Impregnation via Supercritical Fluids - Principles and ... - ISSF 2012
Impregnation via Supercritical Fluids - Principles and ... - ISSF 2012
Impregnation via Supercritical Fluids - Principles and ... - ISSF 2012
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ABSTRACT<br />
<strong>Impregnation</strong> <strong>via</strong> supercritical fluids<br />
<strong>Principles</strong> <strong>and</strong> applications<br />
Eckhard Weidner<br />
Ruhr University, Chair of Process Technology, 44780 Bochum <strong>and</strong><br />
Fraunhofer UMSICHT (www.umsicht.fraunhofer.de), 46047 Oberhausen, Germany<br />
weidner@vtp.rub.de<br />
<strong>Impregnation</strong> is defined as the process of imbuing or saturating a material or substance with something. In<br />
technical applications impregnation is applied for modifying properties of bulk substances by physically or<br />
chemically binding functionalizing compounds (impregnates) to a bulk material or surface. A prominent<br />
example is to render wood resistant to water by impregnation with waxes <strong>and</strong>/or fats <strong>and</strong>/or resistant to<br />
biological degradation by impregnating it with salts of zinc or copper. Providing impregnates in liquid solutes or<br />
from a gas phase is state of the art, connected with disadvantages like low space yield in case of impregnation<br />
from gas phases, slow diffusion processes <strong>and</strong> long process times in case of impregnation from liquid solutions.<br />
Exploiting the specific properties of supercritical fluids is resulting in intensified processes with short cycle<br />
times <strong>and</strong> considerable savings of energy <strong>and</strong> raw materials. In addition pressure allows modifying properties of<br />
the bulk material during pressurizing or depressurizing.<br />
Impregnates might either be bound physically or chemically in the substrate. In the first case the process is<br />
mainly controlled by diffusion <strong>and</strong> adsorption, while in the second case chemical reaction rates have to be<br />
considered as well. Based on a principle process scheme of impregnation the role of pressurized gases for both<br />
binding processes is discussed. The principles are exemplified with recent developments such as the colorization<br />
of polymers, the impregnation of hip implants, the impregnation of nuts with antioxidants <strong>and</strong> the chemical<br />
impregnation (tanning) of leather with either inorganic (e.g. chromium) or organic tanning agents.<br />
The examples illustrate that impregnation <strong>via</strong> supercritical fluids allows low process temperatures <strong>and</strong> high depth<br />
of penetration at (very) short process times <strong>and</strong> avoids the use of (hazardous) solvents, time- <strong>and</strong> energy<br />
consuming drying procedures, the overdosing of (expensive) impregnates. Cost break-down for an industrial<br />
process for tanning leather indicates that impregnation <strong>via</strong> supercritical CO2 is highly competitive, with short<br />
times for return on investment.<br />
IMPREGNATION – DEFINITION, MARKETS<br />
Properties of materials are defined by their chemical nature <strong>and</strong> physical form. Both can be modified in a wide<br />
range by compounding bulk materials with additives. For generating such compounds a variety of mechanical,<br />
physical <strong>and</strong> chemical processes like extrusion, agglomeration, precipitation, crystallization, spray drying <strong>and</strong><br />
grafting are known <strong>and</strong> applied. Following the definition that characterizes impregnation as process of imbuing<br />
or saturating a material or substance with something, all mentioned unit operations can be addressed as<br />
“impregnation”.<br />
In a more detailed approach impregnation means to contact a bulk material (substrate) either in its final physical<br />
form or as an intermediate material with a functionalizing substance (impregnate), which might be provided<br />
from a gas phase, a liquid phase or a solid phase. The concentration of the impregnates in or on the surface of the<br />
final product is low, typically some percent by weight or even (much) lower. They may be homogeneously or<br />
non-uniformly distributed. Depending on their specific properties <strong>and</strong> the specific task, impregnates can be<br />
