Method for the inhibition of (poly)phosphate scale

Abstract: The invention relates to the inhibition of (poly)phosphate scale in aqueous systems involving the use of at least one copolymer comprising the following monomers in polymerized form:- (I) 50-08% by weight of one or more weak acids; (II) 2-50% by weight of one or more strong acids; (III) 0-30% by weight of one or more monoethylenically unsaturated C 4 -C 8 dicarboxylic acids; and (IV) 0-30% by weight of one or more monoethylenically unsaturated monomers polymerizable with (I), (II) and (III); wherein the total of monomers (I), (II), (III) and (IV) equals 100% by weight of copolymer. The invention is particularly suited to the inhibition of (poly)phosphate scale which occurs as a result of using low phosphate (STPP) containing detergent formulations.

Description: The present invention relates to the inhibition of (poly)phosphate salt scale in aqueous systems. It is well known that in hard water areas high concentrations of magnesium and calcium ions can lead to the formation of insoluble calcium and magnesium carbonate deposits (scaling) on washed articles. This is visible, as a white deposit, particularly on glassware when such articles are washed in automatic dishwashing machines, and also on machine parts especially heater elements. Similar precipitation problems also occur in laundry washing, these cause the fabric to become stiff and rough to the touch and give coloured fabrics a faded appearance. Tap water with relatively high water hardness and the use of insufficient water softening chemicals increase the problem dramatically. Other factors involved in causing scaling are temperature (more scaling occurs at higher temperatures) and pH (higher pH also increases scaling). Since the mid 1960's, sodium tripolyphosphate (STPP) has been used in large quantities in most detergent formulations as a "builder"; that is an agent which is able to sequester positive cations such as magnesium and calcium in the washing solution and prevent them from depositing as salts (carbonate, silicate etc.) on the items being washed. However, it is now known that the presence of phosphate, for example in the form of STPP, in lakes and rivers serves as a nutrient for algae growth and this results in a deterioration of water quality. These environmental concerns have lead to the removal of STPP in detergent formulations and their replacement with other sequestering compounds. Unfortunately, the changes that occur in the washing process without inclusion of phosphate are more complex than those expected from the simple decrease in sequestration capacity of the detergent matrix. The multi-purpose capabilities of the STPP in the areas of emulsification of oily particles, stabilisation of solid soil suspension, peptisation of soil agglomerates, neutralisation of acid soils, etc. are all key to obtaining an excellent wash end result. To try to maintain as many of the desirable properties of STPP as possible, whilst at the same time limiting its environmental impact, reduced STPP levels are used. However, this in itself brings new scaling problems. When high levels of STPP are used in the wash bath of dishwashing and laundry washing machines, the predominant species formed in the aqueous system is a water soluble 1:1 metal ion:STPP complex (eg. CaP 3 O 10 -3 ). As STPP levels decrease, water insoluble calcium and magnesium salts of tripholyphosphate (eg. Ca 5 (P 3 O 10 ) 2 ) and pyrophosphate (eg. Ca 2 P 2 O 7 ) are formed which consequently precipitate from the aqueous system. Prior art documents are known, for example US 3806367, US 3928196, and US 3898037, which address the problem of controlling scale in STPP free systems. However, there is no teaching of any effective way to control the (poly)phosphate scales which are formed using low-STPP levels (ie. through the use of "Ultra" or "Compact" detergent formulations) where the concentration of the STPP in the wash bath is, for example, below 1500 ppm. The precise amount of scale observed will depend upon the concentration of divalent cation in the wash bath. For comparison, typical high-STPP wash bath concentrations in current commercial use, have greater than 2000 ppm of STPP. WO98/16612 teaches a laundry detergent composition containing a terpolymer comprising a first monomeric unit comprising a