Surfactant based small molecules for reducing aluminosilicate scale in the Bayer process
09988282 ยท 2018-06-05
Assignee
Inventors
Cpc classification
International classification
C01F7/02
CHEMISTRY; METALLURGY
Abstract
The invention provides methods and compositions for inhibiting the accumulation of DSP scale in the liquor circuit of Bayer process equipment. The method includes adding one or more GPS-surfactant based small molecules to the liquor fluid circuit. These scale inhibitors reduce DSP scale formation and thereby increase fluid throughput, increase the amount of time Bayer process equipment can be operational and reduce the need for expensive and dangerous acid washes of Bayer process equipment. As a result, the invention provides a significant reduction in the total cost of operating a Bayer process.
Claims
1. A method of reducing aluminosilicate containing scale in a Bayer process comprising: adding to a Bayer liquor a non-polymeric reaction product resulting from the reaction of dodecyl-1,3-propanediamine, tetraethylenepentamine, ethylenediamine, and an epoxide binder; and a glycidoxyalkyltrimethoxysilane.
2. The method of claim 1, wherein the epoxide binder is selected from epichlorohydrin and ethylene glycol diglycidylether.
3. The method of claim 1, wherein the epoxide binder is epichlorohydrin.
4. The method of claim 1, wherein the epoxide binder is ethylene glycol diglycidylether.
5. The method of claim 1, wherein the glycidoxyalkyltrimethoxysilane is 3-glycidoxypropyltrimethoxysilane.
6. The method of claim 1, wherein the epoxide binder is a molecule according to formulas (I), (II), and any combination thereof: ##STR00010##
7. The method of claim 1, wherein the epoxide binder is a composition according to formula (I): ##STR00011##
8. The method of claim 1, wherein the epoxide binder is a composition according to formula (II): ##STR00012##
9. The method of claim 1, the non-polymeric reaction product resulting from the reaction of items further comprising a hydrophobe, wherein the hydrophobe is a C8-C10 aliphatic glycidyl ether.
10. The method of claim 1, wherein the non-polymeric reaction product has a molecular weight of less than 500 daltons.
11. The method of claim 1, wherein the non-polymeric reaction product is formed according to one of the methods selected from the group consisting of Methods I, II, III, IV, V, VI, VII, VIII, IX, X, XI, XII, and XIII, and any combination thereof.
12. The method of claim 1, wherein the non-polymeric reaction product is added to the Bayer liquor upstream of or at a heat exchanger.
13. The method of claim 1, wherein the dodecyl-1,3-propanediamine, the tetraethylenepentamine, the ethylenediamine, the epoxide binder, and the glycidoxyalkyltrimethoxysilane are reacted at a molar ratio of about 2:1:1:3:1, respectively.
14. The method of claim 1, wherein the dodecyl-1,3-propanediamine, the tetraethylenepentamine, the ethylenediamine, the epoxide binder, and the glycidoxyalkyltrimethoxysilane are reacted at a molar ratio of about 2:1:1:3:2, respectively.
15. The method of claim 1, wherein the dodecyl-1,3-propanediamine, the tetraethylenepentamine, the ethylenediamine, the epoxide binder, and the glycidoxyalkyltrimethoxysilane are reacted at a molar ratio of about 2:1:1:3:3, respectively.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) A detailed description of the invention is hereafter described with specific reference being made to the drawings in which:
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(9) For the purposes of this disclosure, like reference numerals in the figures shall refer to like features unless otherwise indicated. The drawings are only an exemplification of the principles of the invention and are not intended to limit the invention to the particular embodiments illustrated.
DETAILED DESCRIPTION OF THE INVENTION
(10) The following definitions are provided to determine how terms used in this application, and in particular how the claims, are to be construed. The organization of the definitions is for convenience only and is not intended to limit any of the definitions to any particular category.
(11) Polymer means a chemical compound comprising essentially repeating structural units each containing two or more atoms. While many polymers have large molecular weights of greater than 500, some polymers such as polyethylene can have molecular weights of less than 500. Polymer includes copolymers and homo polymers.
