U.S. patent application number 15/064923 was filed with the patent office on 2017-08-10 for oil-free crystal growth modifiers for alumina recovery.
The applicant listed for this patent is Cytec Industries Inc.. Invention is credited to Marie E. Anderson, Krzysztof ANDRUSZKIEWICZ, Haunn-Lin Tony CHEN, Raymond Salvatore FARINATO, Scott GRIFFIN.
Application Number | 20170225962 15/064923 |
Document ID | / |
Family ID | 55699791 |
Filed Date | 2017-08-10 |
United States Patent
Application |
20170225962 |
Kind Code |
A1 |
ANDRUSZKIEWICZ; Krzysztof ;
et al. |
August 10, 2017 |
OIL-FREE CRYSTAL GROWTH MODIFIERS FOR ALUMINA RECOVERY
Abstract
Disclosed herein is a method of producing alumina trihydrate
crystals from an alumina trihydrate recovery process stream wherein
an aqueous emulsion comprising an alkyl or alkenyl succinic
anhydride is added to the alumina trihydrate recovery process
stream, wherein the aqueous emulsion is substantially free of
mineral oils. The method provides a decrease in percentage of
alumina trihydrate crystals having a volume average diameter of
less than about 45 micrometers compared to the percentage of
alumina trihydrate crystals produced in the absence of the aqueous
emulsion of an alkyl or alkenyl succinic anhydride.
Inventors: |
ANDRUSZKIEWICZ; Krzysztof;
(Gdynia, PL) ; FARINATO; Raymond Salvatore;
(Norwalk, CT) ; CHEN; Haunn-Lin Tony;
(Morganville, CT) ; GRIFFIN; Scott; (Norwalk,
CT) ; Anderson; Marie E.; (Trumbull, CT) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Cytec Industries Inc. |
Woodland Park |
NJ |
US |
|
|
Family ID: |
55699791 |
Appl. No.: |
15/064923 |
Filed: |
March 9, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62131460 |
Mar 11, 2015 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
C01F 7/34 20130101; C01P
2006/80 20130101; C01P 2004/61 20130101; C01F 7/145 20130101 |
International
Class: |
C01F 7/34 20060101
C01F007/34 |
Claims
1. A method of producing alumina trihydrate crystals from an
alumina trihydrate recovery process stream, the method comprising:
adding an aqueous emulsion comprising an alkyl or alkenyl succinic
anhydride to the alumina trihydrate recovery process stream,
wherein the aqueous emulsion is substantially free of mineral oils
and fuel oils; and crystallizing the alumina trihydrate crystals
from the alumina trihydrate recovery process stream, thereby
providing a decrease in percentage of alumina trihydrate crystals
having a volume average diameter of less than about 45 micrometers
compared to the percentage of alumina trihydrate crystals produced
in the absence of the aqueous emulsion of an alkyl or alkenyl
succinic anhydride.
2. The method according to claim 1 wherein the aqueous emulsion is
substantially free of surfactants.
3. The method according to claim 1 wherein the aqueous emulsion is
substantially free of polyalkoxylated non-ionic surfactants, fatty
acids, fatty acid salts or combinations thereof.
4. The method according to claim 1 wherein the aqueous emulsion has
a volume average particle diameter of about 1 to about 100
micrometers.
5. The method according to claim 1 wherein the aqueous emulsion has
a volume average particle diameter of about 1 to about 50
micrometers.
6. The method according to claim 1 wherein the alkyl or alkenyl
succinic anhydride has the structure: ##STR00003## wherein x is
from 1 to 30, and y is 2x-1 or 2x+1.
7. The method according to claim 1 wherein the alkyl or alkenyl
succinic anhydride is a C.sub.14-C.sub.24 alkenyl succinic
anhydride.
8. The method according to claim 1 wherein the aqueous emulsion is
substantially free of distillation bottoms from an oxo process.
9. The method according to claim 1 wherein the aqueous emulsion
further comprises a defoamer.
10. The method according to claim 9 wherein the defoamer is chosen
from polypropylene oxide, polypropylene oxide mono-C1-C6 alkyl
ethers, polyethylene oxide, polyethylene oxide
mono-C.sub.1-C.sub.6alkyl ethers, polysiloxanes, organic-modified
polysiloxanes, hydrophobic silica particles, distillation bottoms
from an oxo process, or combinations thereof.
11. The method according to claim 9 wherein the weight ratio of
alkyl or alkenyl succinic anhydride to defoamer is from 100:1 to
1:1.
12. The method according to claim 1 wherein the alumina trihydrate
recovery process stream is a caustic Bayer process stream.
13. The method according to claim 1 wherein the aqueous emulsion is
added after red mud separation and prior to isolation of alumina
trihydrate crystals.
14. The method according to claim 1 wherein the aqueous emulsion is
prepared with a high shear mixer.
15. The method according to claim 1 wherein the alkyl or alkenyl
succinic anhydride is added at a dose of from about 0.1 to about
100 milligrams per liter of alumina trihydrate recovery process
stream.
16. The method according to claim 1 wherein the aqueous emulsion
comprises from about 1 to about 20 milligrams per 100 milliliters
of alkyl or alkenyl succinic anhydride.
17. The method according to claim 1 wherein alumina trihydrate
yield after about 5 hours crystallizing time is not decreased by
addition of the aqueous emulsion to the alumina trihydrate recovery
process stream.
Description
[0001] This application claims priority to pending U.S. patent
application 62/131,460 filed Mar. 11, 2015 incorporated herein in
its entirety.
BACKGROUND OF THE INVENTION
[0002] The present invention is directed towards a method of
producing alumina trihydrate crystals from an alumina trihydrate
recovery process stream.
[0003] Production by the Bayer process involves the digestion of
bauxite at high temperatures and pressures in caustic soda liquor,
producing a saturated sodium aluminate solution (pregnant liquor)
containing an insoluble ferruginous residue called "red mud". In
the Sinter process, bauxite is combined with lime and heated to
about 1200.degree. C. prior to leaching with caustic soda liquor to
generate a sodium aluminate liquor containing insoluble "sinter
mud". Mud slurries generated in the above processes are treated
with flocculants to flocculate and separate the muds from the
pregnant liquor by gravity settling in thickener vessels
(settlers). After settling, the clarified liquor (overflow) is
removed from the top of the settler. At this point, the Sinter
process often requires another step wherein a desilication additive
such as lime is added to the overflow liquor to remove soluble
silica from the liquor. This slurry is treated with flocculants and
fed to a desilication settler to remove insoluble desilication
products. The liquor is then further purified in a filtration
process in order to remove suspended fine solids and other
impurities.
