METHOD FOR CONCENTRATING AQUEOUS TETRAFLUOROETHYLENE EMULSION BY ELECTRODIALYSIS AND ITS APPARATUS

Abstract: The object of this invention is to provide the method for concentrating aqueous PTFE emulsion in the shortest time compared to conventional methods and its apparatus, which waste water is not produced, the formation of flocculative materials being produced in concentration process is completely prevented, and surfactants using in PTFE emulsion polymerization are recovered. This invention relates to batch or continuous methods and apparatus for concentrating aqueous PTFE emulsion operated by the elevation difference of equipments in which it is fed to cell of electrodialysis after controlling pH, and adding surfactant to PTFE emulsion.

Description: METHOD FOR CONCENTRATING AQUEOUS TETRAl^TUOROETHYLENE EMULSION BY ELECTRODIALYSIS AND ITS APPARATUS Brief description of the drawing Drawing 1 is the process diagram of this invention. * Description of the symbol 1 Storage tank of raw material PTFE emulsion 2 Intermediate tank 3 Electrodialysis apparatus 4, 4 ' Electrodes 5 Storage tank of concentrated emulsion 6 Electrolyte storage tank 7 Electric power supplier 8 Multilayer membranes Detailed description of the invention Field of the Invention This invention relates to the method for concentrating aqueous polytetrafluoroethylene (abbreviated as PTFE, hereinafter) emulsion and its apparatus. Particularly, it relates to the rapid concentration method of aqueous PTFE emulsion without the formation of any kind of coagulating material and its apparatus. Description of the Prior Art Aqueous PTFE emulsion is well known to be used as the raw material for glossy agents, films, metal coatings, and ceramic coatings, etc. The aqueous PTFE emulsion to be commercially interesting has 60% of polymeric solid content, while the solid polymer content of PTFE emulsion prepared by emulsion polymerization is below 30% as the basis on polymeric solid content. Therefore, in order to increase the solid content in emulsion, the process for concentrating aqueous emulsion prepared by polymerization reaction has to surely follow. The traditional concentration methods of emulsions were carried out by sedimentation, vaporization, and adsorption methods using nonionie or cationic surfactant. The sedimentation method is to concentrate emulsions by precipitating solid polymer by means of a non-ionic or anionic surface active agent. The sedimentation method using ionic surfactant has shown the phenomena that the flocculated particles by peptizing of the inactive dispersing agen become emulsified again, when the excess water in the upper layer is eliminated after scdimcntation( U.S. Pat. 2,478,229). Furthermore, the concentration using surfactant is necessary to dilute the. emulsion in the early stage in order to prevent the flocculation phenomena of the emulsion, and ultimately requires a long concentration time. Λnd also, the method using nonionie surlacLant which shows the phenomenon of solubility inversion at above certain temperature has been carried out for the concentration of aqueous PTFF emulsions. 1( is necessary to concentrate emulsion by heating 50 - 80 °C, by dissolving t he surfactant to emulsion and by adding a little amount of electrolytes (Canadian Pat. 536,455). Λs the concentration does not occur without adding the electrolyte or heating in this method, because of the stability of emulsion, it is impossible to obtain the emulsion with high concentration. This method, in fact, has difficulty in controlling the amount of electrolytes, because of the concentration of electrolytes being changed in very narrow temperature range. There arc also concentration method by absorbing water using water - insoluble adsorption agents, such as silica gel or ion exchange resin, as an adsorption method ( U.S.Pat. 3,668,167). As it is also known to carry out the concentration of emulsion by vaporization under reduced pressure of water contained in emulsion after stabilizing emulsion, it is difficult to avoid the formation of foams and any overheating (U.S.Pat. 3,316,201). The methods described above are very hard to apply to emulsions containing 30% of the solid content, but also are very difficult to avoid the flocculation of emulsion. Furthermore, concentration method using a large quantity of surfactants are necessary to recover surfactants contained in water of upper layer, and needs post-treatment processes for separating or treating wastes, after concentration. For conducting this process, much energy is required and environmental contamination problem is taken place. The task to solve the problem According to this invention, the waste water is not produced, and the formation of flocculation materials which can be produced in the conventional concentration process is completely prevented. And also, the object of the present invention is that of providing new process for concentrating PTFE emulsion by electrodialysis. A further object of this invention is