizontal and radial directions, it is desirous to form the dispersing member in such a way that flow lines, which are formed by the falling slurry, become smooth curves. Accordingly, it is more desirable for the slurry-dispersing member to have a conical configuration with its apex confronting the nozzle 4. It should be borne in mind that the term "conical configuration" as used herein may embrance an umbrellalike configuration or a hemispherical configuration. Taking the whole liquid stream into consideration, it is certainly desirable to make the nozzle 4 as wide in diameter as possible. This means that the slurry-dispersing member 3 has a wide area. However, an excessively wide area of the slurry-dispersing member makes the spacing between the slurry-dispersing member and the wall of the tower narrower and induces more violent impact between the slurry and the washing liquid which pass downward and upward, respectively, through the spacing, thereby tending to develop turbulence. Taking both the downward flow of the slurry and the upward flow of the washing liquid into consideration, it is thus necessary to make the area of the spacing sufficiently broad, and more specifically, to make the area of the spacing wider than at least the horizontal cross-sectional area of the leg section of the washing tower. The object of this invention can still be achieved even if the opening of the nozzle 4, through which the slurry is introduced, is located adjacent to the top of the washing tower. If the opening of the nozzle 4 is made somewhat apart from the top of the washing tower to provide a small space between the opening and the top, a stable slurry/spent washing liquid interface is formed below the opening of the nozzle 4. At the above-mentioned interface, the slurry and the spent washing liquid are separated from each other. Thus, the interface-forming part serves as a separation zone for the slurry and the spent washing liquid. Formation of such a zone is preferable because it also contributes to the attainment of the effects of this invention Below the slurry-dispersing member, there is provided an upright leg section 7 (a washing/ separation zone C) of the washing tower. Above the leg section 7, there are provided in order, a sedi- mentation/separation zone A which is the upper portion of the tower, and a connecting zone B. The slurry, which has been dispersed evenly, is brought into countercurrent contact with the upward-flowing washing liquid in these zones while smoothly and freely flowing downward through the zones, thereby carrying out the washing of the slurry. In a lower end part of the leg section 7 of the washing tower, there are provided a plurality of nozzles 8, each of which has a small opening for feeding the washing liquid into the washing tower. These nozzles 8 are provided to feed the washing liquid in such a manner that the washing liquid flows upward through the washing tower. In order to avoid the occurrence of turbulence in the washing tower, the openings of the nozzles 8 are not directed upward but are deliberately formed in a direction between the horizontal and the downward. A discharge opening 6 is formed for the washed slurry through the wall of the washing tower at a lower bottom location (i.e., an inverted conical part D) of the washing tower, through which discharge opening 6 the naturally-settled, washed slurry is discharged. Accordingly, it is desirable for the prevention of turbulence in liquid flows within the washing tower to set the vertical positional relationship between the nozzle 8 and the discharge opening 6 in such a way that the former is located upward of the latter. The nozzle 8, which is adapted to feed the washing liquid into the washing tower, contributes to the stabilization of the liquid flows within the washing tower, because its openings are formed as described above. At each of the openings of the nozzles 8, a plurality of slits may be provided. Alternatively, straightening means such as a sintered grid, a piece of cloth, or a screen may be provided at each of the openings of the nozzles 8. Due to the adoption of the above-described specific structure in the washing tower according to this invention, the tower of this invention is capable of carrying out the washing of a large volume of slurry with stable and high efficiency under macroscopic laminar conditions although it does not employ any mixing means and the washing itself is mere countercurrent washing. It should, however, be borne in mind that actual flow velocities of the slurry and washing liquid may vary considerably depending on the physical properties of the solid material and liquid which make up the slurry to be washed, as well as the physical properties of the washing liquid and have optimum values under specific conditions. The washing tower according to this invention can be used extensively for washing slurries. One