Abstract:
The present invention is drawn to a solid calcium hypochlorite particle having an available chlorine content of at least about 30% by weight and a water content of from about 2% to about 20% by weight; wherein said solid calcium hypochlorite particle is coated with about 0.01 to about 10% by weight of a deposit control agent comprising a sodium, potassium, lithium, calcium or magnesium salt of at least one of polyepoxysuccinic acid and polymaleic acid.

Description:
FIELD OF THE INVENTION 
     This invention relates to calcium hypochlorite blends; particularly to blends of solid calcium hypochlorite in combination with an alkali salt form(s) of anti-scaling polymers, wherein the polymer(s) are present in an alkali salt form effective at reducing the hygroscopic characteristics of the solid polymer(s), and subsequent calcium hypochlorite blend. This invention also relates to a means of reducing the reactivity of solid calcium hypochlorite with the said polymer(s) by applying a coating of the polymer(s) to the solid calcium hypochlorite. 
     BACKGROUND OF THE INVENTION 
     U.S. Pat. Nos. 5,112,521 and 5,004,549 disclose the blending of Phosphono-Butane-Tricarboxylic acid (PBTC) with calcium hypochlorite to produce a solid calcium hypochlorite blend that inhibits scale formation associated with the reconstitution and dispensing of the calcium hypochlorite solution. 
     U.S. Pat. No. 6,146,538, the contents of which are herein incorporated by reference, discloses the use of Polymaleic acid (PMA) and/or Polyepoxysuccinic acid (PESA) in an alkali salt form that is blended with calcium hypochlorite to reduce or eliminate scale formation associated with the reconstitution and dispensing of the calcium hypochlorite solution. 
     It is known that increased moisture, especially localized moisture, increases the rate of decomposition of calcium hypochlorite. During decomposition, oxygen is released, with chlorides and chlorates typically being the resulting byproducts. In the presence of sufficient moisture, exothermic reactions result, oxygen release increases, and a potential fire hazard is produced when fuel sources are available, e.g. cloth, hydrocarbons and the like. 
     PBTC disclosed in U.S. Pat. Nos. 5,112,521 and 5,004,549, when combined with calcium hypochlorite as an anti-scaling agent, can nevertheless compromise manufacturing safety and solid product stability, due to its inherent hygroscopic characteristics. 
     It has now been discovered that the alkali salt forms of PMA, PESA, and similar polymeric salts which are commonly employed as deposit control agents, can significantly reducing the hygroscopic characteristics of calcium hypochlorite when combined therewith, in addition to providing enhanced anti-scaling properties. It has been further discovered that a coating of these polymers or blends thereof significantly reduces the reactivity of the solid calcium hypochlorite blend. 
     Thus, a step forward in the art is realized via provision of a solid calcium hypochlorite combination which simultaneously exhibits anti-scaling properties and reduced hygroscopic and reactivity characteristics. Such a composition yields improvements in both manufacturing safety and product stability by reducing moisture adsorption and subsequent decomposition of the calcium hypochlorite, as well as improved safety by reducing the reactivity of the solid calcium hypochlorite. 
     DESCRIPTION OF THE PRIOR ART 
     U.S. Pat. No. 4,146,676 describes calcium hypochlorite particles coated with about 4 to 45 percent by weight of a low melting inorganic salt, e.g. aluminum sulfate hydrates, to reduce dusting during handling and to increase stability of calcium hypochlorite contacted with lighted cigarettes or reactive organic materials such as glycerine. 
     U.S. Pat. No. 4,965,016 describes a granular calcium hypochlorite composition comprising a particle of calcium hypochlorite, the surface of which has been covered with a double decomposition product of calcium hypochlorite and an alkali metal hydroxide. It was shown the granular strength and stability was enhanced. 
     None of the prior art describes addition of an alkali salt of an organic polymeric anti-scaling agent to provide improved deposit control, while reducing the stability and reactivity of the solid calcium hypochlorite. 
     SUMMARY OF THE INVENTION 
     The instant invention is directed toward a solid calcium hypochlorite product formulation and a method for its production, which product exhibits improved environmental stability and shelf-life while simultaneously inhibiting scale in dispensing equipment, as well as in and on feed equipment used for delivering a calcium hypochlorite solution to a water stream which is to be treated. 
