A new method for recovering the F-110 phenol-formaldehyde resin from waste lye solutions formed in the production of karites

The new no-waste low-energy phys.-chem. concept is to carbonate the waste lye soln. contg. NaOH, water-sol. Na salts of resol-resin poly and oligomers, and PhONa, with either pure CO2 or with cool flue gases. The CO2-satd. soln. stratifies into the heavier resinous (F-110) fraction and the water fraction contg. carbonates, residual NaOH, and trace amts. of PhONa A calcd. amt. of CaO or Ca(OH)(2) is added to the water phase to ppt. CaCO3 and to reconstitute NaOH. The NaOH decanted and replenished to become aq. 10% NaOH, is recycled to wash impregnated karite products. The CaCO3 is filtered, dried, calcined at 900 degrees C and reused. The calcd. economic indices and the considered ecological aspects speak in favor the new process which may replace the existing lye combustion process.