provided as a pure substance, a solution or as a dispersion. In the final product impregnates can either be bound<br />
physically or chemically.<br />
A prominent example is the formation of leather, where an impregnate (tanning agent) is contacted in an<br />
aqueous solution with carefully pretreated animal hides. The tanning agents diffuse in the skin matrix <strong>and</strong> (in<br />
case of chromium or alumina) reacts chemically with collagens. The thus treated (impregnated) skin is called<br />
leather. By impregnation the mechanical strength is improved by orders of magnitudes <strong>and</strong> the product is<br />
rendered water- <strong>and</strong> temperature-resistant. Nowadays over 2 000 km 2 of leather are produced every year. The<br />
turnover of leather as an intermediate product amounts to approx. US $ 45 billion. Approximately 90 % of all<br />
leather is tanned by using chromium-III-salts. Leather manufacturing is extremely intensive with respect to<br />
1
consumption of resources. About 7 million tons of skin, 500 000 tons of salt <strong>and</strong> 500 000 tons of chromium-IIIsalt<br />
are needed. An estimated overall amount of about 14 million m³ of wastewater is generated worldwide [1].<br />
Articles made of plastics have to withst<strong>and</strong> exposure to heat, light, <strong>and</strong> humidity without changes in appearance<br />
<strong>and</strong> mechanical performance. Furthermore neat polymers in most cases do not show satisfactory properties<br />
regarding e. g. colour, surface touch or flammability. Regarding modification of mechanical performance,<br />
appearance <strong>and</strong> functionality a broad variety of additives <strong>and</strong> fillers is used. The total global production of<br />
plastics increased to 260 million tonnes in 2007 (Plastics Europe 2008). The average use of additives in plastics<br />
is 5 to 7 % by weight which corresponds to a global annual additive consumption of 13 to 18 million tonnes a<br />
year. Important groups of additives <strong>and</strong> fillers used in plastics modification are antioxidants, stabilizers,<br />
lubricants, slipping <strong>and</strong> antifogging aids, flame retardants, blowing agents, crosslinkers, colorants <strong>and</strong> whitener,<br />
reinforcing fillers <strong>and</strong> coupling agents [2]. Classically such substances are admixed by extrusion or kneeding<br />
processes. An alternative is to provide the additives as impregnates from liquid dispersion or from gas phases.<br />
The transport in the polymer is than mainly driven by intermolecular forces <strong>and</strong> is not supported by mechanical<br />
forces, as it is the case in extruders. Shear <strong>and</strong> connected temperature stress can thus be avoided.<br />
Fruits of oil plants, like nuts are cultivated worldwide <strong>and</strong> frequently are used for the preparation of food<br />
products, soaps, greases or cosmetics. Well-known examples for fruits of oil plants are soy beans, coconuts,<br />
peanuts, hazelnuts, almonds, walnuts, macadamia nuts, pumpkin seeds <strong>and</strong> sunflower or rape seeds. In Germany<br />
about 250.000 tons of nuts are imported per year <strong>and</strong> the per capita consumption was 3,9 kg in 2009. The high<br />
content of unsaturated fats contributes substantially to the nutritional value, but also makes the product sensitive<br />
to oxygen. Storage time is limited as the product turns rancid. Well established processes to protect nut products<br />
from oxygen are applied to prolong shell life. Coating with sugar or fat hinders the diffusion of oxygen. Roasting<br />
reduces moisture so that the sensitivity for oxidation <strong>and</strong> deterioration is reduced [3]. A new <strong>and</strong> alternative<br />
process would be to impregnate the nuts with antioxidants. Due to the high fat content, lipophilic antioxidants<br />
are first choice. Those additives are typically either viscous liquids (e.g tocopherol, rosemary extract) or solids<br />
(e.g. carnosic acid concentrates). <strong>Impregnation</strong> from liquid phases therefore would either be very slow or would<br />
require the use of diluents (solvents), which have to be carefully removed after having helped to carry the<br />
antioxidants into the solid matrix. To the authors best knowledge such a process has not been realized yet.<br />