providing that the surfactant using in PTFE emulsion polymerization process can be able to recover, the concentration time required in this invention is shorter than that in conventional methods, and the recovered surfactant can be reused, and its apparatus. The means to solve the problem This invention is to provide the method for concentrating aqueous polytetrafluoroethylene emulsions and its apparatus characterizing to obtain effectively concentrated PTFE emulsion by precipitating, which derived PTFE particles in emulsions toward the electrode of opposite charge eliminating anionic surfactant existing in PTFE emulsion by electrodialysis using the properties that PTFE particles in emulsions have anionic charge after emulsion polymerization. This invention is more embodied as following. As PTFE emulsion retains polymer particles of about 30 nanometer, which are suspended with colloidal state, the sedimentation of the stabilized particles does not occur, even though has left for long time, due to repulsion of particles by the anionic surfactant adhered to particle surface and anionic surfactant existing in solution. This invention is to concentrate the emulsion by precipitation, as eliminating anionic surfactant existing in particles in emulsion and water by electrodialysis, as using the properties with anionic charge for PTFE emulsion prepared from polymerization Electrodialysis is the method to concentrate the aqueous colloidal particles by charging the electricity to suspension solution. As charging an electric current to suspension solution, the colloidal particles with electric charge is transferred horizontally to the electrode with opposite electric charge. The concentrated colloidal layer on the surface of the vertical membrane is formed by interrupting of the transferred colloidal particles at the membrane set vertically. As the colloid is precipitated by gravity, the solution is concentrated. In this invention, as charging electric current to PTFE emulsion by electrodialysis, PTFE colloidal particles are transferred to positive electrode. As PTFE colloidal particles being transferred to positive electrode, the concentration occurs at its surface by interrupting on the membrane, established with constant intervals. In here, nonionie surfactant prevents the phenomena adhering PTFE colloids to membrane in the concentration pπx-ess, and the precipitation is accelerated , as inducing the: phen .mcne.n of bridge between them withe)ut coagulation of PTFE colloid at the around of membrane. After precipitation, concentrated PTFE emulsion with above 70% is obtained, as recovering it at the bottom from water layer of upper part.. The concentrated emulsion did not show the flocculation of particles by using the electrodialysis apparatus of this invention. In this invention, it is important that adhering of emulsion to membrane surface can be prevented by using nonionie surfactant, and the coagulation of particles in the concentrated emulsion open occurring can also be eliminated, when the electric charge of the emulsion become neutral. The volatile electrolyte was used at the around of electrode, anionic surfactant transferred from emulsion can be easily recovered from electrolyte. The phenomena adhering of colloidal particles to membrane surface, which can be occurring in the concentration process by above electrodialysis, can be prevented by adding nonionie surfactant, Triton X- 100, and also polyethylene glycol alkyl ether can be used, instead of it . The experiments were carried out with the electrodialysis apparatus manufactured according to this invention, the interval of the membrane can be adjusted in the range from 0.3 Cm to 3 Cm, and the surface of the membrane was 20 Cm 2 . The membrane was set up between electrolyte and emulsion solution, and also can be set up as multilayer to increase the efficiency of concentration. The material of the electrode used was platinum.. In the process of this invention described above, the apparatus like attached drawing 1 was used, and the apparatus of this invention according te. drawing 1 is composed of the following items; ste.rage tank of raw material PTFE cmulsion( l ), intermediate tank in order to feed surfactant and PI 3 control (2), electrodialysis concentrating emulsion(3), storage tank of concentrated cmulsion(5) flowing out from above electrodialysis apparatus, which has separated from aqueous solution of upper layer, electrolyte storage tank(6) in order to supplement the volatile electrolyte feeding to electrodes(4), electric power supplier(7), and multilayer membranes(8). The transportation of emulsion was carried out by pressure difference according to difference of head of apparatuses, (1),(2),(3), and (5), and mechanical transportation devices were not used. For instance, the head difference of the apparatuses was given to place at gradually lower petition as following in order; emulsion storage tank of raw material PTFE( l), intermediate tank(2), electrodialysis apparatus(3), and