Environmentally friendly solvent replaces DMF dreams come true

On July 22, the Qilu Petrochemical Acrylic Fiber Factory initiated the commercial sale of its industrial test production, marking a significant milestone in the development of an environmentally-friendly dry-process acrylic fiber spinning technology. This achievement was the result of joint efforts between the Qilu Petrochemical Research Institute and the Acrylic Fiber Factory. Earlier, on March 28 of this year, the technology passed its industrial spinning test successfully. The research team not only fulfilled their long-standing goal of replacing the traditional solvent DMF with a more eco-friendly alternative but also developed a new dry-spinning process that represents a major breakthrough in acrylic fiber manufacturing. **Overcoming Challenges – Finding Alternatives to DMF** According to Li Liuzhong, director of the Polymer Engineering Institute, the traditional dry-spinning process at the acrylic fiber plant relied heavily on dimethylformamide (DMF). However, due to national environmental regulations, the use of DMF in acrylic fiber production had to be phased out by the end of 2015. Faced with the risk of shutdown, the factory needed to find a suitable replacement for DMF. Extensive research and analysis led the team to explore alternatives that matched DMF’s solubility and rheological properties. Drawing from both domestic and international practices in acrylic and spandex spinning, they proposed the use of an environmentally-friendly new solvent for dry spinning. This innovation not only marked a first in China but also set a global precedent in the field of acrylic fiber technology. **From Concept to Reality – Laying the Groundwork** To ensure the success of the new solvent, the research team conducted numerous feasibility studies, examining factors such as solution concentration, productivity, equipment compatibility, and energy consumption. In June 2011, the institute received an urgent task from the factory: to test polyether nitrile in various concentrations using both DMF and the new solvent, while analyzing the rheological behavior under different temperature conditions. The Polymer Institute quickly mobilized its top researchers, who worked around the clock to generate over 150 sets of data. Their detailed reports provided crucial insights that supported the solvent replacement initiative and paved the way for further development. **First Success – A Major Step Forward** In September 2011, the project began a single-pass full-spinning pilot test at the acrylic fiber plant. Initial attempts faced challenges, as the mixing paddle used in the 1 m³ semi-closed tank failed to produce high-quality spinning dope. The researchers recommended switching to a ribbon-type agitator better suited for high-viscosity materials. The factory adopted the suggestion, and the new design proved effective, solving the issue and enabling successful dissolution. By December, the third continuous dissolution and spinning test achieved a breakthrough. The solution was dissolved, transported, filtered, and spun continuously for nearly 30 minutes without interruption. The filaments remained stable, and the process demonstrated the feasibility of using the new solvent for continuous spinning. This marked a major step forward in the development of the environmentally-friendly dry-spinning technology. **Realizing the Dream – Industrial Production Achieved** The industrialization phase is where the true value of scientific research is tested. In March of this year, under the coordination of the company's science and technology department, the multi-channel industrialization test was launched as planned. Both teams worked closely on-site, monitoring every step of the process carefully. At 3 p.m. on March 28, the first spinning position was smoothly activated. By 11:20 p.m., all 14 positions were running successfully. By 9:30 a.m. on March 29, the entire industrial spinning process was completed. After washing, drawing, curling, and packaging, the first batch of 10 tons of environmentally-friendly acrylic fibers was produced. This achievement confirmed the viability of the new technology and brought it to life on the production line, marking a new era for sustainable acrylic fiber manufacturing.

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