     A solid calcium hypochlorite composition with improved hygroscopic and reactivity characteristics is formulated comprising hydrated calcium hypochlorite and an alkali salt of Polymaleic acid, Polyepoxysuccinic acid or mixtures thereof, having between 0.01 and 10% by weight of said alkali salts, an available chlorine concentration of at least 30% and water in the range of about 2% to about 20% by weight. 
     In a particularly preferred embodiment, the composition is a solid having greater than about 50% active Calcium Hypochlorite which exhibits anti-scaling characteristics and reduced hygroscopicity and reactivity. 
     The solid calcium hypochlorite may be coated and/or encapsulated with at least one polymeric alkali salt selected from within the group including polymaleate, polyacrylate, polyacrylamide, polycarboxylate, polymethacrylate, Phosphinopolycarboxylate, Carboxylate-Sulfonate copolymer, Maleic Anhydride copolymer, Polyepoxysuccinate, maleate-sulfonate copolymer, maleate-phosphonate copolymer, carboxylate-phosphonate copolymer, and/or mixtures thereof. 
     The alkali salt may be selected from at least one of the group including the sodium, potassium, lithium, calcium, or magnesium salts and mixtures thereof. Additionally, the polymeric alkali salt may be in a liquid, slurry, or solid form. 
     At some point in the manufacturing process the calcium hypochlorite may be formulated/treated with a deposit control agent including at least one alkali salt(s), e.g. sodium, potassium, lithium, calcium, magnesium and/or mixtures thereof, of polymaleic acid, polyexpoxysuccinic acid, maleic anhydride copolymer, phosphinopolycarboxylic acid, carboxylic-sulfonic acid copolymer, maleic-sulfonic acid copolymer, maleic-phosphonic acid copolymer, carboxylic-phosphonic acid copolymer, and/or mixtures thereof. The weight percent of deposit control agent is within the range of about 0.01% to about 10% of the final weight of the formulated calcium hypochlorite product. 
     These polymers and copolymers will exhibit similar hygroscopic characteristics in the desired salt forms while providing deposit control capability. Furthermore, all are hydrophilic and possess high thermal stability. Therefore they will reduce reactivity of the solid calcium hypochlorite product. 
     Accordingly, it is an objective of the instant invention to provide a solid calcium hypochlorite product and a method for its production, wherein the resultant product exhibits reduced hygroscopic characteristics thereby improving the manufacturing safety and shelf-life and anti-scaling properties of the solid product. 
     It is a further objective of the instant invention to provide a coated or encapsulated solid calcium hypochlorite product having reduced reactivity and anti-scaling properties. 
     Other objects and advantages of this invention will become apparent from the following description taken in conjunction with the accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention. The drawings constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objects and features thereof. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     As illustrated in Table 1, embodiments disclosed in U.S. Pat. Nos. 5,112,521 and 5,004,549 as well as an alkali salt form of the Polymaleic acid disclosed in U.S. Pat. No. 6,146,538 (all of which are herein incorporated by reference) were tested for their hygroscopic properties by exposing similar quantities of each to a controlled atmospheric environment consisting of the following approximate conditions: 
     72° F., and 50% humidity. 
     The samples were weighed and then exposed to the controlled environment. The samples were weighed before and after exposure. The increase in weight is associated with the increased moisture. 
     The NaPBTC increased moisture through adsorbing moisture from the surrounding environment. 
     It is understood that based upon the known reactivity of calcium hypochlorite, which is a Class 3 oxidizer, and its known increased decomposition with increased moisture, that the addition of an anti-scaling agent that increases hygroscopicity will lead to a potentially dangerous situation. Thus, the instant invention provides a combination of ingredients which simultaneously reduces the hygroscopic characteristics of the final solid product, thereby improving the manufacturing safety and final product stability, while ensuring chemical feed reliability through improved deposit control. 
     