example of an application of this tower will be described below, in which it is applied to wash a slurry of a synthetic resin. A synthetic resin has a specific gravity similar to that of a washing liquid which may be water or an organic solvent. Solid particles of such a synthetic resin thus tend to readily move in a suspension. Therefore, it is extremely difficult to countercurrently wash such a synthetic resin in a large volume. Reference is now made to Figure 1, using a polypropylene slurry as the slurry of the synthetic resin. Production of polypropylene may certainly be carried out in a solvent but the bulk polymerization method has recently been employed in many instances for various reasons. Whenever bulk polymerization is employed, the washing of the resulting polymerization slurry becomes more important for the following reasons: : A polymerization slurry obtained in accordance with the bulk polymerization method has such a big advantage that, compared with a polymerization slurry obtained in accordance with the conventional suspension (or solvent) polymerization method - hereinafter abbreviated as "the conventional solvent polymerization method" - in which the polymerization is carried out using a saturated liquid hydrocarbon generally having a carbon number of 5 or more or desirably 5 - 7 as a solvent, the resultant polymer can be very easily separated from the solvent by virtue of the simple step of depressurizing the polymerization slurry because unsaturated hydrocarbon monomers (propylene, principally) used as the polymerization solvent have high vapor pressures and are thus susceptible to evaporating. On the other hand, a polymer obtained in accordance with the bulk polymerization method is accompanied by such drawbacks that it contains, first of all, polymers soluble in boiling n-heptane and secondly, catalyst residue in high concentrations. The physical properties of a polymer containing such boiling n-heptane-soluble polymers in high concentrations are poor, especially in stiffness, yield stress and the like. Accordingly, characteristic properties of polypropylene are lowered so much that it cannot be used particularly in applications requiring relatively high physical properties such as films or fibers. Use of the bulk polymerization method permits by itself reducing the amount of the catalyst residue, which has been referred to as the second drawback of a polymer obtained in accordance with the bulk polymerization method, because the polymerization velocity is generally faster compared with the conventional solvent polymerization and because the polymerization can be carried out under conditions suitable for efficiency of the catalyst. Under these circumstances, even such a polymer as obtained by the bulk polymerization method cannot, however, be used directly in applications requiring high quality since its heat resistance and hue are poor. For this reason, it is the practice to remove the above-mentioned boiling n-heptane-soluble polymers and catalyst residue from each resultant propylene polymer or copolymer in various ways. Such a polypropylene slurry is charged in accordance with the washing method according to this invention, into the washing tower through the nozzle 4. The slurry-dispersing member 3 disposed underneath the nozzle 4, disperses the slurry evenly throughout the tower and reduces the flow velocity of the slurry introduced through the nozzle 4, thereby forming a stable interface between the slurry and the spent washing liquid and preventing the slurry from being turbulated in the leg section 7 of the washing tower. The flow velocity of the thus-charged slurry is closely correlated with the state of the interface and the turbulence of the slurry in the leg section 7 of the washing tower. Since the washing effect for the polypropylene is considerably lowered if the flow velocity is too fast, the charging flow velocity of the slurry must be 0.5 m/sec. or slower, or preferably 0.1 m/sec. or slower. It is an essential requirement for the attainment of the effects of this invention to limit the charging flow velocity of the slurry to 0.5 m/sec. or slower. The washing efficiency is improved as the charging flow velocity of the slurry becomes slower. The diameter of the slurry-dispersing member 3 has a remarkable effect on the elimination of dynamic pressures in the slurry. The effect of the slurry-dispersing member 3 becomes greater as its diameter becomes larger. However, the diameter of the slurry-dispersing member 3 should not be enlarged too much since any excessively large diameters make the average upward flow velocity of the washing liquid at the annular cross-sectional area between the dispersing member and the inner wall of the countercurrent washing tower faster than the average upward flow velocity of the washing liquid at the horizontal cross-sectional plane in the washing zone C, impair