Processes of spray drying polymer-containing dispersions, water-in-oil emulsions and water-in-oil microemulsions
AssigneeCytec Technology Corp.
InventorsWilliam Bloor Davies, John Edward Healy, Gary Kaui Lani Miller, Joseph J. Kozakiewicz
Life of this patent
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Abstract
Processes for spray drying water-soluble and water-swellable vinyl-addition polymer-containing dispersions, emulsions and microemulsions to obtain substantially dry water-soluble or water-swellable polymer particles, compositions of substantially dry water-soluble or water-swellable polymer particles, methods of agglomerating spray-dried polymer particles, and methods of using spray-dried polymer particles and agglomerates in water-treating, mining, paper, food processing, soil conditioning, solution thickening, biotechnological, and oil recovery applications are disclosed.
Claims30
A process for producing substantially dry water-soluble or water-swellable vinyl-addition polymer particles comprising (a) spray-drying a vinyl-addition polymer-containing water-in-oil emulsion or water-in-oil microemulsion into a gas stream with a residence time of about 8 to about 120 seconds and at an outlet temperature of about 70.degree. C. to less than 100.degree. C. and (b) collecting resultant polymer particles, wherein said vinyl-addition polymer-containing water-in-oil emulsion or water-in-oil microemulsion is comprised of a polymer having pendant groups selected from the group consisting of amide, tertiary aminomethyl, quaternized tertiary aminomethyl, hydroxyl, glyoxal, sulfonate, sulfonate salt, carboxylic acid, carboxylic acid salt, hydroxamic acid, and hydroxamic acid salt, or a polymer having recurring units selected from the group consisting of dialkylaminoalkyl(alk)acrylate, dialkylaminoalkyl(alk)acrylate salt, and quaternized dialkylaminoalkyl(alk)acrylate.
A process for producing substantially dry water-soluble or water-swellable vinyl-addition polymer particles comprising (a) spray-drying a vinyl-addition polymer-containing water-in-oil emulsion or water-in-oil microemulsion into a gas stream with a residence time of about 8 to about 120 seconds and at an outlet temperature of about 70.degree. C. to less than 100.degree. C. and (b) collecting resultant polymer particles, wherein said vinyl-addition polymer-containing water-in-oil emulsion or microemulsion is comprised of a polymer selected from the group consisting of Mannich poly(alk)acrylamide, quaternized Mannich poly(alk)acrylamide, hydroxamated polyacrylamide, esterified (meth)acrylic acid polymer, esterified (meth)acrylic acid copolymer, and hydrolyzed polyacrylamide.
A process for producing substantially dry water-soluble or water-swellable vinyl-addition polymer particles comprising (a) spray-drying a vinyl-addition polymer-containing water-in-oil emulsion or water-in-oil microemulsion into a gas stream with a residence time of about 8 to about 120 seconds and at an outlet temperature of about 70.degree. C. to less than 100.degree. C. and (b) collecting resultant polymer particles, wherein said vinyl-addition polymer-containing water-in-oil emulsion or microemulsion is comprised of a polymer having recurring units selected from the group consisting of acrylamide, dialkylaminoalkyl(alk)acrylate, dialkylaminoalkyl(alk)acrylate salt, quaternized dialkylaminoalkyl(alk)acrylate, acrylic acid, and acrylic acid salt.
A process for producing substantially dry water-soluble or water-swellable vinyl-addition polymer agglomerates comprising (a) spray-drying a vinyl-addition polymer-containing water-in-oil emulsion or water-in-oil microemulsion into a gas stream with a residence time of about 8 to about 120 seconds and at an outlet temperature of about 70.degree. C. to less than 100.degree. C., (b) collecting resultant polymer particles, and (c) agglomerating said polymer particles to form agglomerates, wherein said vinyl-addition polymer-containing water-in-oil emulsion or microemulsion is comprised of a polymer having recurring units selected from the group consisting of acrylamide, dialkylaminoalkyl(alk)acrylate, dialkylaminoalkyl(alk)acrylate salt, quaternized dialkylaminoalkyl(alk)acrylate, acrylic acid, and acrylic acid salt.