weak acid function, a second acid monomeric unit comprising a strong acid function and a third monomeric unit comprising a non-ionic function. Although such a terpolymer is described as being useful to control fabric yellowing, there is no teaching of a method of controlling (poly)phosphate scale in aqueous systems containing low levels of sodium tripolyphosphate. DE3743739, WO96/35728, EP-A-0727448, US-A-5516432, EP0851022, WO83/02607 and EP-A-0271035 all disclose method of controlling phosphate scale and/or detergents that involve the use of polymer compositions. However, as with WO98/16612 above, none of these prior art documents discloses a method of controlling (poly)phosphate scale in aqueous systems containing low levels of sodium tripolyphosphate. The term "(poly)phosphate scale" used herein refers to tripolyphosphate and pyrophosphate scales collectively. Also, the term "copolymer" is used to mean polymers comprising two or more different types of monomer units in polymerized form. Thus the term "copolymer" specifically includes the term "terpolymer". The problem addressed by the present invention, therefore, is to provide a method of controlling (poly)phosphate salt scale in aqueous systems, which aqueous system comprises low STPP levels (less than 1500 ppm) and to also provide detergent formulations which have good anti-filming performance characteristics when used in machine dishwashing detergents and good anti-encrustation and anti-deposition performance characteristics when used in laundry washing detergents. Accordingly, the present invention provides a method of controlling (poly)phosphate scale comprising treating the aqueous system, which aqueous system comprises low STPP levels (less than 1500 ppm) with at least one copolymer comprising the following monomers in polymerized form:- (I) 50-98% by weight of one or more weak acid; (II) 2-50% by weight of one or more unsaturated sulphonic acid monomer selected from the group consisting of 2-acrylamido methyl-1-propanesulfonic acid, 2-methacrylicamido-2-methyl-1-propanesulphonic acid, 3-methacrylamido-2-hydroxy-propanesulphonic acid, allylsulphonic acid, methallylsulphonic acid, allyloxybenzenesulphonic acid, methallyloxybenzenesulphonic acid, 2-hydroxy-3-(2-propenyloxy)propanesulphonic acid, allylsulphonic acid, methallylsulphonic acid, allyloxybenzenesulphonic acid, methallyloxybenzenesulphonic acid, 2-hydroxy-3- (2-propenyloxy)propanesulphonic acid, 2-methyl-2-propene-1-sulphonic acid, styrene sulphonic acid, vinylsulphonic acid, 3-sulphopropyl acrylate, 3-sulphopropyl methacrylate, sulphomethylacrylamide, sulphomethylmethacrylamide, and water soluble salts thereof. (III) 0-30% by weight of one or more monoethylenically unsaturated C 4 -C 8 dicarboxylic acid; and (IV) 0-30% by weight of one or more monoethylenically unsaturated monomers polymerizable with (I), (II), and (III); wherein the total of monomers (I), (II), (III) and (IV) equals 100% by weight of copolymer. Preferably, the copolymer comprises the following monomers in polymerized form:- (I) 50-98% by weight of one or more monoethylenically unsaturated C 3 to C 6 monocarboxylic acid; (II) 2-50% by weight of one or more unsaturated sulphonic acid; (III) 0-30% by weight of one or more monoethylenically unsaturated C 4 to C 8 dicarboxylic acid; (IV) 0-30% by weight of one or more monoethylenically unsaturated monomer polymerizable with (I), (II), and (III); wherein the total of monomers (I), (II), (III) and (IV) equals 100% by weight of the copolymer. Preferably, the copolymer comprises polymerized units of the following monomers: (I) 50-90% by weight of one or monoethylenically unsaturated C 3 -C 6 monocarboxylic acid; (II) 10-50% by weight of unsaturated sulphonic acid; (III) 0-30% by weight of one or more monoethylenically unsaturated C 4 -C 8 dicarboxylic acid; and (IV) 0-30% by weight of one or more monoethylenically unsaturated monomer polymerizable with (I), (II) and (III), wherein the total of monomers (I), (II) (III) and (IV) equals 100% by weight of the copolymer. Advantageously, the copolymer of the present invention comprises polymerized units of the following monomers:- (I) 60-90% by weight of one or monoethylenically unsaturated C 3 -C 6 monocarboxylic acid (II) 10-40% by weight of the unsaturated sulphonic acid; (III) 0-30% by weight of one or more