the settling of fine polypropylene particles and facilitate the occurrence of turbulence. The diameter of the slurry-dispersing member 3 may be 0.1 - 1.5 times or preferably 0.5 - 1.0 times the diameter of the leg section 7 of the countercurrent washing tower. The washing liquid, which consists principally of propylene, is introduced at a lower part through a feed line 5. It is introduced through openings of nozzles 8 in order to facilitate its dispersion. It is desirable for each of the openings to have a sintered grid, a piece of cloth or a screen such as a wire mesh, or to be slit-like. The flow velocity of the washing propylene fed through the nozzles 8 is closely correlated with the stability of the interface formed between the slurry and the spent washing liquid in the upper part of the washing tower and the extent of turbulence of the slurry in the washing zone C. Since the washing efficiency is reduced if the flow velocity is too fast, it is desirable to limit the charging velocity of the washing liquid to 0.2 m/sec. or slower or, preferably 0.05 m/sec. or slower. In addition, the volume of unrecovered slurry is increased unless the charging velocity of the washing liquid is set under such conditions that the upward flow velocity of the washing liquid in the washing tower permits formation of an interface between the slurry and the washing liquid in the washing tower. A slurry of a synthetic resin, such as a polypropylene slurry, can be countercurrently washed in large volume with good washing efficiency and high percentage recovery of the synthetic resin by using the washing tower according to this invention and operating it under such operation conditions as described above. The effects of this invention will hereinafter be described specifically in the following Referential Example, Examples and Comparative Examples: Referential Example: (Preparation of Polypropylene Slurry) A vibrating mill equipped with a grinding pot having an internal volume of 700 liters and containing 2300 kg of steel balls each of 12 mm in diameter was provided. The pot was charged, in a nitrogen gas atmosphere, with 60 kg of magnesium chloride, 12 liters of tetraethoxysilane and 9 liters of 1,2-dichloroethane. The contents of the pot were ground for 40 hours. Thirty-six kilograms of the ground mixture and 240 liters of titanium tetrachloride were charged in a thoroughly dried mixing tank having an internal volume of 600 liters, under a nitrogen gas atmosphere. The contents were mixed at 800C for 120 minutes and then allowed to stand. The resulting supernatant was removed. Then, 420 liters of nheptane were added and the resultant mixture was agitated at 800C for 15 minutes and thereafter allowed to stand. The resulting supernatant was removed. This washing procedure was repeated 7 times and 240 liters of n-heptane were added to form a slurry of a solid catalyst. A portion of the solid catalyst slurry was sampled and n-heptane was evaporated from the slurry. The residue was then subjected to an analysis. This analysis indicated that the solid catalyst contained 1.62 wt.% of Ti. Four thousand kilograms of propylene were charged into a polymerization apparatus equipped with a jacket and 3 having an internal volume of 20 m , which had in advance been dried sufficiently, purged with nitrogen gas and then with propylene. Separately, twenty-two liters of n-heptane, 1056 ml of diethylaluminum chloride, 616 mol of methyl p-toluylate and 220 g of the above-prepared solid catalyst were charged in a small autoclave having an internal volume of 30 liters. The contents were mixed at room temperature for 1 minute, followed by the addition of 220 ml of triethyl aluminum. The resulting mixture was charged under pressure into the above polymerization apparatus 3 with an internal volume of 20 m . Thereafter, 9.00 Nm3 of hydrogen gas were charged into the reaction apparatus and the internal temperature of the reaction apparatus was raised to 750C by causing warm water to flow through the jacket. The polymerization was continued while maintaining the reaction apparatus at 750C and feeding hydrogen gas into the polymerization apparatus so as to keep the hydrogen gas concentration at the same level. On the other hand, a solution containing 660 ml of triethyl aluminum dissolved in 12540 ml of n-heptane was continuously fed under pressure and at 110 ml/min. into an autoclave and liquid propylene was also charged at 27.5 kg/min. into the same autoclave, thereby conducting the polymerization of polypropylene for 2 hours. Thereafter, 16.5 kg of diethylene glycol monoisopropyl ether was charged to terminate the polymerization. Then, the contents were agitated into a slurry of 3300 kg-polypropylene/ 4000 kg-propylene. Example 1: The washing of the polypropylene slurry was effected using a countercurrent washing tower of the type shown in Figure 1. The dimensions of the