Description:FORM 2
THE PATENTS ACT 1970 [39 of 1970]
&
The Patent Rules 2003 5
COMPLETE SPECIFICATION 10
[See sections 10 & rule 13]
TITLE: “METHOD FOR MANUFACTURING FERACRYLUM” 15
Name and Address of the Applicant:
D G CORPORATE INDIA MFG. PRIVATE LIMITED,
Plot no.275, Sector-03, HSIIDC, Phase-II, 20 Growth Centre, Bawal, Rewari, Haryana-123501
25
Nationality: INDIAN
The following specification particularly describes the invention and the manner in which it 30
is to be performed.
35
METHOD FOR MANUFACTURING FERACRYLUM
TECHNICAL FIELD
[0001] The presently disclosed embodiments are related, in general, to a method for manufacturing feracrylum. More particularly, the presently disclosed embodiments are related to utilizing chabazite in the purification of manufacturing feracrylum.
BACKGROUND
[0002] The subject matter discussed in the background section should not be assumed to be prior art merely as a result of its mention in the background section. Similarly, a problem mentioned in the background section or associated with the subject matter of the background section should not be assumed to have been previously recognized in the prior art. The subject matter in the background section merely represents different approaches, which in and of themselves may also be inventions.
[0003] The process of manufacturing Feracrylum, a combination of acrylic polymer and ferrous salts, involves various critical steps, including the purification of the solution mixture formed during partial polymerization. Traditionally, this purification step has relied on ion-exchange resins to remove ferrous and other impurities. While effective, ion-exchange resins can be expensive and pose challenges in terms of availability, scalability, and long-term operational costs, particularly when implemented on a commercial scale.
[0004] Zeolites, including Chabazite, are a class of naturally occurring microporous aluminosilicate minerals widely recognized for their adsorption properties. Zeolites have found applications in various industrial processes, including filtration, catalysis, and gas separation. However, their potential use as an alternative to ion-exchange resins in the purification of Feracrylum during its manufacturing process has not been fully explored.
[0005] The present specification recognizes that there is a need to bridge that gap by introducing Chabazite into the purification step, addressing the limitations of the ion-exchange resin method.
[0006] Thus, in view of the above, there is a long-felt need in the industry to address the aforementioned deficiencies and inadequacies.
[0007] Further limitations and disadvantages of traditional approaches will become apparent to one of skill in the art, through the comparison of described systems with some aspects of the present disclosure, as set forth in the remainder of the present application and with reference to the drawings.

SUMMARY
[0008] A method for manufacturing feracrylum is provided substantially, as shown in and/or described in connection with at least one of the figures.
[0009] An aspect of the present disclosure relates to a method for manufacturing feracrylum. The method includes the step of partially polymerizing acrylic acid with ferrous salts and potassium persulfate to obtain a solution mixture. The method includes a step of purifying the solution mixture to remove one or more impurities by introducing chabazite as a purification medium. The chabazite utilizes an SBA-15 structure to adsorb ferrous and other impurities. The method includes a step of subjecting the purified solution mixture to vacuum drying. The method includes a step of obtaining feracrylum as an end product.
[0010] In an aspect, the chabazite purification step is performed under controlled temperature and pH conditions to optimize the adsorption of impurities.
[0011] In an aspect, the SBA-15 structure of chabazite enhances its adsorption capacity through uniform mesoporous channels.
[0012] In an aspect, the adsorption technology employed with chabazite is designed for the efficient removal of ferrous ions and other metallic impurities.
[0013] In an aspect, the vacuum drying step is performed at a pressure ranging between 0.01 and 0.1 atm to ensure effective moisture removal from the purified solution.
[0014] In an aspect, the purified solution after the chabazite purification step exhibits a reduction in ferrous ion content to less than 5 ppm.
[0015] In an aspect, chabazite is introduced into the solution mixture as a packed column or a filter bed.
[0016] In an aspect, the chabazite purification medium is regenerated after a specified number of purification cycles through chemical or thermal desorption.