monomethylenically unsaturated C 4 -C 8 dicarboxylic acid; and (IV) 0-30% by weight of one or more monoethylenically unsaturated monomer polymerizable with (I), (II) and (III), wherein the total of monomers (I), (II) (III) and (IV) equals 100% by weight of the copolymer. A copolymer with particularly good (poly)phosphate scale inhibition properties comprises polymerized units of the following monomers:- (I) 77% by weight of one or monoethylenically unsaturated C 3 -C 6 monocarboxylic acid (II) 23% by weight of the unsaturated sulphonic acid. The monoethylenically unsaturated C 3 -C 6 monocarboxylic acid is preferably (meth)acrylic acid. The monoethylenically unsaturated C 4 -C 8 dicarboxylic acid is preferably maleic acid, and the monoethylenically unsaturated monomer polymerizable with (I), (II) and (III) is preferably selected from one or more of C 1 - C 4 alkyl esters of (meth)acrylic acid; C 1 - C 4 hydroxyalkyl esters of (meth)acrylic acid; acrylamide; alkyl substituted acrylamide; N,N-dialkyl substituted acrylamides; sulphonated alkyl acrylamides; vinylphosphonic acid; vinyl actetate; allyl alcohols; sulphonated allyl alcohols; styrene and similar monomers; acrylonitrile; N-vinylpyrrolidone; N-vinylformamide; N-Vinylimidazole; and N-vinylpyridine. The weight average molecular weight of the copolymer according to the present invention is from 3,000 to 50,000 and preferably from 4,500 to 35,000. The invention will now be further illustrated by the following examples. General Screening Method Polymers according to the present invention were evaluated for calcium tripolyphosphate precipitation inhibition in a phosphate containing automatic dishwashing detergent formulation, and by titrating a 750 ppm STPP solution with incremental levels of water hardness (2/1 Ca ++ /Mg ++ ) at elevated temperatures (55°C) and a fixed polymer concentration (100 ppm). The onset of turbidity was measured utilizing a Brinkmann PC 701 Probe Colorimeter (520nm), and the experiment was concluded with the observation of a visible precipitate. Detergent Formulations Detergent Formulations Component Det. Form 1 Concentration (%) Det. Form 2 Concentration (%) STPP 20.0 35.0 Soda Ash 30.0 22.0 Sodium disilicate (Britesil H20) 12.0 12.0 Sodium citrate dihydrate 10.0 - Sodium perborate .4H 2 O 7.5 7.5 Bleach activator (TAED) 2.5 2.5 Surfactant (SLF-18) 3.5 3.5 Protease 1.0 1.0 Amylase 0.5 0.5 Sodium sulphate 9.0 14.0 Polymer 4.0 2.0 Detergent formulation 1 is a low STPP containing formulation whereas detergent formulation 2 contains a high percentage of STPP. Key to acronyms used herein: Mw = weight average molecular weight. All molecular weights quoted are weight average molecular weight unless otherwise specified. AA = Acrylic acid Mal =Maleic acid AMPS = 2-acrylarnido-2-propane sulphonic acid TBAM = tertbutylacrylamide TOAM = tertoctylacrylamide DMAM = Dimethylacrylamide EA = Ethyl acrylate HPA = Hydroxypropyl acrylate STY = Styrene SMAS = Sodium methallyl sulphonate. MAA = Methyl acrylic acid. Dishwashing Conditions The anti-filming performance in dishwashing applications of polymers according to the present invention were also tested using conventional procedures; under one or either of the following conditions, (A) or (B):- (A) US Washing Conditions Dishwashing machine: Whirlpool model DU 940 Water Hardness: 300 ppm as calcium carbonate (Ca/Mg=3.5:1) No food soil Normal Programme (50°C) No Rinse Aid Dishwares: glasses Cycles: 5 Filming Scores 0.0 = No visible film 2 = Intermediate 0.5 = Barely Perceptible 3 = Moderate 1.0 = Slight 4 = Heavy (B) European Washing Conditions Dishwashing machine: Miele Deluxe model G590 SC Water Hardness: 600 ppm as calcium carbonate (Ca/Mg=3.5:1) No food soil Normal Programme (65°C) No Rinse Aid Dishwares: glasses Cycles: 5 Filming Scores 0.0 = No visible film 2 = Intermediate 0.5 = Barely Perceptible 3 = Moderate 1.0 = Slight 4 = Heavy EXAMPLE 1 The Effect of AMPS Containing Copolymer on the Inhibition of Calcium Tripolyphosphate Copolymer containing solutions were evaluated according to the general screening method described above to give the results shown in Figure 1. In summary, the calcium tripolyphosphate antiprecipitation improves as the level of AMPS in the copolymer increases up to 50% AMPS; at levels greater than 50% AMPS, the inhibition of tripolyphosphate scale