PROPERTIES OF CLASSICAL PROCESSES<br />
Before impregnating hides with tanning agents the collagen molecules have to be pretreated at high pH-values in<br />
the so-called pickling step. Subsequently tanning takes place in rotating drums over a period of 12 to 20 hours at<br />
low pH-values, starting at pH 2.5 <strong>and</strong> increased to pH 3.8 at the end of the process. Due to partial hydrolysis of<br />
skin compounds, penetration of the tanning agent at low pH value is facilitated. By steadily raising the pH value<br />
the tanning agent bonds with reactive groups of the collagen (carboxyl groups). Leather of good quality is<br />
achieved if 3.8 to 5 % of Cr2O3 by weight are absorbed <strong>and</strong> bound in the leather. Subsequently finishing with<br />
colors, oils <strong>and</strong> specific chemicals brings about different forms of appearance like smooth leather for clothes,<br />
stiff leather for shoes or soft leathers for furniture [1]. The skin can be considered as a chemical reactor, where<br />
the impregnate (e.g. chromium) has to reach the reaction site <strong>and</strong> then reacts. Furthermore macroscopic<br />
movement of skins in rotating drums has a significant influence on the transport of tanning agents, due to<br />
renewing the tanning liquid between folded or attached skins. Therefore this impregnation process requires a<br />
finely adjusted balance between mixing, diffusion <strong>and</strong> reaction rate. If the reaction rate is too high, only outer<br />
layers of the skin are tanned <strong>and</strong> the leather is of very bad quality. If the reaction rate is too low (e.g at low pHvalues),<br />
the skin swells <strong>and</strong> may even be destroyed. If the skins are not moved (mixing) the tanning agent is not<br />
distributed evenly, which results in bad quality.<br />
In contrast to compounding, impregnation techniques have hardly been used in the polymer processing industry<br />
until now. Two processes have been published recently: the Bayer-Aura-Color-Infusion-Technology <strong>and</strong> the<br />
Essilor impregnation-process of optical lenses. The processes differ in pretreatment before impregnation. Both<br />
have in common that transparent bodies of polycarbonate are dipped into a bath for several seconds to hours at<br />
elevated temperatures. Subsequently the parts are dried <strong>and</strong> the solvent has to be recovered. The achieved depth<br />
of impregnation typically is around 20 µm [2].<br />
In both cases the polymer chains have to be mobilised in order to facilitate the diffusion of impregnates. This can<br />
be achieved by temperature <strong>and</strong>/or interaction with solvents or by partial degradation <strong>via</strong> radiation. The depth of<br />
impregnation is rather low <strong>and</strong> the use of solvent requires careful drying.<br />
From the examples can be derived that classical impregnation processes may have the following drawbacks:<br />
• Low diffusion rates<br />
• High temperatures<br />
2
• Limited depth of penetration<br />
• (Very) long contact times<br />
• Use of (hazardous) solvents<br />
• Time <strong>and</strong> energy consuming drying procedures<br />
• Overdosing of impregnates causing pollution <strong>and</strong>/or requiring recovery<br />
• Sometimes, e.g. in the case of nuts impregnation procedures are not known<br />
• High consumption of consumables (water, salts <strong>and</strong> so on)<br />
IMPREGNATION PROCESSES VIA SUPERCRITICAL FLUIDS<br />
Overcoming those drawbacks motivates the search for alternatives. One interesting possibility is the use of nearor<br />
supercritical solvents. In certain applications (e.g. in case of wood) they have already successfully found their<br />
way into industrial application [4] or have reached a ready-to-use stage of development, as it is the case for the<br />
colorization of fibres <strong>and</strong> garments [5]. In recent years a number of new proposals have been made, a selection<br />
of which is highlighted in the following. All processes have more or less similar process steps, which are<br />
illustrated in Figure 1<br />
Impregnate / Additives<br />
Bulk<br />
material<br />
<strong>Supercritical</strong> Fluid<br />
Conditioning<br />
<strong>Supercritical</strong> Fluid<br />
Energy<br />
