Revolutionizing ABS manufacturing, a novel three-stage polybutadiene (PB) latex synthesis process significantly reduces operational costs while improving product consistency. Traditional ABS resin production via emulsion graft polymerization requires precise PB latex particle control, where mid-sized 300nm particles deliver optimal mechanical properties. Conventional methods either used nitrogen-assisted transfers—introducing system contamination—or energy-intensive steam stripping units for monomer removal, creating complex, high-cost operations with suboptimal additive control.

This invention addresses critical inefficiencies through a cascade pressure-utilization approach. First, 80-120nm small-particle latex synthesis occurs in reactors at 65-85°C and 0.6-0.8MPaG pressure, achieving 98% butadiene conversion. Crucially, post-reaction transfer eliminates pumps: Vacuum degassing tanks are depressurized to 50-70mmHg, leveraging the reactor's inherent pressure differential for energy-neutral latex transfer. Simultaneously, this vacuum initiates monomer separation—replacing steam strippers—while residual reactor monomers are directly routed to flare systems without nitrogen purging.

Precision chemical management underpins the innovation. Proprietary reagent systems ensure additive concentrations and doses deviate by ≤±0.01% and ±0.05kg/batch. Flowmeter-controlled liquid dosing valves and gravimetric solid dispensers operate within temperature-regulated (steam-jacketed) mixing vessels, enabling real-time concentration corrections before injection into reactors.

The final agglomeration phase transforms processed small particles into 300-450nm PB latex using routine additives like potassium acetate under ambient conditions. By utilizing existing process pressures instead of external energy inputs and scrapping redundant chemical handling units, plants achieve 20-35% operational savings. Furthermore, eliminating nitrogen and steam minimizes effluent volume while enhancing ABS graft stability downstream.

Industrial validation confirms robust scalability. Pilot batches produced 98% conversion latex in 9-hour cycles, with consistently uniform 320-340nm agglomerates requiring less surfactants than traditional methods. Material testing revealed improved interfacial compatibility with SAN copolymers during grafting—attributed to the novel monomer stripping’s non-thermal particle treatment. This process redesign cuts unit count from typical setups while increasing automation resilience.

Economic analyses highlight compounded gains: Capital expenditure drops 40% from removing pumps, compressors, and steam towers. Sustainability metrics improve via 90% nitrogen reduction and a 150% steam consumption cut, positioning this as the new benchmark for low-carbon ABS feedstocks. Industry forecasts predict rapid adoption among licensors transitioning to cost-efficient continuous production schemes.

The methodology transcends PB latex—its vacuum-assisted transfer and reagent control systems show promise for wider emulsion polymer sectors requiring particle engineering precision.