[0004] The purified pregnant liquor--an example of an alumina
trihydrate recovery process stream--is then cooled and seeded with
fine alumina trihydrate crystals or neutralized with CO.sub.2 gas
in a precipitation process to produce alumina trihydrate as
gibbsite crystals, followed by calcination to produce the final
alumina product. In the Bayer process, precipitation of alumina
trihydrate from supersaturated caustic aluminate solutions is the
rate limiting step, taking up over half of the residence time in an
alumina refinery. Precipitation does not take place under ideal
conditions because the digestion of bauxite ore in refinery "spent"
liquor results in a solution supersaturated in alumina, and which
also contains significant amounts of organic and inorganic
impurities. Precipitation is accelerated by the use of seed alumina
trihydrate crystals.
[0005] Bayer process operators optimize precipitation to maximize
yield while still obtaining high quality product having a target
crystal size distribution. It is desirable to produce relatively
large crystals as this facilitates subsequent processing steps. A
large percentage of fine crystals (i.e., below 45 micrometers) are
undesirable. However the presence of some fine crystals may be
desirable for seeding purposes. The yield and properties of the
alumina trihydrate crystals can be significantly affected by the
process conditions used, such as temperature, residence time, and
the nature of the seed crystal used, and these conditions can vary
from plant to plant.
[0006] A crystal growth modifier (CGM) can be added to the alumina
trihydrate recovery process stream to impose a deliberate
modification of the alumina trihydrate crystals. A modification
generally used is a reduction in the proportion of fines, and
therefore, an increase in the average alumina trihydrate particle
size. Crystal growth modifiers can be used to control particle size
and strength. Not only must product quality crystals (.gtoreq.45
micrometers) be produced, but sufficient seed crystals (.ltoreq.45
micrometers) are also needed to promote precipitation. Crystal
growth modifiers can also enhance agglomeration by combining and
cementing smaller particles. Crystal growth modifiers can also
suppress or control primary nucleation (generation of new
particles) and secondary nucleation (generation of new particles on
surfaces of existing particles). A crystal growth modifier can
modify the crystal particle size distribution, allowing the user to
use a lower fill temperature and higher seed charge. Crystal growth
modifiers can also be used to affect the morphology of oxalate
crystals that often co-precipitate in the alumina trihydrate
precipitation circuit.
[0007] Extensive efforts have been invested into finding effective
crystal growth modifiers and methods of their use in optimizing
crystal particle size. Many crystal growth modifiers (e.g.,
C18-fatty acids) require the addition of an oil or secondary
surfactant to aid in dispersion of the CGM into pregnant liquor.
Added oil or surfactant increases the impurity load in the liquor,
negatively impacting precipitation yield, and may cause
discoloration of the alumina trihydrate, which is highly
undesirable.
[0008] Because of the organic content of Bayer liquor
(predominantly humic substances), it has a natural tendency to
foam. Foaming of the liquor is aggravated by the mixing steps in
the Bayer process. Foaming is especially a problem after
clarification (separation of the red mud) and during precipitation.
The amount of pregnant liquor cannot be maximized in vessels partly
filled with foam, and therefore maximum product throughput cannot
be obtained. Foam also poses a safety hazard in that overflow can
expose workers to high levels of caustic, which can cause severe
chemical burns. Since foam is an insulator, reduction in foam can
improve heat transfer efficiency. Reduction of foam can reduce
scaling in precipitators and improve operation of alumina
trihydrate classification systems due to reduced alumina trihydrate
retention in foam.
[0009] In view of these factors, a way to economically reduce the
generation of fine particles in the precipitation of alumina
trihydrate is desirable. In particular, the method should provide a
decrease in percentage of crystals having a volume average diameter
of less than about 45 micrometers. The crystal growth modifier
employed should be effective at low doses (i.e., less than about
100 milligrams per liter of pregnant liquor), and should be
substantially free of ancillary oils or surfactants, thereby
minimizing contamination and discoloration of the alumina
trihydrate crystals. Moreover, foam generation in the method should
also be minimized.
BRIEF DESCRIPTION OF THE INVENTION
[0010] An improved method of producing alumina trihydrate crystals
from an alumina trihydrate recovery process stream is provided. The
method comprises adding an aqueous emulsion comprising an alkyl or
alkenyl succinic anhydride to the alumina trihydrate recovery
process stream, wherein the aqueous emulsion is substantially free
of mineral oils (e.g., paraffinic oil, naphthenic oil) and fuel
oils. The alumina trihydrate crystals are crystallized from the
alumina trihydrate recovery process stream, thereby providing a
decrease in percentage of alumina trihydrate crystals having a
volume average diameter of less than about 45 micrometers compared
to the percentage of alumina trihydrate crystals produced in the
absence of the aqueous emulsion of an alkyl or alkenyl succinic
anhydride.
DETAILED DESCRIPTION OF THE INVENTION
[0011] A method of producing alumina trihydrate crystals from an
alumina trihydrate recovery process stream provides a decrease in
percentage of crystals having a volume average diameter of less
than 45 micrometers. The method employs a crystal growth modifier
which is effective at low doses (less than 100 milligrams per liter
of pregnant liquor). Advantageously, the crystal growth modifier is
provided neat (100% active ingredients) and is substantially free
of ancillary oils or surfactants to minimize discoloration of the
alumina trihydrate crystals. The effective amount of alkyl or
alkenyl succinic anhydride is low enough to be economical and to
minimize contamination of the alumina trihydrate crystals. The
crystal growth modifier is added to alumina trihydrate recovery
process streams as an aqueous emulsion. Moreover, foam generation
in the method can be reduced with a defoamer.
[0012] The improved method of producing alumina trihydrate crystals
in an alumina recovery process stream comprises: adding an aqueous
emulsion comprising an alkyl or alkenyl succinic anhydride to the
alumina trihydrate recovery process stream, wherein the aqueous
emulsion is substantially free of mineral oils and fuel oils; and
crystallizing the alumina trihydrate crystals from the alumina
trihydrate recovery process stream, thereby providing a decrease in
percentage of alumina trihydrate crystals having a volume average
diameter of less than about 45 micrometers compared to the
percentage of alumina trihydrate crystals produced in the absence
of the aqueous emulsion of an alkyl or alkenyl succinic anhydride
collectively abbreviated herein as "ASA".