Compression<br />
Mixing<br />
Solution / Dispersion<br />
Sorption<br />
Expansion<br />
Conditioning<br />
(e.g. Drying)<br />
End product<br />
Figure 1: Basic Process Scheme for impregnation <strong>via</strong> near- or supercritical fluids<br />
Impregnates <strong>and</strong> possibly additives have to be admixed with a compressed SF, mostly CO2. The phases leaving<br />
the mixing stage can be:<br />
• a homogeneous, molecularly dispersed liquid phase, comprising impregnate(s) <strong>and</strong> additive(s), that are<br />
containing dissolved CO2<br />
• a liquid phase that may comprise two or more partially miscible liquids (e.g. emulsion)<br />
• a liquid phase that may comprise partially miscible solids (e.g. suspension)<br />
• a gas phase, in which the impregnates are dissolved homogeneously (e.g. supercritical fluid phase)<br />
• a gas phase, where liquid droplets <strong>and</strong> or solid particles are dispersed (e.g aerosol)<br />
• <strong>and</strong> of course mixtures of the described phases<br />
In opposition to classical impregnation processes, the use of near-critical fluids allows tuning the properties of<br />
impregnates <strong>via</strong> pressure, temperature <strong>and</strong> the kind of gas used. For instance it is well known that viscosities <strong>and</strong><br />
interfacial tensions of liquids can be reduced by orders of magnitude, if a near-critical fluid is dissolved. It is also<br />
well known, that near- or supercritical fluids may have a high solubility for large molecules <strong>and</strong> that this<br />
solutions are characterised by very high diffusion constants. Near-critical fluids may also influence the<br />
agglomeration between solid particles, which may favour their use for carrying suspended nanoparticles.<br />
3<br />
<strong>Supercritical</strong> Fluid<br />
Compression<br />
Recovery<br />
Optional steps<br />
Required steps<br />
<strong>Supercritical</strong> Fluid<br />
Impregnate /<br />
Additives
In the next step (sorption), the mixture of impregnate, additives <strong>and</strong> nearcritical fluid is contacted with the<br />
substrate to be impregnated. This can either be done by once filling the vessel, containing the substrate, with the<br />
near-critical mixture containing the impregnate (stagnant impregnation). Alternatively the near-critical mixture<br />
can continuously be renewed (flow impregnation). In this case recovery of non-used impregnate <strong>and</strong> nearcritical<br />
fluid might be required.<br />
The involved species interact with the substrate <strong>via</strong> sorptive forces. For designing <strong>and</strong> underst<strong>and</strong>ing the<br />
impregnation process knowledge of the number of phases <strong>and</strong> the properties of such mixtures <strong>and</strong> of the<br />
interaction with the substrate is essential. Especially the interaction with the substrate is not entirely understood.<br />
For polymers it is know, that glass transition temperature may be considerably reduced by near-critical fluids,<br />
which results in an increased mobility of the polymer chains. As mentioned this is essential for transporting<br />
impregnates into polymers.<br />
If lipophilic substances such as fats or oils (e.g. in nuts) have to be impregnated, CO2 or propane have a rather<br />
high solubility in such phases. The fat may swell by the dissolved gas <strong>and</strong> viscosity <strong>and</strong> interfacial tension will<br />
be diminished. Lipophilic impregnates may be transported fast <strong>and</strong> effectively into such fat phases by means of<br />
near-critical fluids.<br />
In the presence of water pH-values may be of relevance for diffusion <strong>and</strong> reaction rates (e.g.in tanning).<br />
Pressurized CO2 will form carbonic acid which, depending on pressure, may be as low as pH 3. In animal skins,<br />
both lipophilic <strong>and</strong> hydrophilic regions are present. Collagens can be considered as biopolymeric compound,<br />
with specific <strong>and</strong> not well understood interactions with CO2. If a water soluble tanning agents has to be<br />
transported into the skin, accompanied <strong>and</strong>/or followed by a pH-triggered reaction with a biopolymer all the<br />
above described transport phenomena may be of relevance.<br />