concentrated emulsion storage tank(5), And also, these apparatus is operated as batch and continuous system. According to the process and its apparatus of this invention, it has the following advantage in the concentration of PTFE emulsion. First, Time for concentration of PTFE emulsion by this invention is outstandingly shorter than that by the conventional methods. Second, Flocculation phenomena being able to occur during the concentration does not occur. Third, Post-treatment processes for treating wastes and separating surfactants are not necessary, and waste materials are not produced. Fourth, Recovery of anionic surfactants used in polymerization process is possible. Fifth, Apparatus is simple. According to this invention, concentrated PTFE having the advantage above and its own inherent property of PTFE emulsion, can be used as glossy agents, films metal and ceramic coatings, etc. This invention is more embodied according te) the following examples. Example 1 PTFE emulsion with 25wt% of polymeric solid content from the storage lank( l ) of raw material PTFE emulsion was fed to intermediate st .rage tank(2), and 5wt% of Triton X-100 based on pe)lymeric solid content was added to it, and then adjusted to PH 7 using ammonia solution and slowly agitated. Emulsion mixture of intermediate tank(2) was divided into many parts by Multilayer membranes(δ) of elcctrodialysis(3), and introduced to center cell of electrodialysis apparatus(S) composed of membrane passing the particle only with molecular weight, above 1000, and then 0.1 mole of volatile electrolyte was introduced to both of electrode cell. 10V voltage generated by electric supplier was charged to the cell with 30mm interval of membranes, and emulsion was concentrated for 80 min. in the batch system. In this case, the initial electric current density was 80 mA/ m 2 , and aqueous PTFE emulsion was concentrated to 70%, by polymeric solid content.. Example 2-5 The experiments were carried .ut under the same conditions as example 1 , except changing concentration of fed emulsion, initial electric current density, voltage, and concentration time as in Table 1, and the results were summarized in Table 1 . The concentration time means the time required for concentrating PTFE emulsion to 70%, by polymeric solid content. Table 1 . Result for the concentration of PTFE emulsion by changing the voltage Example 6 ~ 9 The experiments were carried out under the same conditions of Example 1, except changing concentration of fed emulsion, initial electric current density, voltage, and concentration time as in Table 2, and setting up membrane interval with 7 mm instead of 30 mm in Example 1 , and results were summarized in Table 2. The concentration time is the time required for concentrating PTFE emulsion to 70%, by polymeric solid content. Table 2. The results for PTFE concentration when the membrane interval is 7 mm Example 10-13 The experiments were carried out under the same condition of Example 1 , except changing the concentration of fc.cl emulsion, initial electric current density, voltage, and concentration time as in Table 3, The concentration time is the time required for concentrating PTFE emulsion to 70%, by polymeric solid content. Table 3. The results for PTFE concentration, when the membrane interval is 0.5 mm Example 14 The experiment was carried out under the same condition of Example 1, except using polyethylene glycol alkyl ether instead of anionic surfactant, Triton X-100 in Example 1. When below 5 wt% of anionic surfactant to weight of PTFE emulsion was used, there was appeared the phenomena adhering PTFE colloid to the membrane of electrodialysis apparatus. The adhering phenomena like this was disappeared, as using above 5wt% anionic surfactant. Example 15 The experiment was carried out under the same condition of Example 1 , except changing PH of PTFE emulsion, as 2, 4, 10, and 12 in Example 1. As the results in this case, the required time to concentrate PTFE emulsion to 70 wt% was 95, 75, 85, and 80 min., respectively. Example 16 Continuous concentration was carried out by feeding PTFE emulsion with 25 wt% e)f polymeric solid content, stored at storage tank of raw material PTFE emulsionO ) to intermediate tank(2), and feeding 5wt% of Trite>n X-100 based on pe)lymeric solid content to tank(2) under gentle agitaion, adjusting PI 1 of emusion to 7 by using ammonia solution, and then feeding emulsion mixture of intermediate tank(2) to respective cell of electrodialysis apparatus with 3cc/min. by the elevation difference of the equipments. Membranes passing the material with molecular weight above 1000 was set and divided into many parts by multilayer membranes(8) in electrodialysis cell(5). 0.1 mole of volatile electrolyte to both electrode cells was feeded and 30V of voltage by electric power supplier was charged into cell composed of 3 compartment with 30 mm interval between membranes. A PTFΕ emulsion was concentrated into 60% - 70% by polymeric solid content.