A process for producing substantially dry water-soluble or water-swellable vinyl-addition polymer particles comprising (a) spray-drying a vinyl-addition polymer-containing water-in-oil emulsion or water-in-oil microemulsion into a gas stream with a residence time of about 8 to about 120 seconds and at an outlet temperature of about 70.degree. C. to less than 100.degree. C. and (b) collecting resultant polymer particles, wherein said vinyl-addition polymer-containing water-in-oil emulsion or water-in-oil microemulsion is comprised of a polymer selected from the group consisting of (1) a polymer containing 10 mole % or more of recurring units having pendant groups selected from the group consisting of carboxylic acid and carboxylic acid salt and having a standard viscosity of at least about 8.0 cps, (2) a polymer containing 20 mole % or more of recurring units having pendant groups selected from the group consisting of carboxylic acid and carboxylic acid salt and having a standard viscosity of at least about 9.0 cps, (3) a polymer containing at least about 1 mole % of tertiary aminomethyl groups, (4) an acrylamide polymer containing at least about 1 mole % of quaternized tertiary aminomethyl groups, (5) an acrylamide polymer containing at least about 1 mole % of hydroxamic acid or hydroxamic acid salt groups, (6) an esterified polymer containing hydroxamic acid groups and carboxylic acid groups or salts thereof, and (7) an ionic, organic, polymer microbead being less than about 750 nanometers in diameter if crosslinked and less than about 60 nanometers in diameter if non-crosslinked and water-insoluble, the ionicity of the microbead being at least about 1%.
A process for producing substantially dry water-soluble or water-swellable vinyl-addition polymer agglomerates comprising (a) spray-drying a vinyl-addition polymer-containing water-in-oil emulsion or water-in-oil microemulsion into a gas stream with a residence time of about 8 to about 120 seconds and at an outlet temperature of about 70.degree. C. to less than 100.degree. C., (b) collecting resultant polymer particles, and (c) agglomerating said polymer particles to form agglomerates, wherein said vinyl-addition polymer-containing water-in-oil emulsion or water-in-oil microemulsion is comprised of a polymer having pendant groups selected from the group consisting of tertiary aminomethyl, quaternized tertiary aminomethyl, carboxylic acid, carboxylic acid salt, hydroxamic acid, and hydroxamic acid salt.
A process for producing substantially dry water-soluble or water-swellable vinyl-addition polymer particles comprising (a) spray-drying a vinyl-addition polymer-containing dispersion into a gas stream with a residence time of about 8 to about 120 seconds and at an outlet temperature of about 70.degree. C. to less than 100.degree. C. and (b) collecting resultant polymer particles, wherein said vinyl-addition polymer-containing dispersion is comprised of a polymer having pendant groups selected from the group consisting of amide, tertiary aminomethyl, quaternized tertiary aminomethyl, hydroxyl, glyoxal, sulfonate, sulfonate salt, carboxylic acid, carboxylic acid salt, hydroxamic acid, and hydroxamic acid salt, or a polymer having recurring units selected from the group consisting of dialkylaminoalkyl(alk)acrylate, dialkylaminoalkyl(alk)acrylate salt, and quaternized dialkylaminoalkyl(alk)acrylate.
A process for producing substantially dry water-soluble or water-swellable polymer particles from a blend, comprising:
- (a) spray-drying a blend made by intermixing (i) a first water-soluble or water-swellable vinyl-addition polymer-containing dispersion, water-in-oil emulsion or water-in-oil microemulsion and (ii) a second water-soluble or water-swellable vinyl-addition polymer-containing dispersion, water-in-oil emulsion or water-in-oil microemulsion, into a gas stream with a residence time of about 8 to about 120 seconds and at an outlet temperature of about 70.degree. C. to about 150.degree. C. and (b) collecting resultant polymer particles.