countercurrent washing tower were as follows: Inner diameter of the washing zone C: 80 cm Length of the washing zone C: 500 cm Inner diameter of the slurry sedimentation/separation zone A: 120 cm Length of the slurry sedimentation/ 200 cn separation zone A: Height of the bottom part D: 100 cm Height of the connecting zone B between the upper sedimentation/ separation zone A and the washing/ separation zone C: Diameter of the bottom face of the conical slurry-dispersing member 3 60 Cm disposed underneath the slurry charging nozzle 3: Diameter (at the position indicated by numeral 1) of the line for charging the polypropylene slurry 1 inch to be washed: Diameter of the nozzle 4: 6 inches The washing propylene was introduced through the line 5 into the countercurrent washing tower. It was fed into the tower through 9 cylindrical nozzles 8 of a sintered metal as illustrated in Figure 2, in order to facilitate the dispersion of the washing liquid. Each of the nozzles 8 has such a structure as shown in Figure 3. The washed slurry was removed through the discharge opening 6. The spent washing liquid was withdrawn through the discharge opening 2 and delivered to a point outside the system. Using the above tower, the slurry obtained in the Referential Example was fed through the feed line 1 at 1880 kg/hr. (850 kg/hr. as polypropylene) and charged at a flow velocity of 0.06 m/sec. into the tower through the nozzle 4. At the same time, washing propylene was supplied through the line 5 at 2900 kg/hr. and introduced at a flow velocity of 0.01 m/sec. into the tower through the nozzles 8. On the other hand, washed slurry was removed at 1880 kg/hr. from the slurry discharge opening 6 while spent propylene was withdrawn at 2900 kg/hr through the upper discharge opening 2 for the washing liquid. The washing operation was continued for 2 hours while controlling the introduction of the slurry and propylene and the removal of the washed slurry and spent propylene at the abovedescribed levels. The following analyses were made of the powder obtained by drying the slurry obtained in Referential Example, the supernatant withdrawn by stopping the mixing of the autoclave in Referential Example and the powder obtained by drying the washed slurry to determine the washing efficiency: Analyzed were the intrinsic viscosity (hereinafter abbreviated as "it") of the powder obtained EMI22.1 Similarly, the percentage of Mg dissolved in propylene to the whole Mg was calculated as follows: by drying the slurry obtained in Referential Example, the percentage remainder of the polymer after being extracted with the boiling n-heptane (calculated as polymer after extraction ------------------------ x 100%; hereinafter polymer before extraction abbreviated as "it"), Al, Mg and methyl p-toluylate. The mixing of the autoclave was stopped and the supernatant was taken out of the autoclave in the Referential Example. Non-volatile components (dissolved polymer + dissolved ash), Al, Mg and methyl p-toluylate present in the supernatant were analyzed. In addition, II, , Al, Mg and methyl p-toluylate were also analyzed in the powder obtained by drying the washed slurry. Results are shown in Table 1. Based on the analysis data of Al and Mg present in the powder and those of Al, Mg and the non-volatile components present in the supernatant, the percentage of Al dissolved in propylene to the whole Al, was calculated on the basis of Table 1 by the following equation, EMI23.1 The supernatant was dried to determine the weight of polypropylene dissolved therein. The dissolved polypropylene was found to account for 1.4% of the whole polymer. Supposing that methyl ptoluylate adhered in its entirety to undissolved polypropylene present in the polymerization apparatus, the concentration of the thus-adhered methyl ptoluylate was calculated by the following equation: EMI23.2 Based on the analysis data of the purified polypropylene, the percentage remainders of the dissolved portions in the purified polymer were calculated as follows: EMI23.3 Dissolved polymer: EMI24.1 Therefore, the purification efficiency is 98.7% in terms of Al, 98.0% interms of Mg, 98.5% in terms of methyl p-toluylate and 100% in terms of dissolved polypropylene. On average, the purification efficiency is accordingly 98.8%. In order to determine the percentage recovery of polypropylene, the amounts of polypropylene and catalyst residue, which were discharged together with the spent propylene, were determined by evaporating the spent propylene to dryness. As a result, the percentage recovery of polypropylene was found to be 98.4%. Table 1 EMI25.1 <SEP> Al <SEP> (g) <SEP> Mg <SEP> (g) <SEP> Amount <SEP> of <SEP> Non-vola- <SEP> Al <SEP> (g) <SEP> Mg <SEP> (g) <tb> Analyzed <SEP> Intrinsic <SEP> II <SEP> Powder <SEP> (g) <SEP> Powder <SEP> (g) <SEP> methyl <SEP> tiles <SEP> (g) <SEP> ----------- <SEP> --------- <SEP> item <SEP> viscosity <SEP> (%) <SEP> x <SEP> 104 <SEP> x <SEP> 104 <SEP> toluylate <SEP> --------- <SEP> Liquid <SEP> (g) <SEP> Liquid <SEP> (g) <tb> <SEP> adhered <SEP> Liquid <SEP> (g) <SEP> x <SEP> 104 <SEP> x <SEP> 104 <tb> <SEP> (ppm) <SEP> x <SEP> 104 <tb> ---------------------------------------------------------------------------------------------------------------------------- Powder <SEP> obtained <SEP> by <tb> drying <SEP> the <SEP> slurry <SEP> of <SEP> 1.60 <SEP> 96,5 <SEP> 1.28 <SEP> 1.32 <SEP> 197* <SEP> - <SEP> - <SEP> Referential <SEP> Example <tb> ------------------------------------------------------------------------------------------------------------------------------ Supernatant <SEP> of <SEP> - <SEP> - <SEP> . <SEP> - <SEP> - <SEP> - <SEP> 1.16 <SEP> 1.00 <SEP> 0.851 <tb> Referential <SEP> Example <tb> ------------------------------------------------------------------------------------------------------------------------------ Purified <SEP> powder <tb> obtained <SEP> in <SEP> 1.62 <SEP> 97.9 <SEP> 0.076 <SEP> 0.313 <SEP> 2.9 <SEP> - <SEP> - <SEP> Example <SEP> 1 <tb> ----------------------------------------------------------------------------------------------------------------------------- * Mèthyl p-toluylate was assumed to have adhered in its entirety to undissolved polypropylene. Comparative Example 1: An experiment was carried out in exactly the same manner as in Example 1 except that the diameter of the nozzle 4 for introducing polypropylene, which was to be washed, into the countercurrent washing tower was made smaller so as to change the charging flow velocity of the slurry to 1.5 m/sec. Washing efficiency determined on the basis of analyses of Al and methyl toluylate in the same manner as in Example 1 and the amount of residue discharged together with the spent washing propylene and determined by evaporating the spent washing propylene are shown in Table 2. The washing efficiency and recovery of polypropylene were both lowered compared with Example 1. Comparative Example 2: An experiment was carried out in exactly the same manner as in Example 1 except that the nozzles 8, which were adapted to introduce the washing propylene into the countercurrent washing tower, were arranged in a rrng- shaped pattern as-shown-in Figure 4 and that the washing propylene was introduced at an average flow velocity of 1.5 m/sec. through the 8 openings into the countercurrent washing tower. Results of analyses, which were conducted in the same manner as in Comparative Example 1, are also shown in Table 2. Compared with Example 1, the washing efficiency was lowered and the percentage recovery of polypropylene was somewhat lowered. Comparative Example 3: An experiment was carried out in exactly the same manner as in Example 1 except that the slurry-dispersing member was removed from the countercurrent washing tower. Results of analyses, which were obtained in the same manner as in Comparative Example 1, are given in Table 2. Compared with Example 1, the washing efficiency was lowered to a great extent and the percentage recovery of polypropylene was also lowered significantly. Comparative Example 4: An experiment was carried out in exactly the same manner as in Example 1 except that the bottom diameter of the slurry-dispersing member was reduced to one-third of the bottom diameter of the slurry-dispersing member used in Example 1. Results of analyses, which were conducted in the same manner as in Comparative Example 1, are shown in Table 2. Compared with Example 1, the washing efficiency and percentage recovery of polypropylene were both lowered. Table 2 EMI28.1 (Comparative) <SEP> Analyzed <SEP> Washing <SEP> efficiency <SEP> Washing <SEP> efficiency <SEP> Percentage <tb> <SEP> Example <SEP> item <SEP> determined <SEP> on <SEP> the <SEP> determined <SEP> on <SEP> the <SEP> recovery <tb> <SEP> basis <SEP> of <SEP> analyti- <SEP> basis <SEP> of <SEP> analyti- <SEP> of <SEP> poly <SEP> cal <SEP> data <SEP> of <SEP> Al <SEP> (%) <SEP> cal <SEP> data <SEP> of <SEP> methyl <SEP> propylene <tb> <SEP> p-toluylate. <SEP> (%) <SEP> (%) <tb> ------------------------------------------------------------------------------------------ Example <SEP> 1 <SEP> - <SEP> 98.7 <SEP> 98.5 <SEP> 98.4 <tb> ------------------------------------------------------------------------------------------- Comparative <SEP> Charging <SEP> flow <SEP> 89.5 <SEP> 90.7 <SEP> 96.5 <tb> Example <SEP> 1 <SEP> velocity <SEP> of <tb> <SEP> slurry <SEP> as <tb> <SEP> measured <SEP> at <tb> <SEP> the <SEP> nozzle: <tb> <SEP> 1.5 <SEP> m/sec. <tb> -------------------------------------------------------------------------------------------- Comparative <SEP> Charging <SEP> flow <SEP> 79.2 <SEP> 77.6 <SEP> 97.7 <tb> Example <SEP> 2 <SEP> velocity <SEP> of <tb> <SEP> washing <tb> <SEP> propylene: : <tb> <SEP> 1.5 <SEP> m/sec. <tb> --------------------------------------------------------------------------------------------- Comparative <SEP> Without <SEP> the <SEP> 25.5 <SEP> 31.2 <SEP> 94.3 <tb> Example <SEP> 3 <SEP> conical <SEP> slurry <SEP> dispersing <tb> <SEP> member <tb> ---------------------------------------------------------------------------------------------- Comparative <SEP> Bottom <SEP> diameter <SEP> 95.2 <SEP> 94.8 <SEP> 97.3 <tb> Example <SEP> 4 <SEP> of <SEP> the <SEP> conical <tb> <SEP> member: <SEP> 1/3 <SEP> of <tb> <SEP> that <SEP> in <SEP> Ex. <SEP> 1 <tb> ----------------------------------------------------------------------------------------------

