Processes and compositions for cleaning mixing devices to improve polycarbonate production
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
C11D-003/37
C11D-001/22
출원번호
US-0774498
(2013-02-22)
등록번호
US-8729003
(2014-05-20)
발명자
/ 주소
Gallucci, Robert Russell
Ehrensbeck, Franklin
출원인 / 주소
Sabic Innovative Plastics IP B.V.
대리인 / 주소
Cantor Colburn LLP
인용정보
피인용 횟수 :
2인용 특허 :
16
초록▼
Processes and compositions for cleaning mixing devices are disclosed that improve the production and quality of polycarbonate resins subsequently produced in the mixing device, while reducing the time needed for cleaning and/or change over. A cleaning mixture comprising polycarbonate resin pellets c
Processes and compositions for cleaning mixing devices are disclosed that improve the production and quality of polycarbonate resins subsequently produced in the mixing device, while reducing the time needed for cleaning and/or change over. A cleaning mixture comprising polycarbonate resin pellets coated with an alkyl aryl sulfonate salt aqueous solution are used to purge the mixing device.
대표청구항▼
1. A process to clean melt processing equipment used to compound, mold or extrude polycarbonate-containing resins, comprising: purging the melt processing equipment with a cleaning mixture (purge) comprising from 50 to 99.5 wt % of polycarbonate resin pellets and from 0.5 to 50 wt % of an aqueous so
1. A process to clean melt processing equipment used to compound, mold or extrude polycarbonate-containing resins, comprising: purging the melt processing equipment with a cleaning mixture (purge) comprising from 50 to 99.5 wt % of polycarbonate resin pellets and from 0.5 to 50 wt % of an aqueous solution containing an alkyl aryl sulfonate salt, wherein the alkyl aryl sulfonate salt is present in the solution in an amount of 0.2 to 50 wt % of the solution, the solution having a pH of 6.0 to 7.9;heating the melt processing equipment to a temperature of 250 to 380° C.; andrunning the equipment to obtain a purged resin while cleaning the melt processing equipment. 2. The process of claim 1, wherein the alkyl aryl sulfonate salt is present in the solution at 5 to 50 wt % of the solution. 3. The process of claim 1, further comprising feeding a first portion of aryl sulfonate surfactant coated pellets into the melt processing equipment, wherein the melt processing equipment is run at a rate of 25 to 150 rpm; andfeeding a second portion of aryl sulfonate surfactant coated pellets into the melt processing equipment, wherein the melt processing equipment is run at rate of 150 to 500 rpm;wherein the coated pellets comprise 1 to 10 wt % of an aqueous sulfonate salt solution having a pH of 6.0 to 7.9, a concentration from 10 to 40 wt % of alkyl aryl sulfonate salt, the aqueous solution having a viscosity at 23° C. of 20 to 1000 centipoise, as measured by ASTM method D445. 4. The process of claim 1, wherein the alkyl aryl sulfonate salt is added to the cleaning mixture as an aqueous solution with a pH of 6.0 to 7.0 and containing from 10 to 40 wt % of the alkyl aryl sulfonate salt. 5. The process of claim 1, wherein the alkyl aryl sulfonate salt is present in the solution at 0.1 to 9 wt % of the solution. 6. The process of claim 5, wherein the alkyl aryl sulfonate salt is present in the solution at 0.2 to 5 wt % of the solution. 7. The process of claim 5, wherein the alkyl aryl sulfonate salt is present in the solution at 0.5 to 5 wt % of the solution. 8. The process of claim 1, wherein the alkyl aryl sulfonate salt has one of the following structures: wherein each M is an alkali metal or alkaline earth metal cation each R is independently alkyl having from 1 to 36 carbon atoms; x is 1 to 5; y is 0 to 5; p is 1 to 3; q is 1 to 3; s is 0 to 3; and t is 0 to 3. 9. The process of claim 8, wherein x=1 and y=1. 