(12) Small molecule means a chemical compound comprising essentially non-repeating structural units. Because an oligomer (with more than 10 repeating units) and a polymer are essentially comprised of repeating structural units, they are not small molecules. Small molecules can have molecular weights above and below 500. The terms small molecule and polymer are mutually exclusive.
(13) Foulant means a material deposit that accumulates on equipment during the operation of a manufacturing and/or chemical process which may be unwanted and which may impair the cost and/or efficiency of the process. DSP is a type of foulant.
(14) Amine means a molecule containing one or more nitrogen atoms and having at least one secondary amine or primary amine group. By this definition, monoamines such as dodecylamine, diamines such as hexanediamine, and triamines such as diethylenetriamine, are all amines.
(15) GPS is glycidoxyalkyltrimethoxysilane which includes 3-glycidoxypropyltrimethoxysilane, one possible formula for GPS can be represented by the structure:
(16) ##STR00002##
(17) Ethoxylated Alcohol means an alcohol according to the formula:
R(EO).sub.nOH
wherein EO is an ethoxy group (OCH2CH2) and n is an integer within the range 1-50.
(18) Ethoxylated Amine means an amine according to the formula:
(19) ##STR00003##
wherein EO is an ethoxy group (OCH2CH2), m is an integer within the range 1-50, and n is an integer within the range 1-50.
(20) G12A7 means a C12-C14 non-ionic alcohol ethoxylate surfactant, a representative example of which is Teric G12A7 sold by Huntsman.
(21) G12A4 means a C12-C14 non-ionic alcohol ethoxylate surfactant, a representative example of which is Teric G12A4 sold by Huntsman.
(22) G17A3 means a C16-C18 straight chain non-ionic alcohol ethoxylate surfactant, a representative example of which is Teric G17A3 sold by Huntsman.
(23) G9A6 means a C9-C11 straight chain non-ionic alcohol ethoxylate surfactant, a representative example of which is Teric G9A6 sold by Huntsman.
(24) G9A8 means a C9-C11 straight chain non-ionic alcohol ethoxylate surfactant, a representative example of which is Teric G9A8 sold by Huntsman.
(25) 18M20 means a C18-C22 alkyl amine ethoxylate surfactant, a representative example of which is Teric 18M20 sold by Huntsman.
(26) 18M2 means a C18-C22 alkyl amine ethoxylate surfactant, a representative example of which is Teric 18M2 sold by Huntsman.
(27) 16M2 means a C16-C18 alkyl amine ethoxylate surfactant, a representative example of which is Teric 16M2 sold by Huntsman.
(28) TAM5 means tallow alkyl amine ethoxylate surfactant, a representative example of which is Agnique TAM5 sold by Cognis.
(29) DPD means dodecyl-1,3-propanediamine
(30) EGDGE means ethylene glycol diglycidylether
(31) OPD means oleyl-1,3-propanediamine
(32) EPI means epichlorohydrin
(33) OA means octylamine
(34) ED means ethylenediamine
(35) OLA means oleylamine
(36) TEPA means tetraethylenepentamine
(37) AGE means C8-C10 aliphatic glycidyl ether
(38) Alkyloxy means having the structure of OX where X is a hydrocarbon and O is oxygen. It can also be used interchangeably with the term alkoxy. Typically in this application, the oxygen is bonded both to the X group as well as to a silicon atom of the small molecule. When X is C.sub.1 the alkyloxy group consists of a methyl group bonded to the oxygen atom. When X is C.sub.2 the alkyloxy group consists of an ethyl group bonded to the oxygen atom. When X is C.sub.3 the alkyloxy group consists of a propyl group bonded to the oxygen atom. When X is C.sub.4 the alkyloxy group consists of a butyl group bonded to the oxygen atom. When X is C.sub.5 the alkyloxy group consists of a pentyl group bonded to the oxygen atom. When X is C.sub.6 the alkyloxy group consists of a hexyl group bonded to the oxygen atom.
(39) Monoalkyloxy means that attached to a silicon atom is one alkyloxy group.
(40) Dialkyloxy means that attached to a silicon atom are two alkyloxy groups.
