Suspension of water-soluble polymers in aqueous media containing dissolved salts

Abstract: A suspension of an anionic or nonionic water-soluble polymer in an aqueous solution of an inorganic ammonium salt is characterized in that the polymer comprises at least 15% of the total weight of the suspension, the ammonium salt has a multivalent anion, and the weight ratio of the ammonium salt to the water is at least 0.15.

Description: This invention relates to stable aqueous suspensions of water-soluble polymers. Water-soluble polymers have traditionally been handled in production, storage, transportation and use facilities in their dry, particulate form. The dust associated with dry, particulate water-soluble polymers presents the same handling problems as are encountered with similar particulate materials, including physiologically undesirable dust in the environment and the possibility of dust explosions. They do not disperse readily when added to aqueous systems, and tend to agglomerate by absorption of water from the air. The resulting long dissolution times substantially reduce the speed of manufacturing operations. Organic-solvent-based dispersions are well known. For instance, U.S. Patent 4,726,912 discloses a stable suspension of carboxymethylcellulose having a moisture content of 12 to 25 weight percent in a hydrocarbon oil that additionally contains anionic surfactants and suspending agents; U.S. Patent 4,312,675, discloses slurries containing up to 65 weight % of a hydrophilic polymer colloid in a hydrophobic solvent; U.S. Patent 3,894,879 discloses highly concentrated suspensions of water-soluble xanthan gum in alcohol-water carriers, using hydroxyalkyl cellulose derivatives as the suspending agents; U.S.Patent 3,894,880 discloses highly concentrated suspensions of water-soluble alginates in alcohol-water carriers using xanthan gum as a suspending agent; and U.S. Patent 4,325,861 discloses a nonaqueous composition adapted to provide, upon dilution with water, a solution containing a high molecular weight water-soluble polymer, which composition comprises (a) a particulate water-soluble polymer, (b) a water-insoluble, organic liquid vehicle, (c) an inert, nonionic surfactant, and (d) an inert thickening agent. The organic liquid materials present in such systems are undesirable for many applications, and they may be flammable as well as being expensive. There is a need for water-based dispersions for water-soluble polymers. U.S. Patent 4,069,062 describes a method for incorporating water-soluble polymers into mortar or concrete by dispersing an unswollen, water-soluble, swellable polymer in an aqueous solution of an inorganic salt (or an organic solvent) in which the polymer is only partially soluble or totally insoluble and mixing this dispersion into the mortar or concrete. The salt (or organic solvent) is said to prevent dissolution and swelling of the polymeric substance. Aqueous solutions of NaCl, Na₂SO₄, MgSO₄, Al₂(SO₄)₃ and NaH₂PO₄, alcohol and glycol are mentioned, and bentonite is used as a stabilizer. U.S. Patent 4,283,229 discloses a stable suspension of a nonionic, water-soluble cellulose ether derivative in a solution of an electrolyte containing alumina. Suitable electrolytes include metal or ammonium salts of mineral acids or organic acids, especially salts that contain an alkali metal ion, an alkaline earth metal ion, an earth metal ion, or a zinc, copper, iron or manganese ion as the cation, and a sulfate, carbonate, silicate, sulfite, halide, phosphate, nitrate, nitrite, acetate, formiate, tartate, or citrate ion (including their hydrogen salts) as the anion. None of these water-based dispersions for water-soluble polymers provide satisfactory dispersions containing high concentrations of water-soluble polymers that avoid the formation of gels and provide products that smoothly flow and are readily pumpable. JP-A-51[1976]-23535 discloses a method for promoting solubility of water-soluble polymers, especially polyacrylamides by dispersing the water soluble polymer in the alkali metal salt or ammonium salt of a bivalent or higher-valeucy acid. The polymers according to the present invention, however, are not mentioned. According to the invention, a suspension of an anionic or nonionic water-soluble polymer in an aqueous solution of an inorganic ammonium salt is characterized by the features of claim 1. The suspension according to the invention is a stable, pourable fluid containing high concentrations of water-soluble polymer that can be used to incorporate the polymers in aqueous solutions without formation of agglomerates or clumps, and that may be handled without the problems associated with water-soluble polymers in dry powder form. "Suspension", "dispersion", "solution" and other terms are often confused. Thus, it should be understood that herein "suspension" and "dispersion" are used interchangeably to mean a system in which solid particles (water-soluble polymer) are dispersed