starts to decrease. EXAMPLE 2 The Effect of AMPS Containing Copolymer on Filming. Copolymers according to Example 1 were included in various automatic dish washing detergent formulations and were tested under wash conditions (A). Table 2 shows the glass filming scores obtained; these confirm the observation that increasing AMPS levels up to 50% increases inhibition of (poly)phosphate scale. Polymer Molecular Weight Filming Score Det. Form 1 Filming Score Det. Form 2 No Polymer - 3.5 3.0 100AA (Comparative) 2,000 1.5 1.75 100AA (Comparative) 4,500 1.1 2.0 90 AA/10 Mal (Comp) 3,200 1.3 1.75 80 AA/20 Mal (Comp) 16,000 1.2 1.3 70 AA/30 Mal (Comp) 30,000 1.0 2.0 50 AA/50 Mal (Comp) 3,500 1.1 1.2 50 AA/50 Mal (Comp) 25,000 1.1 2 30 AA/70 Mal (Comp) 5,500 1.4 1.2 95 AA/5 EA (Comp) 2,500 1.75 2.5 80 AA/20 EA (Comp) 4,300 1.25 1.1 70 AA/30 MAA (Comp) 3,500 1.1 1.0 77 AA/23 AMPS 4,500 0.5 0.6 60 AA/40 AMPS 10,000 0.5 0.3 77 AA/23 SMAS 6,600 0.8 0.9 60 AA/40 SMAS 3,870 0.3 EXAMPLE 3 The Effect of the Molecular Weight of AMPS Containing Copolymers on the Inhibition of Calcium Tripolvphosphate Copolymer-containing solutions were evaluated according to the general screen method described above to give the results in Figure 2. This Example focuses on the effect of molecular weight of the copolymers at two different AA/AMPS molar ratios. In both cases, increasing the molecular weight of the copolymer significantly enhances the tripolyphosphate antiprecipitation properties of the copolymer. The particle size of the precipitated scale was visibly smaller (higher transmittance) with higher molecular weight analogues. EXAMPLE 4 The Effect of AMPS Containing Terpolymers on the Inhibition of Calcium Tripolyphosphate Solutions containing AA/AMPS/X terpolymers (where X is anther monomer unit which is not AA or AMPS) were tested using the general screening method described above. The results are presented in Figure 3 and from these it is observed that (poly)phosphate scale inhibition by AA/AMPS/X terpolymers, at approximately constant molecular weight, increases with increasing AMPS levels. EXAMPLE 5 The Effect of AA/AMPS/Hydrophobe Terpolymers on the Inhibition of Calcium Tripolyphosphate AA/AMPS/hydrophobe terpolymers were tested using the general screening described above; the results are illustrated in Figure 4. It is observed that AA/AMPS/Hydrophobe terpolymers exhibit favourable calcium phosphate scale inhibition, as compared with the control and comparative samples. EXAMPLE 6 The Effect of AA/AMPS/Hydrophobe Terpolymers on Filming AA/AMPS/Hydrophobe terpolymers were tested in detergent formulations, DF 1 and DF2, under wash conditions (A). The results are given in table 3 below; it is found that AA/AMPS/Hydrophobe terpolymers exhibit favourable (poly)phosphate film inhibition when compared against the control and comparative samples. Polymer Molecular Weight Filming Score Det. Form 1 Filming Score Det. Form 2 No Polymer - 3.5 3.0 100AA (Comparative) 4,500 1.1 2.0 90 AA/10 Mal (Comp) 3,200 1.3 1.75 70 AA/30 Mal (Comp) 30,000 1.0 2.0 50 AA/50 Mal (Comp) 25,000 1.1 2 30 AA/70 Mal (Comp) 5,500 1.4 1.2 95 AA/5 EA (Comp) 2,500 1.75 2.5 70 AA/30 MAA (Comp) 3,500 1.1 1.0 62 AA/23 AMPS/15 TBAM 24,800 0.4 0.5 64.5 AA/27 SMAS/8.5 TBAM 5,130 0.8 64.5 AA/27 SMAS/8.5 TBAM 4,120 1.1 EXAMPLE 7 The Effect of Molecular Weight On AA/AMPS/Hydrophobe Terpolymers on the Inhibition of Calcium Tripolyphosphate Solutions containing AA/AMPS/Hydrophobe terpolymers were tested using the general screening method described above; the results are shown in Figure 5. It is observed that inhibition of calcium tripolyphosphate scale increases as the molecular weight of AMPS containing copolymers increases. EXAMPLE 8 The effect of Various Polycarboxylates on (Poly)phosphate Film Inhibition Using Conditions (B) The (poly)phosphate film performance for a solution containing 15g/ dosagewash of 77AA/23AMPS (Mw 4,500) copolymer was compared against that for a control solution without polymer, and two comparative solutions, one containing 70AA/30MAL (Mw 30,000),and the other containing 100%pAA (Mw 4,500). In all cases, wash conditions (B) were used. The results are shown in Figure 6 and indicate a dramatic increase in (poly)phosphate scale inhibition using the copolymer comprising 77AA/23AMPS as compared with the control and comparative samples.

