Renewable Propylene Polymer via Fermentation and Dehydration
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Solution Overview
Problem
Conventional processes for manufacturing propylene-based polymers rely on non-renewable fossil resources, leading to environmental concerns and high energy consumption, with recycling methods causing material degradation and not fully utilizing renewable resources.
Innovation Solution
A process that utilizes renewable raw materials through fermentation to produce alcohols, which are then dehydrated to obtain propylene, followed by polymerization and optional grafting, reducing energy consumption and greenhouse gas emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If conventional catalytic or thermal cracking of petroleum fractions is used to obtain propylene, then propylene can be manufactured, but it relies on non-renewable fossil resources and consumes high energy
Solution Approach 1:
The patent changes the fundamental parameter of raw material source from fossil petroleum to renewable biomass. The process converts biomass (sugars, starches, or cellulosic materials) through fermentation to produce alcohol, which is then dehydrated to yield propylene. This parameter change eliminates dependence on non-renewable resources and reduces environmental harm associated with petroleum extraction and processing.
Solution Approach 2:
The patent replaces the mechanical/thermal cracking system with a biochemical system. Instead of using high-temperature thermal cracking or catalytic processes on petroleum, the invention uses fermentation (biological process) to convert biomass into alcohol, followed by dehydration. This substitution of mechanical/thermal systems with biochemical systems reduces energy consumption and environmental impact.
2Ease of manufacture
If recycling polyolefins above their melting temperatures is performed, then recycled materials can be obtained, but the material degrades and loses its initial properties
Solution Approach 1:
The patent applies preliminary action by converting recycled polyolefins into monomers or chemical building blocks before re-polymerization. Instead of directly melting and reforming recycled polyolefins (which causes degradation), the process breaks down the polymer chains into constituent units through controlled degradation, then re-synthesizes them into fresh polymer. This preliminary chemical transformation preserves material quality while enabling recycling.
Solution Approach 2:
The patent changes the parameter of recycling approach from physical recycling (melting and reforming) to chemical recycling (breaking down into monomers and re-polymerizing). This parameter change allows the material to be recycled multiple times without degradation, as each cycle regenerates fresh polymer chains with full properties intact.
3Object-generated harmful factors
If biomass gasification at very high temperature (1100°C to 1300°C) is used to synthesize olefin, then propylene can be obtained from renewable resources, but energy consumption increases and greenhouse gases are released
Solution Approach 1:
The patent dramatically changes the temperature parameter from very high (1100-1300°C) to moderate (fermentation conditions followed by dehydration). Instead of gasifying biomass at extreme temperatures, the invention uses fermentation to convert biomass into alcohol at ambient or mild temperatures, then dehydrates the alcohol to produce propylene. This parameter change reduces energy consumption and prevents greenhouse gas emissions associated with high-temperature gasification.
Solution Approach 2:
The patent replaces the thermal gasification system with a biochemical system. Instead of using high-temperature combustion or gasification to convert biomass to chemicals, the invention uses fermentation (biological process) to transform biomass into alcohol, followed by dehydration. This substitution of thermal/mechanical systems with biochemical systems eliminates greenhouse gas emissions and reduces energy consumption.
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 produces high-quality propylene polymers with a significant portion of carbon atoms from renewable sources, suitable for various applications while minimizing environmental impact and energy usage.
Implementation Method 1
a. fermentation of renewable raw materials, and optionally purification, to produce an alcohol or a mixture of alcohols
Implementation Method 2
b. dehydration of the alcohol or mixture of alcohols obtained with a view to producing, in at least a first reactor, an alkene or a mixture of alkenes, said alkene or mixture of alkenes comprising at least propylene
Implementation Method 3
c. polymerization, in at least a second reactor, of propylene, optionally in the presence of a comonomer, to produce a propylene polymer
Data Source
Figure 1
AI summary
The present application relates to a method for manufacturing a propylene polymer, including the following steps: a) fermenting and optionally purifying first renewable materials to produce an alcohol or an alcohol mixture, said alcohol or alcohol mixture including at least isopropanol and/or at least a mixture of ethanol and 1-butanol; b) dehydrating the resulting alcohol or the alcohol mixture with a view to producing an alkene or alkene mixture in a first series of reactors, said alkene or alkene mixture containing at least propylene, and optionally purifying the alkene mixture to obtain propylene; c) polymerizing the propylene in a second reactor, optionally in the presence of a comonomer, so as to produce a propylene polymer; d) isolating the propylene polymer obtained in step c); and e) grafting the propylene polymer obtained from step d). The invention also relates to the grafted propylene polymer capable of being obtained by said method, to the compositions containing said polymer, as well as to the uses of said polymer.