in a liquid (water). It should also be understood that "solution" means a homogenous mixture of a solvent (e.g., water) with a solute (e.g., a dissolved ammonium salt or a dissolved water-soluble polymer). By "stable" is meant that the dispersed phase (water-soluble polymer) and aqueous phase do not separate for some minimum time after preparation, or if separation does occur the polymer may be readily redispersed with a relatively minor amount of agitation. Stability is a function of the polymer and salt used, as well as their concentration. The suspensions of this invention are stable as made. They will normally be stable for at least three hours after preparation, and depending on the polymer and salt used, may be stable for at least a day after preparation, and can be made to be stable for a month or more after preparation. The stability of the suspensions of this invention can be further improved by mixing the solution in a vacuum, so as to remove entrained air. The prolonged stability of the suspensions of this invention permits preparation at one location and transportation to another location for use. Any ammonium salt that has a multivalent anion and that may be dissolved in water to a concentration in which the weight-ratio of the ammonium salt to the water is at least 0.15 may be used in the suspension according to the invention. Preferred salts are diammonium phosphate, diammonium sulfate (also known as ammonium sulfate), ammonium polyphosphate, and mixtures thereof. Diammonium phosphate is available from Monsanto Company, St. Louis, MO., J. T. Baker Chemical Co., Phillipsburgh, NJ, and FMC Corporation, Philadelphia, PA. Diammonium sulfate is readily available from numerous sources such as Agway, Inc., Syracuse, NY. Fertilizer fluids, such as "10-34" ammonium polyphosphate fertilizer fluid, are available from numerous producers such as Willard Agricultural Service, Lynch, MD. Salts that render the polymer insoluble with minimal swelling are generally desirable. The weight ratio of the ammonium salt to the water, which is at least 0.15, varies with the polymer type to be suspended, and is preferably 0.18 to 0.6. For suspending polymers such as hydroxyethylcellulose, for example, a salt-to-water ratio of 0.18 to 0.25 is preferred, whereas for suspending carboxymethylhydroxyethylcellulose a salt-to-water ratio of 0.3 to 0.4 is preferred, and for suspending carboxymethylcellulose a salt-to-water ratio of 0.4 to 0.6 is preferred. A number of other additives have been found to be beneficial. Preferred additives are stabilizers, such as hydrophilic fumed silica and clays such as attapulgite clay. They increase the time for which the suspension will remain stable. Carboxymethylcellulose, xanthan gum and other water-soluble polymers may also be useful for stabilization. The most preferred stabilizers for hydroxyethylcellulose suspensions are sodium carboxymethylcellulose and xanthan gum. Stabilizers are generally used in amounts up to about 2%, and are preferably used in an amount of 0.5% to 1%, by weight of the total suspension. Other additives that can be used include such conventional ones as pigments, dispersants, surfactants, glycols and thickening agents. These are generally used in amounts up to 10%, preferably 0.5% to 2%, by weight of the total suspension. The water-soluble polymers as mentioned in claim 1 are conventional nonionic or anionic polymers that may possess numerous hydrophilic substituents, such as hydroxyl, carboxyl, ether or amide substituents, attached directly or indirectly to a polymeric molecular backbone or chain, such that the number average molecular weight of the polymer is relatively high, with for instance a solution viscosity is on the order of 1,000 or more, preferably 5,000 or more centipoise in a 5 weight-percent aqueous polymer solution, and in a 5-10 weight percent, so high that their aqueous solutions cannot normally be pumped and may form a gel. The water-soluble polymers are cellulose derivatives, guar and its derivatives and xanthan gum. They include carboxymethylcellulose (sodium and other salts), hydroxyethylcellulose, hydroxypropylcellulose, carboxymethylhydroxyethylcellulose, hydrophobically modified hydroxyethylcellulose (such as hydroxyethylcellulose polymers that comprise C₆-C₂₄ alkyl groups as described by in U.S. Patents 4,288,277 and 4,352,916), hydroxyethylhydroxypropylcellulose, hydroxypropyl guar, methylhydroxypropylcellulose (also well known as hydroxypropylmethylcellulose), methylhydroxyethylcellulose, and 3-alkoxy-2-hydroxypropylhydroxyethylcellulose (e.g., 3-alkoxy-2-hydroxypropylhydroxyethylcellulose wherein the alkyl group contains 2-8 carbon atoms, and 3-alkoxy-2-hydroxypropylhydroxylethylcellulosee wherein the alkyl group contains 6-24 carbon atoms). Preferred are sodium carboxymethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, carboxymethylhydroxyethylcellulose, hydrophobically modified hydroxyethylcellulose and 