[0017] In an aspect, the combination of chabazite and adsorption technology provides a cost-effective alternative to ion-exchange resin for feracrylum manufacturing.
[0018] In an aspect, the use of chabazite enhances the overall yield of feracrylum by reducing impurities that adversely affect the final product quality.
[0019] These and other features and advantages of the present disclosure may be appreciated from a review of the following detailed description of the present disclosure, along with the accompanying figures in which reference numerals refer to like parts throughout.

BRIEF DESCRIPTION OF DRAWINGS
[0020] The accompanying drawings illustrate the various embodiments of systems, methods, and other aspects of the disclosure. Any person with ordinary skills in the art will appreciate that the illustrated element boundaries (e.g., boxes, groups of boxes, or other shapes) in the figures represent one example of the boundaries. In some examples, one element may be designed as multiple elements, or multiple elements may be designed as one element. In some examples, an element shown as an internal component of one element may be implemented as an external component in another and vice versa. Further, the elements may not be drawn to scale.
[0021] Various embodiments will hereinafter be described in accordance with the appended drawings, which are provided to illustrate and not to limit the scope in any manner, wherein similar designations denote similar elements, and in which:
[0022] FIG. 1 is a flowchart of a method for manufacturing Feracrylum, in accordance with at least one embodiment.

DETAILED DESCRIPTION
[0023] The present disclosure may be best understood with reference to the detailed figures and description set forth herein. Various embodiments are discussed below with reference to the figures. However, those skilled in the art will readily appreciate that the detailed descriptions given herein with respect to the figures are simply for explanatory purposes as the apparatuses, methods, and systems may extend beyond the described embodiments. For example, the teachings presented and the needs of a particular application may yield multiple alternative and suitable approaches to implement the functionality of any detail described herein. Therefore, any approach may extend beyond the particular implementation choices in the following embodiments described and shown.
[0024] References to “one embodiment,” “at least one embodiment,” “an embodiment,” “one example,” “an example,” “for example,” and so on indicate that the embodiment(s) or example(s) may include a particular feature, structure, characteristic, property, element, or limitation but that not every embodiment or example necessarily includes that particular feature, structure, characteristic, property, element, or limitation. Further, repeated use of the phrase “in an embodiment” does not necessarily refer to the same embodiment.
[0025] The present invention provides a purification method for the manufacturing of Feracrylum by utilizing Chabazite, a type of zeolite, as an alternative to traditional ion-exchange resins. This invention addresses the limitations of current purification processes by leveraging the high adsorption capacity and cost-effective nature of Chabazite. During the purification step, Chabazite effectively removes ferrous impurities through its microporous SBA-15 structure, mimicking a filtration or sieve mechanism.
[0026] The use of Chabazite not only ensures efficient impurity removal but also reduces operational costs and complexity, particularly when applied at a commercial scale. Furthermore, the natural abundance and environmental friendliness of Chabazite make it a sustainable and innovative choice for industrial purification processes. This advancement in Feracrylum manufacturing presents a scalable and economically viable solution, paving the way for improved production efficiency and quality.
[0027] FIG. 1 is a flowchart of a method 100 for manufacturing Feracrylum, in accordance with at least one embodiment. Method 100 includes the step 102 of partially polymerizing acrylic acid with ferrous salts and potassium persulfate to obtain a solution mixture. Method 100 includes a step 104 of purifying the solution mixture to remove one or more impurities by introducing chabazite as a purification medium. The chabazite utilizes an SBA-15 structure to adsorb ferrous and other impurities. Method 100 includes a step 106 of subjecting the purified solution mixture to vacuum drying. Method 100 includes a step 108 of obtaining feracrylum as an end product. In an embodiment, the chabazite purification step is performed under controlled temperature and pH conditions to optimize the adsorption of impurities. In an embodiment, the SBA-15 structure of chabazite enhances its adsorption capacity through uniform mesoporous channels. In an embodiment, the adsorption technology employed with chabazite is designed for the efficient removal of ferrous ions and other metallic impurities. In an embodiment, the vacuum drying step is performed at a pressure ranging between 0.01 and 0.1 atm to ensure effective moisture removal from the purified solution. In an embodiment, the purified solution after the chabazite purification step exhibits a reduction in ferrous ion content to less than 5 ppm. In an embodiment, chabazite is introduced into the solution mixture as a packed column or a filter bed. In an embodiment, the chabazite purification medium is regenerated after a specified number of purification cycles through chemical or thermal desorption. In an embodiment, the combination of chabazite and adsorption technology provides a cost-effective alternative to ion-exchange resin for feracrylum manufacturing. In an embodiment, the use of chabazite enhances the overall yield of feracrylum by reducing impurities that adversely affect the final product quality.
