PROCESS FOR THE PREPARATION OF POLYACRYLAMIDES USING AN ECO-FRIENDLY LUBRICANT COMPOSITION

Abstract

Process for preparing water-soluble polymers in powder form by polymerization of water-soluble monoethylenically unsaturated monomers comprising the successive steps: a) Spraying on the inner wall of a polymerization vessel, the lubricant composition LC1: alkyl oleate/polyoxyethylene oleyl ether phosphate/sorbitan monolaurate, b) Polymerizing in aqueous solution in the presence of polymerization initiators at least one water-soluble monounsaturated ethylenic monomer, c) Discharging the polymer gel, d) Granulating the polymer gel thus obtained in a granulator, in presence of a lubricant composition LC2: alkyl oleate/polyxoyethylene oleyl ether phosphate/sorbitan monol aurate, e) Drying the polymer gel to obtain a polymer in powder form, f) Grinding and sifting the powder.

Claims

1. Process for preparing water-soluble polymers in powder form by polymerization of water-soluble monoethylenically unsaturated monomers comprising the successive steps: a) Spraying on the inner wall of the polymerization vessel the lubricant composition LC1: alkyl oleate (25-40 weight %)/polyoxyethylene oleyl ether phosphate (50-65 weight %)/sorbitan monolaurate (5-15 weight %), b) Polymerizing in aqueous solution, in the polymerization vessel, in the presence of polymerization initiators at an initiation temperature between −20° C. and 50° C., at least one water-soluble monounsaturated ethylenic monomer, the total mass concentration of monomer relative to the polymerization charge being between 10 and 60%, c) Discharging the polymer gel from the polymerisation vessel, d) Granulating the polymer gel thus obtained in a granulator, in presence of a lubricant composition LC2: alkyl oleate (15-35 weight %)/polyoxyethylene oleyl ether phosphate (15-45 weight %)/sorbitan monolaurate (35-55 weight %), e) Drying the polymer gel to obtain a polymer in powder form, f) Grinding and sifting the powder.

2. Process for preparing water-soluble polymers in powder form according to claim 1 wherein water-soluble monoethylenically unsaturated monomers are nonionic and/or anionic and/or cationic: Non-ionic monomers are selected from the group comprising acrylamide; methacrylamide; N-mono derivatives of acrylamide; N-mono derivatives of methacrylamide; N,N derivatives of acrylamide; N,N derivatives of methacrylamide; acrylic esters; and methacrylic esters, preferably acrylamide, Anionic monomers are selected from the group comprising monomers having a carboxylic function and salts thereof including acrylic acid, methacrylic acid, itaconic acid; maleic acid, monomers having a sulfonic acid function and salts thereof; including acrylamide tertio butyl sulfonic acid (ATBS), monomers having a phosphonic acid function and salts thereof, preferably: acrylic acid, acrylamide tertio butyl sulfonic acid. Cationic monomers are selected from the group comprising dimethylaminoethyl acrylate (DMAEA) quaternized or salified; dimethylaminoethyl methacrylate (DMAEMA) quaternized or salified; diallyldimethyl ammonium chloride (DADMAC); acrylamidopropyltrimethylammonium chloride (APTAC); methacrylamidopropyltrimethylammonium chloride (MAPTAC).

3. Process for preparing water-soluble polymers in powder form according to claims 1 wherein the alkyloleate of lubricant compositions LC1 and/or LC2, is selected form the group: methyl oleate, ethyl oleate, propyl oleate; isopropyl oleate, butyl oleate, isobutyl oleate, amyl oleate, ethylhexyl oleate.

4. Process for preparing water-soluble polymers in powder form according to claim 1 wherein the polyoxyethylene group of the polyxoyethylene oleyl ether phosphate of lubricant compositions LC1 and/or LC2, contains between 2 and 50 oxyethylene moieties.

5. Process for preparing water-soluble polymers in powder form according to claim 1 wherein in step a) of the process 0.01 to 0.8 weight % of the lubricant composition LC1 is sprayed based on the weight of the polymerization charge.

6. Process for preparing water-soluble polymers in powder form according to claim 1 wherein in step d) of the process 0.01 to 1.2 weight % of the lubricant composition LC2 based on the weight of the polymerization charge is sprayed on the polymer in the cutting chamber of the granulator.

7. (canceled)

8. The process for preparing water-soluble polymers in powder form according to claim 2 wherein the water-soluble monoethylenically unsaturated monomers comprise anionic monomers selected from acrylic acid, acrylamide tertio butyl sulfonic acid (ATBS), and alkaline or alkaline earth or ammonium salts thereof

9. Process for preparing water-soluble polymers in powder form according to claim 2 wherein the alkyloleate of lubricant compositions LC1 and/or LC2, is selected form the group: methyl oleate, ethyl oleate, propyl oleate; isopropyl oleate, butyl oleate, isobutyl oleate, amyl oleate, ethylhexyl oleate.

10. Process for preparing water-soluble polymers in powder form according to claim 2 wherein the polyoxyethylene group of the polyxoyethylene oleyl ether phosphate of lubricant compositions LC1 and/or LC2, contains between 2 and 50 oxyethylene moieties.

11. Process for preparing water-soluble polymers in powder form according to claim 3 wherein the polyoxyethylene group of the polyxoyethylene oleyl ether phosphate of lubricant compositions LC1 and/or LC2, contains between 2 and 50 oxyethylene moieties.

12. Process for preparing water-soluble polymers in powder form according to claim 8 wherein the polyoxyethylene group of the polyxoyethylene oleyl ether phosphate of lubricant compositions LC1 and/or LC2, contains between 2 and 50 oxyethylene moieties.

