POLYMERIZATION PROCESS WITH ANTI-SCALING AGENTS

Abstract: Procedure for the polymerization of monomers in aqueous suspension and/or emulsion carried out in reactors inside of which an anti-scaling product is deposited, characterized in that, the said anti-scaling product comes from the cross-linking of polyvinyl alcohol with the product formed by the reaction of sodium salt of the hydroxymethansulphincal acid with naphthols.

Description: DESCRIPTION Polymerization process with anti-seal1ng agents. Technical Field The object of this invention is a procedure for polymerizing of monomers in suspension or aqueous emulsion carried out in reactors inside of which a coating has been deposited capable of eliminating any scale formation or polymer film, and an application of technology that leads to a composition of colourless and effective coating for the entire duration of the polymerization reaction. Anti-scaling agents for polymerizing reactors and their application techniques are already well known in prior art. Background Art At the present state of the art there are also different types of anti-scalers for each type of polymer and for each of these there are different methods of application to form a anti-scaling coating on the inside of the reactors themselves. For example the anti-sealer and its application technique for the polymerization of the vinyl chloride is not the same as that used in the reactor for the production of polystyrene or of that for the production of acrylic polymers, and so on. This fact necessitates in the storing of various products, spraying and application devices with all the consequences of high management costs. Disclosure of Invention A first aim of this invention is that to make an anti-sealer and a simple application technique that operates well in any type of polymerizing reactor and for the most varied types of different materials, therefore for polystyrene as well as for acrylic polymers, ABS, polyurethane and Polyvinylchloride, etc. In the specific case of polymerization in aqueous suspension and of the polymerization in aqueous emulsion of the vinyl chloride for example, it is known that in the reactors a substantial deposit of scale forms having as main drawbacks: - a consistent maintenance for the removing of the scaling with consequent interruption of the production, opening of the reactor and therefore high quantities of gaseous vinyl monomer chloride (VCM) emissions into the atmosphere; - pollution of the resultant product as some of the scaling parts go into the respective polymerized product with consequent worsening in quality and complaints by the users; - in conclusion there are obstacles both in the productive system and in ecological problems for the areas in which the industrial Polyvinylchloride plants (P.V.C.) operates. This problem practically exists for all types of polymerizations. Furthermore the anti-scaling products destined to coat the surfaces of the respective reactors are of a bluish colour or dark brown nearly black, wherefore the particles that detach from the crust, pollute the obtained polymer (for example obtained polyvinyl chloride) from the reactor under the form of black dots, that for example in the finished products worsens the qualitative aspect of the said product. Furthermore it is to be noted that the material particles that detach from the crust of the wall, end up in the product in reaction, constituting the pollution of the same, dealing generally with toxic products. In prior art, the technique of condensation or polycondensation of naphthols and phenol with an aldehydic cross- linking product (e.g. formaldehyde and others), to obtain anti-scaling products is known. For this purpose one refers to: • US-A-3669946 (filed in the U.S. on August 31st, 1970, disclosed on June 13th, 1972), that suggests the use of formaldehyde and ketonic composites, naphthol etc. and also alpha-naphthylamine and nigrosin. This teaching predivulges the general concept of forming anti-scalers condensate parting from the formaldehyde with phenols and naphthols derivatives. • U.S.-A-3825434 (23rd July 1974) describes an anti-scaling agent for the polymerizing of vinyl chloride, obtained from the condensation of the phenol with formaldehyde, where obviously for definition in this patent the obtained product is always classified as pertinent to the phenol-formaldehyde or polyarilphenol family. • US-4,068,059 (filed on 17-2-77; published on the 10-1 -78) explains furthermore the importance of using as anti-scalers, products that in their chemical structure contain one or more of the following groups: -OH; -COOH; SO3H and SO3Na. These groups are usually attached to an aromatic nucleus. • EP-A-0052421 describes a process for obtaining an anti- scaling product formed with formaldehyde that is made to react with 1-naphthol (alpha-naphthol), in which both the nuclear positions 2 and 4 are not replaced and the nuclear position 3 is not replaced or has a substitute that is not strongly eletron-attractor to obtain a condensate. Even in this case the product obtained according to the chemistry is to be considered always as pertinent to the polyarilphenol family. These last products have the drawback to supply, a dark brown or dark blue nearly black product, and not always being suitable for usages in sectors of polymerizing with different materials. The reaction is difficult to control and leads to reticulate products insoluble in alkaline aqueous solution. Furthermore, the coating of the reactor with these anti-scalers is consumed easily dispersing itself in the material in reaction, polluting it by colour and by toxicity. Furthermore we must point out that these anti-scalers are of poor efficacy, or however require a massive deposit of scale on the wall, such to preclude some usages, as for example, sanitary and alimentary, where the requested limits of polluting products in the finished product are decidedly lower etc.. To obtain a good anti-scale efficacy, they must however deposit on the wall in high quantities which also affects costs. The colour of the anti-scalers of the known technique is dark and little appreciated by the user also because it makes one think of a pollutant product. The dark colour of the product leads to a crust on the wall, also of dark colour (blackish) and this does not allow to see eventual application defects. But much more serious is that already mentioned, that during the reaction crust particles detach and mix with the polymer. As these crust parts are black it is clear that there is a qualitative worsening of the product. It is thought that these anti-scaling coatings, even if additives of partially hydrolysed polyvinyl acetates of other binders and sprayers with nitrogen or aqueous vapour on the inside of the 1 polymerization reactors, form colloidal films not attached to the 2 metallic structure of the walls with electronic ties. In conclusion 3 these films, dried and placed in the interface between the mass in 4 polymerization and the surface of the reactor itself when they are 5 subjected to abrasion phenomena due to solid particles of polymers in 6 aqueous suspension subjected to rotational agitation, in a short time 7 detach from the reactor walls. 