[0013] The alkyl or alkenyl succinic anhydride can have the
structure:
##STR00001##
wherein x is from 1 to 30, and y is 2x-1 or 2x+1. Within this
range, x can be from 6 to 24, 12 to 24, or 14 to 20. The alkyl and
alkenyl groups can be branched or unbranched. Examples of alkyl or
alkenyl succinic anhydrides include tetracocenyl succinic anhydride
(C-24 ASA), eicosenyl succinic anhydride (C-20 ASA), n-octadecenyl
succinic anhydride, (C-18 ASA), iso-octadecenyl succinic anhydride,
n-hexadecenyl succinic anhydride (C-16 ASA), dodecenyl succinic
anhydride (C-12 ASA), octenyl succinic anhydride, triisobutenyl
succinic anhydride, tetrapropenyl succinic anhydride, and
combinations thereof. Alkyl or alkenyl succinic anhydrides can be
provided as mixtures, for example mixtures of one or more of
C14-ASA, C-16 ASA, C18-ASA, and C-20 ASA can be used. In some
embodiments, the alkyl or alkenyl succinic anhydride is a C14-C20
alkenyl succinic anhydride.
[0014] Alkenyl succinic anhydrides are produced by the reaction of
internal alkenes with maleic anhydride at temperatures of about
200.degree. C. Alkyl succinic anhydride can be produced by
hydrogenation of alkenyl succinic anhydrides. The internal olefins
can be produced by isomerization of alpha-olefins under
thermodynamic conditions, or by acid-catalyzed oligomerization of
alpha-olefins (e.g., triisobutene, tetrapropene). Alkyl or alkenyl
succinic anhydrides can also be produced from vegetable oils
(triglycerides) having a high content of mono-unsaturated fatty
acid groups, for example oleic acid groups or esters produced
during esterification of fatty acid or triglycerides. These alkenyl
succinic anhydrides are referred to as "maleated
triglycerides".
[0015] The aqueous emulsion is substantially free of mineral oils
and fuel oils, including paraffinic oils and naphthenic oils, based
on total weight of the aqueous emulsion. As used herein,
"substantially free of" means less than about 5, 4, 3, 2, 1, or 0.1
weight percent of the indicated material. In some embodiments
"substantially free of" means that there is no measureable amount
of the material. The mineral oil and fuel oil can have a boiling
point of greater than about 93.degree. C. (200.degree. F.).
Advantageously, the absence of mineral oils and fuel oils minimizes
contamination and discoloration of the alumina trihydrate with
organic material.
[0016] In some embodiments, the aqueous emulsion is substantially
free of distillation bottoms from the production of alkyl alcohols
by the oxo process (hydroformylation). The distillation bottoms are
sometimes referred to as "heavy oxo fraction". The distillation
bottoms can be high boiling, and can contain a mixture of alkyl
alcohols, hydroformylation reactants (olefins), as well as ether
and ester by-products.
[0017] In some embodiments, the aqueous emulsion is substantially
free of surfactants. Surfactants are organic compounds that are
amphiphilic, meaning they contain both hydrophobic groups ("tails")
and hydrophilic groups ("heads"). The hydrophobic groups can
comprise, for example, aliphatic, branched aliphatic, or
alkylaromatic hydrophobes of about 8 to about 24 carbon atoms. In
some embodiments, the aqueous emulsion is substantially free of
polyalkoxylated non-ionic surfactants, fatty acids, fatty acid
salts, or combinations thereof. Polyalkoxylated non-ionic
surfactants are composed of ethylene oxide (EO) repeat units,
propylene oxide (PO) repeat units, butylene oxide (BO) repeat
units, and combinations thereof. The polyalkoxylated non-ionic
surfactant can be a homopolymer, a random copolymer, an alternating
copolymer, a periodic copolymer, a block copolymer, a graft
copolymer, or a branched copolymer of EO, PO, BO, and combinations
thereof. The polyalkoxylated non-ionic surfactant can be, for
example, a poly(ethylene oxide-propylene oxide) block copolymer,
commercially available under the trade names PLURONIC.TM.
SYNPERONIC.TM. PE, DOWFAX.TM., and MONOLAN.TM..
[0018] The polyalkoxylated non-ionic surfactant can be an ethylene
oxide, propylene oxide, and butylene oxide polymers and copolymers
formed with alcohol, phenolic, or amine initiators. The alcohol can
be, for example, a mono-, di-, tri- or tetrol. The alcohol can be,
for example, a fatty alcohol. Polyalkoxylated non-ionic surfactants
of this type are commercially available under the trade name
PLURAFAC.TM.. The diol can be ethylene glycol or propylene glycol
and the triol can be glycerol or trimethylol propane.
Polyalkoxylated non-ionic surfactants of this type are commercially
available under the trade names UKANIL.TM. and DOWFAX.TM.. The
tetrols can be pentaerythritol. Polyalkoxylated non-ionic
surfactants based on ethylene diamine are available under the trade
name TETRONICS.TM.. In polyalkoxylated non-ionic surfactants having
ethylene oxide, propylene oxide, and butylene oxide repeat units,
the amount of butylene oxide is about 1 to about 40 weight percent.
The polyalkoxylated non-ionic surfactant can have a molecular
weight of the EO/PO (and optionally BO) chain of about 600 Daltons
or greater, specifically about 2,000 to about 5,000 Daltons.
[0019] Fatty acids are carboxylic acids (head) having a long alkyl
or alkenyl chain (tail). Most naturally occurring fatty acids have
an even number chain of from about 4 to about 28 carbon atoms. The
fatty acid can be a mixture of fatty acids having different even
carbon chain lengths. For example, the fatty acid can be a mixture
of C6, C8, C10 and C12 fatty acids, or it can be tall oil, which is
mainly composed of oleic acid. The fatty acid can be present as its
conjugate base (e.g., as metal or ammonium carboxylate salts),
which are formed in situ in the presence of alkali.
