EMULSION FOAM REDUCER FOR WET PROCESSING OF CELLULOSE OR WOOD-BASED PRODUCTS OR IN FOOD PROCESSING

Abstract

Methods are provided for defoaming water used in processing of various products such as cellulose or wood-based products or in food processing which is formed by reacting a fatty acid with a compound selected from the group consisting of ammonia, sodium, potassium and combinations thereof so as to form a water soluble soap, dispersing the water soluble soap in water, and homogenizing the dispersed water soluble soap with hydrophobic oil or hydrocarbon oil to produce the emulsion. Methods for preparing an emulsion used in this process are also provided. The emulsion is advantageous in that it can improve water resistance and/or reduce the use of water resistant additives during processing of cellulose or wood-based products or food-grade products.

Claims

1. A method of reducing foam and/or reducing water absorption in wet processing of manufactured board, paperboard or other cellulose or wood-based product, said method comprising: providing an emulsion composition having emulsifiers that undergo an exchange reaction with a hardness ion used in the wet process, said wet process containing hardness ions and used in processing of manufactured board, paperboard or other cellulose or wood based product; and adding said emulsion composition to processing water used in said wet process in a manner so as to distribute said emulsion into said wet process so as to allow emulsifiers in said emulsion composition to react with said hardness ions in the processing water so as to form hydrophobic particles and thus change the emulsifiers into a water resistant compound while also suppressing or eliminating foam in the processing water.

2. The method according to claim 1 further comprising drying said manufactured board, paperboard or other cellulose or wood-based product processed by said method so as to obtain a water-resistant manufactured board, paperboard or other cellulose or wood-based product so that it absorbs less water when submerged in water.

3. The method according to claim 1 wherein the hardness ion is selected from the group consisting of magnesium, calcium, aluminum, iron, and zinc.

4. The method according to claim 1 wherein the product is insulation board or paper.

5. The method according to claim 1 wherein said hardness ion is present in sufficient concentration so that an exchange reaction to take place

6. A method of making an emulsion comprising: reacting a fatty acid, or other emulsifiers that undergo an exchange reaction, with ammonia, amines, sodium or potassium hydroxide, or combinations thereof so that said fatty acid or other emulsifiers no longer act as emulsifiers, soaps, or detergents when added to a wet process containing hardness ions and used in processing of manufactured board, paperboard or other cellulose or wood based product. adding a hydrophobic oil, a hydrocarbon oil, or a hydrophobic hydrocarbon wax to said fatty acid or other emulsifiers and homogenizing until an emulsion is formed.

7. The method of making an emulsion according to claim 6, wherein the hydrocarbon oil is a non-polar hydrocarbon oil.

8. The method of making an emulsion according to claim 6, wherein the hydrophobic oil is a hydrophobic hydrocarbon oil.

9. The method of making an emulsion according to claim 6, further comprising: adding said emulsion to a wet process containing hardness ions and used in processing of manufactured board, paperboard or other cellulose or wood based product; and drying a product obtained by said wet process to obtain a finished product with greater water resistance.

10. The method of making an emulsion according to claim 9, wherein the finished product is insulting board or paper.

11. The method of making an emulsion according to claim 6, wherein the fatty acid is selected from the group consisting of stearic acid, caprylic acid, capric acid, lauric acid, myristic acid, palmitic acid, arachidic acid, behenic acid, lignoceric acid, cerotic acid, palmitoleic acid, sepienic acid, oleic acid, elaidic acid, vaccennic acid, linoleic acid, linolaidic acid, arachidonic acid, eicosapentaenoic acid, erucic acid, docosahexexaenoic acid, tall oil and mixtures thereof.