(41) Trialkyloxy means that attached to a silicon atom are three alkyloxy groups.
(42) Synthetic Liquor or Synthetic Spent Liquor is a laboratory created liquid used for experimentation whose composition in respect to alumina, soda, and caustic corresponds with the liquor produced by recycling through the Bayer process.
(43) Bayer Liquor is actual liquor that has run through a Bayer process in an industrial facility.
(44) Separation means a mass transfer process that converts a mixture of substances into two or more distinct product mixtures, at least one of which is enriched in one or more of the mixture's constituents, it includes but is not limited to such processes as: Adsorption, Centrifugation, cyclonic separation, density based separation, Chromatography, Crystallization, Decantation, Distillation, Drying, Electrophoresis, Elutriation, Evaporation, Extraction, Leaching extraction, Liquid-liquid extraction, Solid phase extraction, Flotation, Dissolved air flotation, Froth flotation, Flocculation, Filtration, Mesh filtration, membrane filtration, microfiltration, ultrafiltration, nanofiltration, reverse osmosis, Fractional distillation, Fractional freezing, Magnetic separation, Precipitation, Recrystallization, Sedimentation, Gravity separation, Sieving, Stripping, Sublimation, Vapor-liquid separation, Winnowing, Zone refining, and any combination thereof.
(45) Thickener or Settler means a vessel used to effect a solid-liquid separation of a slurry, often with the addition of flocculants, the vessel constructed and arranged to receive a slurry, retain the slurry for a period of time sufficient to allow solid portions of the slurry to settle downward (underflow) away from a more liquid portion of the slurry (overflow), decant the overflow, and remove the underflow. Thickener underflow and thickener overflow are often passed on to filters to further separate solids from liquids.
(46) In the event that the above definitions or a description stated elsewhere in this application is inconsistent with a meaning (explicit or implicit) which is commonly used, in a dictionary, or stated in a source incorporated by reference into this application, the application and the claim terms in particular are understood to be construed according to the definition or description in this application, and not according to the common definition, dictionary definition, or the definition that was incorporated by reference. In light of the above, in the event that a term can only be understood if it is construed by a dictionary, if the term is defined by the Kirk-Othmer Encyclopedia of Chemical Technology, 5th Edition, (2005), (Published by Wiley, John & Sons, Inc.) this definition shall control how the term is to be defined in the claims.
(47) In the Bayer process for manufacturing alumina, bauxite ore passes through a grinding stage and alumina, together with some impurities including silica, are dissolved in added liquor. The mixture then typically passes through a desilication stage where silica is deliberately precipitated as DSP to reduce the amount of silica in solution. The slurry is passed on to a digestion stage where any remaining reactive silica dissolves, thus again increasing the concentration of silica in solution which may subsequently form more DSP as the process temperature increases. The liquor is later separated from undissolved solids, and alumina is recovered by precipitation as gibbsite. The spent liquor completes its circuit as it passes through a heat exchanger and back into the grinding stage. DSP scale accumulates throughout the Bayer process but particularly at the digestion stage and most particularly at or near the heat exchanger, where the recycled liquor passes through.
(48) In this invention, it was discovered that dosing of various types of small molecule based products can reduce the amount of DSP scale formed. The small molecules are reaction products of surfactants with GPS and optionally also with one or more of: hydrophobes, amine binders, epoxide binders, and any combination thereof.
(49) As described in U.S. Pat. No. 8,545,776 the small molecule DG12 is an example of a small molecule which is a reaction product of a surfactant and GPS. Similarly small molecule TG14 also in U.S. Pat. No. 8,545,776, and the various small molecules such as GEN1, GEN2, and GEN3 are described in US Published Patent Applications 2011/0212006 and 2012/0148462 are reaction products of some of these items. In at least one embodiment the invention excludes TG14, DG12, GEN1, GEN2, and GEN3.