3-butoxy-2-hydroxypropylhydroxyethylcellulose. Preferably, suspensions according to this invention contain more than 15% of the particulate water-soluble polymer, in the range of greater than 20 and up to 50%, and most preferably in the range of 22 to 35%. The suspensions of this invention can be prepared by dissolving the ammonium salt in water to form an aqueous salt solution and dispersing the water-soluble polymer in the solution with agitation. In the case where other additives are employed, these are typically added to the water before the salt. The water-soluble polymer suspensions of this invention are useful in virtually all applications where dry water-soluble polymers are presently used, except of course in the rare applications where the presence of ammonium salts is objectionable. The applications in which the dispersions of this invention may be used include, e.g., water clarification, mineral processing, food and pharmaceutical thickening, cosmetics thickening, agricultural products thickening, oil field applications, building products (e.g., joint cements), ceramics latex paints, paper coatings, emulsion polymerization, and suspension polymerization. Advantages of using the high concentration water-soluble polymer suspensions of this invention include the ability to control thickening action of the polymer (thickening time is reduced substantially), ease of handling and dosage control and the avoidance of polymer dusting. The suspensions may be added to aqueous systems (e.g., aqueous solutions, by simply adding, e.g., pouring, the suspension into the aqueous system. Agitation enhances dissolution. The suspension may also be sprinkled, sprayed, on etc., where desired for a specific end use. This invention is demonstrated in the following examples, wherein all parts, percentages, etc., are by weight. Distilled water was used in each instance. Example 1 In an open reaction vessel, 22.5 parts of technical grade diammonium phosphate (obtained from Monsanto Company, St. Louis, MO.) was dissolved into 52.5 parts of distilled water with stirring. With continued stirring, 25 parts of Natrosol® 250GR hydroxyethylcellulose (Aqualon Company, Wilmington, DE) was dispersed in the solution. After addition was completed, the vessel was sealed and 98kPa (29'' Hg) of vacuum was applied for 15 minutes, with stirring, to remove entrained air. The resultant suspension was poured into a glass storage container and stored at room temperature for three days, after which time no appreciable settling of the solid hydroxyethylcellulose particles was noted, and the suspension remained fluid and pourable. Example 2 In an open reaction vessel, 30 parts of fertilizer grade diammonium sulfate (Agway, Inc., Syracuse, NY) was dissolved into 45 parts of distilled water with stirring. With continued stirring, 25 parts of Aqualon™ carboxymethylhydroxyethylcellulose 420H (Aqualon Company, Wilmington, DE) was dispersed in the solution. After addition was completed, mixing was continued for 15 minutes, and the resultant suspension was poured into a glass storage container and stored at room temperature. One day later no appreciable settling of the solid carboxymethylhydroxyethylcellulose particles was noted, and the suspension remained fluid and pourable. Example 3 In an open reaction vessel, 75 parts of "10-34" ammonium polyphosphate aqueous fertilizer fluid (Agway, Inc., Syracuse, NY) (1.44 gram/cc specific gravity with a dried salt content of 59 weight %) was added to a reaction vessel with stirring. With continued stirring, 25 parts of Aqualon™ carboxymethylcellulose 7H3SXF, (Aqualon Company, Wilmington, DE) was dispersed in the solution. After addition was completed, the vessel was sealed and 98kPa (29'' Hg) of vacuum was applied for 15 minutes, with stirring, to remove entrained air. The resultant suspension was poured into a glass storage container and stored at room temperature for three days, after which time no appreciable settling of the solid carboxymethylcellulose particles was noted, and the suspension remained fluid and pourable. Example 4 In an open reaction vessel, 51.8 parts of diammonium sulfate (Agway, Inc., Syracuse, NY) was dissolved into 96.2 parts of distilled water with stirring. With continued stirring, 1 part of Sylox 15 hydrophilic fumed silica (Davison Chemical Company, Baltimore, MD) was added to the vessel. Then, 50 parts Aqualon™ carboxymethylhydroxyethylcellulose 420H (Aqualon Company, Wilmington, DE) was dispersed in the solution. After addition was completed, mixing was continued for 5 minutes and, then, 2 parts of Min-U-Gel FG attapulgite clay (Floridin Company, Quincy, FL) was added and stirring was continued for 15 minutes. The resultant suspension had a Brookfield Viscosity (#2 spindle, 30 rpm) of 208 centipoise. It was poured into a glass storage container and stored at room temperature for 30 days, after which no appreciable settling of the solid carboxymethylhydroxyethylcellulose particles was noted, and the