[0020] As described above, production of alumina from bauxite is
done by the Bayer process, Sinter process, or various combinations
of the two. Production by the Bayer process involves the digestion
of bauxite at high temperatures and pressures in a caustic soda
solution to produce a caustic saturated sodium aluminate solution
containing an insoluble ferruginous residue called "red mud". A
caustic sodium aluminate solution--"pregnant liquor"--is obtained
after removal of the red mud, fine suspended solids and other
impurities. Caustic pregnant liquor from the Bayer process is an
example of an alumina trihydrate recovery process stream. Thus, in
some embodiments, the alumina trihydrate recovery process stream is
a caustic Bayer process stream. Alumina trihydrate crystals are
precipitated from the resulting caustic sodium aluminate solution
(pregnant liquor). Thus, in some embodiments, the aqueous emulsion
of alkyl or alkenyl succinic anhydride is added after red mud
separation and prior to isolation of alumina trihydrate
crystals.
[0021] Alkyl or alkenyl succinic anhydrides are crystal growth
modifiers (CGM) which can be added to alumina trihydrate recovery
process streams to modify alumina trihydrate crystals. Crystal
growth modifiers can be used to control particle size and strength.
A modification generally used is a reduction in the proportion of
fines, and therefore, an increase in the average alumina trihydrate
particle size. An overall increase in average alumina trihydrate
crystal size is desirable as it reduces energy consumption and
makes the process more economical. For example, an increase in
alumina trihydrate crystal size can facilitate isolation of the
crystals from the alumina trihydrate recovery process stream.
Volume average diameters of less than about 45 micrometers and less
than about 20 micrometers are useful parameters. Advantageously,
the method of producing alumina trihydrate crystals from an alumina
trihydrate recovery process stream provides a decrease in
percentage of alumina trihydrate crystals having a volume average
diameter of less than about 45 micrometers compared to the
percentage of alumina trihydrate crystals produced in the absence
of the aqueous emulsion of an alkyl or alkenyl succinic anhydride.
The method can also provide a decrease in percentage of alumina
trihydrate crystals having a volume average diameter of less than
20 micrometers compared to the percentage of alumina trihydrate
crystals produced in the absence of the aqueous emulsion of an
alkyl or alkenyl succinic anhydride.
[0022] Alkyl or alkenyl succinic anhydrides can be added to the
alumina trihydrate recovery process stream as an aqueous emulsion.
The aqueous emulsion can be an oil-in-water emulsion, where the oil
in this case is the active ingredient (i.e., an alkyl or alkenyl
succinic anhydride). Advantageously, the aqueous emulsion can be
formed in the absence of mineral oil and fuel oil as co-solvents or
diluents, thereby minimizing organic contamination of the alumina
trihydrate crystals. In some embodiments, alkyl or alkenyl succinic
anhydride droplets in the aqueous emulsion have a volume average
particle diameter of about 1 to about 100 micrometers (.mu.m),
about 1 to about 50 .mu.m), or about 10 to about 50 .mu.m.
[0023] In some embodiments, the aqueous emulsion is prepared with a
high shear mixer. For example, on a laboratory scale, the aqueous
emulsion can be prepared using a Polytron PT-2100 homogenizer,
equipped with a 12-millimeter aggregate stirring shaft and
operating at 11,000, 19,000, and 26,000 revolutions per minute
(`rpm`).
[0024] Aqueous emulsions of alkyl or alkenyl succinic anhydride can
be prepared at convenient concentrations. For example, the amount
of alkyl or alkenyl succinic anhydride can be from about 0.1 to
about 25 grams per 100 milliliters, or about 1 to about 10 grams
per 100 milliliters. Thus in some embodiments, the aqueous emulsion
comprises from about 0.1 to about 20 grams per 100 milliliters of
alkyl or alkenyl succinic anhydride.
[0025] The aqueous emulsion of alkyl or alkenyl succinic anhydride
can be added to an alumina trihydrate recovery process stream in an
amount effective to decrease the percentage of alumina trihydrate
crystals having a volume average diameter of less than about 45
micrometers compared to the percentage of alumina trihydrate
crystals produced in the absence of the aqueous emulsion of an
alkyl or alkenyl succinic anhydride. Advantageously, the effective
amount of alkyl or alkenyl succinic anhydride is small enough to be
economical and minimize contamination of the alumina trihydrate
crystals.
[0026] As used herein, the amount of alkyl or alkenyl succinic
anhydride added to the alumina trihydrate recovery process stream
is defined as the "dose", which is expressed in units of milligrams
alkyl or alkenyl succinic anhydride per liter of alumina trihydrate
recovery process stream. The alkyl or alkenyl succinic anhydride
can be added at a dose of from about 0.1 to about 100 milligrams
per liter of alumina trihydrate recovery process stream, from about
1 to about 50 milligrams per liter of alumina trihydrate recovery
process stream, or from about 2 to about 20 milligrams per liter of
alumina trihydrate recovery process stream.
[0027] Advantageously, the alkyl or alkenyl succinic anhydride
provides the beneficial effect of increasing average alumina
trihydrate particle size without adversely affecting the yield of
alumina trihydrate crystals. The alkyl or alkenyl succinic
anhydride can have its greatest effect in the early stages of
precipitation of alumina trihydrate crystals form the alumina
trihydrate recovery process stream. Thus in some embodiments, the
alumina trihydrate yield after about 5 hours crystallizing time is
not decreased by addition of the aqueous emulsion to the alumina
trihydrate recovery process stream. Total crystallizing time in the
Bayer process can be greater than 24 hours in a refinery.
[0028] Foam can occur in the crystallizing step in alumina
trihydrate production, wherein the alumina trihydrate recovery
process stream is agitated. Foam is a stable dispersion of air in a
liquid (here, a stable dispersion of air in the alumina trihydrate
recovery process stream). Foam is generated by the introduction of
air into the alumina trihydrate recovery process stream by
agitation. The bubbles produced tend to assume a spherical shape,
and since they are lighter than the liquid phase, rise to the
liquid-air interface. Foam reduces the effective volume of
crystallizing vessels by occupying head space above the liquid.
Foam can also interfere with liquid transfer operations (e.g.,
pumping).
