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Syringe Pump Application Note AN1 such as methylene chloride, using an apparatus called a Soxhlet extractor. Supercritical CO2, with its ability to mimic solvents and penetrate matrices easily, can replace Soxhlet extractions while reducing a chemist’s exposure to hazardous chemicals, improving the envi- ronment and reducing costs. Other examples are the use of supercritical CO2 com- bined with chelating agents for the extraction of uranium from aqueous solutions produced in the pro- cessing of the ore and removal of heavy metals from soils and sludges. Supercritical Fluid Chromatography (SFC) — Chroma- tography is an analytical technique used in separating chemical mixtures into separate components. SFC uses supercritical CO2 to replace solvents as the mobile phase in HPLC. Because of supercritical CO2, advan- tages in diffusion and performance of the separation columns are improved, with higher resolutions and faster separations. Catalysis/Reactant Feed — Reactions with supercritical CO2 may have important applications in fields such as catalysis and polymerization. The use of supercritical CO2 to replace solvents has the benefit of increasing and controlling reaction kinetics by altering the pressure. Also, there is the possibility of producing unique mate- rials, which would be difficult to do with conventional techniques. Injection Molding and Extrusion — The presence of CO2 in plastic melts lowers viscosities thereby decreasing the injection molding pressures required, and/or decreasing the injection times. These advantages will increase the life of molding equipment and increase production rates. Also by lowering the melt tempera- tures, you can mold thermally labile compounds. CO2 is also used as an expanding or foaming agent for injection molding or extrusions. Adding air pockets in plastic reduces the amount of material used, decreases shrinkage, warpage and improved tolerances. The use of CO2 in forming micro cells produces denser foams, making thin wall applications possible. Particle Formation — Supercritical fluids can be used in the production of powders or microparticles with possible uses in the pharmaceutical industry. With con- ventional techniques, there is little control over powder properties, such as particle size. By rapidly depressur- izing materials dissolved in CO2, microparticles are produced with drugs or other components of interest embedded in a substrate. This is accomplished by pumping the mixture through a capillary where the CO2 is vaporized at the outlet, leaving powders behind. This powder has uses such as time released drugs. Cleaning — Supercritical fluids can be an effective sol- vent for cleaning many kinds of parts, electronics, plastics, or clothing. With the enhanced wetting and dif- fusion properties, supercritical CO2 can improve the cleaning of components with small openings, delicate equipment, or porous materials. It can remove oils, fats, waxes, and other contaminates without damaging the matrix. Electronic Chip Manufacturing — One possible impor- tant industrial application may be in the electronic chip fabrication process. Chip manufacturing creates a large environmental burden. It is estimated that the produc- tion of a 2.0g chip consumes at a minimum 72g of chemicals and 1.6Kg of fossil fuels. This gives a 630:1 weight ratio of chemical–fossil fuels and product. In comparison, the manufacturing of a typical automobile has a corresponding ratio of 2:1. Also, in the manufac- turing of a 2.0g chip, 32L of water are used during the washing and rinsing steps during photolithography. Even though water can be recycled, this process requires extra energy. Supercritical CO2 along with appropriate detergents may eliminate the need for water and reduce energy consumption in the manufacturing process. Due to the low surface-tension of supercritical fluids compared to water, finer surface features and structures can be better cleaned without risk of causing damage. Plastics Production — Currently, PTFE and other fluo- ropolymers are being synthesized in refrigerant, and since perfluoro monomers and oligomers are soluble in CO2, it can replace refrigerant in this application. After the 1986 Montreal Protocol, CO2 has successfully replaced Freon as a polymer foaming agent. Finally, due to its inertness, CO2 can be an excellent solvent for reac- tion involving a strong oxidizing or reducing agent. Supercritical Fluid Pumps For the applications above, there are generally two types of pumps used: reciprocating and syringe. Recip- rocating pumps have pistons with short strokes, so they need to frequently refill. Since fluid flow stops during refill, pressure fluctuations and density changes will result. This can cause unwanted precipitation of compo- nents, or other problems. Syringe pumps, considered pulseless, are better suited for these applications, as pressure and flow rates can be more accurately controlled. For most supercritical fluids applications, pressure must be maintained, so a constant pressure mode is needed. When pumps compress CO2, even in the liquid state, heat generated will accumulate in the pump head. If this heat is not removed, incoming CO2 could be inadver- tently heated above the critical point, thereby impacting fill efficiencies. For proper operation, CO2 pumps must incorporate some means to remove this heat. Not all materials are suitable for use with CO2, so wetted materials must be checked for compatibility.PDF Image | Supercritical Fluid Applications in Manufacturing and Materials Production
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