Claims: What we claim is - 1 . Method for concentrating aqueous PTFE emulsion by batch type electrodialysis, feeding aqueous PTFE emulsion, in which surfactant is added and PI I is controlled, to the membrane cell set up with cont rolled intervals of electrodialysis, in the concentration of aqueous PTFE emulsion containing 2-40%, by weight of PTFE polymeric solid. 2. Method for concentrating aqueous PTFE emulsion by batch type electrodialysis characterizing that membranes are types of cellulose being blocked the molecules with me)lecular weight above 1000, in the claim 1 . 3. Method for concentrating aqueems PTFE emulsion by batch \ y\)c electrodialysis characterizing that electric current density is 90-320 mΛ/m ' in the claim 1. 4. Method for concentrating aqueous PTFE emulsion by batch type electrodialysis characterizing Pl l range is 7-10, in the claim 1. 5. Method for ce)ncentrating aqueous PTFE emulsion by batch type electrodialysis characterizing passing electrolyte to the chambers of electrode, in the claim 1 . 6. Method for concentrating aqueous PTFE emulsion by batch type electrodialysis characterizing that anionic surfactant is above 5wt% based on polymeric solid content of PTFE emulsion, in the claim 1. 7. Method for concentrating aqueous PTFE emulsion by batch type electrodialysis characterizing that anionic surfactant is polyethylene glycol alkyl ethers, in the claim 1 or 6. 8. Method for concentrating aqueous PTFE emulsion by batch type electrodialysis characterizing anionic surfactant is Triton X-100, in the claim 1 or 6. 9. Method for concentrating aqueous PTFE emulsion by batch type electrodialysis characterizing required voltage per interval of membrane is 2-60V/cm, in the claim 1. 10. Method for concentrating aqueous PTFE emulsion by batch type electrodialysis characterizing interval of membrane is 0.5-30 mm, in the claim 1. 11. Method for concentrating aqueous PTFE emulsion by continuous electrodialysis using pressure difference according to the elevation of apparatuses of storage tank of raw material PTFE emulsion( l ), intermediate tank(2), electrodialysis apparatus (3), and storage tank of concentrated emulsion(5), and feeding raw material added surfactant and controlled PI-I to cell of electrodialysis, in the conccntratk)iι of PTFE emulsk)n containing 2-40% of PTFE polymeric solid content based on weight. 12. Apparatus for concentrating aqueous PTFE emulsion by batch type electrodialysis using pressure difference according to the elevation of apparatuses of storage tank of raw material of PTFE emulsion( l ), intermediate tank(2), electrodialysis apparatus(3), and storage tank of concentrated emulsion, comprising with storage tank of raw material PTFE emulsion(l ), intermediate tank(2), electrodialysis apparatus(3) with positive clcctrodc(4) and negative electrode(4' ) or multilayer membranc(8), electrolyte storage tank(6), and electric power supplier(7). 13. Apparatus for concentrating aqueous PTFE emulsion by batch type electrodialysis characterizing electrodialysis apparatus(3) is monolayer ιnembrane(8), in the claim 12. 14. Apparatus for concentrating aqueous PTFE emulsion by batch type electrodialysis characterizing electrodialysis apparatus(3) is multilayer membrane(8), in the claim 12. 15. Apparatus for concentrating aqueous PTFE emulsion by batch type electrodialysis characterizing membrane is cellulose membrane being blocked the molecule with molecular weight above 1000, in the claim 12 or 13. 16. Apparatus for concentrating aqueous PTFE emulsion by batch type electrodialysis characterizing electric current density is 90-320 mA/m, 2, in the claim 12. 17. Apparatus for concentrating aqueous PTFE emulsion by batch type electrodialysis characterizing required voltage per interval of membrane is 2-60V/cm, in the claim 12. 18. Apparatus for concentrating aqueous PTFE emulsion by batch type electrodialysis characterizing interval of membrane is 0.5-30mm, in the claim 12. 