Emulsion foam reducer for wet processing of cellulose or woodbased products or in food processing

Abstract

An emulsion is 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 the emulsion and using the emulsion 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 in water used in processing of manufactured board, paperboard or other cellulose or wood based product or food processing, comprising: providing an emulsion formed by reacting a fatty acid that can form a water-soluble soap with a material selected from the group consisting of ammonia, solutions of ammonia, hydroxides of sodium or potassium, and combinations thereof, so as to form a water-soluble soap with a pH of 5 or greater, dispersing the water-soluble soap in water and homogenizing soap solution with a material selected from the group consisting of hydrocarbon oil, hydrophobic hydrocarbon oil, hydrocarbon wax, non-polar hydrocarbon liquid, biodiesel, and combinations thereof; adding said emulsion to the water used in processing of manufactured board, paperboard, or other cellulose or wood based product or in food processing in a manner to distribute the emulsion into the process water so as to allow the fatty acid soap in said emulsion to undergo an exchange reaction with hardness ions or aluminum ions in the processing water so as to form hydrophobic particles and thus change the soap into a water-resistant or hydrophobic particle or compound; while also suppressing or eliminating foam in the processing water.

2. The method of claim 1 wherein the emulsion comprises by weight: TABLE-US-00008 Water 5-95% Stearic Acid 0.4%-20% A base selected from the group consisting of ammonia, 0.02-5% solutions of ammonia, hydroxides of sodium or potassium, and combinations thereof Hydrophobic hydrocarbon oil, Hydrocarbon Oil 2-90%. or Hydrophobic wax

3. The method of claim 2 wherein the hydrocarbon oil is selected from the group consisting of bio diesel, diesel, Kerosene, mineral spirits, mineral oil, vegetable oils or fats, and combinations thereof.

4. The method of claim 2 wherein the pH of the emulsion is between 6 and 9.

5. The method of claim 1 wherein the emulsion comprises by weight: TABLE-US-00009 Water 30-80% Stearic Acid 0.4%-10% A base selected from the group consisting 0.02-5% of ammonia and solutions of ammonia Paraffin wax or paraffin oil or blends thereof: 14-69%.

6. A method of improving water resistance in a finished product and reducing foam in water used in processing of manufactured board, paperboard or other cellulose or wood based product, comprising: providing an emulsion formed by reacting a fatty acid with ammonia forming a water-soluble soap with a pH greater than 6, dispersing soap in water and homogenizing the soap and 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 the water used in processing of manufactured board, paperboard or other cellulose or wood based product in a manner to distribute emulsion into the process so as to allow the fatty acid soap in said emulsion to undergo an exchange reaction with hardness ions or aluminum ions in the processing water so as to form hydrophobic particles or compound and thus change the soap into a water resistant compound; while also suppressing foam in the processing water wherein the method further comprises drying or pressing the manufactured board, paperboard or other cellulose or wood based product to produce a finished manufactured board, paperboard or other cellulose or wood based product with improved or lower cost water resistance.

7. The method of claim 6 wherein the emulsion comprises by weight: TABLE-US-00010 Water 5-95% Stearic Acid 0.4%-20% A base selected from the group consisting of ammonia, 0.02-5% solutions of ammonia, hydroxides of sodium or potassium, and combinations thereof Hydrophobic oil, Hydrocarbon oil, or Hydrocarbon wax 2-90%.

8. The method of claim 7 wherein the hydrocarbon oil is selected from the group consisting of bio diesel, diesel, Kerosene, mineral spirits, mineral oil, vegetable oils or fats, and combinations thereof.

9. The method of claim 7 wherein the pH of the emulsion is between 6 and 9.

10. The method of claim 9 wherein the pH of the emulsion is greater than 9.

11. The method of claim 6 wherein the emulsion comprises by weight: TABLE-US-00011 Water 30-80% Stearic Acid 0.4%-10% A base selected from the group consisting of ammonia and 0.02-5% solutions of ammonia Paraffin wax or paraffin oil or blends thereof: 14-69%.

Description

DETAILED DESCRIPTION OF THE INVENTION

(1) Testing of Defoamer:

(2) 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.

(3) 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.

(4) Exemplary methods to make the defoamer are as follows:

(5) Method A

(6) 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.

(7) Method B

(8) 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.

(9) Method C

(10) Add all ingredients to mix tank and homogenize.

(11) The following non-limiting Examples are provided which reflect embodiments of the invention (with the percentages being given by weight):

EXAMPLE 1

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

EXAMPLE 2

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

EXAMPLE 3

(14) Water

(15) Stearate soap selected from Ammonium Stearate, Potassium Stearate or Sodium Stearate

(16) Non polar hydrocarbon selected from Kerosene, diesel, mineral spirits, mineral oil and other liquid non polar solvents or fuels and combinations thereof.

EXAMPLE 4

(17) Water

(18) Ammonia, potassium, or sodium fatty acid soap

(19) Liquid non polar hydrocarbon

EXAMPLE 5

(20) Water

(21) Ammonia, potassium, or sodium fatty acid soap

(22) Non polar hydrocarbon selected from Kerosene, diesel, mineral spirits, or mineral oil

EXAMPLE 6

(23) Water

(24) Ammonia, potassium, or sodium fatty acid soap

(25) Non polar hydrocarbon selected from corn, palm, peanut, canola or other vegetable oil

EXAMPLE 7

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

EXAMPLE 8

(27) 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

(28) 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 bio 2-90% diesel, diesel, Kerosene, mineral spirits, mineral oil, vegetable oil or fat, and combinations thereof:

EXAMPLE 10

(29) 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.

(30) 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

(31) An emulsion composition comprising

(32) TABLE-US-00007 Water 30-80% Stearic Acid 0.4%-10% Ammonia 0.02-5% Bio Diesel 8-69%