Meeting the Difficulties - Proposing DMF Alternatives
According to Li Liuzhong, director of the Institute of Polymer Engineering of the Institute, the solvent used in the dry spinning process of the acrylic fiber plant is dimethylformamide (DMF). In accordance with the relevant national industrial policy requirements, before the end of 2015, the DMF solvent method acrylic fiber production process will be eliminated. The acrylic fiber plant needs to replace the DMF with a new solvent, otherwise it will face the danger of shutting down.
After investigation and analysis, the acrylic fiber plant found that the alternative solvent should first have similar solubility properties to DMF, and the rheological properties of the prepared solution should be comparable to those of DMF solution. They refer to the acrylic spinning process and the spandex spinning process at home and abroad, and propose the idea of ​​environmentally friendly new solvent instead of DMF for dry spinning.
The realization of the replacement of DMF by new solvents means that a new process of dry acrylic spinning will be developed, which is not only a domestic and a worldwide pioneer in the field of acrylic spinning.
Peak-to-loop transition - the foundation for feasibility studies
What is the success rate of environmentally friendly new solvents to replace DMF? This needs to be verified by a large number of preliminary feasibility studies, such as the effect of the solubility of acrylic powder on the concentration of the stock solution, the productivity, the device adaptability caused by the rheology of the stock solution, and the changes in the temperature and energy consumption of the ramp caused by the volatility of the stock solution. Wait……
On June 24, 2011, the institute received an emergency service task from the acrylic fiber plant: in the shortest time, the polyether nitrile was tested in various concentrations in DMF and new solvents, and various concentrations of liquid were tested in multiple Rheological properties under temperature conditions.
After receiving the task, the Institute Polymer Institute immediately organized the elite to invest in the intense experiment. Researchers worked overtime and worked hard to produce more than 150 sets of data, and provided experimental reports with examples, which provided an important basis for solvent replacement in the acrylic fiber plant, and laid the foundation for further research.
The first battle was successful - the pilot test made significant progress
In September 2011, the dry spinning solvent alternative feasibility study project began a single-pass full-spinning pilot test in the acrylic fiber plant. The dissolution test was carried out in a 1 m3 semi-closed stirred tank using a screw paddle. Due to improper selection of the agitating paddle, no qualified spinning dope was formed. Researchers at the institute suggested replacing the existing screw-type mixing paddle with a ribbon-type agitating method suitable for high-viscosity fluid agitation. The acrylic fiber plant adopted this mixing paddle design scheme, and the special agitating paddle successfully solved the problem after being put into use.
At the beginning of December, in the third continuous dissolution and spinning test, the stock solution was dissolved, transported and filtered. After entering the tunnel, it was successfully spun and continuously spun for nearly 30 minutes. The filament was stable without breaking, and the environment was realized. The friendly solvent is a continuous stable spinning of the spinning solvent, and the finished wire section is equivalent to the industrial finished wire. This marks a significant advance in the development of a new process for environmentally friendly dry acrylic spinning.
Dreams come true - industrialized qualified fibers
The stage of industrialization is the stage in which the gold content of scientific research achievements is fully demonstrated. Take time back to March of this year. Under the unified arrangement of the company's science and technology department, the multi-channel industrialization test was finally launched as scheduled in the acrylic fiber plant.
The responsible persons of both parties rely on the site to guide the test, and the technicians closely monitor the process and the operators carefully operate. At 3 o'clock on the afternoon of March 28, the first spinning position was smoothly spun. At 11:20 in the evening, all 14 spinning positions were successfully upgraded and smoothly spun. At 9:30 on March 29, the industrial spinning was successfully completed. Wire test, after the afternoon to complete the washing, traction, curling and other post-treatment process, and complete the packaging of all solvents to replace the spinning products. The entire industrialization test process progressed smoothly, eventually producing 10 tons of fiber products. The new technology of environmentally friendly dry-process acrylic spinning finally comes to life on the production device.
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