13. Process for preparing water-soluble polymers in powder form according to claim 9 wherein the polyoxyethylene group of the polyxoyethylene oleyl ether phosphate of lubricant compositions LC1 and/or LC2, contains between 2 and 50 oxyethylene moieties.

14. Process for preparing water-soluble polymers in powder form according to claim 2 wherein in step a) of the process 0.01 to 0.8 weight % of the lubricant composition LC1 is sprayed based on the weight of the polymerization charge.

15. Process for preparing water-soluble polymers in powder form according to claim 3 wherein in step a) of the process 0.01 to 0.8 weight % of the lubricant composition LC1 is sprayed based on the weight of the polymerization charge.

16. Process for preparing water-soluble polymers in powder form according to claim 4 wherein in step a) of the process 0.01 to 0.8 weight % of the lubricant composition LC1 is sprayed based on the weight of the polymerization charge.

17. Process for preparing water-soluble polymers in powder form according to claim 8 wherein in step a) of the process 0.01 to 0.8 weight % of the lubricant composition LC1 is sprayed based on the weight of the polymerization charge.

18. Process for preparing water-soluble polymers in powder form according to claim 2 wherein in step d) of the process 0.01 to 1.2 weight % of the lubricant composition LC2 based on the weight of the polymerization charge is sprayed on the polymer in the cutting chamber of the granulator.

19. Process for preparing water-soluble polymers in powder form according to claim 3 wherein in step d) of the process 0.01 to 1.2 weight % of the lubricant composition LC2 based on the weight of the polymerization charge is sprayed on the polymer in the cutting chamber of the granulator.

20. Process for preparing water-soluble polymers in powder form according to claim 4 wherein in step d) of the process 0.01 to 1.2 weight % of the lubricant composition LC2 based on the weight of the polymerization charge is sprayed on the polymer in the cutting chamber of the granulator.

21. Process for preparing water-soluble polymers in powder form according to claim 5 wherein in step d) of the process 0.01 to 1.2 weight % of the lubricant composition LC2 based on the weight of the polymerization charge is sprayed on the polymer in the cutting chamber of the granulator.

Description

EXAMPLES

CE1 & CE2: Preparation of an Anionic and Cationic Polyacrylamide in Powder Form

[0042] LC1: Hydrocarbons, C16-C20, n-alkanes, isoalkanes, cyclics/polyoxyethylene 10 oleyl ether phosphate/sorbitan monolaurate, (30/60/10, weight %) [0043] LC2: Hydrocarbons, C16-C20, n-alkanes, isoalkanes, cyclics/polyoxyethylene 10 oleyl ether phosphate/sorbitan monolaurate, (50/06/44, weight %)

Anionic Polymer (CE1):

[0044] In a in inverted conical tubular reactor (capacity: 7.5 T), the polymerization charge was composed by 3137 kg of acrylamide (50 weight % in water) 757 kg of acrylic acid (90% in water) 757 kg of NaOH (50% in water) and 2849 kg of water.

[0045] Before polymerization, 10 L of lubricant composition LC1 is sprayed by a pig tail sprayer on the inner wall of the reactor.

[0046] After polymerization, the gel of polymer was discharged from the reactor, and granulated in a presence of 16 L.h.sup.−1 of lubricant composition LC2 sprayed by one atomizer nozzle.

Cationic Polymer (CE2):

[0047] In a in inverted conical tubular reactor (capacity: 7.5 T), the polymerization charge was composed by 1593 kg of acrylamide (50 weight % in water) 3317 kg of dimethylaminoethyl acrylate (DMAEA) quaternized with methyl chloride (80% in water) and 2590 kg of water. Before polymerization, 20 L of lubricant composition LC1 is sprayed by a pig tail sprayer on the inner wall of the reactor.

[0048] After polymerization, the gel of polymer was discharged from the reactor, and granulated in a presence of 8 L.h.sup.−1 of lubricant composition LC2 sprayed by one atomizer nozzle.

E1 & E2: Preparation of an Anionic and Cationic Polyacrylamide in Powder Form with Low VOC Lubricant Composition [0049] LC1: ethylhexyl oleate/polyoxyethylene 10 oleyl ether phosphate/sorbitan monolaurate, (30/60/10, weight %) [0050] LC2: ethylhexyl oleate/polyoxyethylene 10 oleyl ether phosphate/sorbitan monolaurate, (25/30/45, weight %)

[0051] For E1 (anionic polymer) and E2 (cationic polymer), same reactor and polymerization charge than respectively CE1 & CE2 were used.

Anionic Polymer (E1):

[0052] Before polymerization, 5 L of lubricant composition LC1 is sprayed by a pig tail sprayer on the inner wall of the reactor.

[0053] After polymerization, the gel of polymer was discharged from the reactor, and granulated in a presence of 11 L.h.sup.−1 of lubricant composition LC2 sprayed by one atomizer nozzle. Cationic Polymer (E2):

[0054] Before polymerization, 10 L of lubricant composition LC1 is sprayed by a pig tail sprayer on the inner wall of the reactor.

[0055] After polymerization, the gel of polymer was discharged from the reactor, and granulated in a presence of 4.6 L.h.sup.−1 of lubricant composition LC2 sprayed by one atomizer nozzle.

COVs Measure:

[0056] COV measure was performed by a Flame Ionization Detector (FID) according to NFX 43 301 standard. [0057] E1: 18 mg. Nm.sup.−3; E2: 22 mg.Nm.sup.−3 [0058] CE1: 42 mg. Nm.sup.−3; CE2 50 mg.Nm.sup.−3

[0059] Conclusion: Comparatively for E1 and E2/CE1 and CE2, quantity of lubricant LC1 and LC2 were decreased with less COVs emission.