METHOD FOR OBTAINING WATER-BASED PAINTS USING EXPANDED POLYSTYRENE (EPS) WASTE AND/OR EXTRUDED POLYSTYRENE (XPS) WASTE AS RAW MATERIAL

Abstract

A process for obtaining water-based paints using expanded polystyrene (EPS) and/or extruded polystyrene (XPS) waste as raw material by a) cleaning the EPS and/or XPS waste with a surfactant to remove organic matter; b) rinse and remove all surfactants and solvents; c) treating the EPS and/or XPS waste with an organic solvent until obtaining a mixture with a concentration of EPS and/or XPS of 20 and 80% w/w; d) decanting the impurities from the mixture obtained in step (c) for 24 hours to 120 hours; e) collecting the supernatant obtained from step (d); f) make a mixture of the supernatant obtained in step (e) with emulsifier and then water; g) pigment dispersion in the mixture obtained in (f), for 5 to 50 minutes at a 500 and 3.000 rpm and 20 and 90° C.; h) mix the product of step (g) with water until the desired concentration is achieved.

Claims

1. A process for obtaining water-based paints using waste expanded polystyrene (EPS) and/or extruded polystyrene (XPS) as raw material, comprising: a) cleaning EPS and/or XPS waste with a surfactant to remove organic matter; b) rinsing and removing all surfactants and solvents used for cleaning; c) treat the EPS and/or XPS waste from step (b) with an organic solvent until obtaining a first mixture with a concentration of EPS and/or XPS in the organic solvent of between 20 and 80% w/w; d) decanting impurities from the mixture obtained in step (c) for a period of time between 24 hours to 120 hours; e) collecting a supernatant obtained from step (d); f) making a second mixture of the supernatant obtained in step (e) with emulsifier and then water; g) carrying out a pigment dispersion in the second mixture obtained in (f), for 5 to 50 minutes at a speed between 500 and 3.000 3,000 rpm and at a temperature between 20 and 90° C.; h) mixing the product of step (g) with water, between 200 and 2,000 rpm, until the a desired concentration is achieved.

2. The process according to claim 1, wherein the organic solvents are selected from the group consisting of propanone, 2-butanone, 2-pentanone, 3-pentanone, 2-hexanone, 3-hexanone, 2-heptanone, 3-heptanone, 4-heptanone, 2-octanone, 3-octanone, 4-octanone, 2-nonanone, 3-nonanone, 4-nonanone, 5-nonanone, 2-decanone, 3-decanone, 4-decanone, 5-decanone, 2-undecanone, 3-undecanone, 4-undecanone, 5-undecanone, 6-undecanone, 2,4-pentanedione, 2,4-hexanedione, 2,5-hexanedione, 2,4-heptanedione, 2,5-heptanedione, 2,6-heptanedione, 3,5-heptanedione, 3,6-heptanedione, methyl ethanoate, ethyl ethanoate, propyl ethanoate, isopropyl ethanoate, butyl ethanoate, isobutyl ethanoate, sec-butyl ethanoate, tert-butyl ethanoate, pentyl ethanoate, methylbutyl ethanoate, 2-methylbutyl ethanoate, 3-methylbutyl ethanoate, 1,2-dimethylpropyl ethanoate, 2-ethylpropyl ethanoate, hexyl ethanoate, methylpentyl ethanoate, 2-methylpentyl ethanoate, 3-methylpentyl ethanoate, 4-methylpentyl ethanoate, ethylbutyl ethanoate, ethanoate 2-ethylbutyl, 3-ethylbutyl ethanoate, methyl propanoate, ethyl propanoate, propyl propanoate, isopropyl propanoate, butyl propanoate, isobutyl propanoate, sec-butyl propanoate, tert-butyl propanoate, pentyl propanoate, methylbutyl propanoate, 2-methylbutyl propanoate, 3-methylbutyl propanoate, 1,2-dimethylpropyl propanoate, 2-ethylpropyl propanoate, hexyl propanoate, methylpentyl propanoate, 2-methylpentyl propanoate, 3-methylpentyl propanoate, 4-methylpentyl propanoate, ethylbutyl propanoate, 2-ethylbutyl propanoate, 3-ethylbutyl propanoate, pentane, 2-methylpentane, 3-methylpentane, hexane, 2-methylhexane, 3-methylhexane, heptane, 2-methylheptane, 3-methylheptane, 4-methylheptane, octane, 2-methyloctane, 3-methyloctane, 4-methyloctane, nonane, 2-methylnonane, 3-methylnonane, 4-methylnonane, 5-methylnonane, decane, 2-methyldecane, 3-methyldecane, 4-methyldecane, 5-methyldecane, 2-ethylpentane, 3-ethylpentane, 2-ethylhexane, 3-ethylhexane, 2-ethylheptane, 3-ethylheptane, 4-ethylheptane, 2-ethyloctane, 3-ethyloctane, 4-ethyloctane, 2-ethylnonane, 3-ethylnonane, 4-ethylnonane, 5-ethylnonane, 2-ethyldecane, 3-ethyldecane, 4-ethyldecane, 5-ethyldecane, benzene, toluene, xylene, trimethylbenzene, ethylbenzene, diethylbenzene, propylbenzene, dipropylbenzene, chloroform, dichloromethane, gasoline, kerosene, carbon tetrachloride, cyclohexene, cyclyl monoterpene, among others, and/or their and mixtures thereof.

