Recycling CO2 Byproduct in Polyester Resin Production
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Solution Overview
Problem
The production of polyester resins for toners generates significant carbon dioxide as a byproduct, which is costly to recycle and release into the atmosphere, and existing processes are inefficient in minimizing CO2 emissions and lowering production costs.
Innovation Solution
A process involving the reaction of an organic diol and a cyclic alkylene carbonate to produce carbon dioxide and a polyalkoxy diol, followed by reacting the CO2 with an alkylene glycol or alkylene oxide to regenerate a cyclic alkylene carbonate, which is then added back to the reaction mixture, allowing for the recycling of CO2 and reducing the amount of CO2 released into the environment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If carbon dioxide is collected and liquefied/solidified for recycling, then the amount of CO2 released into the environment is reduced, but the cost of recycling increases significantly
Solution Approach 1:
The patent converts the harmful CO2 byproduct into a valuable chemical intermediate (cyclic carbonate) that can be reused in the polyester production process. Instead of treating CO2 as waste requiring expensive removal and storage, the process utilizes it as a raw material for synthesizing cyclic carbonates, which then react with diols to produce more CO2 in a controlled manner, creating a circular economy approach that eliminates emissions while generating economic value
Solution Approach 2:
The patent changes the physical and chemical parameters of CO2 from a gaseous emission to a dissolved reactant in liquid phase. By controlling pressure and temperature parameters, CO2 is transformed from a harmful gas into a useful reagent that reacts with cyclic carbonates and diols. This parameter transformation enables CO2 to be incorporated into the chemical synthesis process rather than being released, simultaneously achieving emission reduction and cost efficiency
2Ease of manufacture
If carbon dioxide is released into the atmosphere without recycling, then the production cost is lower, but environmental harm increases
Solution Approach 1:
The patent transforms CO2 from a waste product into a valuable chemical intermediate (cyclic carbonate) that can be reused in the polyester production process. Instead of treating CO2 as waste requiring expensive removal and storage, the process utilizes it as a raw material for synthesizing cyclic carbonates, which then react with diols to produce more CO2 in a controlled manner, creating a circular economy approach that eliminates emissions while generating economic value
Solution Approach 2:
The patent changes the physical and chemical parameters of CO2 from a gaseous emission to a dissolved reactant in liquid phase. By controlling pressure and temperature parameters, CO2 is transformed from a harmful gas into a useful reagent that reacts with cyclic carbonates and diols. This parameter transformation enables CO2 to be incorporated into the chemical synthesis process rather than being released, simultaneously achieving emission reduction and cost efficiency
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 process effectively recycles carbon dioxide, reducing environmental emissions and lowering the costs associated with polyester resin production by reusing CO2 in the production of toner components, such as unsaturated and saturated polyester resins.
Implementation Method 1
reacting an organic diol and a first cyclic alkylene carbonate in a first reaction mixture, thereby producing carbon dioxide (CO2) and a polyalkoxy diol
Implementation Method 2
reacting the CO2 with an alkylene glycol or alkylene oxide in a second reaction mixture, thereby producing a second cyclic alkylene carbonate
Data Source
AI summary
Processes for preparing polyester resins as toner production components. The processes include reacting an organic diol and a cyclic alkylene carbonate to produce carbon dioxide (CO2) and a polyalkoxy diol. The carbon dioxide is reacted with an alkylene glycol or alkylene oxide to produce additional cyclic alkylene carbonate having the same chemical structure as the cyclic alkylene carbonate used to produce the polyalkoxy diol. The additional cyclic alkylene carbonate is added with the cyclic alkylene carbonate used to produce the polyalkoxy diol. The polyalkoxy diol can be reacted with an organic diacid or diester in preparing a polyester resin. To prepare a toner, the polyester resin can be contacted with at least one toner production component.