10. The process of claim 8, the alkyl aryl sulfonate salt has the structure of Formula (B) and wherein Formula (B) has the following structure: where M is an alkali metal or alkaline earth metal cation; R1 is an alkyl group containing from 5 to 35 carbon atoms; and R2 is hydrogen or an alkyl group containing from 1 to 12 carbon atoms, with R1 and R2 having no more than 36 total carbon atoms. 11. The process of claim 1, wherein the alkyl aryl sulfonate salt is an alkyl benzene sulfonate salt. 12. The process of claim 1, wherein the purged resin has a weight average molecular weight (Mw) within 30% of the polycarbonate resin before purging and a phenolic end group content of 100 ppm or less. 13. The process of claim 1, wherein the alkyl aryl sulfonate salt solution has 50 ppm or less of carboxylic acid salts, fatty acid salts, ammonium salts, amines, carbonate salts, bicarbonate salts, or a mixture thereof. 14. The process of claim 1, wherein the melt processing equipment is contaminated with a colorant at least one of the following: Solvent Green 3, Solvent Green 28, Solvent Green 38, Pigment Green 50, Pigment Green 36, Solvent Red 52, Solvent Red 101, Solvent Red 111, Solvent Red 135, Solvent Red 169, Solvent Red 179, Solvent Red 207, Pigment Red 101, Disperse Red 22, Vat Red 41, Solvent Orange 60, Solvent Orange 63, Disperse Orange 47, Solvent Violet 13, Solvent Violet 14, Solvent Violet 36, Solvent Violet 50, Disperse Violet 26/31, Pigment Blue 29, Pigment Blue 60, Copper Phthalocyanine Pigment Blue 15.4, Disperse Blue 73, Solvent Blue 97, Solvent Blue 101, Solvent Blue 104, Solvent Blue 122, Solvent Blue 138, Pigment Yellow 53, Pigment Yellow 138, Pigment Yellow 139, Disperse Yellow 201, Solvent Yellow 33, Solvent Yellow 114, Solvent Yellow 93, Solvent Yellow 98, Solvent Yellow 163, Solvent Yellow 160:1, Solvent Yellow 188, Pigment Brown 24, Amino Ketone Black, chrome oxides, carbon black, channel black, Pigment Black 6, zinc sulfide, zinc oxide, titanium dioxide, and mixtures thereof. 15. The process of claim 14, wherein the colorant comprises titanium dioxide, and the titanium dioxide is passivated with a silicone containing compound and has a particle size of 0.1 to 3.0 micrometers. 16. The process of claim 1, wherein the melt processing equipment is an extruder with a length to diameter (L/D) ratio of 20:1 to 40:1, a screw diameter of 0.5 to 8.0 inches, and is run at a speed of 50 to 500 rpm at a temperature of 250 to 380° C. 17. The process of claim 1, wherein the purged resin has 100 ppm or less of halogen. 18. The process of claim 1, wherein the polycarbonate resin pellets in the cleaning mixture have a weight average molecular weight (Mw) at least 10% higher than a polycarbonate resin previously run in the melt processing equipment, wherein the Mw is determined by ASTM D5296 using polycarbonate standards. 19. The process of claim 1, wherein the aqueous alkyl aryl sulfonate salt solution has a viscosity at 23° C. of 20 to 1000 centipoise as measured by ASTM method D445. 20. The process of claim 1, wherein the polycarbonate resin pellets are cylinders with an average length of 2.0 to 6.0 mm and an average diameter of 0.5 to 4.0 mm. 21. The process of claim 1, wherein the polycarbonate resin pellets have at least one angular face. 22. The process of claim 21, and wherein surfaces defining the angular face meet at an angle of from 60 to 120 degrees. 23. The process of claim 1, wherein the polycarbonate resin pellets have at least one angular face and wherein the surfaces defining the angular face meet at an angle of 80 to 100 degrees. 24. The process of claim 1, wherein the polycarbonate resin pellets have a bulk density, as measured by ASTM method D1895, of 0.5 to 0.9 g/cc. 25. The process of claim 1, wherein the polycarbonate resin pellets are a bisphenol-A homopolymer. 