3. The process according to claim 2, wherein the organic solvent is selected from the group consisting of butyl ethyl ketone, acetone, xylene, butyl ethanoate, toluene, cyclohexene, cyclic monoterpene, and mixtures thereof.

4. The process according to claim 1, wherein the emulsifiers are selected from the group consisting of fatty alcohol polyglycol ether, sodium di-isodecyl sulfosuccinate, sodium alkylaryl polyglycol ether sulfate, sodium oleyl acetyl alcohol sulfate, phosphoric acid ester, alkyl polyglycol ether sulfate, sodium tetrapropylbenzylsulfonate, polyoxyethylene sorbitan monolaurate, polyoxyethylene sorbitan monopalmitate, polyoxyethylene sorbitan monostearate, polyoxyethylene sorbitan tristearate, polyoxyethylene sorbitan monooleate, polyoxyethylene sorbitan trioleate, polyoxyethylene sorbitan monoisostearate, sodium alkylaryl polyglycol ether sulfate, ammonium alkylaryl polyglycol ether sulfate, soy lecithin, and tridecyl alcohol ethoxylate.

5. The process according to claim 1, wherein the dispersing agent is selected from the group consisting of soybean lecithin, octadecen-1-ol ethoxylate, acrylic acid polymer in sodium salt, benzenesulfonic acid, C10-13-alkyl derivatives with triethanolamine, tetramethyldecynediol/nonylphenolethoxylate, oxide copolymer of ethylene and propylene, polyacrylic acid salt, and sodium dodecylbenzenesulfonate.

6. The process according to claim 1, wherein the pigment is selected from the group consisting of titanium dioxide, talc, calcium carbonate, carbon black, iron oxides, and phthalocyanines.

7. A paint obtained by the process of claim 1 comprising between 1 and 70% pigment, 70 and 1% EPS and/or XPS, between 0.01 and 15.0% emulsifier, 0.01 and 10.0% dispersant, and between 20 and 75% of a mixture of organic solvent water in a ratio between 4:1 and 23.

Description

APPLICATION EXAMPLES

Example 1

[0028] a) 100 g of XPS and EPS waste were cleaned with commercial surfactants to remove household organic matter.

[0029] b) 96.2 g of XPS waste from step (a) was mixed with 133.8 g of xylene at 25° C.

[0030] c) The mixture from step (b) was left to stand for 48 h until decantation of the impurities was observed.

[0031] d) At least 52.6 g of the supernatant of the mixture resulting from step (c) were separated from impurities.

[0032] e) The 52.6 g of the supernatant from step (d) are mixed with 8 g of ammonium alkylarylpolyglycol ether sulfate emulsifier and 20 g of water at 500 rpm.

[0033] f) 25 g of pigment (TiO.sub.2) and 18 g of CaCO.sub.3 were dispersed in 40.3 g of the mixture from step (e), which was previously mixed with 2 g of dispersant. Dispersion was performed at 1.100 rpm for 15 min at 50° C.

[0034] g) After step (f) was completed, the resulting mixture was mixed with 14.7 g of water. Mixing was carried out at 500 rpm.

Example 2

[0035] In another embodiment of the present invention and only by way of example, polyoxyethylene sorbitan monooleate was used, using the following conditions.

[0036] a) 200 g of XPS waste were cleaned with commercial surfactants to remove organic matter.

[0037] b) 171.42 g of XPS waste from step (a) was mixed with 28.58 g of xylene at 25° C.

[0038] c) The mixture from step (b) was left to stand for 48 h until decantation of the impurities was observed.