[0029] Defoamers can be added to the alumina trihydrate recovery
process stream to reduce the formation of foam. Suitable defoamers
include polypropylene oxide (also known as polypropylene glycol),
polypropylene oxide mono-C1-C6 alkyl ethers (also known as
polypropylene glycol mono-C1-C6 alkyl ethers), polyethylene oxide
(also known as polyethylene glycol), polyethylene oxide mono-C1-C6
alkyl ethers (also known as polyethylene glycol mono-C1-C6 alkyl
ethers), polysiloxanes, organic-modified polysiloxanes, hydrophobic
silica particles, distillation bottoms from the oxo process, or
combinations thereof. The defoamer can be added to the alumina
trihydrate recovery process stream together with the alkyl or
alkenyl succinic anhydride.
[0030] The defoamer can be combined with the alkyl or alkenyl
succinic anhydride in the aqueous emulsion. Thus, in some
embodiments, the aqueous emulsion further comprises a defoamer
chosen from polypropylene oxide, polypropylene oxide mono-C1-C6
alkyl ethers, polyethylene oxide, polyethylene oxide mono-C1-C6
alkyl ethers, polysiloxanes, organic-modified polysiloxanes,
hydrophobic silica particles, distillation bottoms from the oxo
process, or combinations thereof. While the alkyl or alkenyl
succinic anhydride can be added in an amount effective to increase
the average size of the alumina trihydrate crystals, the defoamer
can be added in an amount effective to reduce foam in the aqueous
emulsion and/or alumina trihydrate recovery process stream. In some
embodiments, the weight ratio of the alkyl or alkenyl succinic
anhydride to defoamer is from about 100:1 to about 1:1. Within this
range, the weight ratio of alkyl or alkenyl succinic anhydride to
defoamer can be from about 20:1 to about 1:1, about 10:1 to about
1:1, about 5:1 to about 1:1, or about 3:1 to about 1:1.
[0031] The method of producing alumina trihydrate crystals from an
alumina trihydrate recovery process stream provides a decrease in
percentage of crystals having a volume average diameter of less
than about 45 micrometers. The method employs a crystal growth
modifier which is effective at low doses (i.e., less than about 100
milligrams per liter of pregnant liquor). Advantageously, the
crystal growth modifier is provided neat (100% active ingredients)
and is substantially free of ancillary oils or surfactants to
minimize discoloration of the alumina trihydrate crystals. The
effective amount of alkyl or alkenyl succinic anhydride is low
enough to be economical and to minimize contamination of the
alumina trihydrate crystals. The crystal growth modifier can be
added to alumina trihydrate recovery process streams as an aqueous
emulsion. Moreover, foam in the alumina trihydrate recovery process
stream can be reduced with a defoamer.
[0032] This invention includes at least the following
embodiments.
[0033] In general, the present invention is directed towards a
method of producing alumina trihydrate crystals from an alumina
trihydrate recovery process stream. This method includes the steps
of adding an aqueous emulsion comprising alkyl or alkenyl succinic
anhydride to the alumina trihydrate recovery process stream,
wherein the aqueous emulsion is substantially free of mineral oils
(e.g., paraffinic oil, naphthenic oil) and fuel oils; and
crystallizing the alumina trihydrate crystals from the alumina
trihydrate recovery process stream. This provides a decrease in the
percentage of alumina trihydrate crystals having a volume average
diameter of less than about 45 micrometers compared to the
percentage of alumina trihydrate crystals produced in the absence
of the aqueous emulsion of alkyl or alkenyl succinic anhydride.
[0034] In one embodiment, the aqueous emulsion is substantially
free of surfactants.
[0035] In another embodiment, the aqueous emulsion is substantially
free of polyalkoxylated non-ionic surfactants, fatty acids, fatty
acid salts, and a combination thereof
[0036] In one embodiment, the aqueous emulsion has a volume average
particle diameter of about 1 to about 100 micrometers. Preferably,
the aqueous emulsion has a volume average particle diameter of
about 1 to about 50 micrometers. In another embodiment, the aqueous
emulsion has a volume average particle diameter of about 10 to
about 50 micrometers.
[0037] In one embodiment, the alkyl or alkenyl succinic anhydride
used in the method described above has the structure:
##STR00002##
wherein x is from 1 to 30, and y is 2x-1 or 2x+1.
[0038] In one embodiment, the alkyl or alkenyl succinic anhydride
is a C.sub.14-C.sub.24 alkenyl succinic anhydride.
[0039] In one embodiment, the aqueous emulsion is substantially
free of distillation bottoms from the oxo process
(hydroformylation).
[0040] The aqueous emulsion used in the method described above can
further include a defoamer. The defoamer can be polypropylene
oxide, polypropylene oxide mono-C.sub.1-C.sub.6 alkyl ethers,
polyethylene oxide, polyethylene oxide mono-C.sub.1-C.sub.6 alkyl
ethers, polysiloxanes, organic-modified polysiloxanes, hydrophobic
silica particles, distillation bottoms from the oxo process, or
combinations thereof.
[0041] In the embodiment wherein a defoamer is added to the aqueous
emulsion, the weight ratio of alkyl or alkenyl succinic anhydride
to defoamer is from 100:1 to 1:1.
[0042] In one embodiment, the alumina trihydrate recovery process
stream is a caustic Bayer process stream.
[0043] In one embodiment, the aqueous emulsion is added after red
mud separation and prior to isolation of alumina trihydrate
crystals.
[0044] In one embodiment, the aqueous emulsion is prepared with a
high shear mixer.
[0045] In one embodiment, the alkyl or alkenyl succinic anhydride
is added at a dose from about 0.1 to about 100 milligrams per liter
of alumina trihydrate recovery process stream.
[0046] In one embodiment, the aqueous emulsion comprises from about
1 to about 20 milligrams per 100 milliliters of alkyl or alkenyl
succinic anhydride.
[0047] In one embodiment, the alumina trihydrate yield after about
5 hours crystallizing time is not decreased by addition of the
aqueous emulsion to the alumina trihydrate recovery process
stream.
[0048] This invention is further illustrated by the following
non-limiting examples.
Examples
[0049] Materials used in Examples 1-8 are described in Table 1.
TABLE-US-00001 TABLE 1 Description of Materials Used in Examples
1-8. Substance Chemical Description and Source C18-ASA C.sub.18
alkenyl succinic anhydride, or dihydro-3-(octadecenyl)-
2,5-furandione, available from Dixie Chemicals. C18-ASA 5 g/100 mL
C18-ASA in deionized water at pH 3.5. Emulsion C18-FA C.sub.18
fatty acid, available from Arizona Chemical as SYLFAT .TM. FA1.
