Resol beads, methods of making them and methods of using them
AssigneeEastman Chemical Company
InventorsCharles Sumner, Ramesh Munjal, Ruairi O'Meadhra, Chester Sink, Jerry Fauver, Robert Schisla, Shriram Bagrodia
Life of this patent
Estimating the term…
Abstract
Resol beads are disclosed that are prepared in high yield by reaction of a phenol with an aldehyde, with a base as catalyst, a colloidal stabilizer, and optionally a surfactant. The resol beads have a variety of uses, and may be thermally treated and carbonized to obtain activated carbon beads.
Claims82
A process for producing resol beads, the process comprising reacting a phenol with an aldehyde, in the presence of a base as catalyst, in an agitated aqueous medium provided with a colloidal stabilizer, optionally a surfactant, and previously-formed resol beads, for a period of time and at a temperature sufficient to produce an aqueous dispersion of resol beads.
A process for producing resol beads, the process comprising:
- reacting a phenol with an aldehyde, in the presence of a base as catalyst, in an agitated aqueous medium provided with a colloidal stabilizer, and optionally a surfactant, for a period of time and at a temperature sufficient to produce an aqueous dispersion of resol beads;
- recovering from the aqueous dispersion resol beads above a minimum particle size;
- and
- retaining or recycling resol beads below the minimum particle size in the aqueous dispersion.
A process for producing resol beads, the process comprising:
- a) reacting a phenol with an aldehyde in the presence of a base as catalyst, in an agitated aqueous medium that includes a colloidal stabilizer, and optionally a surfactant, for a period of time and at a temperature sufficient to produce an aqueous dispersion of resol beads;
- b) recovering the resol beads from the aqueous dispersion;
- c) separating beads below a minimum particle size;
- and
- d) recycling the beads below a minimum particle size to the aqueous medium of step a).
A process for producing resol beads, the process comprising:
- providing a phenol, a portion of an aldehyde, and a portion of a base as catalyst to a reaction mixture which is an agitated aqueous medium provided with a colloidal stabilizer, optionally a surfactant, and previously-formed resol beads;
- reacting in the reaction mixture for a period of time and at a temperature sufficient to produce an aqueous dispersion of partially-formed resol beads;
- thereafter adding a remaining portion of the base and the aldehyde over a period of time and further reacting the reaction mixture to obtain fully-formed resol beads.
A process for producing resol beads, the process comprising:
- providing a portion of a phenol, a portion of an aldehyde, and a portion of a base as catalyst to a reaction mixture which is an agitated aqueous medium that includes a colloidal stabilizer, optionally a surfactant, and previously-formed resol beads;
- reacting for a period of time and at a temperature sufficient to produce an aqueous dispersion of partially-formed resol beads;
- thereafter providing a further portion of the phenol, a further portion of the aldehyde, and a further portion of the base to the reaction mixture and reacting for a further period of time;
- and
- thereafter adding any remaining portion of the phenol, the aldehyde, and the base over a period of time and at a temperature sufficient to obtain fully-formed resol beads.
Resol beads made by a process comprising reacting a phenol with an aldehyde, in the presence of a base as catalyst, in an agitated aqueous medium provided with a colloidal stabilizer, optionally a surfactant, and previously-formed resol beads, for a period of time and at a temperature sufficient to produce an aqueous dispersion of resol beads.
Resol beads made by a process comprising:
- reacting a phenol with an aldehyde, in the presence of a base as catalyst, in an agitated aqueous medium provided with a colloidal stabilizer, and optionally a surfactant, for a period of time and at a temperature sufficient to produce an aqueous dispersion of resol beads;
- recovering from the aqueous dispersion resol beads above a minimum particle size;
- and
- retaining or recycling resol beads below the minimum particle size in the aqueous dispersion.
Resol beads made by a process comprising:
- a) reacting a phenol with an aldehyde in the presence of a base as catalyst, in an agitated aqueous medium that includes a colloidal stabilizer, and optionally a surfactant, for a period of time and at a temperature sufficient to produce an aqueous dispersion of resol beads;
- b) recovering the resol beads from the aqueous dispersion;
- c) separating beads below a minimum particle size;
- and
- d) recycling the beads below a minimum particle size to the aqueous medium of step a).
Resol beads made by a process comprising:
- providing a phenol, a portion of an aldehyde, and a portion of a base as catalyst to a reaction mixture which is an agitated aqueous medium provided with a colloidal stabilizer, optionally a surfactant, and previously-formed resol beads;
- reacting in the reaction mixture for a period of time and at a temperature sufficient to produce an aqueous dispersion of partially-formed resol beads;
- thereafter adding a remaining portion of the base and the aldehyde over a period of time and further reacting the reaction mixture to obtain fully-formed resol beads.
Resol beads made by a process comprising:
- providing a portion of a phenol, a portion of an aldehyde, and a portion of a base as catalyst to a reaction mixture which is an agitated aqueous medium that includes a colloidal stabilizer, optionally a surfactant, and previously-formed resol beads;
- reacting for a period of time and at a temperature sufficient to produce an aqueous dispersion of partially-formed resol beads;
- thereafter providing a further portion of the phenol, a further portion of the aldehyde, and a further portion of the base to the reaction mixture and reacting for a further period of time;
- and
- thereafter adding any remaining portion of the phenol, the aldehyde, and the base over a period of time and at a temperature sufficient to obtain fully-formed resol beads.
Dependencies are inferred from the claim text.