DODGEN
Polysulfate Industrialization Process Package Development Project Case Study
Case Introduction
Leveraging its extensive expertise in reaction and separation technologies, DODGEN Chemical provided a complete process package development service for polysulfate to a leading domestic new materials enterprise. To address the engineering challenges of scaling this novel material from laboratory research to industrial production, DODGEN completed critical physical property data, optimized key unit operations (such as extraction and crystallization), and successfully transformed research achievements into an implementable engineering solution—bridging the “last mile” toward large-scale polysulfate manufacturing.
Project Background
Industry Demand: Polysulfate is a novel material produced via the sulfur(VI) fluoride exchange (SuFEx) click chemistry reaction, featuring outstanding chemical stability and mechanical properties. As a highly promising new engineering plastic, it can not only replace traditional specialty plastics such as polysulfone and polycarbonate, but also offers significant market potential in high-end applications including automotive, electronics and electrical appliances, aerospace, medical devices, and construction machinery.
Traditional Pain Points: Despite its excellent performance, limitations in conventional synthesis routes and outdated process technologies have prevented stable large-scale production. Previously, polysulfate faced the long-standing challenge of “achievable in the lab, but not manufacturable in the plant,” severely hindering its commercialization.
Project Type: New project (pilot-scale scale-up and industrialization). Based on the customer’s lab-scale R&D data, DODGEN carried out engineering scale-up design to bridge the gap from scientific成果 to an industrial production unit.
Project Highlights
DODGEN delivered a deeply empowering service—from fundamental data measurement to full process package compilation. The core technologies and value delivered are as follows:
Comprehensive Customized Process Package Design:
Leveraging extensive engineering experience, DODGEN completed critical missing data required for scale-up from lab to industrial production, including key parameters for separation, transfer, and handling. The deliverables covered complete engineering design work such as process simulation and calculations, material balance, equipment and piping layout, and instrumentation selection.
Core Technology Breakthroughs and Process Upgrading:
Unit operation optimization: Existing operations such as extraction and centrifugation were fully upgraded, and pilot-scale validation confirmed the feasibility of separation approaches including distillation, extraction, and crystallization.
Accurate data support: Key physical property data were precisely measured, including vapor–liquid equilibrium (VLE), liquid–liquid equilibrium (LLE), melting point, and heat of fusion, ensuring design reliability.
Green closed-loop system: Halogen recovery, recycling and cascading use of multiple organic solvents, as well as wastewater and heat-transfer medium circulation systems were improved, enabling efficient treatment and resource utilization of the “three wastes”.
Value Delivered:
Significantly improved yield: Through precise process control and advanced separation technology, the yield of the target product was substantially increased.
Industrialization breakthrough achieved: The long-standing challenge of mass production of polysulfate was successfully addressed, enabling the customer to transition from laboratory technology to an industrial production unit.
Chemical Process Solutions
Process Technology
Separation Equipment
Continuous Flow Reactor
Application
Sustainability
Reaction and Separation Professional, Low Carbon Technology Partners
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