DF225 Alumina trihydrate, available from R. J. Marshall as DF225,
having 60% fines (<45 .mu.m) (Alcoa C-31 equivalent). Commercial
C.sub.18 fatty acid, 15 g/100 mL in oil. Product A Commercial
C.sub.18 fatty acid, 15 g/100 mL in oil. Product B Defoamer Liquid,
glycol ether-based defoaming reagent, available from Cytec
Industries as CYBREAK .TM. 632.
[0050] Each test was run using spent liquor samples A or B
(obtained from two different alumina plants) reconstituted to
pregnant liquor by adding alumina and dissolving it at 145.degree.
C. The pregnant liquor comprised 165 g/L .+-.10 g/L alumina (A,
expressed as Al.sub.2O.sub.3), 230 g/L.+-.10 g/L caustic soda (C,
expressed as Na.sub.2CO.sub.3), and 320 g/L.+-.10 g/L total soda
(S, expressed as Na.sub.2CO.sub.3), wherein the A/C ratio was 0.72.
(A/C ratios in pregnant liquor are generally in the range of 0.68
to 0.72.)
[0051] C18-ASA Emulsions were prepared by weighing out the required
amounts of deionized water (adjusted to a pH of 3.5 with sulfuric
acid) and C18-ASA or C18-ASA and defoamer. The amounts used were
calculated to give a 5 g/100 mL C18-ASA emulsion. The water was
added first, and then the C18-ASA. The mixture was then homogenized
for 1 minute (min.) at 19,000 revolutions per minute (19 k rpm)
using a Polytron PT-2100 homogenizer, equipped with a 12-millimeter
aggregate stirring shaft, unless otherwise stated.
[0052] Precipitation tests were performed in 250-mL NALGENE.TM.
bottles rotated end-over-end at approximately 15 rpm in a
temperature controlled water bath (Thornton Engineering) at either
50.degree. C. or 70.degree. C. In the tests, 200 mL of pregnant
liquor was added to the bottles. CGM was then mixed into the
pregnant liquor. All the bottles were tightly sealed and placed
into the water bath for 15-20 minutes at 50.degree. C. or
70.degree. C. to allow the samples to come to equilibrium. After
equilibrium, the bottles were removed and charged with the
designated quantity of seed alumina trihydrate and returned to the
water bath. The bottles were rotated for 5 hours (hr.) or 18 hr. at
the desired temperature.
[0053] After precipitation of alumina trihydrate for 5 or 18 hr.,
the bottles were removed from the water bath one at a time, and a
15 mL sample was removed for liquor analysis. 2-3 drops of sodium
gluconate solution (400 g/L) were added to this sub-sample to
prevent further precipitation from the liquor. The remaining slurry
sample was immediately filtered and the solids were collected by
vacuum filtration, and then thoroughly washed with hot deionized
water and dried at 105.degree. C. Volume average diameter was
determined on a Horiba LA 920 light scattering instrument using a
laser diffraction method that is well known in the art. The effect
of the CGM on particle size distribution was determined by
comparing the amounts (%) of particles below 45 .mu.m (fines) and
below 20 .mu.m (super-fines) in the precipitated product from
CGM-treated pregnant liquor versus commercially available crystal
growth modifier-treated pregnant liquors and untreated control
pregnant liquor.
Example 1 and Comparative Examples 1-3
[0054] Alumina trihydrate crystal growth from pregnant liquor
reconstituted from spent liquor A was evaluated in the presence of
C18-ASA, C18-FA, and C18-ASA emulsion at doses of 5, 10, and 15
parts per million (ppm) real each. Units of parts per million (ppm)
are on a mg/L basis. 50 g/L of DF225 was added as seed crystal.
Precipitation was conducted at 70.degree. C. for 5 hrs. The results
are summarized in Table 2.
TABLE-US-00002 TABLE 2 Comparative effect of ASA emulsion against
ASA neat Crystal Dose, ppm % Fines % Super fines Growth Modifier
(real) (<45 .mu.m) (<20 .mu.m) C. Ex. 1 None 0 62.1 12.3 C.
Ex. 2 C18-ASA Neat 5 62.85 11.45 10 64.35 13.1 15 64.3 14.15 C. Ex.
3 C18-FA Neat 5 62.05 14.35 10 63.1 15.1 15 62.8 15.2 Ex. 1 C18-ASA
Emulsion 5 61.55 11.9 10 61.15 12.15 15 59.8 12
[0055] As can be seen from Table 2, adding neat CGM as in
Comparative Examples 2 (neat C18-ASA) and 3 (neat C18-FA) resulted
in increased levels of fines (negative result) as compared to
emulsified C18-ASA, Example 1, which lowered the amount of fines
(positive result).
Example 2 and Comparative Examples 4-6
[0056] Alumina trihydrate crystal growth from pregnant liquor
reconstituted from spent liquor A was evaluated in the presence of
Commercial Product A, Commercial Product B, and C18-ASA emulsion at
doses of 1.5, 3, 4.5, 6, and 7.5 ppm real each. 50 g/L of DF225 was
added as seed crystal. Precipitation was conducted at 50.degree. C.
for 5 hrs. The results are summarized in Table 3.
TABLE-US-00003 TABLE 3 Comparative effect of ASA emulsion against
ASA in oil Crystal Growth Dose % Fines % Super fines Yield Modifier
ppm (real) (<45 .mu.m) (<20 .mu.m) (g/L) C. Ex. 4 None 0
52.95 4.7 40.15 Ex. 2 C18-ASA 1.5 47.7 3.05 41.20 Emulsion 3 42.95
2.3 40.83 4.5 42.05 2.3 41.26 6 39.4 2.15 41.27 7.5 38.3 1.9 40.76
C. Ex. 5 Commercial 1.5 51.45 3.55 40.03 Product A 3 48.65 3.2
39.99 4.5 46.8 2.85 39.97 6 41.75 2.25 40.03 7.5 38 1.85 40.46 C.