8 Aim of the present invention is that to obviate the above- 9 mentioned drawbacks and in particular to obviate the dark colour of I 0 the product and to the poor adherence of the coating that it will form I I on the wall of the reactor. 1 2 The inventors originally thought of making an anti-scaling 1 3 product that once applied onto the wall of the reactor is substantially 1 4 colourless and strongly adherent to the metallic surfaces of the 1 5 reactor itself. 1 6 It is known that for whitening an aromatic product, for 1 7 example colorants, hydrosulphite sodium or hydrosulphite potassium 1 8 is used. 1 9 Attempts to make colourless with hydrosulphite the condensate 2 0 of formaldehyde and 1-naphthol have given negative results because 2 1 the condensate result always remained bluish black tending to form 2 2 deposits even if conducted in absence of oxygen, example presence of 2 3 nitrogen. 2 4 In proceeding the research it was thought to avoid the reaction 2 5 between formaldehyde and 1-naphthol in order to substitute it with a 2 6 less toxic substance and able to form a colourless product. 2 7 After innumerable experimentations it was found that the best 2 8 result can be obtained by combining the 1 -naphthol with hydroxymethansulphincal acid with the following formula: O = S - ONa I CH2OH The product obtained was perfectly colourless. Using the hydroxymethansulphincal acid mixed with the 1 - naphthol in the weight proportions of 1 to 1,5, in an aqueous solution of 10 to 40%, and bringing the temperature of the solution between 70° and 95°C in a nitrogen atmosphere, alkaline environment (pH 11- 13), a clear transparent coloured product is obtained, fully reaching the prefixed aim and without decreasing the quality of the product, infact improving it. The product results physically of clear aspect, transparent, but if left in the presence of air for a certain period it oxidizes slightly verging towards a green blue colour. If the contact with oxygen is interrupted, the product reverts to its original transparent clear aspect. This physical behaviour proves that one has reached a completely new and structurally different product if compared to the products of prior art, where this physical phenomenon could not be observed. If is thought that the reversibility of the phenomenon could be tied to the presence of a radical in the product, that depending on the concentrations of oxygen it may or may not be tied to the molecular structure of the primary compound In conclusion according to the more probable deductions it should deal with an abducted bisulphitic of the first product that forms in the reaction between 1 -naphthol and hydroxymethansulphincal acid. The product applied onto the surface of the reactor in an atmosphere deprived of oxygen, after drying, results an opalescent white opaque colour, contrarily to the dark colour of the present anti- sealers. It is also noted that to make the polyvinyl alcohol's less soluble in water and able to form a very resistant film, cross-linking reactions are made between the hydroxyl groups of the polyvinyl alcohol with substances containing radicals able to inter-act with the hydroxyl groups themselves. Therefore we had the idea to apply this technique adding to the previously described colourless product, polyvinyl alcohol's having a degree of hydrolysis higher than 99% OH and the molecular weight between 70.000 and 90.000 and to apply this mixture to the internal walls of the reactor, maintained at about 85°C, by means of mixing and injection with aqueous vapour with a pressure of about 10 Kg./cm2. The results were surprisingly good. Advantageously it was discovered that the coating inside the reactors was colourless, very uniform and resistant to rubbing. Spraying the product with water vapour at high temperature the maximum adherence result is obtained. As the reaction of polymerizing in reactor lasts on average from four to six hours it is evident that in this time and in absence of oxygen, there are no substantial degradations of the product, and consequently colorimetric degradations, therefore once the reaction of polymerizing is completed and once the smallest anti-scaling percent is integrated in the polymerized mass, this will not undergo further important contaminations and degradations. Instead, whilst in prior art using the anti-scaling products previously known, one had to fully wash and empty the reactor of every minimum trace of the residue of the product applied onto the wall as an anti-sealer, with this new product, it is possible to send the rinse of the reactor to the tank collection of the aqueous suspensions of the polymer obtained without requiring further refuse discharges, realizing in this way a complete and effective and above all economic technology of the loading and unloading of reactors of polymerization with the technique named by the experts of the sector as man hole closed. As the hydroxymethansulphincal acid may be also used with a molar hydrosulphite excess, even using this product a condensate of analogous or improved performance (largely reducing conditions) is obtained. As both in this case and that of the preceding, the activity of the product is always given from the presence of bisulphate derivatives and in particular of radical bisulphites present in the derivative, this characteristic clearly distinguishes the new product from the prior art, and in particular with reference to the resulting structure of the derived product, this identifies as innovator for the presence of an interposed carbon atom between the aromatic rings and tied to a sulphonic group. This bisulphitic product inhibited from sodium salt of hydroxymethansulphincal acid is perfectly able to cross-link polyvinyl alcohol present and therefore form strongly resistant reticulated combinations with the metals of the walls of the reactors (Iron, Nickel, Chrome). Hydroxymethansulphincal acid is also found in trade under the name rhongalite.