After the impregnate has been transported into the substrate, gas <strong>and</strong> possibly other solvents have to be removed.<br />
Here the compressibility of the near-critical fluid has to be considered. Even be a slight reduction of pressure,<br />
solubility of impregnates in near-critical gases may be reduced considerably. Assuming a porous substrate, the<br />
impregnate might precipitate in these pores during expansion <strong>and</strong> adhere to pore walls. The volume increase of<br />
the exp<strong>and</strong>ing gas might induce rather high gas velocities in the pores which might withdraw precipitates. Gas<br />
that is physically dissolved in the substrate under the impregnation pressure may form bubbles during expansion.<br />
Thus mechanical forces are induced, that may cause cracks or even destroy the substrate or could be used for<br />
structuring effects (e.g. foaming). During expansion, the gas cools down considerably, which may result in<br />
formation of ice (if water is present) or dry ice (in case of CO2) or of other solids (e.g. solidification of<br />
impregnates).<br />
This short overview illustrates that nearcritical fluids have unique properties opening ways to new processes <strong>and</strong><br />
products. Some examples will be highlighted in the following chapter:<br />
EXAMPLES – POLYMERS<br />
Polyamid 12 in powdery form is used as a material for laser sintering. The polymer has a glass transition<br />
temperature of around 37°C <strong>and</strong> a melting temperature of around 178°C. Two physically different substrates<br />
(powder <strong>and</strong> a laser-sintered body) have been impregnated <strong>via</strong> supercritical CO2 with yellow dye (Teratop<br />
yellow GWL, Huntsman Textile Effects, CH). It turned out that temperature has to be considerably above the<br />
glass transition temperature to yield a satisfying result in reasonable time. The dye was introduced as powder<br />
into the autoclave equipped with windows. From the chemical structure it is unlikely that the dye is soluble in<br />
CO2. But at a pressure of about 19 MPa the gas phase looked uniformely <strong>and</strong> deep colored. It is assumed that the<br />
dye is dispersed in CO2 <strong>and</strong> forms a kind of aerosol. <strong>Impregnation</strong>s have been carried out above 19 MPa. While<br />
at 23 MPa, 90 °C <strong>and</strong> duration of up to 20 minutes the results were not sufficient, an increase of temperature to<br />
110°C at a pressure of 23 MPa resulted in a homogeneous colour distribution in the powder [2], as shown in<br />
Figure 2.<br />
CO2 has a limited solubility in PA 12. In own measurements in a magnetic suspension balance it was found that<br />
under equilibrium 12,5 wt% of CO2 are dissolved in molten PA12 at a temperature of 175°C <strong>and</strong> pressure of<br />
22MPa. It took several hours to reach equilibrium at a layer thickness of some mm of PA 12. The solubility in<br />
solid PA12 at 110°C is not known, but is assumed to be in the same range. Furthermore it is likely that due to the<br />
low contact time of 25 min equilibrium is not reached by far during impregnation. Due to a low content of CO2,<br />
a rather high expansion rate of 3 bar/s (compared to nuts – see below) did not result in cracks, bubble formation<br />
or changes in morphology of the powder. The colour was homogeneously distributed, stable during washing in<br />
water at 70°C <strong>and</strong> after drying a homogeneous powder was obtained. The shape of the particles remained<br />
spherical <strong>and</strong> the impregnated powder has a good flowability, which is a key parameter for laser sintering.<br />
Alternatively a white laser-sintered body was impregnated at similar conditions (Figure 3). Complete<br />
4
impregnation was obtained, which is an indication, that the sintered structure has pores that do not form a<br />
separate resistance to mass transfer, but that impregnation of the single particles is still the time limiting step.<br />
Similar impregnations with colour <strong>and</strong> nanosilver dispersions have successfully been applied to other polymeric<br />
materials such as amorphous thermoplastic polyurethane (TPU), polycarbonate (PC), semicrystalline polyamide<br />
<strong>and</strong> polypropylene (PP) [2]. In addition to rather deep impregnation it turned out that the crystallinity of the<br />