Ex. 6 Commercial 1.5 48.75 3.2 37.94 Product B 3 43.1 2.3 38.28 4.5
39.7 2 37.44 6 37.9 1.85 37.99 7.5 38.45 1.85 38.19
[0057] Yield was calculated from the difference in the A/C values
before and after precipitation, multiplied by C after
precipitation:
Yield=(.DELTA..DELTA./C)=([A/C].sub.initial-[A/C].sub.final).times.C.sub-
.final
[0058] As can be seen from Table 3, C18-ASA Emulsion can have a
positive effect on yield, while Commercial Products A and B tend to
decrease yield. These data demonstrate that on a real or active
component basis, C18-ASA Emulsion performance is equal or better
than commercial CGM's. An advantage of C18-ASA is its much higher
solids content (neat), and thus lower dosage requirements, than
Commercial Products A and B, having only 15 g/100 mL CGM.
Examples 3-5 and Comparative Example 7
[0059] Alumina trihydrate crystal growth from pregnant liquor
reconstituted from spent liquor A was evaluated in the presence of
a C18-ASA/defoamer emulsion at the C18-ASA doses indicated in Table
4 below. C18-ASA and defoamer (CYBREAK.TM. 632) in a 90:10 weight
ratio were emulsified in deionized water adjusted to pH 3.5 with
sulfuric acid to give an emulsion having 5 g/100 mL C18-ASA and
0.56 g/100 mL defoamer. Emulsification conditions are provided in
Table 4. 50 g/L of DF225 was added to the pregnant liquor as seed
crystal, and precipitation was conducted at 50.degree. C. for 18
hrs. The results are summarized in Table 4.
TABLE-US-00004 TABLE 4 Effect of Defoamer on ASA Emulsion
performance. Volume Avg. Particle Diam. of C-18 ASA % Super
Emulsification Emulsion Dose % Fines Fines Conditions (.mu.m) (ppm
real) <45 .mu.m <20 .mu.m C. Ex. 7 None -- 0 50.15 1.25 Ex. 3
11k rpm, 1 min. 48.8 2.7 46.25 1.1 5.4 44.7 1 8.1 34.9 0.85 Ex. 4
19k rpm, 1 min. 29.4 2.7 34.05 0.8 5.4 34.6 0.9 8.1 41.6 0.95 Ex. 5
26k rpm, 1 min. 14.4 2.7 42.2 0.95 5.4 42.75 0.95 8.1 35.75 0.8
[0060] These data show that C18-ASA/defoamer emulsions with
emulsion droplet sizes in the range of about 14 to 50 micrometers
(volume average particle diameter) are effective in reducing the
percentage of fines compared to untreated pregnant liquor.
Examples 6-8 and Comparative Example 8
[0061] The C18-ASA can result in increased foam during agitation
with pregnant liquor. The effect of C18-ASA and defoamers on foam
generation was evaluated in the presence of C18-ASA at a dose of 3
ppm (Examples 6-8). C18-ASA was added as a 5 g/100 mL emulsion. In
Example 7, C18-ASA was added in a 90:10 weight/weight mixture with
defoamer (CYBREAK.TM. 632) to give a defoamer dose of 0.33 ppm; and
in Example 8, C18-ASA was added in a 75/25 weight/weight mixture
with defoamer to give a defoamer dose of 1 ppm.
[0062] Spent liquor B was reconstituted to pregnant liquor by
adding alumina trihydrate and dissolving (as above). The pregnant
liquor composition was also the same. 125 g/L of fine alumina
trihydrate seed was added to 400 mL of hot pregnant liquor
(90.degree. C.), and the resulting mixture was shook. The resulting
slurry was poured into a 1-L graduated cylinder placed in a water
bath at 70.degree. C. The slurry temperature was allowed to
equilibrate to 70.degree. C. and checked internally with a
thermometer at approximately 30 minutes. The slurry was kept in
suspension by means of a magnetic stir bar placed in the bottom of
the graduated cylinder. The dose of CGM/defoamer was placed on the
end of a stainless steel rod and immersed into the hot slurry with
agitation. CGM/defoamer blends were prepared as 5% ASA emulsions as
described above. The treated slurry was then allowed to mix and
come to equilibrium for 2 min. (conditioning step). A gas
dispersion tube (sparger) was then immersed in the slurry to a
depth of .about.1 inch from the bottom of the cylinder. Air was
introduced into the pregnant liquor via the sparger, generating air
bubbles in the pregnant liquor. The height of the resulting foam
head was then monitored as a function of time. By comparing the
rate of foam generation of the chemically treated slurry to
untreated slurry, the efficacy of the treatment to reduce foam was
evaluated. The results are summarized in Table 5.
TABLE-US-00005 TABLE 5 Effect of Defoamer Rate of Foam Crystal
Growth Modifier Generation (mL/s) C. Ex. 8 None 2.23 Ex. 6 C18-ASA
Emulsion 2.59 Ex. 7 C18-ASA Emulsion + 10% 1.47 Defoamer Ex. 8
C18-ASA Emulsion + 25% 1.38 Defoamer
[0063] As can be seen from Table 5, defoamer can reduce the rate of
foam generated in the presence of C18-ASA emulsion and also
relative to untreated pregnant liquor.
Examples 9-17 and Comparative Examples 9 and 10
[0064] Each test was run using spent liquor obtained from an
aluminum plant and reconstituted to pregnant liquor by adding
alumina trihydrate to the plant spent liquor and dissolving at
145.degree. C. Typical starting A/C ratio for the pregnant liquors
used was in the range of 0.68-0.72.
[0065] The precipitation tests were performed in 250 mL Nalgene
bottles rotated end-over-end at .about.15 rpm in a temperature
controlled water bath (Thornton Engineering) at 50.degree. C. 200
mL of pregnant liquor was added to the bottles. The CGM was then
dosed to the appropriate bottles and then all the bottles were
tightly sealed and placed into the water bath for 15-20 minutes to
allow the samples to come to equilibrium. After equilibrium, the
bottles were removed and charged with the required quantity of seed
and returned to the water bath. The bottles were rotated 18 hrs at
the stated temperature.
[0066] The CGM was prepared by weighing out the required amounts of
deionized water (adjusted to a pH of 3.5 with sulfuric acid) and
ASA or ASA/defoamer/anti-foam blend. The amounts used are
calculated to give a 5% ASA emulsion. The water was added first,
and then the ASA. The mixture was then homogenized for 1 minute at
19K rpm, unless otherwise stated.