Claims: Method of controlling (poly)phosphate scale in aqueous systems comprising low sodium tripolyphosphate levels (below 1500 ppm) wherein the method comprises treating said aqueous system with at least one copolymer comprising the following monomers in polymeric form:- (I) 50-98% by weight of one or more weak acid; (II) 2-50% by weight of one or more unsaturated sulphonic acid monomer selected from the group consisting of 2-acrylamido methyl-1-propanesulfonic acid, 2-methacrylicamido-2-methyl-1-propanesulphonic acid, 3-methacrylamido- 2-hydroxy-propanesulphonic acid, allylsulphonic acid, methallylsulphonic acid, allyloxybenzenesulphonic acid, methallyloxybenzenesulphonic acid, 2-hydroxy-3- (2-propenyloxy)propanesulphonic acid, allylsulphonic acid, methallylsulphonic acid, allyloxybenzenesulphonic acid, methallyloxybenzenesulphonic acid, 2-hydroxy-3- (2-propenyloxy)propanesulphonic acid, 2-methyl-2-propene-1-sulphonic acid, styrene sulphonic acid, vinylsulphonic acid, 3-sulphopropyl acrylate, 3-sulphopropyl methacrylate, sulphomethylacrylamide, sulphomethylmethacrylamide, and water soluble salts thereof. (III) 0-30% by weight of one or more monoethylenically unsaturated C 4 -C 8 dicarboxylic acid; and (IV) 0-30% by weight of one or more monoethylenically unsaturated monomers polymerizable with (I), (II) and (III); wherein the total of monomers (I), (II), (III) and (IV) equals 100% by weight of copolymer Method according to Claim 1 wherein the at least one copolymer comprises the following monomers in polymeric form: (I) 50-98% by weight of one or more weak acids selected from the group consisting of monoethylenically unsaturated C 3 to C 6 monocarboxylic acid; (II) 2-50% by weight of one or more strong acids selected from the group consisting of 2-acrylamido methyl-1-propanesulfonic acid, 2-methacrylicamido-2-methyl-1-propanesulphonic acid, 3-methacrylamido- 2-hydroxy-propanesulphonic acid, allylsulphonic acid, methallylsulphonic acid, allyloxybenzenesulphonic acid, methallyloxybenzenesulphonic acid, 2-hydroxy-3- (2-propenyloxy)propanesulphonic acid, allylsulphonic acid, methallylsulphonic acid, allyloxybenzenesulphonic acid, methallyloxybenzenesulphonic acid, 2-hydroxy-3- (2-propenyloxy)propanesulphonic acid, 2-methyl-2-propene-1-sulphonic acid, styrene sulphonic acid, vinylsulphonic acid, 3-sulphopropyl acrylate, 3- sulphopropyl methacrylate, sulphomethylacrylamide, sulphomethylmethacrylamide, and water soluble salts thereof. (III) 0-30% by weight of one or more monoethylenically unsaturated C 4 to C 8 dicarboxylic acid; (IV) 0-30% by weight of one or more monoethylenically unsaturated monomer polymerizable with (I), (II) and (III); wherein the total of monomers (I), (II), (III) and (IV) equals 100% by weight of the copolymer. Method according to Claim 1 or 2 wherein the copolymer comprises the following monomers in polymeric form: (I) 50-90% by weight of one of weak acids selected from the group consisting of monoethylenically unsaturated C 3 -C 6 monocarboxylic acid; (II) 10-50% by weight of one or more unsaturated sulphonic acid selected from the group consisting of 2-acrylamido methyl-1-propanesulfonic acid, 2-methacrylicamido-2-methyl-1-propanesulphonic acid, 3-methacrylamido- 