polymers may be modified. This is believed to be connected with the change in glass transition <strong>via</strong> pressurized<br />
CO2 <strong>and</strong> the cooling rates during expansion.<br />
Figure 2: Colorimpregnated Figure 3:High pressure colorized laser-sinter body<br />
PA 12 powder[2]<br />
before <strong>and</strong> after impregnation [2]<br />
Gamse et al [6] investigated the impregnation of medical products with antioxidants. Hip implants can be made<br />
from specific titanium alloys. Hip cups from polymers like crosslinked polyethylene (PE) are preferred in<br />
combination with metal implants to reduce wear <strong>and</strong> friction. It is tried to<br />
improve biocompatibility by adding antioxidants like alpha-Tocopherol to the<br />
polymer. It is to be slowly released from the polymer after implantation. If the<br />
antioxidant is added before cross-linking of PE at least a part of the Tocopherol<br />
is destroyed during polymerization by free radicals. As an alternative the<br />
crosslinked polymer is impregnated with antioxidant <strong>via</strong> supercritical CO2. The<br />
tocopherol is dissolved in the gas <strong>and</strong> contacted with the polymer. The<br />
supercritical solution of tocopherol in CO2 was contacted with model cubes<br />
with a size of 20*20*20mm. The tocopherol is physically adsorbed. An<br />
intermediate result is shown in Figure 5. If the temperature is in the range of the<br />
glass transition temperature of UHWMPE (around 170°C) concentrations are<br />
rising, but homogeneous distribution is not reached.<br />
By optimizing process conditions uniform concentration of tocopherol in model<br />
cubes was achieved. Finally hip cups were impregnated with tocopherol from<br />
CO2 at 300 bar, 170°C in 12 hours. The absolute concentration <strong>and</strong> the rather<br />
uniform distribution are shown in Figure 6. Finally it was found that careful<br />
Figure 4: Hip implant from <strong>and</strong> optimised depressurization is required for a product of high quality.<br />
Polyethylene with ultrahigh Expansion takes minimum 4 hours (average rate 1,25 bar/min) but 12 hours<br />
molecular weight<br />
(approx. 0,5 bar/min) are preferred.<br />
Figure 5: Tocopherol concentration<br />
in model cubes [6]<br />
5<br />
Figure 6: Tocopherol distribution in a cross section of a<br />
hip cup after process optimization [6]
EXAMPLES - NUTS<br />
<strong>Impregnation</strong> with antioxidants is not only of interest for medical products but also for food. Different types of<br />
peeled nuts (almond, hazelnut, peanut, walnut, macadamia nut) were used in total, chopped, planed, grated or<br />
ground form. As antioxidant two different rosemary extracts were selected. Extract 1 is a lightly yellow<br />
deodorized <strong>and</strong> decolorized powdery extract obtained by solvent extraction containing 40% of carnosic acid<br />
(CS). Extract 2 is a light orange oily liquid, which was obtained by high pressure extraction with supercritical<br />
CO2 with containing 20% of CA. Different modes of mixing of extracts, nuts <strong>and</strong> CO2 have been tested. The<br />
powdery extracts where provided in an impregnation autoclave located below a large volume (some liters) of<br />
nuts. The system was pressurized <strong>and</strong> the extract diffuses through the CO2 phase into the layer of nuts (stagnant<br />
impregnation). In a different approach the CO2 was admixed with the liquid extract before being continuously<br />
introduced into the autoclave (flow impregnation). In a third mode the liquid extract was sprayed onto the nuts<br />
before introducing them into the autoclave. Then the system was pressurized <strong>and</strong> the impregnation started<br />
(stagnant impregnation).<br />
Satisfying results with significantly prolonged shelf life without affecting the taste was obtained at pressures<br />
between 28 <strong>and</strong> 32 MPa, temperatures between 50 <strong>and</strong> 60°C <strong>and</strong> an impregnation time of 60 min. From the<br />
powdery extract at stagnant impregnation only one third of CS was extracted. With increasing distance to the<br />
extract layer of the powdery extract the content of CS in nuts decreases. The liquid extract with lower content of<br />
CA was significantly better as it is completely dissolvable in supercritical CO2. Stagnant impregnation with<br />