suspension remained fluid and pourable. After 11 days of storage, 8 parts of the suspension was added to 192 parts of water with stirring. The carboxymethylhydroxyethylcellulose dispersed without lumps, then rapidly thickened the water to form a smooth solution. Comparative Example 5 In order to demonstrate the advantages of this invention, 2 parts of Aqualon™ carboxymethylhydroxyethylcellulose 420H (Aqualon Company, Wilmington, DE) was added to 198 parts of water under identical mixing conditions to those used in adding the suspension to water in Example 4. The carboxymethylhydroxyethylcellulose, in this case, formed lumps that were extremely difficult to dissolve. Comparative Example 6 In order to compare the claimed invention with the invention of U.S. Patent No. 4,283,229, an experiment similar to example V 1 of that patent was conducted using Aqualon™ carboxymethylhydroxyethylcellulose 420H. A salt solution was prepared by dissolving 21 parts of K₂CO₃ in 54 parts of water with stirring and, then, 25 parts of carboxymethylhydroxyethylcellulose was dispersed in the solution with stirring. The solids separated from the liquid after 1 day. Comparative Example 7 In order to compare the claimed invention with the invention of U.S. Patent No. 4,283,229, an experiment similar to example V 4 of that patent was conducted using Aqualon™ carboxymethylhydroxyethylcellulose 420H. A salt solution was prepared by dissolving 19.2 parts of MgSO₄ in 60.8 parts of water with stirring and, then, 20 parts carboxymethylhydroxyethylcellulose was dispersed in the solution with stirring. The solids separated from the liquid after 1 day. Comparative Example 8 In order to compare the claimed invention with the invention of U.S. Patent No. 4,069,062, an experiment similar to example 1 of that patent was conducted using Aqualon™ carboxymethylhydroxyethylcellulose 420H. A salt solution was prepared by dissolving 22.3 parts of aluminum sulfate in 66.7 parts of water with stirring and, then, 10 parts of carboxymethylhydroxyethylcellulose together with 1 part of bentonite clay were added to the solution with stirring. A gel formed. Comparative Example 9 In order to compare the claimed invention with the invention of U.S. Patent No. 4,069,062, an experiment similar to example 2 of that patent was conducted using Aqualon™ carboxymethylhydroxyethylcellulose 420H. A salt solution was prepared by dissolving 11.9 parts of sodium sulfate in 67.1 parts water with stirring and, then, 16 parts carboxymethylhydroxyethylcellulose together with 1 part of bentonite clay were added to the solution with stirring. A paste formed. Example 10 In an open reaction vessel containing 149 parts of "10-34" concentrated aqueous ammonium polyphosphate fertilizer solution, measuring 1.44 specific gravity and having a dried salt content of 59% by weight (Agway, Inc., Syracuse, NY) was added 1 part of Min-U-Gel FG attapulgite clay (Floridin Company, Quincy, FL). Then, 50 parts Aqualon™ carboxymethylcellulose 7HXF (Aqualon Company, Wilmington, DE) was added to the solution and stirring was continued for 15 minutes. The resulting suspension was poured into a glass storage container and stored at room temperature for one week, after which no appreciable settling of the solid carboxymethylcellulose particles was noted, and the suspension remained fluid and pourable. After 6 days of storage, 4 parts of the suspension was added to 196 parts of water with stirring. The carboxymethylcellulose dispersed without lumps, then rapidly thickened the water to form a solution having a Brookfield Viscosity (#3 spindle, 30 rpm) of greater than 2000 centipoise. Example 11 The procedures of Example 10 were repeated using Aqualon™ carboxymethylcellulose 7H3SXF (Aqualon Company, Wilmington, DE). Similar results to those of Example 10 were obtained. Comparative Example 12 In order to compare the claimed invention with the invention of U.S. Patent No. 4,069,062, a process similar to that of example 1, from column 2, lines 15-19, of that patent was run using Aqualon™ carboxymethylcellulose 7H3SXF. Thus, a salt solution was prepared by dissolving 22.3 parts of aluminum sulfate in 66.7 parts water with stirring and, then, 10 parts carboxymethylcellulose together with 1 part of bentonite clay were added to the solution with stirring. Gross separation of the solids from the liquid phase occurred within one day. The separated phases were mixed so as to prepare a homogenized mixture and, then, 4 parts of the suspension was added to 196 parts of water with stirring. The mixture did not impart a viscosity increase to the water, indicating that the carboxymethylcellulose had been rendered ineffective as a thickening agent. Comparative Example 13 In order to compare the claimed invention with the invention of U.S. Patent No. 4,069,062, a comparison similar to example 2 of that patent was run using Aqualon™ carboxymethylcellulose 7H3SXF. A salt solution was prepared by dissolving 11.9 parts of sodium