       
         
               
               
               
               
             
           
               
                 TABLE 1 
               
               
                   
               
             
             
               
                   
                 Weight 
                 Weight After 
                 w/w % Change 
               
               
                   
                 before 
                 2 hr 
                 2 hr 
               
               
                   
               
               
                 Dry Polymaleate 
                 0.99 grams 
                 1.01 grams 
                  2.02% 
               
               
                 Polymer 
               
               
                 BAYHIBIT (PBTC) 
                 1.09 grams 
                 1.27 grams 
                 16.51% 
               
               
                   
               
               
                   
                   
                 Weight 
                 w/w % Change 
               
               
                   
                   
                 After 24 hr 
                 24 hr 
               
               
                   
               
               
                 Dry Polymaleate 
                   
                 1.06 grams 
                  7.07% 
               
               
                 Polymer 
               
               
                 BAYHIBIT (PBTC) 
                   
                 1.93 grams 
                 77.06% 
               
               
                   
               
             
          
         
       
     
     Adsorption of localized moisture creates the greatest concern. While the % weight increase to a 1.5% blend would appear to be minimal, localized moisture increase will correlate to the data exemplified in Table 1, reducing shelf life, chlorine activity, and potential increased risk of combustion when fuel sources are contacted as outlined in Table 2, below. 
     While not wishing to be bound to any particular physical form, the combination of calcium hypochlorite and polymer may be in the form of a homogeneous mixture, may alternatively take the form of an outer layer or covering which coats or encapsulates the cal-hypo for increased stability and reduced reactivity, or a combination thereof. 
     Table 2 illustrates the reaction of 68% calcium hypochlorite shock, sold under the brand name HTH SHOCK, with and without a coating of a calcium polymaleate salt, upon exposure to oil. 
     Each sample used approximately 7.5 grams of solid calcium hypochlorite. The treated sample was mixed with 4.7 grams of polymer salt (slurry weight), followed by convective drying. Each sample was placed in a dish where 1 oz. of oil (brake fluid) was added as a fuel source. 
     The results clearly illustrate that coating the solid calcium hypochlorite with a polymeric salt(s) of Polymaleic acid or PESA as described in U.S. Pat. No. 6,146,538 dramatically reduces the reactivity of calcium hypochlorite. Even in the case of extended exposure to combustible materials, the formulation described has the ability to significantly reduce the rate of decomposition of the calcium hypochlorite and prevent ignition when ignition would otherwise occur without treatment. It is therefore also reasonable to extrapolate from the data that further improvement would be achieved by encapsulation of the solid calcium hypochlorite. 
     
       
         
               
               
               
               
             
               
               
               
               
             
               
               
               
               
             
           
               
                   
                 TABLE 2 
               
             
             
               
                   
                   
               
               
                   
                 Time to 
                 Time to 
                   
               
             
          
           
               
                   
                 Fuming 
                 Combustion 
                 Residue 
               
               
                   
                   
               
             
          
           
               
                 HTH Shock 
                 58 
                 62 
                 Charred, light 
               
               
                   
                 seconds 
                 seconds 
                 weight, ash like 
               
               
                   
                   
                   
                 residue 
               
               
                 Treated HTH Shock 
                 525 
                 Not 
                 No charred, 
               
               
                   
                 seconds 
                 Applicable 
                 heavy, polymer 
               
               
                   
                   
                   
                 cal-hypo mix 
               
               
                   
               
             
          
         
       
     
     Additional tests were performed using various polymeric salts with known anti-scaling abilities. These polymers all possess thermal stability sufficient to prevent their decomposition during exposure to exothermic reactions from the decomposition of exposed calcium hypochlorite as well as hot fuming fuels. The thermal stability ensures the polymer coating prevents exposure of coated calcium hypochlorite thereby preventing a self-sustaining decomposition or runaway reaction. 
     Salt samples of polyacrylate and polymaleate were produced for reactivity testing as illustrated in Table 3. 
     
       
         
               
               
               
               
             
               
               
               
               
             
           
               
                   
                 TABLE 3 
               
             
             
               
                   
                   
               
               
                   
                 Polymer Salt 
                 Grams 68% 
                 Grams Polymer 
               
             
          
           
               
                 Sample 
                 Form 
                 Cal-Hypo 
                 (solids) 
               
               
                   
               
               
                 1 
                 Na/Ca Polyacrylate 
                 45 
                 Approx. 2 
               
               
                 2 
                 Ca Polyacrylate 
                 45 
                 Approx. 2 
               
               
                 3 
                 Na/Ca Polymaleate 
                 45 
                 Approx. 2 
               
               
                   
               
             
          
         
       
     
     These polymer salt samples were applied in either the form of a slurry or foam to 45 gram samples of &gt;68% calcium hypochlorite sold under the brand name HTH. Foam (table 4 sample 3b) was used to enhance the distribution of the polymer. After drying, the treated samples were compared to blank samples for reactivity. 10 ml of brake oil fluid was used as a fuel source, and the time from addition to fuming and ignition was measured, along with their weights. 
     Table 4 illustrates the results of the testing. 
     