(50) ##STR00004## ##STR00005##
(51) In at least one embodiment the reaction product is formed at least in part by allowing two or more of the reactants to contact each other for a period of time between 1 minute and 55 days, and/or by allowing the reactants to contact each other at a temperature of between 20 C. and 500 C. The invention encompasses adding any of some or all the reactants to the reaction simultaneously and/or in any sequential order. Any portion of the reaction may occur within one or more of: a liquid medium, a water medium, in the presence of acid and/or base, and or under acidic, basic, or neutral conditions. Any portion of the reaction may occur at least in part in the presence of one or more catalysts.
(52) In at least one embodiment the surfactant includes but is not limited to one selected from the list consisting of: ethoxylated fatty alcohols, ethoxylated fatty amines, fatty amines, G12A7, G12A4, G17A3, G9A6, G9A8, 18M20, 18M2, 16M2, DPD, OPD, OLA, and any combination thereof.
(53) In at least one embodiment the epoxide binder is according to one or more of the formulas (I) and (II):
(54) ##STR00006##
(55) In at least one embodiment the hydrophobe is a C8-C10 aliphatic glycidyl ether. The hydrophobe may be may be described as a linear or branched, aromatic or aliphatic hydrocarbon chain which may optionally contain an ether linkage or additional functional end group such as an epoxide which allows the hydrophobe to be reacted with and attached to other molecules. The hydrocarbon chain may consist of between 3 and 50 carbon atoms
(56) In at least one embodiment the hydrophobe is according to formula (III) where R is a linear or branched hydrocarbon chain containing at least 3 carbon atoms:
(57) ##STR00007##
(58) In at least one embodiment, the amine binder is selected from a linear or branched, aliphatic or cycloaliphatic monoamines, diamines, triamines, butamines, and pentamines. The total number of carbon atoms in the amine is preferred to be less than 30 and more preferred to be less than 20. In at least one embodiment the amine is selected from a list consisting of: tetraethylene pentamine, ethylene diamene, and any combination thereof.
(59) In at least one embodiment, an amine small molecule is reacted with both 3-glycidoxypropyltrialkoxysilane (GPS) and a hydrophobic molecule to form a DSP inhibition composition. The hydrophobic molecule is an amine-reactive compound having an amine-reactive functional group such as glycidyl, chloro, bromo, or isocyanato groups. Besides the amine-reactive group, the hydrophobic molecule has at least one C.sub.3-C.sub.22 hydrophobic carbon chain, aromatic or aliphatic, linear or branched.
(60) In at least one embodiment, the amine molecule is selected from linear or branched, aliphatic or cycloaliphatic monoamines or diamines. The total number of carbon atoms in the amine is preferred to be less than 30 and more preferred to be less than 20.
(61) In at least one embodiment the amine is selected from a list consisting of: isophoronediamine, xylenediamine, bis(aminomethyl)cyclohexane, hexanediamine, C,C,C-trimethylhexanediamine, methylene bis(aminocyclohexane), saturated fatty amines, unsaturated fatty amines such as oleylamine and soyamine, N-fatty-1,3-propanediamine such as cocoalkylpropanediamine, oleylpropanediamine, dodecylpropanediamine, hydrogenized tallowalkylpropanediamine, and tallowalkylpropanediamine and any combination thereof.
(62) In at least one embodiment the reaction product is Product P, which is a reaction product of GPS with a surfactant having a formula of:
(63) ##STR00008##
(64) In at least one embodiment the reaction product is Product U, which is a reaction product of GPS with a surfactant and a hydrophobe having a formula of:
(65) ##STR00009##
(66) In at least one embodiment the reaction product is Product X, which is a reaction product of GPS with a surfactant, a hydrophobe and an epoxide binder having a formula illustrated in
(67) In at least one embodiment the reaction product is Product BB, which is a reaction product of GPS with a surfactant, a hydrophobe, an epoxide binder and an amine binder having a formula illustrated in
(68) In at least one embodiment the reaction conditions results in the formation of two or more of the aforementioned and incorporated reaction products. In at least one embodiment the composition introduced to address DSP contains one, two, or more of the aforementioned and incorporated reaction products.
(69) In at least one embodiment the resulting surfactant based small molecules are added to a dilute caustic solution prior to addition to the process stream.
(70) These small molecules reduce the amount of DSP scale formed and thereby prevents its accumulation on Bayer process equipment.