sulfate in 67.1 parts water with stirring and, then, 20 parts carboxymethylhydroxyethylcellulose, together with 1 part of bentonite clay, were added to the solution with stirring. A paste formed. Comparative Example 14 In order to compare the claimed invention with the invention of U.S. Patent No. 4,283,229, an experiment similar to example V 1 of that patent was conducted using Aqualon™ carboxymethylcellulose 7H3SXF. A salt solution was prepared by dissolving 21 parts of K₂CO₃ in 54 parts water with stirring and, then, it was attempted to add 20 parts carboxymethylcellulose to the solution while stirring. A solid gel resulted during addition of carboxymethylcellulose. Comparative Example 15 In order to compare the claimed invention with the invention of U.S. Patent No. 4,283,229, an experiment similar to example V 4 of that patent was conducted using Aqualon™ carboxymethylcellulose 7H3SXF. A salt solution was prepared by dissolving 19.2 parts of MgSO₄ in 60.8 parts water with stirring. Then, during the subsequent addition of 10.8 parts carboxymethylcellulose with stirring a solid gel resulted. Example 16 In an open reaction vessel, 34.5 parts of technical grade diammonium phosphate (obtained from Monsanto Company, St. Louis, MO) was dissolved into 103.5 parts of distilled water with stirring. With continued stirring, 1 part of Sylox 15 hydrophilic fumed silica (Davison Chemical Company, Baltimore, MD) and 1 part of Min-U-Gel FG (attapulgite clay) (Floridin Company, Quincy, FL) were added to the solution. Then, with continued stirring, 60 parts of Natrosol® Plus Grade D-330 hydrophobically modified hydroxyethylcellulose (Aqualon Company, Wilmington, DE) was dispersed in the solution. The resultant suspension was poured into a glass storage container and stored at room temperature for over 60 days, after which time no appreciable separation of the solid hydrophobically modified hydroxyethylcellulose particles was noted, and the suspension remained fluid and pourable. Example 17 In an open reaction vessel, 238.2 parts of technical grade diammonium phosphate (Monsanto Company, St. Louis, MO) was dissolved into 643.8 parts of distilled water with stirring. With continued stirring, 6 parts Sylox 15 hydrophilic fumed silica (Davison Chemical Company, Baltimore, MD) and 12 parts Min-U-Gel FG attapulgite clay (Floridin Company, Quincy, FL) were added to the solution. Then, 300 parts of Natrosol® 250 GR hydroxyethyl cellulose (Aqualon Company, Wilmington, DE) was dispersed in the solution and stirring was continued for 15 minutes. The resultant suspension had a Brookfield viscosity (#3 spindle, 30 rpm) of 2500 mPa.s (cps). It was poured into a glass storage container and stored at room temperature for over 60 days, after which time no appreciable separation of the solid hydrophobically modified hydroxyethylcellulose particles was noted, and the suspension remained fluid and pourable. Example 18 In an open reaction vessel, 40 parts of fertilizer grade diammonium sulfate (Agway, Inc., Syracuse, NY) was added to 60 parts of distilled water and dissolved with stirring. With continued stirring, 1 part Sylox 15 hydrophilic fumed silica (Davison Chemical Company, Baltimore, MD) and 1 part Min-U-Gel FG attapulgite clay (Floridin Company, Quincy, FL) were added to the solution. Then, with continued stirring, 50 parts of Natrosol R GXR hydroxyethylcellulose (Aqualon Company, Wilmington, DE) was dispersed in the solution to produce a 33 weight % suspension of hydroxyethylcellulose. Afterwards, the vessel was sealed and vacuum was applied for 10 minutes, with continued stirring, to remove entrained air. The resultant suspension was poured into a glass vessel and measured to have a Brookfield viscosity (#3 spindle, 30 rpm) of 1100 mPa.s (cps). Comparative Example 19 This comparative example was carried out using a salt described in U.S. Patent No. 4,069,062. A saturated sodium chloride solution was prepared by adding 50 parts sodium chloride to 80 parts distilled water, stirring the solution for 60 minutes, allowing the undissolved sodium chloride to settle and decanting the supernatant liquid. Then, 25 parts of Aqualon™ carboxymethylcellulose 7H3SXF (Aqualon Company, Wilmington, DE) was added to 75 parts of the sodium chloride solution while stirring. A gelled product formed during the course of carboxymethylcellulose addition. Comparative Example 20 This comparative example was carried out using a salt described in U.S. Patent No. 4,069,062. A saturated sodium phosphate monobasic (Mallinkrodt, Inc., St. Louis, MO) solution was prepared by adding 50 parts sodium to 80 parts distilled water, stirring the solution for 60 minutes, allowing the undissolved sodium phosphate monobasic to settle and decanting the supernatant liquid. Then, 25 parts of Aqualon™ carboxymethylcellulose 7H3SXF (Aqualon Company, Wilmington, DE) was added to 75 parts of the sodium phosphate monobasic solution while stirring. A gelled product formed during the