ASA Paper Sizing Emulsion Stability via In Situ Anionic Emulsifiers

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Solution Overview

Problem

Current methods for forming an alkenylsuccinic anhydride (ASA) emulsion on-site in paper production are costly due to the need for high shearing forces and result in low sizing efficiency and instability, especially when using hot starch, which complicates the process and increases costs.

Innovation Solution

A composition using an emulsifier system with alkali metal salts of aliphatic carboxylic acids as anionic emulsifiers and polyethylene glycols (PEG) as nonionic components, allowing for emulsification with low shearing forces and improved stability, with the anionic emulsifier formed in situ by adding alkali metal hydroxide to ASA and dissolving PEG at elevated temperatures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If high shearing forces are used to form ASA emulsion on-site, then emulsion formation is achieved, but costs increase and sizing efficiency decreases

Engineering Contradiction:
Improveemulsion stabilityVSAvoidemulsifying unit costs
Core Design Contradiction:
ReliabilityVSEase of manufacture

Solution Approach 1:

The patent applies preliminary action by pre-forming the ASA emulsion at the producer site before transport to the customer. This eliminates the need for on-site emulsification equipment and high shearing forces, while ensuring the emulsion maintains its stability during storage and application.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The patent uses a specific emulsifier system as an intermediary substance to stabilize the ASA emulsion. This emulsifier system enables the emulsion to remain stable during transport and storage without requiring high shearing forces for formation, thus reducing equipment costs while maintaining reliability.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Quantity of substance

If ASA is transported as pure substance, then transport costs are reduced, but emulsification equipment and costs are required at customer site

Engineering Contradiction:
Improvetransport efficiencyVSAvoidemulsifying unit
Core Design Contradiction:
Quantity of substanceVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by pre-forming the ASA emulsion at the producer site before transport to the customer. This eliminates the need for on-site emulsification equipment and high shearing forces, while ensuring the emulsion maintains its stability during storage and application.

Inventive Principle:
Principle #10Preliminary action

3Ease of manufacture

If conventional emulsifier systems are used with ASA, then emulsion formation is possible, but sizing efficiency is low and stability is poor especially with hot starch

Engineering Contradiction:
Improveemulsion formationVSAvoidsizing efficiency
Core Design Contradiction:
Ease of manufactureVSReliability

Solution Approach 1:

The patent applies parameter changes by optimizing the emulsifier system composition and the emulsification process parameters. This results in an emulsion with improved stability and sizing efficiency that can be used with hot starch without requiring continuous cooling, thus maintaining reliability while ease of manufacture.

Inventive Principle:
Principle #35Parameter changes

4Adaptability or versatility

If continuous cooling of starch is implemented, then hot starch can be used with ASA, but process complexity and installation costs increase

Engineering Contradiction:
Improvestarch temperature compatibilityVSAvoidcooling system
Core Design Contradiction:
Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent converts the harmful effect of hot starch (which causes ASA emulsion instability) into a benefit by developing a specially formulated emulsifier system that not only tolerates but benefits from higher temperatures. This eliminates the need for cooling systems while improving the overall process efficiency and allowing the use of hot starch for better paper sizing performance.

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

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 composition achieves high sizing efficiency and stability with reduced costs by using low shearing forces, maintaining performance even after storage, and providing a concentrate that can be easily diluted for use, resulting in improved water resistance and particle size control in paper sizing.

Implementation Method 1

the formation of an aqueous sizing emulsion containing an alkenylsuccinic anhydride component in the absence of high shearing forces

Methodology Applied
Scientific EffectEmulsion: Emulsion

Implementation Method 2

an emulsifier system of anionic emulsifiers and nonionic components

Methodology Applied
Scientific EffectSurfactant: Surfactant

Implementation Method 3

since ASA is sensitive to hydrolysis, the emulsion must be formed directly on site at the papermaking machine

Methodology Applied
Scientific EffectHydrolysis: Hydrolysis

Data Source

PatentUS10513828B2Composition for sizing paper
Publication Date: 2019.12.24 KEMIRA CHEM

AI summary

A composition for sizing paper includes alkenylsuccinic anhydride (ASA) as the sizing agent and an emulsifier system of anionic emulsifiers and nonionic components, wherein the anionic emulsifiers are chosen from alkali metal salts of aliphatic carboxylic acids or aliphatic dicarboxylic acids and the nonionic components are chosen from polyethylene glycols.