(71) The effectiveness of these small molecules was unexpected as the prior art teaches that only high molecular weight polymers are effective. Polymer effectiveness was presumed to depend on their hydrophobic nature and their size. This was confirmed by the fact that cross-linked polymers are even more effective than single chain polymers. As a result it was assumed that small molecules only serve as building blocks for these polymers and are not effective in their own right. (WO 2008/045677 [0030]). Furthermore, the scientific literature states small molecules containing . . . [an] SiO.sub.3 grouping are not effective in preventing sodalite scaling . . . because . . . [t]he bulky group . . . is essential [in] keeping the molecule from being incorporated into the growing sodalite. Page 57 9 Light Metals 2008, (2008). However it has recently been discovered that in fact, as further explained in the provided examples, small molecules such as those described herein are actually effective at reducing DSP scale.
(72) It is believed that there are at least three advantages to using a small molecule-based inhibitor as opposed to a polymeric inhibitor with multiple repeating units of silane and hydrophobes. A first advantage is that the smaller molecular weight of the product means that there are a larger number of active, inhibiting moieties available around the DSP seed crystal sites at the DSP formation stage. A second advantage is that the lower molecular weight allows for an increased rate of diffusion of the inhibitor, which in turn favors fast attachment of the inhibitor molecules onto DSP seed crystals. A third advantage is that the lower molecular weight avoids high product viscosity and so makes handling and injection into the Bayer process stream more convenient and effective.
(73) In at least one embodiment DSP scale is addressed using one or more of the compositions and/or methods of application described in U.S. patent applications Ser. Nos. 13/035,124, 13/403,282, 13/791,577, 14/011,051, U.S. Pat. Nos. 5,314,626, 6,814,873, 7,390,415, 7,442,755, 7,763,698, International Patent Applications WO 02/070411, WO 2008/045677, WO 2012/115769, and US Published Patent Applications 2004/0162406, 2004/0011744, 2010/0256317, 2011/0076209, 2011/0212006, and 2012/0148462.
Examples
(74) The foregoing may be better understood by reference to the following examples, which are presented for purposes of illustration and are not intended to limit the scope of the invention. In particular the examples demonstrate representative examples of principles innate to the invention and these principles are not strictly limited to the specific condition recited in these examples. As a result it should be understood that the invention encompasses various changes and modifications to the examples described herein and such changes and modifications can be made without departing from the spirit and scope of the invention and without diminishing its intended advantages. It is therefore intended that such changes and modifications be covered by the appended claims.
(75) A number of reaction products were produced using the reactants listed in
(76) Hydroxy-Terminated Surfactants
(77) Method I: A mixture of surfactant (di-hydroxy terminated) and hydrophobe was stirred and heated at 65 C. A solution of NaOH (50% in water) was added and the mixture left for 30 min at 65 C. Glycidoxypropyltrimethoxysilane was then added and the mixture left for 2 h at 65 C. The reaction mixture was cooled then diluted to 5% w/w in 20 g/L NaOH solution. NaOH was added at 2 molar equivalents to that of added epoxide. For A-O products, Method I was used excluding incorporation of hydrophobe.
Amino-Terminated Surfactants
(78) Method II: Surfactant was stirred and heated at 65 C. Hydrophobe was added and the mixture left for 30 min at 65 C. Glycidoxypropyltrimethoxysilane was then added and the mixture left for 2 h at 65 C. The reaction mixture was cooled then diluted to 5% w/w in 20 g/L NaOH solution. For products P and Q, Method II was used excluding incorporation of hydrophobe.
(79) Method III: Surfactant was stirred and heated at 65 C. Epoxide binder was added and the mixture left for 30 min at 65 C. Glycidoxypropyltrimethoxysilane was then added and the mixture left for 2 h at 65 C. The reaction mixture was cooled then diluted to 5% w/w in 20 g/L NaOH solution.
