Emulsion Polymerization to produce Fluoropolymers
The polymerization reaction in the production of fluoropolymers is highly exothermic. It could make a temperature runaway polymer synthesis system. Commercial operating conditions need to be very carefully monitored and controlled. The reaction mechanism, combined heat and mass transfer, and control of critical micelle concentration were investigated experimentally on a specially designed system, which was designed as a scaled-down version of the commercial manufacturing system. In this project, the heat & mass transfer conditions involving the exothermic polymerization were analyzed on a real-time basis and its mechanistic pathway was elucidated. The sponsor of the project was ATOFINA [later, Arkema].
Clean Coal Technology
Under the research sponsorship of EPRI, perchloroethylene (PCE) coal refining process has been investigated. All aspects of process and reaction engineering were studied and the process was in the pilot demonstration stage by the Midwest Ore Processing Co (MOPC). For some more information about the PCE coal refining process, please visit a dedicated section of Clean Coal Technology on this webpage.
An extensive process engineering study was also carried out on desulfurization of Eastern U.S. coals using synergistic mixtures of supercritical fluids, with the sponsorship of the Ohio Coal Development Office (OCDO). A U.S. patent on the process was awarded.
- Lee and V. Parameswaran, “Extraction of Organic Sulfur from Coal by Use of Supercritical Fluids”, U.S. Patent No. 5,080,692, January 14, 1992.
Although the supercritical desulfurization technology was not commercially exploited for coal cleaning due to its prohibitive cost, the novel process concept of utilizing synergistic supercritical fluid mixtures has impacted broadly on other materials processing applications such as spent rubber reclamation and offered a new enabling technology of tuning supercritical fluids and their mixtures for specifically targeted outcomes.
Bioremediation of Contaminated Soil
Very efficient bioremediation processes have been developed for polycyclic aromatic hydrocarbon (PAH) treatment. The purification process has demonstrated high destruction efficiencies in a short period of time. The process is also applicable to industrial spills or contamination of hydrocarbons. The processes can be adapted to other contaminated sites such as coal and shale oil sites. Two U.S. patents have been received for this process.
- S. Lee and T. J. Cutright, “Bioremediation of PAH Contaminated Soil”, U.S. Patent No. 5,427,944, June 27, 1995.
- S. Lee and T. J. Cutright, “Nutrient Medium for the Bioremediation of PAH-Contaminated Soil”, U.S. Patent No. 5,508,194, April 16, 1996.
These processes can be adapted to other bioremediated applications. Our Bioremediation technology is available for licensing through the Technology Transfer Office of University of Akron.
Polycrystalline Silicon Synthesis, Polysilicon
A novel process that is totally different from the Siemens process has been devised. Key reaction steps and associated enabling technologies are being investigated and perfected. The process is envisioned to possess the following merits:
- no chlorine or hydrochloric acid involvement in the synthesis process;
- no involvement of harsh halogenated chemicals in any part of the process;
- organic synthesis route via innovative catalytic chemistry;
- superior purity and resultant crystalline quality;
- significant manufacturing cost reduction;
- mitigated risk for production and enhanced process safety
The current R&D efforts by the Chemtech Innovators LLC are being fully sponsored by Alberee R&D Company, Inc. and CLFT1, LLC. For more information, please also refer to the page for Semiconductor Grade Polysilicon Synthesis
Recycle and Recovery of Valuable Chemical, Polymeric, and Medicinal Ingredients
Many novel process technologies have been developed for the recovery of valuable chemical, biological, medicinal ingredients from natural, processed, herbal, or. scrap materials. The technologies are applicable to a wide variety of materials and species. Selective monomer recovery from scrap or waste polymers and re-vulcanizable rubber recovery from crosslinked rubber products such as spent tires are two of such examples.
Nano Biological Medicines
A number of Oriental medicines can be directly converted into Western-style medicines via unique nano-enabling technologies. The conversion is accomplished by nondestructive, low-temperature, chemical-free methods. The very same assertion is true for uncontaminated extraction of beneficial herbs and nutritional ingredients contained in natural food resources. We call this “the most natural way of delivery”. For example, ginseng, in particular Korean ginseng, has been very effectively used beneficially for human health maintenance and speedy recovery from illness in many Asian countries for thousands of years. Saponin, the potent ingredient in ginseng, has to be effectively absorbed into human body for maximum beneficial effect. The current method of intaking ginseng products includes high concentration extracts, dry powdered tea, aqueous extraction/leaching in boiling water, immersed roots in alcoholic beverages, etc. However, all of these forms of delivery undergo harsh physical, thermal, and chemical stresses in addition to failing to overcome the severe diffusional limitation for saponin molecules. in our lab, nano-ginseng and nanostructured ginseng samples were successfully prepared by our proprietary process, wherein the medicinal and nutrient biomolecules were preserved without experiencing thermal or other destructive degradation. As a quick proof of the process validity and effectiveness, we have noticed a remarkably subliming nature of saponin when the product sample is directly exposed to the atmospheric condition. In this sentence, “remarkable” means “quite strong, but never experienced before from other ginseng products claiming to contain saponin”. The applicability of this novel processing and its potential impacts in this field and other related areas are immense and nearly limitless. It has to be clearly noted that the novel method described in this section is neither a supercritical fluid technology (SCFT), nor a SCFT inspired technology.
The current phase of this R&D project has been supported by Samwha Solutions Inc.
Other Major Industrial Projects and Accomplishments in Novel Processes and Products
Projects dealing with various chemical and petrochemical reaction processes leading to novel materials, new synthesis routes, efficient process design, and effective trouble-shooting have long been conducted by Dr. Lee and his team. Some of the noteworthy projects in this category include:
- Latex Rubber (Natural Rubber) Glove Manufacturing Process Design project with Green Cross Medical Supplies Company — Fully Commercialized as a fully-automated dip molding process system in the 1980s.
- Development of High Purity Sodium Dithionite Manufacturing Process by Upgrading the Current Process Design with Young Woo Chemical Company — 92+% purity level (the highest in the world back then) achieved in late 1980s — Fully implemented on a commercial scale.
- Continuous Fermentation Process Technology for Production of Lactase Enzyme from Cheese Whey with Green Cross Pharmaceutical Company — Conceptual design completed, but not commercialized in mid 1980s.
- Evaluation of Osborne’s Dielectric Retorting Process for Nye Metals/Synfuel Co. 1985-1986 — Favorable process assessment results reported to the developer (1986) and highlights of the technology were later introduced in Dr. Lee’s authored book “Oil Shale Technology” (1991). This specific process idea is still relevant in the field, as long as it is properly applied.
- TVSM Fuel Performance Booster Project (2008-2012) for Motor Bicycles and Three Wheelers using supplementary on-board hydrogen fuel injection technology. The technology is based on the novel reverse equilibrium reaction of methanol synthesis using the ICE generated heat, which achieves a very high fuel efficiency. The process has been awarded a U.S. patent and a number of foreign patents. The TVS Motor Company (Hosur, India) is one of the major global manufacturers of motor bicycles and three wheelers.
- S. Lee, “Fuel Performance Booster”, U.S. Patent No. 8,720,390, Issued May 13, 2014.
The above process technologies are listed here for the sole purpose of cataloguing and introducing the expertise of the Chemtech Innovators team and therefore the listed technologies as presented here are not offered for licensing. For any serious commercial interests of each specific process technology, please directly contact the above-listed manufacturers.
If you would like to discuss about potential R&D collaboration for development of advanced chemical/petrochemical/polymeric processes and/or novel products as you envision to pursue with commercialization focus, please contact us.
Sunggyu Lee, PhD 