A process for producing substantially dry water-soluble or water-swellable polymer particles from a blend, comprising:
- (a) spray-drying a blend comprised of, or made by intermixing, (i) a first water-soluble or water-swellable vinyl-addition polymer-containing water-in-oil emulsion or water-in-oil microemulsion and (ii) a second water-soluble or water-swellable vinyl-addition polymer-containing water-in-oil emulsion or water-in-oil microemulsion, into a gas stream with a residence time of about 8 to about 120 seconds and at an outlet temperature of about 70.degree. C. to about 150.degree. C. and (b) collecting resultant polymer particles.
A process for producing substantially dry water-soluble or water-swellable polymer particles from a blend, comprising:
- (A) spray-drying a blend comprised of, or made by intermixing, (I) a first water-soluble or water-swellable vinyl-addition polymer-containing water-in-oil emulsion or water-in-oil microemulsion and (II) a second water-soluble or water-swellable vinyl-addition polymer-containing water-in-oil emulsion or water-in-oil microemulsion, into a gas stream with a residence time of about 8 to about 120 seconds and at an outlet temperature of about 70.degree. C. to about 150.degree. C. and (B) collecting resultant polymer particles, wherein either (a) said first water-soluble or water-swellable vinyl-addition polymer-containing water-in-oil emulsion or microemulsion, or (b) said second water-soluble or water-swellable vinyl-addition polymer-containing water-in-oil emulsion or microemulsion, or (c) both, is comprised of a polymer having pendant groups selected from the group consisting of amide, tertiary aminomethyl, quaternized tertiary aminomethyl, hydroxyl, glyoxal, sulfonate, sulfonate salt, carboxylic acid, carboxylic acid salt, hydroxamic acid, and hydroxamic acid salt, or a polymer having recurring units selected from the group consisting of dialkylaminoalkyl(alk)acrylate, dialkylaminoalkyl(alk)acrylate salt, and quaternized dialkylaminoalkyl(alk)acrylate.
A process for producing substantially dry water-soluble or water-swellable polymer agglomerates from a blend, comprising:
- (A) spray-drying a blend comprised of, or made by intermixing, (I) a first water-soluble or water-swellable vinyl-addition polymer-containing water-in-oil emulsion or water-in-oil microemulsion and (II) a second water-soluble or water-swellable vinyl-addition polymer-containing water-in-oil emulsion or water-in-oil microemulsion, into a gas stream with a residence time of about 8 to about 120 seconds and at an outlet temperature of about 70.degree. C. to about 150.degree. C., (B) collecting resultant polymer particles, and (C) agglomerating resultant polymer particles, wherein either (a) said first water-soluble or water-swellable vinyl-addition polymer-containing water-in-oil emulsion or microemulsion, or (b) said second water-soluble or water-swellable vinyl-addition polymer-containing water-in-oil emulsion or microemulsion, or (c) both, is comprised of a polymer selected from the group consisting of Mannich poly(alk)acrylamide, quaternized Mannich poly(alk)acrylamide, hydroxamated polyacrylamide, esterified (meth)acrylic acid polymer, esterified (meth)acrylic acid copolymer, and hydrolyzed polyacrylamide.
A process for producing substantially dry water-soluble or water-swellable polymer agglomerates from a blend, comprising:
- (A) spray-drying a blend comprised of, or made by intermixing, (I) a first water-soluble or water-swellable vinyl-addition polymer-containing water-in-oil emulsion or water-in-oil microemulsion and (II) a second water-soluble or water-swellable vinyl-addition polymer-containing water-in-oil emulsion or water-in-oil microemulsion, into a gas stream with a residence time of about 8 to about 120 seconds and at an outlet temperature of about 70.degree. C. to about 150.degree. C., (B) collecting resultant polymer particles, and (C) agglomerating resultant polymer particles, wherein either (a) said first water-soluble or water-swellable vinyl-addition polymer-containing water-in-oil emulsion or microemulsion, or (b) said second water-soluble or water-swellable vinyl-addition polymer-containing water-in-oil emulsion or microemulsion, or (c) both, is comprised of a polymer having recurring units selected from the group consisting of acrylamide, dialkylaminoalkyl(alk)acrylate, dialkylaminoalkyl(alk)acrylate salt, quaternized dialkylaminoalkyl(alk)acrylate, acrylic acid, and acrylic acid salt.