(80) Method IV: A mixture of surfactant and amine binder was stirred and heated at 65 C. Epoxide binder was added and the mixture left for 30 min at 65 C. Glycidoxypropyltrimethoxysilane was then added and the mixture left for 2 h at 65 C. The reaction mixture was cooled then diluted to 5% w/w in 20 g/L NaOH solution. Products EE and FF were allowed to react for 60 min at 65 C. prior to addition of the glycidoxypropyltrimethoxysilane.
(81) Method V: A mixture of surfactant and amine binder was stirred and heated at 65 C. Epoxide binder was slowly added to the mixture then left for 2 h total at 65 C. Glycidoxypropyltrimethoxysilane was then slowly added and the mixture left for 1 h total at 65 C. The reaction mixture was cooled then diluted to 5% w/w in 20 g/L NaOH solution.
(82) Method VI: A mixture of surfactant, amine binder and DMSO was stirred and heated at 65 C. Epoxide binder was slowly added to the mixture then left for 3 h total at 65 C. Glycidoxypropyltrimethoxysilane was then slowly added to the mixture. After 30 min a sample was taken from the reaction mixture and added slowly to a stirred 20 g/L NaOH solution, diluting the sample to a concentration of 13.3% w/w.
(83) Method VII: A mixture of surfactant and amine binder was stirred and heated at 65 C. Epoxide binder was slowly added to the mixture then left for 30 min total at 65 C. Glycidoxypropyltrimethoxysilane was then slowly added to the mixture. After 19 min a sample was taken from the reaction mixture and added slowly to a stirred 20 g/L NaOH solution, diluting the sample to a concentration of 10% w/w.
(84) Method VIII: A mixture of surfactant and amine binder was stirred and heated at 65 C. Epoxide binder was slowly added to the mixture then left for 1 h total at 65 C. Glycidoxypropyltrimethoxysilane was then slowly added to the mixture. After 15 min a sample was taken from the reaction mixture and added slowly to a stirred 20 g/L NaOH solution, diluting the sample to a concentration of 10% w/w.
(85) Method IX: A mixture of surfactant, amine binder and DMSO was stirred and heated at 65 C. Epoxide binder was slowly added to the mixture then left for 1 h total at 65 C. Glycidoxypropyltrimethoxysilane was then slowly added to the mixture and the mixture left for 1 h. The reaction mixture was cooled then diluted to 10% w/w in 20 g/L NaOH solution.
(86) Method X: A mixture of surfactant, amine binder and DMSO was stirred and heated at 65 C. Epoxide binder was slowly added to the mixture then left for 3 h total at 65 C. Glycidoxypropyltrimethoxysilane was then slowly added to the mixture. After 16 min a sample was taken from the reaction mixture and added slowly to a stirred 20 g/L NaOH solution, diluting the sample to a concentration of 11.8%.
(87) Method XI: The reaction mixture from Method X was left at 65 C. for a further 44 min post sampling, cooled then diluted to 11.8% w/w in 20 g/L NaOH solution.
(88) Method XII: A mixture of surfactant, amine binder and DMSO was stirred and heated at 65 C. Epoxide binder was slowly added to the mixture then left for 2 h and 2 min total at 65 C. Glycidoxypropyltrimethoxysilane was then slowly added to the mixture. After 20 min a sample was taken from the reaction mixture and added slowly to a stirred 20 g/L NaOH solution, diluting the sample to a concentration of 11.8%.
(89) Method XIII: The reaction mixture from Method XII was left at 65 C. for a further 40 min post sampling, cooled then diluted to 11.8% w/w in 20 g/L NaOH solution.
(90) Results: Test 1 Bottle Test Method
(91) Assessment of inhibition of DSP formation used test conditions similar to those previously used and published. To a stirred sample of plant spent liquor, a small volume of concentrated sodium metasilicate pentahydrate solution was added slowly so as to increase the amount of silica in the liquor (typically the concentration was increased by approximately 1 g/L as SiO.sub.2). This spiked liquor was then split into batches of 500 mL for treatment by addition of the appropriate inhibitor at the desired dose. One batch of spiked liquor was kept as untreated liquor.
