Continuous Liquid-Liquid Extraction and in-Situ Membrane Separation of Miscible Liquid Mixtures.

Separation operations are critical across a wide variety of manufacturing industries and account for about one-quarter of all in-plant energy consumption in the United States. Conventional liquid-liquid separation operations require either thermal or chemical treatment, both of which have a large environmental impact and carbon footprint. Consequently, there is a great need to develop sustainable, clean methodologies for separation of miscible liquid mixtures. The greatest opportunities to achieve this lie in replacing high-energy separation operations (e.g., distillation) with low-energy alternatives such as liquid-liquid extraction. One of the primary design challenges in liquid-liquid extraction is to maximize the interfacial area between two immiscible (e.g., polar and nonpolar) liquids for efficient mass transfer. However, this often involves energy-intensive methods including ultrasonication, pumping the feed and the extractant through packed columns with high tortuosity, or using a supercritical fluid as an extractant. Emulsifying the feed and the extractant, especially with a surfactant, offers a large interfacial area, but subsequent separation of emulsions can be energy-intensive and expensive. Thus, emulsions are typically avoided in conventional extraction operations. Herein, we discuss a novel, easily scalable, platform separation methodology termed CLEANS (continuous liquid-liquid extraction and in-situ membrane separation). CLEANS integrates emulsion-enhanced extraction with continuous, gravity-driven, membrane-based separation of emulsions into a single unit operation. Our results demonstrate that the addition of a surfactant and emulsification significantly enhance extraction (by >250% in certain cases), even for systems where the best extractants for miscible liquid mixtures are known. Utilizing the CLEANS methodology, we demonstrate continuous separation of a wide range of miscible liquid mixtures, including soluble organic molecules from oils, alcohols from esters, and even azeotropes.

Synthesis, characterization, and cure chemistry of renewable bis(cyanate) esters derived from 2-methoxy-4-methylphenol.

A series of renewable bis(cyanate) esters have been prepared from bisphenols synthesized by condensation of 2-methoxy-4-methylphenol (creosol) with formaldehyde, acetaldehyde, and propionaldehyde. The cyanate esters have been fully characterized by infrared spectroscopy, (1)H and (13)C NMR spectroscopy, and single crystal X-ray diffraction. These compounds melt from 88 to 143 °C, while cured resins have glass transition temperatures from 219 to 248 °C, water uptake (96 h, 85 °C immersion) in the range of 2.05-3.21%, and wet glass transition temperatures from 174 to 193 °C. These properties suggest that creosol-derived cyanate esters may be useful for a wide variety of military and commercial applications. The cure chemistry of the cyanate esters has been studied with FTIR spectroscopy and differential scanning calorimetry. The results show that cyanate esters with more sterically demanding bridging groups cure more slowly, but also more completely than those with a bridging methylene group. In addition to the structural differences, the purity of the cyanate esters has a significant effect on both the cure chemistry and final Tg of the materials. In some cases, post-cure of the resins at 350 °C resulted in significant decomposition and off-gassing, but cure protocols that terminated at 250-300 °C generated void-free resin pucks without degradation. Thermogravimetric analysis revealed that cured resins were stable up to 400 °C and then rapidly degraded. TGA/FTIR and mass spectrometry results showed that the resins decomposed to phenols, isocyanic acid, and secondary decomposition products, including CO2. Char yields of cured resins under N2 ranged from 27 to 35%, while char yields in air ranged from 8 to 11%. These data suggest that resins of this type may potentially be recycled to parent phenols, creosol, and other alkylated creosols by pyrolysis in the presence of excess water vapor. The ability to synthesize these high temperature resins from a phenol (creosol) that can be derived from lignin, coupled with the potential to recycle the composites, provides a possible route to the production of sustainable, high-performance, thermosetting resins with reduced environmental impact.

Bis-phenylethynyl polyhedral oligomeric silsesquioxanes: new high-temperature, processable thermosetting materials.

Bis-phenylethynyl polyhedral oligomeric silsesquioxane (bis-PE-POSS) compounds were synthesized and thermally cured yielding crosslinked materials. After curing at 370 °C, thermal decomposition occurs near 600 °C under nitrogen. These materials were synthesized by condensation of a new phenylethynyl-functional dichlorosilane onto tetrasilanol phenyl POSS, yielding two geometric isomers.

A high-performance renewable thermosetting resin derived from eugenol.