[0028] According to an embodiment herein, the present method relates to an improved method for manufacturing Feracrylum, a pharmaceutical compound formed by the combination of acrylic polymers with ferrous salts. The conventional process of manufacturing Feracrylum involves two key steps: the partial polymerization of acrylic acid with ferrous salts and potassium persulfate, followed by the purification of the resulting solution mixture to remove impurities. Traditionally, the purification step has relied on ion-exchange resins, which, while effective, have limitations in terms of cost and scalability.
[0029] The present method introduces the use of Chabazite, a type of zeolite, as an innovative and efficient alternative to ion-exchange resins in the purification process. Chabazite has demonstrated high adsorption efficiency for removing ferrous and other impurities from the solution mixture. This approach not only simplifies the purification process but also offers a cost-effective and sustainable method. The purified solution can then undergo vacuum drying and subsequent processing to yield Feracrylum as the final product. The adoption of Chabazite provides a pathway to exploring alternative purification methods and optimizing the Feracrylum manufacturing process.
[0030] Chabazite crystals can be synthesized directly from a template-free aluminum silicate gel combined with nanosized (100 nm) zeolite T. The synthesis method follows a procedure originally developed by Zhao and colleagues for SBA-15, a mesoporous silica material. The process involves dissolving an amphiphilic triblock copolymer in an acidic solution at approximately 40°C under constant agitation for 2 hours. A silica source is then added to the mixture while maintaining the same temperature and stirring conditions for 24 hours.
[0031] The next stage includes hydrothermal treatment at 100°C for 48 hours, after which the formed product is cooled to room temperature, filtered, washed with water, dried, and calcined at temperatures ranging from 500°C to 550°C for 5 hours. Variations in the calcination temperature, such as maintaining it at 525°C, allow for adjustments in the structural properties of the synthesized Chabazite. This synthesis method ensures the production of Chabazite crystals with high adsorption capacity, making them ideal for use in the purification of Feracrylum solutions.
[0032] Further, the present method leverages Chabazite's properties to create a more efficient, cost-effective, and environmentally friendly purification process, thereby advancing the manufacturing of Feracrylum.
[0033] Chabazite offers several advantages as a purification material in the manufacturing of Feracrylum, making it a superior alternative to traditional ion exchange resins. It is highly cost-effective, particularly when applied on a commercial scale, significantly reducing operational expenses. The wide availability of zeolites, including Chabazite, ensures a reliable and easily accessible supply chain, enhancing its practicality for industrial use. Additionally, Chabazite demonstrates exceptional adsorption efficiency, effectively removing ferrous impurities and other contaminants from the solution mixture during the purification step. Its utilization simplifies the purification process through innovative adsorption technology, providing a user-friendly and efficient operational framework. Moreover, as a naturally occurring material, Chabazite is environmentally friendly, making it a sustainable and greener choice for industrial purification applications. These combined benefits underscore its potential to revolutionize the purification process in Feracrylum manufacturing.
[0034] The use of Chabazite in the purification process for manufacturing Feracrylum operates by introducing the Feracrylum mixture onto an SBA-15 mesoporous structure. Similar to conventional filtration or sieving methods, this approach leverages Chabazite's high adsorption capacity to effectively remove iron and other impurities. Adsorption technology is recognized as an economical and innovative method due to its operational efficiency, simplicity, and adaptability for designing various adsorbent materials.
