Aryl Ether Ketone Residue Recovery Using Rotor Shear Evaporation
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Solution Overview
Problem
The recovery of residual solvents and reactants from aryl ether ketone synthesis is challenging due to the formation of a viscous slurry that is difficult to handle and hazardous, leading to high costs and waste volume.
Innovation Solution
A method involving a shear-generating evaporating device is used to treat the shear-thinning residue composition, applying a shear rate of at least 10 s^-1 to separate a liquid fraction and concentrated solid residues, utilizing devices like thin-film evaporators or devolatilizing extruders.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional means (large quantity of solvent or diluent fluids) are used to handle the slurry, then the viscosity is reduced and handling is improved, but the volume of hazardous waste increases and costs increase
Solution Approach 1:
The invention extracts and removes the harmful component (hazardous waste) from the system through selective evaporation of volatile substances, separating it from the non-volatile polymer product. This allows the polymer to be recovered in a concentrated form without requiring additional solvents or diluents, thereby reducing hazardous waste volume while maintaining ease of handling.
Solution Approach 2:
The invention changes the physical parameters of the slurry by applying heat to evaporate volatile components, transforming the mixture from a liquid slurry state to a concentrated polymer state. This parameter change (temperature increase leading to evaporation) enables the polymer to be recovered in a handleable form without adding more liquid media, thus reducing hazardous waste volume.
2Reliability
If the slurry is treated as hazardous waste requiring special handling, then safety is ensured, but the costs and complexity of disposal increase
Solution Approach 1:
The invention converts the harmful characteristic of the slurry (presence of volatile hazardous substances) into a beneficial separation mechanism. The volatility difference between the polymer product and hazardous waste allows for selective evaporation, transforming the hazardous mixture into separated streams: recovered polymer and concentrated hazardous waste, simplifying disposal while maintaining safety.
Solution Approach 2:
The invention extracts the hazardous waste component from the polymer product through evaporation of volatile substances. This separation removes the harmful elements, allowing the polymer to be recovered in a safe, concentrated form and reducing the complexity of hazardous waste disposal by concentrating it into a smaller, more manageable volume.
3Loss of substance
If a thin-film evaporator is used to remove volatile substances, then solvent recovery is improved, but the device complexity and processing requirements increase
Solution Approach 1:
The thin-film evaporator operates on the self-service principle by utilizing the natural volatility difference between components. The polymer product, being non-volatile, remains in the residue while volatile hazardous substances automatically evaporate and can be recovered. This self-separation mechanism reduces the need for complex additional separation equipment while achieving effective solvent recovery.
Solution Approach 2:
The invention utilizes phase transition (evaporation) to separate the polymer product from volatile hazardous substances. By heating the slurry, the volatile components transition from liquid to vapor phase, allowing for their recovery while the non-volatile polymer remains in the liquid/residue phase. This phase transition enables effective separation without requiring complex multi-stage equipment.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method effectively reduces raw material costs, minimizes hazardous waste volume, and simplifies handling by allowing residual solvents and reactants to be recovered and disposed of safely.
Implementation Method 1
The invention relates to a method for treating a shear-thinning residue composition deriving from the synthesis of an aryl ether ketone
Implementation Method 2
passing said shear-thinning residue composition through a shear-generating evaporating device, between a rotating part and a stationary part
Implementation Method 3
recovering a condensed liquid fraction
Data Source
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AI summary
The invention relates to a method for treating a shear-thinning residue composition deriving from the synthesis of an aryl ether ketone, the residue composition including a liquid fraction and solid residues, the method including the steps of: passing said shear-thinning residue composition through a shear-generating evaporating device, between a rotating part and a stationary part; and recovering a condensed liquid fraction and separately recover concentrated solid residues.