A method for forming a polyarylene sulfide with a relatively low content of volatile malodorous compounds is provided. More particularly, such low compound levels may be achieved by subjecting a washed polyarylene sulfide to a heat treatment in the presence of an atmosphere that includes an inert gas, wherein the heat treatment occurs at a temperature of from about 150° C. to about 275° C.

A method for forming a polyarylene sulfide with a relatively low content of volatile malodorous compounds is provided. More particularly, such low compound levels may be achieved by subjecting a washed polyarylene sulfide to a heat treatment in the presence of an atmosphere that includes an inert gas, wherein the heat treatment occurs at a temperature of from about 150° C. to about 275° C.

The present invention provides a continuous polymerization apparatus capable of simply and efficiently separating a polymer and solid matter from a reaction mixture while having an apparatus configuration conducive to washing and maintenance, and a continuous production method for a polymer. A continuous polymerization apparatus (100) includes a plurality of reaction vessels (1a to 1c), wherein the plurality of reaction vessels are configured such that reaction mixtures (9a to 9c) successively move through each reaction vessel; in the plurality of reaction vessels, gas phase parts formed above the reaction mixture communicate with one another; and the continuous polymerization apparatus includes a washing part (5), the washing part configured to separate a solid included in the reaction mixture by sedimentation and to perform countercurrent washing.

Provided is a continuous production apparatus and a continuous production method capable of preventing the countercurrent of evaporation components generated at the time of polymerization so that continuous solution polymerization reactions can progress reliably. A continuous production apparatus (100) includes a housing chamber (2) configured to house a plurality of reaction vessels (1a to 1d); wherein a reaction mixture is formed by subjecting monomers to a polymerization reaction in a solvent in at least one of the reaction vessels; the reaction vessels communicate with one another via a gas phase part (4); the reaction vessels are sequentially connected; the reaction mixture successively moves to each of the reaction vessels; and the housing chamber includes a baffle (9) configured to narrow the cross-sectional area of the gas phase part at the boundary between at least one pair of adjacent reaction vessels or in the vicinity of the boundary.

A method of producing a PAS, which is the method capable of providing a PAS having a high melt viscosity in high yield in a shorter polymerization time, is provided. The method including: a preparation step; a first polymerization step; and subsequently a second polymerization step for continuing to perform a polymerization reaction by adding to the reaction mixture from 0.09 to 0.2 mol of an additional alkali metal hydroxide relative to 1 mol of the sulfur source. In the first polymerization step, the polymerization reaction is performed on condition that a pH of the reaction mixture is 11 or higher until a conversion ratio of the dihalo aromatic compound being 50 mol % or greater.

A method of producing a PAS, which is the method capable of providing a PAS having a high melt viscosity in high yield in a shorter polymerization time, is provided. The method including: a preparation step; a first polymerization step; and subsequently a second polymerization step for continuing to perform a polymerization reaction by adding to the reaction mixture from 0.09 to 0.2 mol of an additional alkali metal hydroxide relative to 1 mol of the sulfur source. In the first polymerization step, the polymerization reaction is performed on condition that a pH of the reaction mixture is 11 or higher until a conversion ratio of the dihalo aromatic compound being 50 mol % or greater.

Provided is a continuous production apparatus and a continuous production method capable of preventing the countercurrent of evaporation components generated at the time of polymerization so that continuous solution polymerization reactions can progress reliably. A continuous production apparatus (100) includes a housing chamber (2) configured to house a plurality of reaction vessels (1a to 1d); wherein a reaction mixture is formed by subjecting monomers to a polymerization reaction in a solvent in at least one of the reaction vessels; the reaction vessels communicate with one another via a gas phase part (4); the reaction vessels are sequentially connected; the reaction mixture successively moves to each of the reaction vessels; and the housing chamber includes a baffle (9) configured to narrow the cross-sectional area of the gas phase part at the boundary between at least one pair of adjacent reaction vessels or in the vicinity of the boundary.

A continuous production device and a continuous production method which are configured to produce a polymer and can efficiently advance solution polycondensation with a simple device configuration which is easy to wash and maintenance. A continuous production device (100) includes a reactor main body (1), divider plates (6a to 6c) configured to divide the interior of the reactor main body into a plurality of reaction vessels (2a to 2d), and a raw material supply unit. The divider plate has a rotation center. Gas-phase parts of the reaction vessels adjacent to each other are communicating with each other, and liquid-phase parts of the reaction vessels adjacent to each other are communicating with each other. A reaction mixture generated in the reaction vessel sequentially moves through the reaction vessels.

An object of the present invention is to provide a method for producing a crosslinked polyarylene sulfide (PAS) that reduces a difference in melt viscosity among lots and has excellent quality stability. Further specifically, the present invention provides a method for producing a crosslinked PAS including steps of compression-molding an uncrosslinked PAS in a powder form to obtain a compression-molded material, measuring a porosity of the compression-molded material, grinding the compression-molded product having a specific range of porosity to obtain a pulverized material, granulating the pulverized material to obtain a granulated material, and oxidatively crosslinking the granulated material obtained in the preceding step. Also provided are a method for producing a composition containing the crosslinked PAS, and a method for producing a molded article by melt-molding the composition.

An object of the present invention is to provide a method for producing a crosslinked polyarylene sulfide (PAS) that reduces a difference in melt viscosity among lots and has excellent quality stability. Further specifically, the present invention provides a method for producing a crosslinked PAS including steps of compression-molding an uncrosslinked PAS in a powder form to obtain a compression-molded material, measuring a porosity of the compression-molded material, grinding the compression-molded product having a specific range of porosity to obtain a pulverized material, granulating the pulverized material to obtain a granulated material, and oxidatively crosslinking the granulated material obtained in the preceding step. Also provided are a method for producing a composition containing the crosslinked PAS, and a method for producing a molded article by melt-molding the composition.