12. A method of improving water resistance in a finished product obtained by processing of manufactured board, paperboard or other cellulose or wood-based product using a wet process, said method comprising: providing an emulsion with a water-soluble soap that undergoes an exchange reaction in processing water of said wet process with a hardness ion of calcium, magnesium, iron, aluminum, or zinc and thereby no longer acts as soap; dispersing said water-soluble soap in said processing water and homogenizing the soap and said processing water with a material selected from the group consisting of hydrophobic hydrocarbon wax, slack wax, paraffin wax, paraffin oil, hydrocarbon oil, and hydrophobic hydrocarbon oil; adding said emulsion to said processing water to distribute emulsion into the wet process so as to allow soap in said emulsion to undergo an exchange reaction with hardness ions in the processing water so as to form hydrophobic particles or compounds and thereby change said soap into a water resistant compound in said processing water; and drying or pressing the manufactured board, paperboard, or other cellulose or wood-based product obtained in said method so as to improve water resistance.

13. The method according to claim 12 wherein said method also suppresses, reduces, or eliminates foam in the processing water.

14. The method according to claim 12 wherein said hardness ion is present in sufficient concentration so that an exchange reaction to take place

15. The method according to claim 12 wherein the pH of the emulsion is between 6 and 9.

16. The method according to claim 12 wherein the pH of the emulsion is greater than 6.

17. A method of reducing foam in industrial water used it a wet process to obtain manufactured board, paperboard, or other cellulose or wood-based product comprising: providing an emulsion having emulsifiers or a water-soluble soap that undergoes an exchange reaction with a hardness ion used in the wet process, said wet process containing hardness ions used in processing of manufactured board, paperboard or other cellulose or wood based product, said exchange reaction forming a water-soluble salt and an insoluble organometallic solid which acts as a defoamer; adding said emulsion to industrial water used in said wet process in a manner so as to distribute said emulsion into said wet process so as to allow emulsifiers in said emulsion to react with said hardness ions in the processing water so as to form hydrophobic particles and thus change the emulsifiers into a water resistant compound while also suppressing or eliminating foam in the industrial water during said wet process.

18. The method of claim 17 wherein the hardness ion is selected from the group consisting of calcium, magnesium, iron, aluminum, and zinc.

19. The method of claim 17 wherein said method results in the reduction of water absorption of a product produced by the wet processing of manufactured board, paperboard or other cellulose or wood based product.

20. The method of claim 19 wherein said product is insulated board or paper.

Description

DETAILED DESCRIPTION OF THE INVENTION

Testing of Defoamer:

[0027] Defoamer effectiveness was determined by the following method: Fill quart jar half full with water with foam issue. Put on jar lid and shake vigorously. Note foam generated and add one drop of defoamer. Observer the defoamers' effect on foam, then put lid on jar, and shake vigorously again. To compare two different defoamers, two jars are used and attached together with tape so that each liquid is exposed to the same vigorous shaking. This method was used to determine effective range of formulation. It was observed that the soap solution by itself was not as effective as the emulsion defoamer. The non-polar oils were not as effective as the emulsion defoamer. For this liquid one of the most effective defoamer contained 15 to 40 percent ammonium stearate and biodiesel or diesel or mineral oil or vegetable oil. Decreasing the water percentage increases the cost without observed benefit. There may be benefit of higher solids in other defoamer application or diluting before use with water.

[0028] The selection of which hydrophobic oil, hydrocarbon oil or non-polar hydrocarbon used in defoamer emulsion depends on what other properties are important. For example: Vegetable oils and bio-diesel produce less water resistance than kerosene, paraffin oil and paraffin wax. The soaps once reacted with the previously listed ions prevent this new defoamer made with bio-diesel and vegetable oil from destroying water resistance even when used in excess. To improve water resistance of a pulp or fiberboard product, Kerosene or petroleum diesel is better than vegetable oil or bio-diesel. If VOC emissions are important then canola oil is better than corn oil, Bio-diesel is better than petroleum diesel, Paraffin oil or wax is better than petroleum diesel. Emulsions made with paraffin oil or wax can improve water resistance of a pulp or manufactured board product, while having an impact on reducing foam. If food grade is important then food grade components must be used. Suitable food grade applications include pulp, paper and food or food processes that contain aluminum sulfate (alum) like some pickles. Waste water which contains enough of the ions needed to produce insoluble organometallic solids could also benefit from this new defoamer.