[0039] d) At least 120 g of the supernatant of the mixture resulting from step (c) were separated from impurities.

[0040] e) The 120 g of the supernatant from step (d) are mixed with 20 g of polyoxyethylene sorbitan monooleate emulsifier and 20 g of water at 500 rpm.

[0041] f) 3 g of pigment (TiO.sub.2) and 10 g of Talc were dispersed in 80 g of the mixture from step (e), which was previously mixed with 0.05 g of dispersant. Dispersion was performed at 3000 rpm for 45 min at 60° C.

[0042] g) After step (f) was completed, the resulting mixture was mixed with 6.95 g of water. Mixing was carried out at 800 rpm.

Example 3

[0043] In another embodiment of the present invention and only by way of example, polyoxyethylene sorbitan monooleate was used, using the following conditions.

[0044] a) 60 g of EPS waste was cleaned with commercial surfactants to remove organic matter.

[0045] b) 50 g of EPS waste from step (a) was mixed with 150 g of xylene at 25° C.

[0046] c) The mixture from step (b) was left to stand for 48 h until decantation of the impurities was observed.

[0047] d) At least 40 g of the supernatant of the mixture resulting from step (c) were separated from impurities.

[0048] e) The 40 g of the supernatant from step (d) are mixed with 4 g of polyoxyethylene sorbitan monooleate emulsifier, and 18 g of water at 500 rpm.

[0049] f) 30 g of pigment (TiO.sub.2) and 30 g of Talc were dispersed in 31 g of the mixture from step (e), which was previously mixed with 7 g of dispersant. Dispersion was performed at 600 rpm for 25 min at 50° C.

[0050] g) Once step (f) was finished, the resulting mixture was mixed with 2 g of water. Mixing was carried out at 500 rpm.

Example 4

[0051] In another embodiment of the present invention and only by way of example, ammonium alkylarylpolyglycol ether sulfate was used, using the following conditions.

[0052] a) 30 g of XPS and EPS waste were cleaned with commercial surfactants to remove organic matter.

[0053] b) 25.4 g of EPS waste from step (a) was mixed with 19.6 g of butyl ethanoate at 25° C.

[0054] c) The mixture from step (b) was left to stand for 48 h until decantation of the impurities was observed.

[0055] d) At least 22.5 g of the supernatant of the mixture resulting from step (c) were separated from impurities.

[0056] e) The 22.5 g of the supernatant from step (d) are mixed with 1.8 g of ammonium alkylarylpolyglycol ether sulfate emulsifier and 18.05 g of water at 500 rpm.

[0057] f) 8 g of TiO.sub.2 pigment and 35 g of CaCO.sub.3 were dispersed in 38.03 g of the mixture from step (e), which was previously mixed with 2 g of dispersant. Dispersion was performed at 600 rpm for 25 min at 50° C.

[0058] g) Once step (f) was finished, the resulting mixture was mixed with 12.65 g of water. Mixing was carried out at 500 rpm.

[0059] Properties measured to the product obtained using the process of the present invention.

Water Impermeability

[0060] Tests were carried out to determine product features such as water impermeability and

[0061] Permeability to water vapor.

[0062] A Karsten test tube was glued to the surface to be measured for impermeability, filled with water until the upper level of the water reaching a height of 10 ml. The amount of water that had to be added over time to maintain the column with 10 ml was measured.

[0063] The results obtained were the following:

[0064] Water absorption without paint applied=5 mL

[0065] Water absorption with paint applied=0.2 mL

[0066] In other words, the paint obtained according to the process of the present invention reduces the permeability to water by 96%. (Karsten Tube test)

Water Vapor Permeability (Humidity)

[0067] The test (NCh 2457.0F.2001, wet method): Test tubes of the material (asbestos-cement plate) were assembled in a test plate containing liquid water (wet method). This assembly is placed in a test atmosphere with controlled temperature and humidity. Due to the difference between the different partial pressures of water vapor in the test assembly and in the chamber, a flow of water vapor passes through the test tubes. The assembly is periodically weighed in order to determine the water vapor transmission coefficient when the steady state is reached.

[0068] The results obtained were the following:

[0069] Water vapor permeability without paint applied=3.8365 g/(m.sup.2.Math.h)

[0070] Water vapor permeability with paint applied=2.6705 g/(m.sup.2.Math.h)

[0071] In other words, the paint obtained according to the process of the present invention allows permeability to water vapor by 69.6%.