(92) Each of the treated batches was then sub-sampled to deliver duplicate samples which were individually placed into 250 mL Nalgene polypropylene bottles and placed into a rotating water bath at 95 C. Duplicate untreated control samples were also included. After heating for 3 hours, the bottles were removed from the bath and the solids were collected by filtration, washed with hot water and dried in the oven at 110 C. After drying the resulting mass of DSP solids precipitated was weighed. The efficacy of the treatment was determined by comparing the mass of DSP precipitated from the individual treated samples to the untreated control samples in the same test.
(93) Results are presented as a percent calculated as: (Average mass treated/Average mass untreated)100. A value of 100% means no effective inhibition (same mass as untreated) while a value less than 100% indicates some inhibitory activity. Lower numbers indicate more effective inhibition.
(94) Type 1.1 Ethoxylated Alcohol Surfactant/Siloxane
(95) TABLE-US-00001 TABLE 1 % Sodalite Precipitated Dose (ppm) Product 80 120 160 A 88 75 A* 78 73 A* 66 57 B 72 61 C 72 61 D 69 45 E 70 61 61 *test repeated under the same test conditions as previous
Type 1.2 Ethoxylated Amine Surfactant/Siloxane
(96) TABLE-US-00002 TABLE 2 % Sodalite Precipitated Dose (ppm) Product 80 120 160 200 220 F 77 91 G 6 0.6 H 16 2 H* 8 2 1 H* 11 2 0.8 J 91 58 K 36 11 L 17 4 M 23 6 M* 28 5 4 M* 25 6 N 27 7 O 30 4 *test repeated under the same test conditions as previous
Type 1.3 Fatty Amine Surfactant/Siloxane
(97) TABLE-US-00003 TABLE 3 % Sodalite Precipitated Dose (ppm) Product 40 80 120 P 59 16 7 Q 43 58 48
Type 2.1 Ethoxylated Amine Surfactant/Siloxane/Hydrophobe
(98) TABLE-US-00004 TABLE 4 % Sodalite Precipitated Dose (ppm) Product 80 120 R 95 101 S 71 81 T 33 9 T* 32 6 *test repeated under the same conditions as previous
Type 2.2 Fatty Amine Surfactant/Siloxane/Hydrophobe
(99) TABLE-US-00005 TABLE 5 % Sodalite Precipitated Dose (ppm) Product 40 80 120 U 13 9 U* 56 28 7 V 86 72 *test repeated under the same conditions as previous
Type 3.1 Fatty Amine Surfactant/Siloxane/Epoxide Binder
(100) TABLE-US-00006 TABLE 6 % Sodalite Precipitated Dose (ppm) Product 20 40 80 100 120 140 X 37 3 1 Y 22 4 0.2 Y* 58 28 13 8 4 3 Y* 15 1.5 0.4 Z 27 13 5 ZA 52 3 3 *test repeated under the same conditions as previous tests
Type 4.1 Fatty Amine Surfactant/Siloxane/Amine Binder/Epoxide Binder
(101) TABLE-US-00007 TABLE 7 % Sodalite Precipitated Dose (ppm) Product 10 20 40 60 80 140 AA 57 11 4 BB 25 4 0.1 CC 78 45 0.7 DD 12 0 0 DD* 90 73 18 0 0 EE 84 59 9 FF 49 0 0 FF* 93 85 46 9 0 *test repeated under the same conditions as previous
Results: Test 2 Bottle Test Method
(102) Test 2 conditions were similar to those of Test 1 but were designed to assess the effect on the initial formation of DSP solids from solution. As a result, a shorter holding time for the precipitation step and an increased initial concentration (higher spike) of silica in the liquor was used in this method. Data is again presented as a percent of mass precipitated compared to an undosed control sample.