       
         
               
               
               
             
               
               
               
               
               
               
               
               
             
               
               
               
               
               
               
               
               
             
               
               
               
               
               
               
               
               
             
           
               
                   
                 TABLE 4 
               
             
             
               
                   
                   
               
               
                   
                 Final 
                   
               
             
          
           
               
                   
                 Cal-hypo 
                 Total 
                 Fuming 
                 Ignition 
                 Weight 
                 Appear- 
                 Polymer 
               
             
          
           
               
                 Sample 
                 wt. (gm) 
                 wt. (gm) 
                 (sec) 
                 (sec) 
                 (gm) 
                 ance 
                 applied 
               
               
                   
               
             
          
           
               
                 Untreated 
                   
                   
                   
                   
                   
                   
                   
               
               
                 1 
                 7.72 
                 9.99 
                 spilled 
                 n/a 
                 n/a 
                 n/a 
                 n/a 
               
               
                 2 
                 7.84 
                 10.02 
                 12 
                 14 
                 10.13 
                 Charred Ash 
                 n/a 
               
               
                 3 
                 7.81 
                 9.99 
                 13 
                 15 
                 9.74 
                 Charred Ash 
                 n/a 
               
               
                 4 
                 7.86 
                 10.03 
                 13 
                 15 
                 9.37 
                 Charred Ash 
                 n/a 
               
               
                 Treated 
               
               
                   
                 7.88 
                 9.95 
                 100 
                 N/A 
                 15.97 
                 Cal-hypo 
                 Slurry 
               
               
                   
                   
                   
                   
                   
                   
                 residue 
               
               
                   
                 7.77 
                 10.03 
                 105 
                 N/A 
                 16.8 
                 Cal-hypo 
                 Slurry 
               
               
                   
                   
                   
                   
                   
                   
                 residue 
               
               
                   
                 7.89 
                 9.99 
                 45 
                 N/A 
                 14.67 
                 Cal-hypo 
                 Slurry 
               
               
                   
                   
                   
                   
                   
                   
                 residue 
               
               
                   
                 7.88 
                 9.92 
                 195 
                 N/A 
                 18.83 
                 Cal-hypo 
                 Foam 
               
               
                   
                   
                   
                   
                   
                   
                 residue 
               
               
                   
               
             
          
         
       
     
     The results of these test illustrate that treating the &gt;68% calcium hypochlorite with an alkali salt form of hydrophilic polymer with thermal stability exceeding 300° F. significantly reduces the reactivity of the calcium hypochlorite. 
     The reaction is self-limiting in that only exposed (untreated) calcium hypochlorite is involved in the reaction and once consumed in the reaction, residual fuel remains in contact with the stabilized (treated) calcium hypochlorite. 
     These test results further illustrate that by limiting exposure of calcium hypochlorite to the fuel source, the rate of reaction is significantly reduced, and ignition is avoided all together. 
     Yet another result of these tests is that increased coverage of the calcium hypochlorite yields further reduction in reactivity of the treated calcium hypochlorite. In this example, application of the polymer by use of an expanded foam to increase its volume improved coverage and distribution, correlating to improved performance at reducing the samples reactivity. 
     As previously presented, improving the hygroscopic characteristics of the calcium hypochlorite improves the manufacturing safety and shelf-life of the solid product. This is true regardless of whether the solid product is in a granular, pellet, tablet or briquette form. By adding an anti-scaling agent with improved hygroscopic characteristics, the potential for compromising safety and shelf-life is reduced. 
     By reducing the surface area of the calcium hypochlorite by coating the solid material with a hydrophilic polymeric salt with thermal stability exceeding 300° F., the reactivity of the calcium hypochlorite is reduced, while allowing rapid dissolution of the calcium hypochlorite when diluted with water, as in the case of a calcium hypochlorite dispenser. 
     To further improve the hygroscopic characteristics of the hydrophilic salt, divalent salts, or increased percentages thereof, should be included in the final salt form of the polymer. 
     It is to be understood that while a certain form of the invention is illustrated, it is not to be limited to the specific form or arrangement of parts herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown and described in the specification. 
     One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objects and obtain the ends and advantages mentioned, as well as those inherent therein. The compounds, compositions, and any biologically related compounds, methods, procedures and techniques described herein are presently representative of the preferred embodiments, are intended to be exemplary, and are not intended as limitations on the scope. Changes therein and other uses will occur to those skilled in the art, which are encompassed within the spirit of the invention and are defined by the scope of the appended claims. 
     Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in the art are intended to be within the scope of the following claims.