Environmentally friendly solvent replaces DMF dreams come true

On July 22, the Qilu Petrochemical Acrylic Fiber Factory initiated the sale of its industrial test production, marking a significant milestone in the application of an environmentally-friendly dry-process acrylic fiber spinning technology. This achievement was the result of a collaborative effort between the Qilu Petrochemical Research Institute and the Acrylic Fiber Factory. Earlier, on March 28, the technology passed its first industrial spinning test, proving its viability and potential. The project team successfully replaced the traditional solvent, dimethylformamide (DMF), with a new, eco-friendly alternative, leading to the development of a novel dry-spinning process for acrylic fibers. This breakthrough represents a major technological advancement in the industry, setting a new standard for sustainable manufacturing. **Meeting the Challenges – Seeking Alternatives to DMF** According to Li Liuzhong, director of the Polymer Engineering Institute, the factory had long relied on DMF for its dry-spinning process. However, under national environmental regulations, the use of DMF in acrylic fiber production was scheduled to be phased out by the end of 2015. Faced with this deadline, the factory needed to find a suitable replacement or risk closure. Extensive research and analysis led to the idea of using a new, environmentally-friendly solvent that could match DMF’s solubility and rheological properties. By studying processes from both domestic and international sources, the team proposed an innovative solution that would not only meet regulatory requirements but also set a new benchmark in the industry. **From Concept to Reality – Laying the Groundwork** Before implementation, the success rate of the new solvent had to be thoroughly tested through extensive feasibility studies. These included evaluating the impact of solvent concentration on solution viscosity, assessing equipment compatibility, and analyzing temperature and energy consumption changes during the process. In June 2011, the institute received an urgent task: to test polyether nitrile in various concentrations using both DMF and the new solvent, while measuring rheological properties at different temperatures. The team worked around the clock, generating over 150 data sets and providing detailed reports that became critical for the solvent replacement initiative. **A Major Breakthrough – Successful Pilot Testing** By September 2011, the pilot test began at the factory. During the initial trials, issues arose due to improper mixing methods, preventing the formation of high-quality spinning dope. Researchers suggested switching to a ribbon-type agitator, which proved effective in handling high-viscosity solutions. The new design was implemented, solving the problem and paving the way for further progress. In December, the third continuous dissolution and spinning test was conducted successfully. For nearly 30 minutes, the filament spun smoothly without breaks, demonstrating the stability of the new process. This marked a key step forward in the development of the eco-friendly dry-spinning technology. **Achieving the Dream – Industrial Production Success** The final stage of the project—industrialization—was where the true value of the research was realized. 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 parties worked closely on-site, with technicians monitoring every step and operators executing procedures with precision. At 3:00 PM on March 28, the first spinning position started smoothly. By 11:20 PM, all 14 spinning positions were up and running. By 9:30 AM on March 29, the entire industrial spinning process was completed. After washing, stretching, curling, and packaging, the first batch of 10 tons of environmentally-friendly acrylic fiber products were produced, marking the successful commercialization of the new technology.

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