(103) Type 4.2 Fatty Amine Surfactant/Siloxane/Pentamine Binder/Epoxide Binder
(104) TABLE-US-00008 TABLE 8 % Sodalite Precipitated Dose (ppm) Product 25 45 50 JJ 36 DS 40 0 ES 18 0 FS 55 24 GS 50 12
(105) TABLE-US-00009 TABLE 9 % Sodalite Precipitated Dose (ppm) Product 20 25 30 40 45 50 60 80 100 200 400 SA 71 62 SB 41 1.8 1 SC 36 2.5 SD 59 7 SE 23 3.4 SF 12.8 2.3 SG 45 0 SH 78 57 SI 0 0 SJ 26 0.3 SK 70 27 SL 7 2 SM 77 0 0 SN 156 37 SO 24 14 SP 97 77 3.6 0 SQ 82 62 1.5 0 SR 69 28 ST 78 33 2 0 SU 74 77 0 0 SV 30 4 SW 56 27 0.5 SX 41 2 AS 70 12 BS 40 3.3 CS 32 0 DS 40 0 ES 18 0 FS 55 24 GS 50 12 HS 31 0
Type 4.3 Fatty Monoamine Surfactant/Siloxane/Pentamine Binder/Epoxide Binder
(106) TABLE-US-00010 TABLE 10 % Sodalite Precipitated Dose (ppm) Product 20 40 LL 44 42 MM 47 41
Test 2Surfactant-Based Molecules Versus Gen 2 and Gen 3
(107) TABLE-US-00011 TABLE 11 % Sodalite Precipitated Dose (ppm) Product 20 25 30 50 100 200 400 500 800 1100 1200 Gen2 106 114 76 39 40 37 Gen3 88 92 81 55 32 32 DD 103 79 41 1 HS 58 16 0
Results in table 11 above demonstrate the surprising difference between the inhibitory effects of previously identified small molecule inhibitors (Gen 2 and Gen 3 products) and surfactant based products (DD and HS). The latter are effective in eliminating DSP formation at doses as low as 30 ppm. However, for the Gen 2 and Gen 3 products some DSP precipitation still occurs under these test conditions even at doses greater than 1000 ppm. Given the efficacy of the Gen 2 and Gen 3 products under test 1 conditions, such a result is unexpected and novel.
Results: Test 3Metal Coupon Test
(108) Test 3 conditions were the same as test 2 however, metal coupons were included in the bottles and small amounts of DSP were precipitated onto the surface of the metal. As shown in
(109) TABLE-US-00012 TABLE 2.15 Treatment of liquor exposed to metal coupons in test method 3. Coupon Product type Product Dose (ppm) I No Treatment N/A N/A II Product Type D GEN2 1,000 III Product Type E GEN3 1,000 IV Product Type 4.2 KK 100
(110) While this invention may be embodied in many different forms, there are described in detail herein specific preferred embodiments of the invention. The present disclosure is an exemplification of the principles of the invention and is not intended to limit the invention to the particular embodiments illustrated. All patents, patent applications, scientific papers, and any other referenced materials mentioned herein are incorporated by reference in their entirety. Furthermore, the invention encompasses any possible combination of some or all of the various embodiments mentioned herein, described herein and/or incorporated herein. In addition the invention encompasses any possible combination that also specifically excludes any one or some of the various embodiments mentioned herein, described herein and/or incorporated herein.
(111) The above disclosure is intended to be illustrative and not exhaustive. This description will suggest many variations and alternatives to one of ordinary skill in this art. All these alternatives and variations are intended to be included within the scope of the claims where the term comprising means including, but not limited to. Those familiar with the art may recognize other equivalents to the specific embodiments described herein which equivalents are also intended to be encompassed by the claims.
(112) All ranges and parameters disclosed herein are understood to encompass any and all subranges subsumed therein, and every number between the endpoints. For example, a stated range of 1 to 10 should be considered to include any and all subranges between (and inclusive of) the minimum value of 1 and the maximum value of 10; that is, all subranges beginning with a minimum value of 1 or more, (e.g. 1 to 6.1), and ending with a maximum value of 10 or less, (e.g. 2.3 to 9.4, 3 to 8, 4 to 7), and finally to each number 1, 2, 3, 4, 5, 6, 7, 8, 9, and 10 contained within the range. All percentages, ratios and proportions herein are by weight unless otherwise specified.
(113) This completes the description of the preferred and alternate embodiments of the invention. Those skilled in the art may recognize other equivalents to the specific embodiment described herein which equivalents are intended to be encompassed by the claims attached hereto.