Vinyl Polymerisation Solvent Recycling via Microfiltration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The polymerization of vinyl-containing monomers, such as vinyl chloride to PVC, generates significant waste and requires high-purity solvents, leading to increased costs and environmental concerns due to the disposal of used solvent waste.
Innovation Solution
A process where the reaction mixture is purified and reused, reducing the need for fresh high-purity solvents and minimizing waste, by separating and recycling polymerization products, including PVC, and using microfiltration to maintain product quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If fresh fully demineralised water is used as solvent in polymerisation, then product quality is maintained, but solvent consumption and waste water generation increase
Solution Approach 1:
The patent recovers and reuses the reaction mixture (solvent containing micropolymers) instead of discarding it as waste. The solvent is filtered to remove micropolymers and then reused in subsequent polymerisation batches, transforming a waste disposal problem into a resource recovery solution that maintains product quality while dramatically reducing waste water generation
Solution Approach 2:
The patent converts the harmful effect of micropolymers (which normally act as unwanted polymerisation seeds) into a beneficial process feature. By filtering and reusing the solvent containing micropolymers, the system transforms what was previously a quality-impairing contaminant into a manageable component that can be controlled through filtration, thereby converting a harm into a recoverable resource
2Object-affected harmful factors
If used solvent is sent to biological purification plant, then environmental compliance is achieved, but disposal costs increase
Solution Approach 1:
The patent implements a self-service system where the reaction mixture is filtered and reused within the same production process. This internal recycling system eliminates the need for external biological purification plants and waste disposal services, making the process self-sufficient and dramatically reducing both disposal costs and energy consumption associated with waste treatment
3Loss of substance
If reaction mixture is filtered and reused, then waste water generation is reduced, but micropolymers may affect product quality
Solution Approach 1:
The patent extracts and removes micropolymers from the reaction mixture through filtration before reuse. This extraction process separates the potentially harmful micropolymers from the valuable solvent, allowing the purified solvent to be reused without compromising product quality while still achieving waste water reduction through recycling
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 allows for the economical and environmentally friendly production of polymer products with consistent quality, reducing solvent waste and costs, while maintaining product purity by recycling the reaction mixture and filtering out impurities.
Implementation Method 1
the reaction mixture is purified and used again... by means of a microfiltration apparatus (7)
Implementation Method 2
a centrifugal separator (5)... for separating a polymerisation product from the reaction mixture
Data Source
AI summary
The invention relates to a process for the polymerization of vinyl-containing monomers such as, for example, monomeric vinyl halides, in a reaction mixture, in which process less waste is generated.