[0067] After the precipitation time was complete, the bottles were
removed from the water bath, one at a time, and a 15 mL sample was
removed for liquor analysis. 2-3 drops of sodium gluconate solution
(400 g/L) was added to this sub-sample to prevent further
precipitation of the liquor. The remaining slurry sample was
immediately filtered and the solids were collected by vacuum
filtration and then thoroughly washed with hot deionized water,
finally dried at 105.degree. C. The particle size distribution of
the solids was determined on a Horiba LA 920 light scattering
instrument using a laser diffraction method that is well known in
the art. The effect of the CGM on the particle size distribution is
determined by comparing the amount (%) of particles below 45 .mu.m
(the fines) in the new CGM treated precipitated product vs. an
un-dosed control sample and/or commercially available products.
[0068] Typical Pregnant liquor composition:
A: 165 g/L.+-.10 g/L (as Al.sub.2O.sub.3) C: 230 g/L.+-.10 g/L (as
Na.sub.2CO.sub.3) S: 320 g/L.+-.10 g/L (as Na.sub.2CO.sub.3)
A/C: 0.72
[0069] Table 6 below describes the ASA's used in EXAMPLES 9-17:
TABLE-US-00006 Product Supplier Composition ASA A Dixie, ASA 100
C16-ASA, 3- (hexadecenyl)dihydro-2,5- Furandione ASA B Dixie, ASA
2024 C20/C24 mixture, n-eicosane succinic anhydride/n- tetracosane
succinic anhydride ASA C Electron Microscopy C12 ASA, dihydro-3-
Sciences (EMS), (tetrapropenyl)-2,5-Furandione DDSA ASA D Aldrich
C9-ASA, (2-nonen-1-yl) succinic anhydride ASA E Electron Microscopy
Mainly C9-ASA, (2-nonen-1- Sciences (EMS) yl) succinic anhydride
ASA F Tokyo Chemical Ind. C8-ASA, dihydro-3-(octenyl)- (TCI) 2,5
Furandione ASA F Tokyo Chemical Ind. C8-ASA, dihydro-3-(octenyl)-
(TCI) 2,5 Furandione
[0070] Conditions used for EXAMPLES 9-12 and Comparative example
9:
Temperature=50.degree. C.
[0071] Precipitation time=18 h Liquor: Reconstituted pregnant
liquor using plant spent liquor A Seed: DF225 from RJ Marshall
& Co. (60% fines, Alcoa-C31 equivalent) Seed charge: 50 g/L
[0072] The results for EXAMPLES 9-12 and Comparative example 9 are
shown in Table 7 below.
TABLE-US-00007 TABLE 7 Crystal Dose, % Super Growth ppm % Fines
fines Example Modifier (real) (-45.mu.) (-20.mu.) C. Ex. 9 None 0
58.28 11.41 EXAMPLE 9 C18- 1.5 56.0 10.6 ASA 3 53.9 9.4 Emulsion
4.5 50.2 8.1 EXAMPLE 10 ASA A 1.5 51.1 8.6 Emulsion 3 50.4 8.4 4.5
52.7 8.4 EXAMPLE 11 ASA B 1.5 51.9 7.7 Emulsion 3 50 9.0 4.5 48.7
9.9 EXAMPLE 12 ASA C 1.5 52.3 9.6 Emulsion 3 47.9 7.9 4.5 52.9
9.6
[0073] Conditions used for EXAMPLE 13-17 and Comparative example
10:
Temperature=50.degree. C.
[0074] Precipitation time=18 h Liquor: Reconstituted pregnant
liquor using plant spent liquor A Seed: DF225 from RJ Marshall
& Co. (60% fines, Alcoa-C31 equivalent) Seed charge: 50 g/L
[0075] The results are shown in Table 8.
TABLE-US-00008 TABLE 8 Crystal Dose, % Super Growth ppm % Fines
fines Example Modifier (real) (-45.mu.) (-20.mu.) C Ex. 10 None 0
67.6 5.8 EXAMPLE C18- 1.5 63.7 4.55 13 ASA 3 64.9 5.1 Emulsion 4.5
61.7 4.6 EXAMPLE ASA C 1.5 63.8 5.4 14 Emulsion 3 60.6 4.5 4.5 64.8
5.5 EXAMPLE ASA D 1.5 68.6 6.3 15 Emulsion 3 70.8 7.5 4.5 64.3 5.4
EXAMPLE ASA E 1.5 67.7 6.5 16 Emulsion 3 65.1 5.7 4.5 62.3 5.2
EXAMPLE ASA F 1.5 65.7 5.6 17 Emulsion 3 62.6 5.2 4.5 62 5.0
[0076] The results shown in Tables 7 and 8 show that ASA's
containing a range of alkyl/alkenyl chain lengths can be used in
the process of the invention.
[0077] Unless indicated otherwise, concentrations of crystal growth
modifier and defoamer in emulsions and doses in pregnant liquor are
expressed on a "real" basis (i.e., the concentrations reflect the
amount of active ingredient in solution). Unless indicated
otherwise, concentration units are on a weight/volume basis (i.e.,
percent (%) is on a g/100 mL basis, and parts per million (ppm) is
on a mg/L basis).
[0078] The defoamers described herein can have both anti-foam and
defoaming properties (i.e., they can prevent foam and can reduce
foam that is already formed).
[0079] As used herein, the terms "a" and "an" do not denote a
limitation of quantity, but rather the presence of at least one of
the referenced items. "Or" means "and/or" unless clearly indicated
to the contrary by the context. Recitation of ranges of values are
merely intended to serve as a shorthand method of referring
individually to each separate value falling within the range, and
each separate value is incorporated into this specification as if
it were individually recited. Thus each range disclosed herein
constitutes a disclosure of any sub-range falling within the
disclosed range. Disclosure of a narrower range or more specific
group in addition to a broader range or larger group is not a
disclaimer of the broader range or larger group. All ranges
disclosed herein are inclusive of the endpoints, and the endpoints
are independently combinable with each other. "Comprises" as used
herein includes embodiments "consisting essentially of" or
"consisting of" the listed elements.
[0080] While typical embodiments have been set forth for the
purpose of illustration, the foregoing descriptions should not be
deemed to be a limitation on the scope herein. Accordingly, various
modifications, adaptations, and alternatives can occur to one
skilled in the art without departing from the spirit and scope
herein.
* * * * *