Recycled Cellulose Ester Syngas Production

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Solution Overview

Problem

There is a global issue with waste disposal of non-biodegradable consumer products like plastics and polymers, which poses environmental sustainability challenges, and there is a market need for products made from renewable, recycled, and biodegradable materials to reduce waste and carbon emissions.

Innovation Solution

The development of cellulose esters made from recycled cellulose and organic compounds derived from environmentally favored raw materials, using a process that involves gasifying a feedstock containing solid fossil fuels and recycled cellulose to produce syngas, which is then used to create cellulose esters with substituents, resulting in biodegradable and compostable products.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If cellulose esters are made from fossil fuel-based organic acids, then the material properties and performance are improved, but the environmental sustainability and renewable content are worsened

Engineering Contradiction:

Improvematerial performanceVSAvoidenvironmental sustainability

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent changes the source parameter of the organic acid from fossil fuel-based to syngas-derived, while maintaining the chemical functionality needed for cellulose ester formation. This allows the material to retain its performance characteristics while improving environmental sustainability through renewable feedstock.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The syngas production process serves multiple functions: it converts recycled cellulose ester waste into useful chemical feedstock, provides organic acids for cellulose ester synthesis, and enables closed-loop recycling. This multi-functionality addresses both material performance and environmental sustainability simultaneously.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of manufacture

If traditional cellulose ester production methods are used, then the manufacturing process is simple, but the recycled content incorporation and waste reduction are limited

Engineering Contradiction:

Improveprocess simplicityVSAvoidwaste reduction

Core Design Contradiction:

Ease of manufactureVSLoss of substance

Solution Approach 1:

The patent recovers recycled cellulose ester that would otherwise be discarded waste material. Through gasification, the recycled CE is converted into syngas, which is then used to produce new cellulose esters, thereby recovering valuable carbon resources and reducing waste sent to landfills.

Inventive Principle:

Principle #34Discarding and recovering

Solution Approach 2:

The patent combines the waste treatment function with the production function by integrating recycled CE gasification into the syngas production stream. This merging allows simultaneous waste reduction and material production without requiring entirely separate processing systems.

Inventive Principle:

Principle #5Merging (Combining)

3Object-affected harmful factors

If recycled cellulose ester is incorporated into the feedstock, then the recycled content and sustainability are improved, but the gasification process complexity and process control are worsened

Engineering Contradiction:

Improverecycled contentVSAvoidgasification process

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent uses syngas as an intermediary medium between the recycled cellulose ester feedstock and the final cellulose ester product. This intermediary approach simplifies the overall process by converting complex recycled material into a standardized intermediate (syngas) that can be readily processed into high-quality product.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 approach enables the production of biodegradable and compostable cellulose ester products that incorporate recycled content, reducing waste and carbon emissions while promoting a closed-loop recycling solution.

Implementation Method 1

preparing a recycled CE content syngas in a synthesis gas operation by gasifying a feedstock containing a solid fossil fuel source, at least some content of recycled cellulose ester

Methodology Applied

Scientific EffectGasification:

Implementation Method 2

using the recycled CE content syngas as a feedstock in a reaction scheme to produce at least one cellulose reactant for preparing a cellulose ester

Methodology Applied

Scientific EffectChemical reaction: Chemical Bonding

Data Source

PatentUS20220289868A1Cellulose ester compositions derived from recycled cellulose ester content syngas

Publication Date: 2022.09.15 EASTMAN CHEM CO

AI summary

A process for preparing a recycle cellulose ester and a recycle cellulose ester composition and articles made with such recycle cellulose esters comprising at least one cellulose ester having at least one substituent on an anhydroglucose unit (AU) derived from recycled cellulose ester content syngas are provided. The recycled cellulose ester content syngas can be obtained by gasifying feedstocks containing a solid fossil fuel such as coal, a cellulose ester, and water. The cellulose ester can be post-consumer or post-industrial cellulose ester.