Ultra-high-purity
propylene glycol monomethyl ether acetate (PGMEA)
is required as an electronic-grade solvent to meet the stringent requirements
of the rapidly developing semiconductor industry. The high demand
for ultra-high-purity PGMEA has created the need for an efficient
sustainable process for reducing energy consumption as well as satisfying
tight waste management regulations. Here, a potentially sustainable
and novel process for efficient continuous electronic-grade PGMEA
manufacturing is presented. This study covers the extensive design
of the novel PGMEA manufacturing
process and its intensification from the conceptual level to rigorous
simulation. The base case of the proposed PGMEA manufacturing process
highlights the feasibility of renewable resource use, single ultra-high-purity
PGMEA, nonrequirement of an additional solvent, less waste generation,
and reduction in the usage of raw materials. The advanced intensification
of PGMEA manufacturing by exploiting reactive pressure-swing distillation
achieves total reduction in energy, cost, and CO2 emissions
of approximately 38.65, 35.05, and 36.25%, respectively, compared
to the base case with rigorous optimal reactive distillation and pressure-swing
distillation. Furthermore, heat integration of intensified case reduced
the total heat utility by 47.27%.
Analysis of ball-milling process under various conditions (i.e. working volume, milling time, and material load) on the material properties (i.e. chemical composition, as well as particle size and morphology), product yield, and electricity consumption was investigated. Turmeric (curcuma longa) was used as a model of size-reduced organic material due to its thermally and chemically stability, and fragile. Thus, clear examination on the size-reduction phenomenon during the milling process can be done without considering any reaction as well as time-consuming process. Results showed that working volume is prospective to control the characteristics of product. Working volume manages the shear stress and the collision phenomena during the process. Specifically, the lower working volume led to the production of particles with blunt-edged morphology and sizes of several micrometers. Although working volume is potentially used for managing the final particle size, this parameter has a direct impact to the product yield and electricity consumption. Adjustment of the milling time is also important due to its relation to breaking material and electrical consumption.
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