Sustainability in the Production of Rayon · carbonized rayon. •Does not provide rocket nozzle or...
Transcript of Sustainability in the Production of Rayon · carbonized rayon. •Does not provide rocket nozzle or...
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Sustainability in the Production of Rayon
Hunter Bray RAM V
October 16 – 17 2012
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What is Rayon?
• Rayon is a manufactured cellulose fiber.
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Rayon’s Uses
• Production of Textiles
• Production of carbon fiber.
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Rayon’s Strengths
• Made from a renewable resource
– Based on cellulose
• Wood pulp
• Cotton linters
• Carbonized rayon has low thermal conductivity
– Excellent for products such as heat shields and rocket nozzles.
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Production Issues
• Several Rayon Methods are cost prohibited in the US
• Result of hazardous production chemicals.
• Harder to acquire American made rayon based products.
• No US supplier of rocket nozzle grade carbon fiber due to EPA regulations.
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Characteristics of Polyacrylonitrile(PAN) Fiber
Strengths:
• Can be used in textiles and to create carbon fiber.
• Superior tensile strength
Weaknesses:
• Carbonized PAN has higher thermal conductivity than carbonized rayon.
• Does not provide rocket nozzle or heat shield grade carbon fiber.
• Cannot replace rayon
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Several Rayon Creation Methods :
Hazardous
• Viscose Rayon Method
• Acetate Method
• Cuprammonium Method
Green
• Ionic Liquid(IL) Method
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Viscose Method
• Cellulose is broken down and is eventually wet spun into a fiber.
• Caustic and acidic chemicals contaminate wash water.
• This process is cost prohibited in the United States
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Acetate Method
• Cellulose is dissolved and dry spun into a fiber.
• Acidic & carcinogenic chemicals involved
• Some manufacturing process are cost prohibited in the United States.
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Cuprammonium Method
• Cellulose is treated to remove impurities.
• Cellulose is converted to copper cellulose and dissolved in ammonia
• Acidic chemicals contaminate wash water
• Cost prohibited in the United States
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What Are Ionic Liquids?
• Organic salts in a liquid state at room temperature
• Almost no vapor pressure
• Very good solvents
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IL Fiber Creation Process
• Cellulose is dissolved in IL
• Ionic liquid/cellulose mix is extruded into a water bath
• IL is recovered
Ionic Liquid is mixed
with cellulose
Fiber is extruded IL dissolves in
water.
Wash water evaporated
off; IL recovered.
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Viscose Process versus
Ionic Liquid Process Viscose Process
Ionic Liquid Process
Pulp Activation Derivation Dissolution Spinning
Pro
du
cts
NaOH CS2 NaOH H2O,
H2SO4
CS2
Pulp Direct Dissolution Spinning
Pro
du
cts
Ionic Liquid
H2O
Ionic Liquid
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IL Creation Process (cont.)
Ionic Liquid/Cellulose Mix Fiber Extrusion Needle extruder
Fiber
Fiber
Fiber
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Our Work at RFAL
• Created fibers from Ionic liquid
• Successfully carbonized fibers
• Recovered Ionic liquid after extruding fibers
• Attempting to produce mass amounts of fiber
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Why the IL Process is Better For the Environment
• No extremely harmful chemicals involved
• Water is the only required wash solution
• Waste water is evaporated off
• IL is reusable • No need for disposal
Caustic Soda
Sulphuric Acid
Acetic Acid
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Why the IL Process is More Sustainable
• Only two chemicals involved
• IL is recoverable
IL dissolved in water Recovered IL