Mixed-Bed Ion Exchange for Ultrapure Organic Solvent Purification
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Solution Overview
Problem
Existing ion exchange resin processes for purifying organic solvents are ineffective in achieving ultrapure levels of metallic ion contaminants below 50 parts per billion and often generate undesirable by-products such as aldehydes or ketones, which are detrimental to semiconductor fabrication processes.
Innovation Solution
A process using a mixed bed of weak-acid cationic and weak-base anionic ion exchange resins to purify hydrophilic and hydrolysable organic solvents, minimizing by-product generation and maintaining solvent integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional ion exchange resin is used to purify organic solvents, then metallic ion contaminants can be removed to some extent, but the solvent purity cannot achieve below 50 ppb level and by-product impurities are generated
Solution Approach 1:
The patent combines cationic ion exchange resin and anionic ion exchange resin into a mixed bed system. This merging allows simultaneous removal of both cationic and anionic contaminants, achieving higher purity levels below 50 ppb while minimizing by-product generation through complementary action of the two resin types.
Solution Approach 2:
The invention uses a composite ion exchange system comprising both cationic and anionic resins with different functional groups. This composite approach enables comprehensive contaminant removal across multiple charge types, achieving ultrapure solvent levels without the by-product issues associated with single-resin systems.
2Productivity
If strong-acid cationic ion exchange resin is used, then metallic ion removal efficiency is improved, but hydrolysis of ester type solvents occurs generating acidic substances
Solution Approach 1:
The patent changes the parameter of acid strength in the cationic resin from strong-acid to weak-acid type. This parameter change reduces the catalytic activity that promotes hydrolysis of ester solvents, thereby preventing acidic substance generation while maintaining adequate metallic ion removal efficiency through the combined action of weak-acid cationic and anionic resins.
Solution Approach 2:
The invention converts the potential harm of hydrolysis into a benefit by using weak-acid cationic resin that selectively removes metallic ions without the strong acid catalysis that causes hydrolysis. The anionic resin component simultaneously addresses anionic contaminants, creating a synergistic effect that achieves high purity without by-product formation.
3Quantity of substance
If conventional ion exchange process is used, then ionic contaminants are removed, but chemical reactions generate impurities such as aldehydes or ketones
Solution Approach 1:
The patent introduces a mixed bed system as an intermediary that mediates between the solvent and ion exchange resins. This mixed bed configuration with weak-acid cationic and anionic resins provides a controlled environment for ion exchange that prevents direct harmful chemical reactions, removing ionic contaminants while preserving solvent integrity and preventing impurity generation.
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
Achieves ultrapure organic solvents with metallic ion contaminants below 100 ppt and avoids impurity generation, suitable for semiconductor fabrication and pharmaceutical applications.
Implementation Method 1
a process for removing metallic and non-metallic ionic contaminants from a hydrophilic organic solvent, from a hydrolysable solvent and/or from a mixture of a hydrophilic organic solvent and a hydrolysable organic solvent by using an ion-exchange resin
Data Source
AI summary
A process for purifying (i) a hydrophilic organic solvent, (ii) a hydrolysable organic solvent, or (iii) a mixture of a hydrophilic organic solvent and a hydrolysable organic solvent by removing ionic contaminants from the hydrophilic organic solvent, from the hydrolysable organic solvent, or from the mixture of a hydrophilic and a hydrolysable organic solvent without generation of by-product impurities, the process including the steps of contacting the hydrophilic organic solvent, the hydrolysable organic solvent, or the mixture of hydrophilic and hydrolysable organic solvents with a mixed bed of ion exchange resin; wherein the mixed bed of ion exchange resin includes a mixture of: (a) a weak-acid cationic ion exchange resin and (b) a weak-base anionic ion exchange resin.