[0035] SBA-15, a mesoporous silica-based material, is characterized by its unidirectional, hexagonally organized pore structure. It features cylindrical and parallel mesopores, with additional micropores or mesopores embedded within its silica walls. The synthesis of SBA-15 typically involves dissolving an amphiphilic triblock copolymer, such as Pluronic P123, in an acidic solution at approximately 40°C under continuous agitation. After two hours, a silica source, such as tetraethyl orthosilicate (TEOS), is added, and the mixture is maintained under the same conditions for 24 hours. Hydrothermal treatment follows at 100°C for 48 hours. The final product is cooled, filtered, washed, dried, and calcined at temperatures between 500°C and 550°C for five hours.
[0036] Pluronic P123 is ideal for SBA-15 synthesis due to its low ethylene oxide to propylene oxide (EO/PO) ratio, which promotes the formation of micelles needed for the desired mesoporous structure. It is commercially available, cost-effective, and biodegradable. TEOS serves as the silica source because of its ability to produce high-purity materials and facilitate doping at low temperatures.
[0037] Although SBA-15 is often classified as an inert support, its remarkable properties—such as well-defined and uniform pores, excellent thermal and hydrothermal stability, pore diameters ranging from 2 to 10 nm, and a high surface area—make it suitable for anchoring nanoparticles or metal oxides. Functionalized SBA-15 has broad applications, including catalysis, wastewater treatment, biorefinery production, drug delivery, CO2 adsorption, and photodegradation. Its multi-functionalized variants are extensively utilized for adsorption, separation, and catalytic processes.
[0038] A person skilled in the art will understand that the usage of chabazite in the purification of manufacturing Feracrylum is described herein for illustrative purposes and should not be construed to limit the scope of the disclosure.
[0039] A person with ordinary skills in the art will appreciate that the compositions and methods have been illustrated and explained to serve as examples and should not be considered limiting in any manner. It will be further appreciated that the variants of the above-disclosed system elements, modules, and other features and functions, or alternatives thereof, may be combined to create other different apparatuses, systems, or applications.
[0040] While the present disclosure has been described with reference to certain embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from its scope. Therefore, it is intended that the present disclosure not be limited to the particular embodiment disclosed, but that the present disclosure will include all embodiments falling within the scope of the appended , Claims:embodiments falling within the scope of the appended claims.
CLAIMS
I/We Claim
1. A method for manufacturing feracrylum, comprising:
partially polymerizing acrylic acid with ferrous salts and potassium persulfate to obtain a solution mixture;
purifying the solution mixture to remove one or more impurities by introducing chabazite as a purification medium, wherein the chabazite utilizes an SBA-15 structure to adsorb ferrous and other impurities;
subjecting the purified solution mixture to vacuum drying; and
obtaining feracrylum as an end product.
2. The method of claim 1, wherein the chabazite purification step is performed under controlled temperature and pH conditions to optimize the adsorption of impurities.
3. The method of claim 1, wherein the SBA-15 structure of chabazite enhances its adsorption capacity through uniform mesoporous channels.
4. The method of claim 1, wherein the adsorption technology employed with chabazite is designed for efficient removal of ferrous ions and other metallic impurities.
5. The method of claim 1, wherein the vacuum drying step is performed at a pressure ranging between 0.01 and 0.1 atm to ensure effective moisture removal from the purified solution.
6. The method of claim 1, wherein the purified solution after the chabazite purification step exhibits a reduction in ferrous ion content to less than 5 ppm.
7. The method of claim 1, wherein chabazite is introduced into the solution mixture as a packed column or a filter bed.
8. The method of claim 1, wherein the chabazite purification medium is regenerated after a specified number of purification cycles through chemical or thermal desorption.
9. The method of claim 1, wherein the combination of chabazite and adsorption technology provides a cost-effective alternative to ion-exchange resin for Feracrylum manufacturing.
10. The method of claim 1, wherein the use of chabazite enhances the overall yield of Feracrylum by reducing impurities that adversely affect the final product quality.