previously contacting the nuts with liquid extract was superior <strong>and</strong> resulted in homogeneous distribution of<br />
antioxidant, while flow impregnation resulted in reducing concentrations from bottom to top of the nut layer.<br />
The CA-concentration in the impregnated samples was ranged from 20 to 100 ppm. Regarding acceptable taste<br />
of the impregnated nuts concentrations below 50 ppm are recommended.<br />
In Figure 7 the peroxide values during storage of chopped hazelnuts at room temperature are shown. Starting<br />
with a peroxide value of 0, indicating a good quality of nuts, it took more than 240 days until a strong increase of<br />
the peroxide value accompanied by a rising rancid taste occurred. <strong>Impregnation</strong> with CS results in significantly<br />
better stability to oxygen depending on the amount of CS applied. Expansion has to be carried out carefully to<br />
avoid cracking or grinding. A maximum rate of 3bar/min was found to be applicable. Results found in smallscale<br />
experiments have successfully been verified in industrial trials with batches of several hundred kilograms<br />
of nuts.<br />
Figure 7: Oxidation measured <strong>via</strong> peroxide value at different concentrations of carnosic acid (CS) [3]<br />
EXAMPLES - LEATHER<br />
About 15 years ago, it was found that the process time for tanning animal skins can be reduced by a factor of 3 to<br />
6 (which means from e.g. 24 hours to 4 to 6 hours) when the process is carried out under CO2 [7] <strong>and</strong> that the<br />
consumption of water can be reduced by about 80 % by multiple use of tanning solutions in simulated countercurrent<br />
process. In recent developments a method was found to reduce the waste water from tanning to almost<br />
zero [8]. During classical pretreatment (softening, liming, pickling) skins that are fully saturated with water are<br />
obtained. A part of that water (typically 20 to 40%), having a high pH-value (pH 11 to 12) is removed <strong>via</strong><br />
pressing or in centrifuges. The partly dewetted skins are contacted with a tanning solution (typically containing<br />
chromium sulfate at a pH of 2,8), which is penetrating into the skin. Those pretreated skins are contacted with<br />
pressurized CO2 (> 3 MPa) in rotating tanning drums. CO2 is partly diffusing into the skin <strong>and</strong> in the tanning<br />
solution. It is believed that the skin structure is widened by the gas <strong>and</strong> that the pH-value of the aqueous tanning<br />
6
solutions is slightly increased by pressurized CO2 to values between 3 <strong>and</strong> 4. In developing the process into<br />
industrial scale (tanning drum of some m³) it was found that tanning times can even be shorter than in smaller<br />
equipment (drum < 20 liters). Leather of high quality is obtained already after 2 hours of contact with CO2. This<br />
further reduction is due to the improved mechanical movement of the skins by rods, mounted in the rotating<br />
tanning baskets.<br />
Under classical tanning conditions the skins are subject to hydrolysis at a low pH-value. To reduce the so-called<br />
swelling a rather large amount of salt (NaCl) is added. It was found that salt becomes obsolete, if the process is<br />
carried out under CO2. After expansion at rates of 1 to 2 bar/min the wet skins are removed from the autoclave.<br />
To find out whether the tanning agent is chemically bound in the skin, they are washed with a defined amount of<br />
boiling water. Shrinking of the impregnated material would be a first indication for bad quality due to<br />
degradation of non-reacted proteins. Leather with shrinking temperatures of 100°C <strong>and</strong> above is obtained.<br />
Chromium content in the hot washing water would be an indication that the chromium is not fully bound. By<br />
ICP-AAS extremely low concentrations of chromium in the washing water are found after CO2-intensified<br />
tanning, indicating that practically all chromium present in the original tanning solutions is chemically bound in<br />
the skin. In classical processes, chromium has to be overdosed in free water, to provide a reservoir <strong>and</strong> to<br />
maintain a concentration gradient from the free liquid phase into the skin. Such overdosing is obsolete, if the<br />
