Polysaccharide Fiber Production Reducing Chemical Consumption
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The viscose process for producing polysaccharide fibers, such as modal fibers, requires large quantities of carbon disulfide (CS2) and aqueous sodium hydroxide, which is environmentally unsustainable and costly, and existing methods have not successfully reduced these usage levels effectively.
Innovation Solution
A modified viscose process that uses reduced amounts of CS2, up to 15% by weight relative to the fiber-forming substance, to produce α(1→3)-glucan fibers, where CS2 is not needed for dissolution but rather to slow down filament formation in the spin bath, with a sodium hydroxide concentration between 4.0 and 5.5% and a degree of polymerization of 200 to 2000 for the α(1→3)-glucan.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the viscose process is used to produce polysaccharide fibers, then fiber production is achieved, but large quantities of CS2 and aqueous sodium hydroxide are consumed
Solution Approach 1:
The patent changes the chemical parameters of the spinning solution by using α(1→3)-glucan instead of cellulose and adjusting the concentration of CS2 and NaOH to optimized levels. This allows fiber production while reducing chemical consumption, as the new polysaccharide structure requires fewer chemicals for dissolution and regeneration
Solution Approach 2:
The patent employs a modified viscose process where chemicals are used in controlled, reduced quantities optimized for each production cycle. The process accepts that chemicals will be consumed but minimizes the amount through precise formulation and process optimization, treating the chemicals as consumables that need efficient utilization rather than regeneration
2Reliability
If CS2 is used in the viscose spin bath, then filament formation is controlled, but environmental sustainability deteriorates and costs increase
Solution Approach 1:
The patent reduces the concentration parameter of CS2 in the spin bath from traditional high levels to optimized lower levels (where at most 30% of CS2 related to fiber-forming substance are used). This parameter change maintains sufficient filament formation control while dramatically reducing the harmful environmental impact and associated costs
3Productivity
If traditional viscose process parameters are used, then fiber production is efficient, but chemical consumption remains high
Solution Approach 1:
The patent optimizes multiple parameters simultaneously: using α(1→3)-glucan with specific degree of polymerization (200-2000), adjusting NaOH concentration to 4.0-5.5%, and reducing CS2 to at most 30% of fiber-forming substance. These coordinated parameter changes maintain production efficiency while reducing chemical quantities to optimized levels
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 significantly reduces the consumption of CS2 and sodium hydroxide while maintaining fiber quality, enabling the production of strong and elongated α(1→3)-glucan fibers suitable for various applications, including textiles and paper products.
Implementation Method 1
Reaction with alkali cellulose into a xanthogenate that is soluble in alkaline solution
Implementation Method 2
In the viscose spin bath, colloid-chemical (coagulation of the sodium cellulose xanthogenate) and chemical (decomposition of the xanthogenate into hydrate cellulose) processes take place in parallel
Implementation Method 3
chemical (decomposition of the xanthogenate into hydrate cellulose) processes take place in parallel
Data Source
AI summary
The present invention relates to a method for the production of polysaccharide fibers which contain α(1→3)-glucan as a fiber-forming substance, as well as to the fibers made thereby, and to their use.