2-hydroxy-propanesulphonic acid, allylsulphonic acid, methallylsulphonic acid, allyloxybenzenesulphonic acid, methallyloxybenzenesulphonic acid, 2-hydroxy-3- (2-propenyloxy)propanesulphonic acid, allylsulphonic acid, methallylsulphonic acid, allyloxybenzenesulphonic acid, methallyloxybenzenesulphonic acid, 2-hydroxy-3- (2-propenyloxy)propanesulphonic acid, 2-methyl-2-propene-1-sulphonic acid, styrene sulphonic acid, vinylsulphonic acid, 3-sulphopropyl acrylate, 3-sulphopropyl methacrylate, sulphomethylacrylamide, sulphomethylmethacrylamide, and water soluble salts thereof. (III) 0-30% by weight of one or more monoethylenically unsaturated C 4 -C 8 dicarboxylic acid; and (IV) 0-30% by weight of one or more monoethylenically unsaturated monomer polymerizable with (I), (II) and (III), wherein the total of monomers (I), (II) (III) and (IV) equals 100% by weight of the copolymer. Method according to Claim 1 wherein the copolymer comprises the following monomers in polymerized form: (I) 60-90% by weight of one or monoethylenically unsaturated C 3 -C 6 monocarboxylic acid (II) 10-40% by weight of an unsaturated sulphonic acid selected from the group consisting of 2-acrylamido methyl-1-propanesulfonic acid, 2-methacrylicamido-2-methyl-1-propanesulphonic acid, 3-methacrylamido-2-hydroxy-propanesulphonic acid, allylsulphonic acid, methallylsulphonic acid, allyloxybenzenesulphonic acid, methallyloxybenzenesulphonic acid, 2-hydroxy-3-(2-propenyloxy)propanesulphonic acid, allylsulphonic acid, methallylsulphonic acid, allyloxybenzenesulphonic acid, methallyloxybenzenesulphonic acid, 2-hydroxy-3-(2-propenyloxy)propanesulphonic acid, 2-methyl-2-propene-1-sulphonic acid, styrene sulphonic acid, vinylsulphonic acid, 3-sulphopropyl acrylate, 3-sulphopropyl methacrylate, sulphomethylacrylamide, sulphomethylmethacrylamide, and water soluble salts thereof. (III) 0-30% by weight of one or more monoethylenically unsaturated C 4 -C 8 dicarboxylic acid; and (IV) 0-30% by weight of one or more monoethylenically unsaturated monomer polymerizable with (I), (II) and (III), wherein the total of monomers (I), (II) (III) and (IV) equals 100% by weight of the copolymer. Method according to Claim 2 wherein the monoethylenically unsaturated C 3 -C 6 monocarboxylic acid is selected from group consisting of one or more of acrylic acid and methacrylic acid. Method according to Claim 1 wherein the monoethylenically unsaturated C 4 -C 8 dicarboxylic acid is maleic acid, and the monoethylenically unsaturated monomer polymerizable with (I), (II) and (III) is selected from the group consisting of C 1 -C 4 alkyl esters of (meth)acrylic acid; C 1 -C 4 hydroxalkyl esters of (meth)acrylic acid; acrylamide; alkyl substituted acrylamide; N,N-dialkyl substituted acrylamides; sulphonated alkyl acrylamides; vinylphosphonic acid; vinyl acetate; allyl alcohols, sulphonated allyl alcohols; acrylonitrile; N-vinylpyrrolidone; N-vinylformamide; N-vinylimidazole; and N-vinylpyridine.

Inventors: DUCCINI YVES, GAUTHIER FRANCOIS, KEENAN ANDREA, SHULMAN JAN, WEINSTEIN BARRY, DUCCINI, YVES, GAUTHIER, FRANCOIS, KEENAN, ANDREA, SHULMAN, JAN, WEINSTEIN, BARRY
Applicants: ROHM & HAAS, ROHM AND HAAS COMPANY
Application year: 1998
Main classification: C02F5
IPC codes: C02F5, C11D3