Processes and systems for making particulate masterbatches, and compositions obtained therefrom

A process for making a particulate masterbatch, said process comprising:

• (a) providing a plurality of particulates;
• (b) optionally introducing said plurality of particulates and a pH-adjusting agent to a first mixing unit;
• (c) conveying an aqueous polymer latex and said plurality of particulates from step (a) or from step (b), if conducted, to a second mixing unit, thereby generating a particulate-latex mixture comprising water, wherein said second mixing unit is a second static inline mixer;
• (d) optionally conveying said particulate-latex mixture and a first process additive to a third mixing unit;
• (e) conveying said particulate-latex mixture to a homogenizer, thereby generating a homogenized particulate-latex mixture;
• (f) optionally conveying said homogenized particulate-latex mixture to a centrifuge to remove a first portion of said water, thereby generating a dewatered and homogenized particulate-latex mixture;
• and
• (g) conveying said dewatered and homogenized particulate-latex mixture or, if step (f) is not conducted, conveying said homogenized particulate-latex mixture from step (e) to a screw mixer, wherein said screw mixer is configured to remove a second portion of said water, thereby generating a particulate masterbatch,
• wherein steps (a), (c), (e), (f), and (g) are substantially conducted sequentially.

A process for making a particulate masterbatch, said process comprising:

• (a) providing a plurality of particulates;
• (b) optionally introducing said plurality of particulates and a pH-adjusting agent to a first mixing unit;
• (c) conveying an aqueous polymer latex and said plurality of particulates from step (a) or from step (b), if conducted, to a second mixing unit, thereby generating a particulate-latex mixture comprising water;
• (d) optionally conveying said particulate-latex mixture and a first process additive to a third mixing unit;
• (e) conveying said particulate-latex mixture to a homogenizer, thereby generating a homogenized particulate-latex mixture;
• (f) conveying said homogenized particulate-latex mixture to a centrifuge to remove a first portion of said water, thereby generating a dewatered and homogenized particulate-latex mixture, wherein step (f) utilizes heating to enhance water removal;
• and
• (g) conveying said dewatered and homogenized particulate-latex mixture to a screw mixer, wherein said screw mixer is configured to remove a second portion of said water, thereby generating a particulate masterbatch,
• wherein steps (a), (c), (e), (f), and (g) are substantially conducted sequentially.