course of carboxymethylcellulose addition. Comparative Example 21 This comparative example was carried out using a salt described in U.S. Patent No. 4,069,062. A saturated magnesium sulfate solution was prepared by adding 50 parts magnesium sulfate to 80 parts distilled water, stirring the solution for 60 minutes, allowing the undissolved magnesium sulfate to settle and decanting the supernatant liquid. Then, 25 parts of Aqualon™ carboxymethylcellulose 7H3SXF (Aqualon Company, Wilmington, DE) was added to 75 parts of the magnesium sulfate solution while stirring. A gelled product formed during the course of carboxymethylcellulose addition. Example 22 In an open reaction vessel, 36.8 parts of diammonium phosphate (Monsanto Company, St. Louis, MO) was added to 110.2 parts of distilled water and dissolved with stirring. With continued stirring, 1 part Sylox 15 hydrophilic fumed silica (Davison Chemical Company, Baltimore, MD) and 2 parts Min-U-Gel FG attapulgite clay (Floridin Company, Quincy, FL) were added to the solution. Then, with continued stirring, 50 parts of Natrosol® 250 GR hydroxyethylcellulose (Aqualon Company, Wilmington, DE) was dispersed in the solution. A stable fluid, pourable suspension of hydroxyethylcellulose resulted. Comparative Example 23 This comparative example was carried out using a salt described in U.S. Patent No. 4,069,062. The procedures of Example 22 were repeated using sodium phosphate, monobasic (Mallinkrodt, Inc. St. Louis, MO). A gelled product was obtained after 10 minutes of stirring the hydroxyethylcellulose containing solution. Comparative Example 24 This comparative example was carried out using a salt described in U.S. Patent No. 4,283,229. In an open reaction vessel, 7.4 parts of potassium carbonate and 1 part powdered alumina "A-15" (ALCOA, Pittsburgh, PA) were dissolved in 66.6 parts distilled water. Upon addition of 25 parts of Natrosol R 250 GR hydroxyethylcellulose (Aqualon Company, Wilmington, DE) a thick paste resulted. Control Example 25 This Control Example shows preparation of a semigloss paint using dry powder Natrosol® Plus hydrophobically modified hydroxyethylcellulose. A pigment grind was prepared by milling 80 parts propylene glycol, 8.5 parts Tamol Sg-1 (Rohm & Haas Co., Philadelphia, PA) dispersant, 2 parts Hercules® SGL defoamer (Hercules Incorporated, Wilmington, DE), 240 parts titanium dioxide R-900 (E. I. duPont de Nemours & Co., Inc., Wilmington, DE) and 25 parts amorphous silica 1160 (Illinois Minerals Company, Cairo, IL) in a high speed Cowles blade for 20 minutes. Then, to the pigment grind were sequentially added 65 parts water, 500 parts Rhoplex AC-417 latex (Rohm and Haas Co., Philadelphia, PA), 2.7 parts Hercules® SGL defoamer, 10 parts propylene glycol, 21.6 parts Texanol™ (Eastman Kodak Co., Eastern Chemical Products, Kingsport, TN), 1 part Super Ad-it (Tenneco, Elizabeth, NJ) and 0.5 parts Triton GR-7M (Rohm & Haas Co., Philadelphia, PA) to form a base paint. Then, a polymer slurry was formed by dispersing 15 parts of Natrosol® Plus hydrophobically modified hydroxyethylcellulose Grade 330 into 85 parts of pH 6.5 water. Then, before the onset of thickening (less than 3 minutes after addition of the polymer to water), 6.4 parts of this slurry was added along with 25.5 parts of water to 400 parts of the base paint to form a thickened paint. Example 26 This Example shows preparation of a semigloss paint using the Natrosol R Plus hydrophobically modified hydroxyethylcellulose suspension of Example 16. A semigloss paint was formed by adding 3.2 parts of the Natrosol R Plus hydrophobically modified hydroxyethyl cellulose solution prepared in Example 16 along with 28.7 parts of water to 400 parts of the base paint prepared as described in Example 23. The paints prepared in Examples 25 and 26 had the characteristics listed in Table 1, below. Semigloss Latex Paint Thickener Thickener Control Example 25 (dry powder control) Example 26 (dispersion) Polymer dosage: (active HEC added to paint) 0.22% 0.22% Paint Viscosity, KU: (overnight) 95 89 ICI Viscosity, mPa.s (cps): 2.0 2.2 Leveling: 3 4 Sag Resistance: 24 19 Scrub Resistance: 1600 cycles+ 1600 cycles+ Gloss 60°/80° 26.7/54.8 27.9/56.5 The data in Table 1 indicate that the paints prepared in Control Example 25 and Example 26 had equivalent rheological and film properties. Thus, it can be seen that the fluid suspension of this invention can be employed to thicken latex paints without adverse effects resulting from the salt. Control Example 27 This Control Example shows use of dry carboxymethyl cellulose in the pelletization of iron ore. Taconite ore concentrate from a U.S. operation comprising greater than 60% iron and less than 5% silica, consisting of fine particles passing 100% through a 75 µm sieve (200 U.S. mesh) were pelletized as follows. In a Hobart oscillating mixer, 3268 parts of ore having a moisture content of 8.2% was mixed with water to reach a moisture content of 9.5%. A measured