Claims: What is Claimed is: 1. A countercurrent washing tower comprising: a slurry-charging nozzle opening in an upper part of the tower; a slurry-dispersing member disposed underneath the slurry-charging nozzle and having a projected top area wider than the area of the opening of the slurrycharging nozzle; a leg section of the washing tower, said leg section being disposed upright below the slurrydispersing member; a plurality of washing liquid feeding nozzles disposed in a lower end part of the leg section, each nozzle having a small opening; a lower discharge opening formed through the wall of the washing tower at a bottom location thereof for removal of washed slurry; and an upper discharge opening formed through the wall of the washing tower at an upper location thereof for withdrawal of spent washing liquid; thereby bringing the slurry from the slurrycharging nozzle into countercurrent contact with the washing liquid from the washing liquid feeding nozzles, both as macroscopically laminar flows, so that the slurry is washed with the washing liquid. 2. The countercurrent washing tower as claimed in Claim 1, wherein the slurry-dispersing member has a conical configuration with the apex confronting the slurry-charging nozzle. 3. The countercurrent washing tower as claimed in Claim 1, wherein the horizontal cross-sectional area of the leg section of the washing tower is smaller than the difference between the horizontal crosssectional area of the washing tower at the location where the slurry-dispersing member is disposed and the projected top area of the slurry-dispersing member. 4. The countercurrent washing tower as claimed in Claim 1, wherein the slurry-charging nozzle is disposed with its opening downwardly apart from the top of the washing tower so as to form a stable slurry/ spent washing liquid interface-forming region in an upper part of the washing tower. 5. The countercurrent washing tower as claimed in Claim 1, wherein a plurality of slits are provided at the opening of each washing liquid feeding nozzle. 6. The countercurrent washing tower as claimed in Claim 1, wherein a sintered grid, a piece of cloth or a screen is applied to the opening of each washing liquid feeding nozzle. 7. The countercurrent washing tower as claimed in Claim 1, wherein the openings of the washing liquid feeding nozzles are located upward of the lower discharge opening for removal of washed slurry. 8. The countercurrent washing tower as claimed in Claim 1, wherein the openings of the washing liquid feeding nozzles each open in a direction between the horizontal and the downward. 9. A method for washing a slurry of a synthetic resin countercurrently with a washing liquid, which method comprises: Charging, into a countercurrent washing tower as claimed in any one of Claims 1 to 8, the slurry through the slurry-charging nozzle at a flow velocity of 0.5 m/sec. or slower as measured at the opening of the slurry-charging nozzle; feeding, into the leg-section of the countercurrent washing tower, the washing liquid from the washing liquid feeding nozzles at such a flow velocity that formation of turbulence is avoided in the leg section of the washing tower, thereby forming a stable slurry/spent washing liquid interface in an upper part of the washing tower so that the slurry is washed countercurrently with the washing liquid; discharging the washed slurry through a lower discharge opening at a lower location of the washing tower; and discharging the spent washing liquid through an upper discharge opening at an upper location of the washing tower. 10. The method as claimed in Claim 9, wherein the slurry is charged at a flow velocity of 0.1 m/sec. or slower as measured at the openings of the slurryfeeding nozzles. 11. The method as claimed in Claim 9, wherein the washing liquid is fed at a flow velocity of 0.2 m/sec. or slower as measured at the openings of the washing liquid feeding nozzles. 12. The method as claimed in Claim 11, wherein the washing liquid is fed at a flow velocity of 0.05 m/sec. or slower as measured at the openings of the washing liquid feeding nozzles.

Inventors: FUNAKOSHI, YOSHIYUKI, OOKA, TATUO, UCHIKAWA, NOBUTAKA
Applicants: MITSUI TOATSU CHEMICALS, INCORPORATED
Application year: 1983
Main classification: B01D11
IPC codes: B29B15, B01D11, C08F6