PEKK Purification via Solvent Phase Transitions
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Solution Overview
Problem
The purification of polyetherketoneketone (PEKK) is laborious and cost-intensive due to high metal content and residual solvent, leading to degradation and impurity issues during processing.
Innovation Solution
A continuous process involving mixing PEKK with a solvent, heating to leach impurities, vaporizing and recycling the solvent, and filtering to achieve high purity PEKK, using an apparatus with specific vessels and heating means.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional multiple washing methods are used to purify PEKK, then solvent usage is reduced, but metallic impurities cannot be effectively removed and huge volumes of solvents are still required
Solution Approach 1:
The patent employs phase transition of solvent between liquid and vapor states through controlled heating and cooling cycles. The solvent is heated to vaporize it, then condensed back to liquid form for reuse. This continuous phase transition enables the solvent to penetrate and extract metallic impurities from PEKK powder effectively while allowing for solvent recovery and reuse, thereby reducing overall solvent consumption and improving purification efficiency
Solution Approach 2:
The patent utilizes parameter changes by controlling temperature variations during the purification process. The system heats the solvent to specific temperatures to achieve vaporization and extraction of impurities, then cools it for condensation and reuse. These temperature parameter changes drive the extraction efficiency while enabling solvent recovery, addressing both the need for effective impurity removal and reduced solvent loss
2Manufacturing precision
If multiple washings are performed to purify PEKK, then purity improves, but processing time increases significantly
Solution Approach 1:
The patent implements continuous circulation of the solvent through heating, vaporization, filtration, condensation, and reuse in a closed loop system. This continuous action allows the solvent to repeatedly contact and extract impurities from PEKK powder over an extended period, achieving high purity levels without requiring multiple discrete washing steps, thereby reducing total processing time while maintaining effective purification
Solution Approach 2:
The patent employs periodic heating and cooling cycles to drive the solvent through phase transitions. The periodic heating vaporizes the solvent for extraction, followed by periodic cooling to condense and reuse it. These periodic actions create a rhythmic purification process that efficiently removes impurities over time without requiring continuous manual intervention or multiple separate washing operations
3Productivity
If large amounts of AlCl3 catalyst are used in polymerization, then polymerization efficiency improves, but metal impurity content in the final polymer increases
Solution Approach 1:
The patent applies extraction by using a solvent to selectively remove metallic impurities (AlCl3 residues) from the PEKK polymer matrix. The solvent penetrates the polymer powder and extracts the metal catalyst residues through dissolution and complexation, then the impurity-laden solvent is separated from the purified polymer. This extraction process effectively removes the harmful metal impurities while preserving the polymer product
Solution Approach 2:
The patent uses a solvent as an intermediary substance to mediate between the polymer containing metal impurities and the desired pure polymer product. The solvent acts as a carrier that binds to and transports the metallic impurities away from the polymer, enabling separation and purification. This intermediary approach allows for effective removal of AlCl3 residues without directly treating or modifying the polymer structure
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
The process effectively reduces metallic impurities and solvent usage, enhancing productivity and product purity, with a yield of 92% and purity of 99.99%, while being cost-efficient and environmentally friendly.
Implementation Method 1
heating the slurry mixture at a first predetermined temperature to leach the impurities present in PEKK into solvent
Implementation Method 2
heating the solvent in the solvent vaporization vessel at a second predetermined temperature to vaporize the solvent in the solvent vaporization vessel
Implementation Method 3
leading the solvent vapours from the solvent vaporization vessel to a first condenser to condense the solvent vapours into the solvent collection vessel
Data Source
AI summary
The present disclosure relates to a process and an apparatus for the purification of polyetherketoneketone (PEKK). The process involves purifying the PEKK by using a solvent with continuous reflux to obtain the purified PEKK with enhanced product characteristics. The process of the present disclosure is simple, and economical, reduces the solvent usage and time for purification, and produces purified PEKK with comparatively high yield and purity.