Method and system for preparing ASA emulsion
OwnerDennis G. Pardikesinventor
Life of this patent
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Abstract
A continuous output system makes paper coating by combining an emulsifier with ASA particles having sizes in the low to sub-micron region. A turbine, pump, blender or other device exposes the ASA to a number of repeated episodes of high shear until the resulting ASA is in the form of particles having a mean average diameter in approximately the 1μ range. A manifold provides the system piping in order to minimize the internal areas where ASA may build up. This manifold has a plurality of holes bored in a solid metal block so that each of the bores forms a short pipe which is only an inch or two in length in order to reduce the interior surface area of an ASA transport and conveyance system.
Claims28
A method of preparing an alkaline size, alkenyl succinic anhydride (“ASA”) in an emulsion, said method comprising the steps of:
- A. supplying a liquid including at least ASA;
- B. feeding a portion of said liquid of step (A) to a first input of a manifold;
- C. feeding a first stream of an emulsifier into a second input to said manifold, said liquid combining with said emulsifier within said manifold to form a first stream comprising a mixture of at least ASA and said emulsifier;
- D. feeding the first stream of step (C) through a mixing means which imparts enough energy to said emulsion to shear and break down said ASA into particles and divide an outflow from said mixing means (i) through a recycling loop to at least a third input of said manifold and (ii) to an output stream of said system, said output stream having a ratio of ASA to emulsifier set by the relative volumes of said streams of Step (B) and Step (C);
- and
- E. feeding said recycled emulsion of step (D) into said mixing means of step (D).
A method of preparing an alkaline size alkenyl succinic anhydride (“ASA”) comprising the steps of:
- A. combining an emulsifier and ASA, with a substantial portion of said ASA being formed into particles having a mean average particle size within the range of 0.25-2μ;
- B. diluting the combination of step (A) with a stream of emulsifier;
- C. carrying out said dilution of step (B) with a mixing means that imparts a shear force to said emulsion, said shear force being less than that which reduces the effectiveness of said emulsion by degrading substantial amounts of said emulsifier;
- D. recycling a first portion of a stream flowing out of said mixing means via a feedback loop extending from an output of said mixing means to a means for returning said stream to said mixing means;
- E. directing a second portion said stream flowing out of said mixing means to an output of the system;
- and
- F. minimizing an internal surface area of a system for carrying out said steps, said system being free of atomizing nozzles.
A method of processing a paper coating liquid containing at least ASA, said method comprises:
- A. processing said coating liquid in a mixing manifold formed by bores in a solid block of metal;
- B. subjected said ASA while outside said manifold to a high level of opportunities to be exposed to shear, said ASA responding to said shear by breaking into emulsion particles having sizes in the order of 0.5 to 5 microns;
- C. forcing said ASA particles of step (B) into a stream containing an emulsifier while inside said manifold;
- D. subjecting said stream of step (C) containing said emulsifier and ASA to a primary dilution while in said manifold;
- E. recycling a majority of said stream of step (D) to re-experience a repeated exposure to said high level of shear of step (B);
- F. sending a minority of said stream containing an emulsifier to a system output after it leaves said exposure to shear of step (B);
- and
- G. subjecting said stream containing an emulsifier and ASA to a secondary dilution while on its way to said system output in order to provide a finely turned amount of emulsifier and ASA relative to the total amount of said system output.
A method of preparing an alkaline sizing comprising the steps of:
- a. forming a fluid by mixing an emulsifier and a sizing agent to form a combined stream;
- b. diluting the combined fluid of step a with a stream of said emulsifier;
- c. applying a shearing force to said fluid during said dilution of step b, with enough shearing events per unit of time to produce a shearing force having an energy factor index which produces particles in a range of about 0.1 to 3 microns;
- d. dividing a stream created in step c into two parts;
- e. recycling one of said two parts of said stream in order to join the fluid formed in step a;
- and
- f. directing the other of said two parts of said stream to an output in order to provide a finished stream.
A method of breaking a blend of a sizing, emulsifier, and a surfactant into fine particles for coating paper, said method comprising the steps of:
- a. selecting a moving mechanical means for imparting shearing events to a fluid during each complete movement;
- b. subjecting said blend to said selected mechanical moving means for imparting shearing events to said blend;
- and
- c. repeating the shearing events of step b at a rate which provides an energy factor determined by the following parameters applied by said mechanical means;
- a number of shearing events per unit of time, multiplied by the velocity at which said mechanical means moves per unit of time, and further multiplied by the duration of said unit of time.
A system for preparing ASA by processing said ASA within a manifold formed in a solid block of metal having a plurality of holes that are formed therein to provide a plurality of bores that function as a network of pipes to convey liquids;
- throttle means associated with inputs to said bores;
- a source of the ASA coupled to a first of said bores via one of said throttle means;
- means for pressurizing and conveying said ASA at a high pressure through said first bore in said block of metal;
- means for introducing an electrolyte into a second of said bores via a second of said throttle means;
- means for introducing an emulsifier into a third of said bores via a third of said throttle means;
- means within said manifold for combining said pressurized ASA, said emulsifier and said electrolyte within a single stream;
- means comprising a recycling loop coupled from said manifold through mixing means for imparting an impacting shear and on to a fourth of said bores;
- a pressure regulating means;
- and means for taking a system output from a fifth of said bores via said pressure regulating means.
A system for preparing ASA by processing said ASA within a manifold formed in a solid block of metal having a plurality of holes that are formed therein to provide a plurality of bores that function as a network of pipes to convey liquids;
- a source of the ASA coupled to a first of said bores;
- means for pressurizing and conveying said ASA at a high pressure through said first bore in said block of metal;
- means for introducing an electrolyte into a second of said bores;
- means for introducing an emulsifier into a third of said bores;
- means within said manifold for combining said pressurized ASA, said emulsifier and said electrolyte within a single stream;
- means comprising a recycling loop coupled from said manifold through said mixing means for imparting an impacting shear and on to a fourth of said bores;
- and means for taking a system output from a fifth of said bores, and replaceable plug means in at least some of said bores.
Dependencies are inferred from the claim text.