Claims: Claims 1. Procedure for the polymerization of monomers in aqueous suspension and/or emulsion carried out in reactors inside of which an anti-scaling product is deposited, characterized in that, the said anti-scaling product comes from the cross-linking of polyvinyl alcohol with the product formed by the reaction of sodium salt of the hydroxymethansulphincal acid with naphthols. 2. Polymerization procedure using an anti-sealer that coats the walls of the reactor according to claim 1, characterized in that said anti- scaling product comes from the cross-linking of polyvinyl alcohol with the product formed by the reaction of sodium salt of the hydroxymethansulphincal acid with 1-naphthol. 3. Anti-scaling product applied onto the walls of a polymerization reactors, according to claim 1 , characterized in that it is obtained by cross-linking of polyvinyl alcohol with the product formed by the reaction of the sodium salt of the hydroxymethansulphincal acid with naphthols. 4. Anti-scaling product applied onto the walls of a polymerizing reactor according to claim 1, characterized by the fact that it is obtained by cross-linking of polyvinyl alcohol with the product formed by the reaction of the sodium salt of the hydroxymethansulphincal acid with 1-naphthol. 5. Anti-scaling product in liquid form to be applied onto the walls of a polymerizing reactor by means of vapour spray obtained according to the procedure of which in claim 1., characterized by the fact that: • in absence of oxygen, it is a clear transparent colour, and if • in the presence of oxygen, it becomes of greeny bluish colour or dark; and if 1 • the contact with oxygen is interrupted, it reverts to its original 2 aspect. 3 6. Product according to claim 2, obtained according to the procedure 4 in claim 1 , characterized by the fact that it contains radical 5 bisulphites. 6 7. Anti-scaling product, obtained according to the procedure in claim 7 1, characterized by the fact that it contains hydrosulphite. 8 8. Procedure for the anti-sealer production for coating polymerizing 9 reactors according to claim 1, characterized by the fact of adding I 0 sodium hydrosulphite into the reaction. I I 9. Procedure for the anti-sealer production for coating the 1 2 polymerizing reactors, characterized by the fact of adding potassium 1 3 hydrosulphite into the reaction. 1 4 10. Anti-scaling product, obtained according to the procedure in claim 1 5 1, characterized by the fact that it contains polyvinyl alcohol. 1 6 11. Procedure for the anti-sealer production for coating the 1 7 polymerizing reactors according to claim 1, characterized by the fact 1 8 that the product is conserved in containers impermeable to oxygen. 1 9 12. Procedure for the anti-sealer production for coating the 2 0 polymerizing reactors according to claim 1 , characterized by the fact 2 1 that the product is conserved in containers impermeable to the 2 2 oxygen by means of pressurisation in inert gas. 2 3 13. Procedure for the anti-sealer production for coating the 2 4 polymerizing reactors according to claim 1 , characterized by the fact 2 5 that the product is conserved in containers impermeable to oxygen by 2 6 means of pressurisation in nitrogen. 2 7 14. Procedure for the anti-sealer production for coating the 2 8 polymerizing reactors according to claim 1 , characterized by the fact that the product is conserved in containers impermeable to oxygen by means of pressurisation in nitrogen by using containers in polyethyleneterephtalar (PET). 15. Procedure for the anti-sealer production for coating the polymerizing reactors according to claim 1, characterized by the fact that the product containing hydrosulphite is added in such a way such that the hydrosulphite prevents the evolution of the reaction into stable condensate forms. 16. Procedure for the anti-sealer production for coating the polymerizing reactors according to claim 1, characterized by the fact that the hydrosulphite addition is carried out in a basic environment. 17. Procedure for the anti-sealer production for coating the polymerizing reactors according to claim 1, characterized by the fact that the hydrosulphite addition is carried out in a basic environment with the pH being about 11-13. 18. Anti-scaling product for coating the polymerizing reactors according to the preceding claims, characterized by the fact of being conserved in containers impermeable to oxygen by means of pressurisation in nitrogen by using containers in polyethyleneterephtalar (PET). 19. Anti-scaling product for coating the polymerizing reactors according to the preceding claims, characterized by the fact of being conserved in containers impermeable to oxygen by means of pressurisation in nitrogen by using transparent containers in polyethyleneterephtalar (PET) 20. Anti-scaling product for coating the polymerizing reactors according to the preceding claims characterized by the fact that it contains bisulphate traces.

Inventors: SATTIN MARIO, SATTIN, MARIO
Applicants: CIRS SPA, SATTIN MARIO, C.I.R.S. S.P.A., SATTIN, MARIO
Application year: 1996
Main classification: C08F2
IPC codes: C08F2, C08F14