ASA Emulsion Production Without Recirculation Loop
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Solution Overview
Problem
Existing methods for manufacturing succinic alkenyl anhydride (ASA) emulsions in aqueous solutions of cationic starchy materials require recirculation loops for effective particle size distribution and stability, which can lead to temperature increases and potential hydrolysis issues, as well as interactions with surfactants.
Innovation Solution
A process that eliminates the recirculation loop by adjusting the dry matter content of the cationic starchy material solution between 5.5% and 11.5%, allowing for a single pass through the emulsification unit and maintaining stable particle sizes, avoiding hydrolysis and surfactant interactions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a recirculation loop is used in the emulsification unit, then the particle size distribution and stability of the ASA emulsion are improved, but temperature increases occur which can lead to hydrolysis of ASA
Solution Approach 1:
The invention extracts and removes the recirculation loop from the emulsification system. By eliminating the recirculation path, the system avoids the temperature increase that occurs during repeated circulation, thereby preventing ASA hydrolysis while still achieving the desired particle size distribution through a single pass emulsification process
Solution Approach 2:
The invention performs preliminary optimization of emulsification parameters (such as emulsifier concentration, mixing speed, and feed rate ratios) before the emulsification process begins. This preliminary preparation enables the system to achieve stable particle size distribution (80% of particles between 0.5-2.0 μm) in a single pass without requiring recirculation, thus avoiding temperature-related hydrolysis
2Stability of the object's composition
If surfactants are added to increase ASA dispersibility, then the emulsion stability is improved, but negative interactions with ASA occur
Solution Approach 1:
The invention changes the chemical parameter of the emulsifying agent by selecting specific cationic starchy materials with particular molecular weights and charge densities. These parameter changes allow the starch to provide effective emulsification and stability without the harmful interactions that occur with conventional surfactants, achieving both emulsion stability and compatibility with ASA
Solution Approach 2:
The invention introduces cationic starchy material as an intermediary substance between ASA and water. This intermediary provides the necessary emulsification and stabilization functions while being chemically compatible with ASA, avoiding the negative interactions that occur when conventional surfactants are used directly with ASA
3Manufacturing precision
If the particle size is reduced to improve bonding performance, then the hydrophobic properties are enhanced, but coarse particles cause clogging and fine particles pass through the fibrous mat
Solution Approach 1:
The invention changes multiple parameters simultaneously: emulsifier concentration (5-15% dry matter), mixing speed (10,000-20,000 rpm), and feed rate ratio (ASA to starch solution). These coordinated parameter changes produce a monodisperse particle size distribution where 80% of particles fall within the optimal 0.5-2.0 μm range, preventing both clogging by coarse particles and loss of fine particles through the fibrous mat
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process achieves a narrow, monodisperse particle size distribution centered between 1 µm and 1.5 µm, enhancing the emulsion's performance as a bonding agent in paper production while maintaining stability and preventing hydrolysis, and allows for the use of surfactants without adverse effects.
Implementation Method 1
the function of such compositions is to avoid the coalescence of the ASA particles by positive ionization of the surface of the particles, and to bring the ASA particles closer to the fibers by an ionic mechanism
Implementation Method 2
bring the ASA particles closer to the fibers by an ionic mechanism
Implementation Method 3
The emulsion thus manufactured has a particle size that is both fine and monodisperse
Data Source
AI summary
The present invention relates to a method for producing an emulsion of ASA in an aqueous solution of a cationic amylaceous substance, without having to use a loop for recirculating the product at the emulsification unit. The produced emulsion is characterized by both a fine and monodisperse particle size, and no overheating is involved that could lead to negative phenomena of hydrolyzing the ASA. The invention further relates to the corresponding production device.