quantity of dry Aqualon™ carboxymethylcellulose 7HX (Aqualon Company, Wilmington, DE) was sprinkled on the ore and mixing was carried out over 3 minutes, after which the mixture was passed through a high speed shredder to form a uniform blend suitable for balling. Balls were made in a 38.1cm (15 inch) diameter (size 6.00-6) airplane tire, rotated at a rate of 65 revolutions per minute with the axis of rotation being horizontal, as follows: 1. Small amounts of concentrated ore were fed by hand into the rotating tire alternately with distilled water mist. As seed balls formed they were removed and hand screened to -4.75, + 4 mm. 800 g of concentrate was set aside for seed preparation. This process was continued until at least 100 g of seed balls were generated. 2. 92 g of prepared seeds were put in the rotating tire and moistened slightly with a fine mist spray of distilled water. Part of the remaining 2440 g of concentrate was added to the seeds as quickly as possible over a 1 minute period. The balls were removed and the newly formed seeds (-4.75 mm) were screened out and discarded. 3. The +4.75 mm balls were returned to the rotating tire and the remainder of the concentrate was added over a 1-1 1/2 minute time period. The finished balls were then rolled for 5 seconds. 4. The wet balls were screened to determine size distribution. A -12.7, + 11.2 mm cut was used for moisture content determination and physical tests. Two standard tests were used to measure performance, the drop test and the compression test. The drop test and compressive strength test demonstrate the ability of wet and dry balls to withstand cracking under normal handling conditions. Balls must have sufficient prefired strength so that they do not crack during handling or transfer in the pellet plant, but must not be so plastic that they disform and impair bed permeability in the indurating furnace. The drop test was carried out by dropping the wet balls repeatedly from a height of 45,72cm (18 inches) onto a smooth steel plate. The number of drops required to crack each ball was recorded and the average value for 10 balls reported. Compressive strength was measured by applying pressure to both wet and dry pellets until the pellets crumbled. The apparatus consisted of a Chatillon spring testing device with appropriate range dial push-pull gauge (2,3kg (5 lb) capacity for wet, 11.3kg (25 lb) for dry). Dried balls were obtained by placing green balls in a 105°C oven for 18 hours. Finished ball moisture was determined simultaneously. Compressive strength results presented are also the average of 10 balls tested. Generally mine operators require that green balls be able to withstand at least 6 drops. Similarly, dry compressive strength of 45kg or more (10 or more pounds) is desired. In practice, however, it has been difficult to attain dry strengths of greater than 2.7kg (5 lbs) with non-bentonite binders at economically acceptable use levels. Example 28 This Example shows use of the carboxymethylcellulose suspension of Example 10 in the pelletization of iron ore. The procedures of Control Example 28 were repeated using the carboxymethylcellulose suspension of Example 10 in place of the dry carboxymethyl cellulose. Results of Control Example 27 and Example 28 are shown in the following Table. Iron Ore Binder Example Binder Dosage Lbs/Ton* Ore Taconite Dry Avg. Compressive Strength 28 1.0 2.7kg(6.0 lbs) 29 4.0 (1.0 lb/ton CMC) 4.2kg(9.3 lbs) The pellets produced using the fluid carboxymethylcellulose suspension had a higher compressive strength, on an equal carboxymethylcellulose weight basis, when compared to the pellets produced using dry carboxymethylcellulose. The results indicate that the salts present in the carboxymethylcellulose suspension were beneficial to performance of the water soluble polymer in this application. Control Example 29 This Control Example shows use of dry powder hydroxyethylcellulose as a thickener for a paper coating. Sequentially, 600 parts water, 14 parts Dispex N-40 (Allied Colloid, Suffolk, VA), and 1400 parts Hydrasperse kaolin clay (J. M. Huber, Macon, GA) were added to a mixing vessel and were mixed at high speed for 30 minutes to form a base clay slip. Next, 429 parts of the base clay slip was mixed with 72 parts of Dow 620 styrene-butadiene latex (Dow Chemical Company, Midland, MI) and 6 parts of Floco 501 lubricant (Henkel Process Chemical, Inc., Morristown, NJ) were added. Then, 38 parts of 4% Natrosol® 250 GR hydroxyethylcellulose solution, prepared by slowly adding the hydroxyethylcellulose to water, along with an additional 40 parts water were added to the base clay slip. Example 30 This Example shows use of the hydroxyethylcellulose suspension of Example 17 as a thickener for a paper coating. Sequentially, 600 parts water, 14 parts Dispex N-40 (Allied Colloid, Suffolk, VA), and 1400 parts Hydrasperse kaolin clay (J. M. Huber, Macon, GA) were added to a mixing vessel and were mixed at high speed for 30 minutes