19. Apparatus for concentrating aqueous PTFE emulsion by continuous electrodialysis is continuously operated using pressure difference according to the elevation of the apparatuses of storage tank of raw material PTPΕ emulsiond ) , intermediate tank(2), electrodialysis apparatus(3), and storage tank e.f concentrated emulsion(5), comprising with ste.ragc tank of raw material of PTFE emulsiond ) , intcrmc.diate tank(2), electrodialysis apparatus(3) with positive electrode(4) and negative elcctrode(4' ) and multilayer membranes(8). AMENDED CLAIMS [received by the International Bureau on 17 December 1997 (17.12.97); original claims 1-19 replaced by amended claims 1-16 (3 pages)] l. Method for concentrating aqueous PTFE emulsion containing 2 - 40 %, by weight, of PTFE polymeric solid, characterized in that after adding a nonionie surfactant to the aqueous PTFE emulsion, the emulsion undergoes an electrodialysis treatment, in which the emulsion is fed to the membran cells of an electrodialysis apparatus. 2 . Method according to claim 1, in which the pH value of the aqueous PTFE emulsion prior to the electrodialysis is controlled to be in the range of 7 - 10. ' 3. Method according to claim 1 or 2, in which for performing the electrodialysis membranes passing molecules with a molecular weight above 1000 are used. 4. Method according to claim 1, 2 or 3, in which the electrodialysis is performed with an electric current density of 90 - 320 mA/m 2 . 5. Method according to anyone of claims 1 to 4, in which the electrodialysis is performed with an electric field intensity of 2 - 60 V/cm between the membranes. 6. Method according to anyone of claims 1 to 5, in which the added surfactant is above 5 wt%, based on polymeric solid content of the PTFE emulsion. 7. Method according to anyone of claims 1 to 6, in which the added surfactant is polyethylene glycol alkyl ether. 8. Method according to anyone of claims 1 to 6, in which the added surfactant is Triton X-100. 9. Method according to anyone of claims 1 to 8, in which an electrolyte is passed to the electrode cells of the electro- dppαTu -US • 10. Method according to anyone of claims 1 to 9, in which the electrodialysis is performed batchwise. 11. Method according to anyone of claims 1 to 9, in which the electrodialysis is performed continuously and the aqueous PTFE emulsion is fed to the electrodialysis apparatus by means of gravity. 12. Apparatus for performing the method according to claim 10, comprising a storage tank ( 1 ) for the aqueous PTFE emulsion to be concentrated, an intermediate tank (2) for adding the nonionie surfactant, an electrodialysis apparatus (3), and a storage tank (5) for the concentrated emulsion, the electrodialysis apparatus (3) comprising a positive and a negative electrode ( 4; 4 ' ) connected to an electric power supply ( 7 ) and monolayer or multilayer membranes (8) between the electrodes . 13. Apparatus for performing the method according to claim 11, comprising a storage tank ( 1 ) for the aqueous PTFE emulsion to be concentrated, an intermediate tank (2) for adding the nonionie surfactant, an electrodialysis apparatus (3), and a storage tank (5) for the concentrated emulsion, the electrodialysis apparatus (3) comprising a positive and a negative electrode (4; 4') connected to an electric power supply (7) and multilayer membranes (8) between the electrodes. 14. Apparatus according to claim 12 or 13, in which the membranes (8) are spaced apart by a distance of 0,5 - 30 mm. 15. Apparatus according to claim 12, 13 or 14, in which tha membranes (8) are passing molecules with a molecular weight above 1000. 16. Apparatus according to claim 15, in which the membranes (8) are of cellulose.

Inventors: JIN HANG KYO, KIM CHUL UNG, KIM KWANG JOO, KOH JAE CHEON, LEE JUNG MIN, MOON SANG JIN, SO WON UOOK, JIN, HANG, KYO, KIM, CHUL, UNG, KIM, KWANG, JOO, KOH, JAE, CHEON, LEE, JUNG, MIN, MOON, SANG, JIN, SO, WON, UOOK
Applicants: JIN HANG KYO, KIM CHUL UNG, KIM KWANG JOO, KOH JAE CHEON, KOREA RES INST CHEM TECH, LEE JUNG MIN, MOON SANG JIN, SO WON UOOK, JIN, HANG, KYO, KIM, CHUL, UNG, KIM, KWANG, JOO, KOH, JAE, CHEON, KOREA RESEARCH INSTITUTE OF CHEMICAL TECHNOLOGY, LEE, JUNG, MIN, MOON, SANG, JIN, SO, WON, UOOK
Application year: 1997
Main classification: C08F6
IPC codes: B01D57, B01D61, B01D71, C08F6, C08F14