impregnation process is carried out under CO2 in the above described way. This leads to a considerably reduced<br />
consumption of chromium for tanning. In Figure 8 the consumption of water, salt <strong>and</strong> chromium for a tanning<br />
batch of typical size (3 t of skin) is compared.<br />
Figure 8: Comparison of consumables in classical <strong>and</strong> CO2-intensified tanning process<br />
Under the theoretical assumption that all skins in the world would be tanned <strong>via</strong> a CO2-intensified process, the<br />
savings with respect to raw materials, required energy <strong>and</strong> Carbon dioxide emissions would be:<br />
• Reduction of waste water containing chromium >95%,<br />
o >14 million m³ per year<br />
• Reduction of tanning time per batch<br />
o from 12 to
sometimes high solubility of impregnates, solid substrates <strong>and</strong> gases there is a number of advantages of<br />
impregnation <strong>via</strong> supercritical fluids compared to classical processes<br />
• Temperatures are moderate or low,<br />
• Depth of penetration can be (very) high,<br />
• Contact times are short,<br />
• Use of (hazardous) solvents can be avoided,<br />
• Time <strong>and</strong> energy consuming drying procedures can be avoided,<br />
• Overdosing of impregnates causing pollution <strong>and</strong>/or requiring recovery is reduced or avoided,<br />
• Dem<strong>and</strong> for consumables is reduced or avoided.<br />
Process analysis <strong>and</strong> examples illustrate that exploiting the interaction of nearcritical fluids with (solid)<br />
materials, the impregnating agents <strong>and</strong> further additives to improve processes <strong>and</strong> to generate new products<br />
requires specific knowledge. Especially the interaction between solid matrices, impregnating agents <strong>and</strong> gas is<br />
highly complex <strong>and</strong> not yet fully understood from the theoretical point of view, especially if solid materials have<br />
directional-dependent properties (anisotropies). Nevertheless by experimental <strong>and</strong> empirical methods selected<br />
processes <strong>and</strong> products have successfully been developed <strong>and</strong> introduced industrially, e.g for impregnating<br />
wood. By experimental studies on the impregnation of other products mostly in research or small technical scale<br />
specific features of the application of near-critical fluids have been discovered (bubble formation, swelling, pHvalue<br />
shift for triggering reactive impregnation, modification of crystallinity, cracking of solids) <strong>and</strong> have partly<br />
been investigated. The examples were selected to highlight the very high potential for that technique in a variety<br />
of markets like technical polymers, medical applications, food products or natural materials like leather. This<br />
selection is far from being complete as very interesting proposals have been made for drug delivery systems,<br />
impregnation of inorganic materials like stone or concrete, for generating new catalyst systems (e.g. making<br />
water soluble enzymes insoluble <strong>via</strong> low temperature impregnation) or for so called interpenetrating networks,<br />
where monomers are introduced into a solid <strong>via</strong> nearcritical fluids <strong>and</strong> subsequently are polymerised. These<br />
examples illustrate that the potential of this specific impregnation process can hardly be underestimated.<br />
LITERATURE<br />
1 Renner, M.; Weidner, E.; Jochems, B., Geihsler, H., Journal of Supercrit <strong>Fluids</strong>,<br />
http://dx.doi.org/10.1016/j.supflu.<strong>2012</strong>.01.007<br />
2 Renner, M., Weidner, E., Bertling, J., Proc 12th Eur. Meeting on Supercrit <strong>Fluids</strong>; Graz, 2010, Vol. 12,<br />
ISBN 978-2905267-72-6<br />
3 Gruener, S., Otto, F., Weidner, E., <strong>Impregnation</strong> of oil containing fruits, J. of Supercrit <strong>Fluids</strong>, accepted<br />
4 http://www.superwood.dk/<br />
5 Bach, E., Cleve, E., Schollmeyer, E., Rev. Prog. Color 32 (1), 2002, 88–102<br />
DOI: 10.1111/j.1478-4408.2002.tb00253.x<br />
6 Gamse, T., Marr, R., Wolf, C., Lederer, K., Chem. Ind. 61 (5), 2007, 229-232<br />
7 Geihsler, H., Weidner, E., DE 197 07 572 A 1, 1995<br />
8 Renner, M.,Geihsler, H., Weidner, E., DE 10 2009 018 323, 2009<br />
8