A renewable bisphenol, 4,4'-(butane-1,4-diyl)bis(2-methoxyphenol), was synthesized on a preparative scale by a solvent-free, Ru-catalyzed olefin metathesis coupling reaction of eugenol followed by hydrogenation. After purification, the bisphenol was converted to a new bis(cyanate) ester by standard techniques. The bisphenol and cyanate ester were characterized rigorously by NMR spectroscopy and single-crystal X-ray diffraction studies. After complete cure, the cyanate ester exhibited thermal stability in excess of 350 °C and a glass transition temperature (Tg ) of 186 °C. As a result of the four-carbon chain between the aromatic rings, the thermoset displayed a water uptake of only 1.8% after a four day immersion in 85 °C water. The wet Tg of the material (167 °C) was only 19 °C lower than the dry Tg , and the material showed no significant degradation as a result of the water treatment. These results suggest that this resin is well suited for maritime environments and provide further evidence that full-performance resins can be generated from sustainable feedstocks.

Di(cyanate Ester) Networks Based on Alternative Fluorinated Bisphenols with Extremely Low Water Uptake.

A new polycyanurate network exhibiting extremely low moisture uptake has been produced via the treatment of perfluorocyclobutane-containing Bisphenol T with cyanogen bromide and subsequent thermal cyclotrimerization. The water uptake, at 0.56 ± 0.10% after immersion in water at 85 °C for 96 h, represents some of the most promising moisture resistance observed to date in polycyanurate networks. This excellent performance derives from a near optimal value of the glass transition at 190 °C at full cure. Superior dielectric loss characteristics compared to commercial polycyanurate networks based on Bisphenol E were also observed. Polycyanurate networks derived from this new monomer appear particularly well-suited for applications such as radomes and spacecrafts where polycyanurates are already widely recognized as providing outstanding properties.

Synergistic physical properties of cocured networks formed from di- and tricyanate esters.

The co-cyclotrimerization of two tricyanate ester monomers, Primaset PT-30 and 1,2,3-tris(4-cyanato)propane (FlexCy) in equal parts by weight with Primaset LECy, a liquid dicyanate ester, was investigated for the purpose of exploring synergistic performance benefits. The monomer mixtures formed stable, homogeneous blends that remained in the supercooled liquid state for long periods at room temperature, thereby providing many of the processing advantages of LECy in combination with significantly higher glass transition temperatures (315-360 °C at full cure) due to the presence of the tricyanate-derived segments in the conetwork. Interestingly, the glass transition temperatures of the conetworks after cure at 210 °C, at full cure, and after immersion in 85 °C water for 96 h were all higher than predicted by the Flory-Fox equation, most significantly for the samples immersed in hot water. Conetworks comprising equal parts by weight of PT-30 and LECy retained a "wet" glass transition temperature near 270 °C. The onset of thermochemical degradation for conetworks was dominated by that of the thermally less stable component, while char yields after the initial degradation step were close to values predicted by a linear rule of mixtures. Values for moisture uptake and density in the conetworks also showed behavior that was not clearly different from a linear rule of mixtures. An analysis of the flexural properties of catalyzed versions of these conetworks revealed that, when cured under the same conditions, conetworks containing 50 wt % PT-30 and 50 wt % LECy exhibited higher modulus than networks containing only LECy while conetworks containing 50 wt % FlexCy and 50 wt % LECy exhibited a lower modulus but significantly higher flexural strength and strain to failure. Thus, in the case of "FlexCy", LECy was copolymerized with a tricyanate that provided both improved toughness and a higher glass transition temperature.

Effect of chemical structure and network formation on physical properties of di(cyanate ester) thermosets.

Key physical properties of three dicyanate ester monomers, bisphenol A dicyanate (BADCy), bisphenol E dicyanate (LECy), and the dicyanate of a silicon-containing analogue of bisphenol A (SiMCy) were investigated as a function of cyanurate conversion at conversions ranging from approximately 70% to greater than 90% in order to assess the range of applicability of both traditional and more unusual structure-property-process relationships known for cyanate ester resins. A more complete understanding of these relationships is essential for the continued development of cyanate ester resins and their composites for a wide variety of aerospace applications. The degree of cure in each system was determined by differential scanning calorimetry (DSC). The degree of conversion achieved at a given temperature was dependent on the structure of the repeat unit, with SiMCy displaying the highest relative ease of cure. The density at room temperature was found to decrease monotonically with increasing conversion for all monomer types studied. In contrast, the water uptake decreased with increasing cure for all three materials over most or all of the conversion range studied, but leveled off or began to increase with increasing conversion at conversions of approximately 90%. The T(g) decreased after exposure to hot water in resins with greater than 85% conversion, but unexpectedly increased in samples with lower conversions. An investigation of the effect of hot water exposure on network chemistry via infrared spectroscopy indicated that carbamate formation varied with both monomer chemistry and extent of cure, but was greatest for the BADCy polycyanurates. On the other hand, the unreacted cyanate ester band tended to disappear uniformly, suggesting that reactions other than carbamate formation (such as cyclotrimerization) may also take place during exposure to hot water, possibly giving rise to the observed unusual increases in T(g) upon exposure.