[0029] Exemplary methods to make the defoamer are as follows:

Method A

[0030] Add fatty acid to water heated above the melt point of the Fatty Acids or add Fatty acid to water and heat until Fatty acid melts. Mix and add base containing Ammonia, Sodium, or Potassium, forming soap solution with a pH of at least 9. To this soap solution, add a non-polar solvent, oil, or other non-polar hydrocarbon and homogenize the solution to form a stable emulsion.

Method B

[0031] Add fatty acid soap containing ammonia, potassium, or sodium to water and mix while ensuring that the pH is at least 9. To this soap solution then add non polar liquid and homogenize or reduce particle size enough to prevent separation forming a stable emulsion.

Method C

[0032] Add all ingredients to mix tank and homogenize.

[0033] The following non-limiting Examples are provided which reflect embodiments of the invention (with all percentages being given by weight %):

Example 1

[0034]

TABLE-US-00001 Water 5-95% Stearate soap selected from Ammonium Stearate, 0.2-20%.sup.  Potassium Stearate or Sodium Stearate or combinations thereof: Biodiesel or methyl ester 2-90%

Example 2

[0035]

TABLE-US-00002 Water 5-95% Stearate soap selected from Ammonium Stearate, 0.2-20%.sup.  Potassium Stearate or Sodium Stearate or combinations thereof, Non Polar Hydrocarbon 2-90%

Example 3

Water

[0036] Stearate soap selected from Ammonium Stearate, Potassium Stearate or Sodium Stearate
Non polar hydrocarbon selected from Kerosene, diesel, mineral spirits, mineral oil and other liquid non polar solvents or fuels and combinations thereof.

Example 4

Water

[0037] Ammonia, potassium, or sodium fatty acid soap
Liquid non polar hydrocarbon

Example 5

Water

[0038] Ammonia, potassium, or sodium fatty acid soap
Non polar hydrocarbon selected from Kerosene, diesel, mineral spirits, or mineral oil

Example 6

Water

[0039] Ammonia, potassium, or sodium fatty acid soap
Non polar hydrocarbon selected from corn, palm, peanut, canola or other vegetable oil

Example 7

[0040]

TABLE-US-00003 Bio diesel or Methyl Ester 55-100% Water insoluble hydrophobic solid like Aluminum,  0-45% Calcium, Magnesium or Zinc Stearate Viscosity modifier as needed

Example 8

[0041]

TABLE-US-00004 Emulsion Composition Water 5-95% Fatty Acid 0.4%-20% Base selected from ammonia, 0.02-5%   or solutions of ammonia, or hydroxide of sodium or potassium, or combinations thereof Hydrophobic oil, hydrocarbon oil or hydrophobic wax 2-90%

Example 9

[0042]

TABLE-US-00005 Emulsion Composition Water 5-95% Stearic Acid 0.4%-20% Ammonia 0.02-5%   Hydrocarbon oil selected from the group consisting of   90% bio diesel, diesel, Kerosene, mineral spirits, mineral oil, vegetable oil or fat, and combinations thereof:

Example 10

[0043] Water resistant additive and method for improved water resistance in manufactured board or wood products. Method includes manufacturing emulsion and applying to wood or to process to achieve improved water resistance and in some cases less foam.

TABLE-US-00006 Water 30-85% Stearic Acid or other Fatty Acid which makes a stable 0.2%-15% emulsion Ammonia As required to make soap 0.02-4%  Paraffin Wax or oil or combinations thereof 14-69%

Example 11

[0044] An emulsion composition comprising

TABLE-US-00007 Water 3 0-80% Stearic Acid 0.4%-10% Ammonia 0.02-5% Bio Diesel   8-69%