26. The process of claim 1, wherein the alkyl aryl sulfonate salt contains more than one sulfonate group. 27. The process of claim 1, wherein an aryl group of the alkyl aryl sulfonate salt is a phenyl, naphthyl, biphenyl, or diphenyl ether group. 28. The process of claim 1, wherein the alkyl aryl sulfonate salt contains an alkali metal or an alkali earth metal. 29. The process of claim 1, wherein the mixing device has a single screw for melt conveying. 30. The process of claim 29, wherein the single screw is part of a molding machine and is at least one of the following; an injection molding machine, a blow molding machine, an injection-blow molding machine, an extrusion-blow molding machine, a stretch-blow molding machine, a gas assist molding machine, a hydraulic molding machine, a mechanical molding machine and an electric molding machine. 31. The process of claim 1, wherein the mixing device is a single screw extruder having a screw diameter from 0.5 to 8.0 inches that is part of a thermoplastic molding machine. 32. The process of claim 1, wherein the mixing device is an intermeshing twin screw extruder. 33. The process of claim 1, wherein the aqueous solution is added to melt processing equipment followed by polycarbonate pellets coated with from 0.5 to 10% of the aqueous surfactant solution and the extruder is run at 50 to 500 rpm. 34. The process of claim 1, wherein the aqueous solution is added to the melt processing equipment at 25 to 150 rpm followed by pellets coated with from 0.5 to 10% of the aqueous alkyl aryl sulfonate salt solution and the extruder is run at 150 to 300 rpm. 35. The process of claim 1, wherein the melt processing equipment has more than one feeding inlet and the inlets are located in the first third of the extruder furthest from an exit die, wherein the inlets closest to the exit die are closed when the aryl sulfonate surfactant coated pellets are fed into the inlet furthest from the exit die. 36. The process of claim 1, wherein the melt processing equipment has more than one feeding inlet and wherein the aqueous surfactant solution coated polycarbonate pellets are fed into at least one feed inlet wherein at least one colorant is added. 37. A cleaning mixture comprising: an alkyl aryl sulfonate salt, polycarbonate resin pellets, and water, wherein the mixture has a pH of 6.0 to 7.9. 38. The cleaning mixture of claim 37, wherein the alkyl aryl sulfonate salt is sodium dodecyl benzene sulfonate. 39. The cleaning mixture of claim 37, wherein the alkyl aryl sulfonate salt is present in an amount of 0.005 wt % to 12 wt % of the cleaning mixture. 40. The cleaning mixture of claim 37, wherein the polycarbonate resin pellets are from 70.0 to 99.5 wt % of the cleaning mixture. 41. The cleaning mixture of claim 37, wherein the water is present in an amount of 0.3 to 27.0 wt % of the cleaning mixture. 42. The cleaning mixture of claim 37, wherein the pH is 6.0 to 7.0. 43. The cleaning mixture of claim 37, wherein the alkyl aryl sulfonate salt and the water form an aqueous solution having a viscosity at 23° C. of 20 to 1000 centipoise as measured by ASTM method D445. 44. The cleaning mixture of claim 37, wherein the polycarbonate resin pellets are cylinders with an average length of 2.0 to 6.0 mm and an average diameter of 0.5 to 4.0 mm. 45. The cleaning mixture of claim 37, wherein the polycarbonate resin pellets have a bulk density, as measured by ASTM method D1895, of 0.5 to 0.9 g/cc. 46. The cleaning mixture of claim 37, wherein the polycarbonate resin pellets have at least one angular face. 47. The cleaning mixture of claim 46, wherein surfaces defining the angular face meet at an angle of 60 to 120 degrees. 48. The cleaning mixture of claim 46, wherein surfaces defining the angular face meet at an angle of 80 to 100 degrees.
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