to form a base clay slip. Next, 429 parts of the base clay slip was mixed with 72 parts of Dow 620 styrene-butadiene latex (Dow Chemical Company, Midland, MI) and 6 parts of Floco 501 lubricant (Henkel Process Chemical, Inc., Morristown, NJ) were added. Then, 6 parts of the the Natrosol R 250 GR hydroxyethylcellulose suspension of Example 17, along with an additional 56 parts water, were added to the base clay slip. The paper coatings were tested for Brookfield viscosity, water retention and high shear viscosity. The results are shown in Table 3 below. Paper Coating Thickener Example Dosage Paper Coating Properties Brookfield Viscosity Water Retention Hercules Viscosity 30 0.5 parts 1200 mPa.s(cps) 7.0 sec 35.4 mPas(cps) 31 0.5 parts (active) 1160 mPa.s(cps) 7.0 sec 42.3mPas(cps) The data in Table 3 indicates that the paper coating prepared with the hydroxyethylcellulose suspension performed equivalently to that prepared with the dry powder hydroxyethylcellulose. Example 31 This example demonstrates use of carboxymethylcellulose as a stabilizer for a hydroxyethylcellulose suspension per this invention. Into a beaker containing 120 parts of distilled water, 1.00 parts of Aqualon™ carboxymethylcellulose 7LlT was added and the mixture was stirred for about 30 minutes until the carboxymethylcellulose dissolved. Then, 28.2 parts of diammonium phosphate (Monsanto Company, St. Louis, MO) was added to the mixture and stirred to dissolve. The carboxymethylcellulose remained stable in this media as evidenced by the fact that no precipitate or haziness were observed. In a final step, 50.8 parts of Natrosol® 250 GR hydroxyethylcellulose was added to the mixture and the mixture was stirred for 15 minutes to disperse the hydroxyethylcellulose. The product was a fluid, pourable suspension that showed minimal solids/liquid separation after storage in a closed container at 50°C for 24 hours.

Claims: A suspension of an anionic or nonionic water-soluble polymer in an aqueous solution of an inorganic salt of ammonium is characterized in that the polymer comprises at least 15% of the total weight of the suspension, the ammonium salt has a multivalent anion, and the weight-ratio of the ammonium salt to the water is at least 0.15 and further characterized in that the nonionic or anionic water-soluble polymer is selected from the group consisting of cellulose derivatives, guar and its derivatives and xanthan gum. A suspension of a water-soluble polymer as claimed in claim 1, further characterized in that the aqueous suspension comprises greater than 20 % and up to 50%, based upon the total weight of the aqueous suspension, of the at least one anionic or nonionic water-soluble polymer. An aqueous suspension of water-soluble polymer as claimed in claim 1, further characterized in that the aqueous suspension comprises 22 to 35%, based upon the total weight of the aqueous suspension, of at least one anionic or nonionic water-soluble polymer. A suspension of a water-soluble polymer as claimed in claim 1, 2 or 3, further characterized in that the weight ratio of the ammonium salt having a multivalent anion to the water is 0.18 to 0.6. A suspension of a water-soluble polymer as claimed in claim 1, 2, 3 or 4, further characterized in that the ammonium salt having a multivalent anion is selected from the group consisting of diammonium phosphate, diammonium sulfate and ammonium polyphosphate. A suspension of a water-soluble polymer as claimed in any of the preceding claims, further characterized in that the cellulose derivative is selected from the group consisting of carboxymethylcellulose (sodium and other salts), hydroxyethylcellulose, hydroxypropylcellulose, carboxymethylhydroxyethylcellulose, hydrophobically modified hydroxyethylcellulose, hydroxyethylhydroxypropylcellulose, methylhydroxypropylcellulose, methylhydroxyethylcellulose, and 3-alkoxy-2-hydroxypropylhydroxyethylcellulose. A suspension of a water-soluble polymer as claimed in any of the preceding claims, further characterized in that it comprises up to 2%, by weight of the total suspension, of a stabilizer. A suspension of a water-soluble polymer as claimed in any of the preceding claims, further characterized in that the water-soluble polymer has a solution viscosity of 1,000 or more mPa.s (centipoise) in a 5% aqueous solution. A suspension of a water-soluble polymer as claimed in any of the preceding claims, further characterized in that the water-soluble polymer has a solution viscosity of 5,000 or more mPa.s (centipoise) in a 5% aqueous solution. A method for making a suspension of a water-soluble polymer as claimed in any of the preceding claims, characterized in that it includes the step of removing entrained air by reducing the ambient air pressure on the suspension.

Inventors: BURDICK CHARLES LEE, BURDICK, CHARLES LEE
Applicants: AQUALON CO, AQUALON COMPANY
Application year: 1989
Main classification: C08J3
IPC codes: C08L29, C08L33, C08L39, C09D201, C08L77, C08J3