A process for producing substantially dry water-soluble or water-swellable polymer agglomerates comprising (a) spray-drying a vinyl-addition polymer-containing dispersion, water-in-oil emulsion, or water-in-oil microemulsion (b) collecting resultant polymer particles;
- and (c) agglomerating said resultant polymer particles, wherein said vinyl-addition polymer-containing water-in-oil emulsion or water-in-oil microemulsion is comprised of a polymer having recurring units selected from the group consisting of acrylamide, dialkylaminoalkyl(alk)acrylate, dialkylaminoalkyl(alk)acrylate salt, quaternized dialkylaminoalkyl(alk)acrylate, (meth)acrylic acid, and (meth)acrylic acid salt.
A process for producing substantially dry water-soluble or water-swellable polymer agglomerates comprising (a) spray-drying a vinyl-addition polymer-containing water-in-oil emulsion or water-in-oil microemulsion into a gas stream with a residence time of about 10 to about 60 seconds and at an outlet temperature of about 70.degree. C. to about 95.degree. C.;
- (b) collecting resultant polymer particles;
- and (c) agglomerating said resultant polymer particles, wherein said vinyl-addition polymer-containing water-in-oil emulsion or water-in-oil microemulsion is comprised of a polymer selected from the group consisting of (1) a polymer containing 10 mole % or more of recurring units having pendant groups selected from the group consisting of carboxylic acid and carboxylic acid salt and having a standard viscosity of at least about 8.0 cps, (2) a polymer containing 20 mole % or more of recurring units having pendant groups selected from the group consisting of carboxylic acid and carboxylic acid salt and having a standard viscosity of at least about 9.0 cps, (3) a polymer containing at least about 1 mole % of tertiary aminomethyl groups, (4) an acrylamide polymer containing at least about 1 mole % of quaternized tertiary aminomethyl groups, (5) an acrylamide polymer containing at least about I mole % of hydroxamic acid or hydroxamic acid salt groups, (6) an esterified polymer containing hydroxamic acid groups and carboxylic acid groups or salts thereof, and (7) an ionic, organic, polymer microbead being less than about 750 nanometers in diameter if crosslinked and less than about 60 nanometers in diameter if non-crosslinked and water-insoluble, the ionicity of the microbead being at least about 1%.
A process for producing substantially dry water-soluble or water-swellable polymer agglomerates comprising (a) spray-drying a vinyl-addition polymer-containing water-in-oil emulsion or water-in-oil microemulsion into a gas stream with a residence time of about 10 to about 30 seconds and at an outlet temperature of about 70.degree. C. to about 95.degree. C.;
- (b) collecting resultant polymer particles;
- and (c) agglomerating said resultant polymer particles, wherein said vinyl-addition polymer-containing water-in-oil emulsion or water-in-oil microemulsion is comprised of a polymer selected from the group consisting of (1) a polymer containing 10 mole % or more of recurring units having pendant groups selected from the group consisting of carboxylic acid and carboxylic acid salt and having a standard viscosity of at least about 8.0 cps, (2) a polymer containing 20 mole % or more of recurring units having pendant groups selected from the group consisting of carboxylic acid and carboxylic acid salt and having a standard viscosity of at least about 9.0 cps, (3) a polymer containing at least about 1 mole % of tertiary aminomethyl groups, (4) an acrylamide polymer containing at least about 1 mole % of quaternized tertiary aminomethyl groups, (5) an acrylamide polymer containing at least about 1 mole % of hydroxamic acid or hydroxamic acid salt groups, (6) an esterified polymer containing hydroxamic acid groups and carboxylic acid groups or salts thereof, and (7) an ionic, organic, polymer microbead being less than about 750 nanometers in diameter if crosslinked and less than about 60 nanometers in diameter if non-crosslinked and water-insoluble, the ionicity of the microbead being at least about 1%;
- said polymer particles having a bulk density of about 0.45 grams per cubic centimeter to about 0.9 grams per cubic centimeter, about 90% or more of said particles being about 10 microns to about 400 microns in diameter.
Dependencies are inferred from the claim text.