Partially Saponified Rice Bran Wax Oxidates for Acid Number Control
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Solution Overview
Problem
Existing methods for preparing rice bran wax oxidates involve high acid numbers and additional esterification steps, leading to inconsistent product quality and process inefficiencies.
Innovation Solution
A process involving the oxidation of rice bran wax with a mixture of chromium trioxide and sulfuric acid, followed by saponification without additional alcohol addition, to produce partly saponified rice bran wax oxidates with a high proportion of genuine esters, eliminating the need for esterification and achieving high thermal stability and light color.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If chromic acid oxidation is used to bleach natural waxes, then light color is achieved, but acid number increases to high levels (130-160 mg KOH/g)
Solution Approach 1:
The patent applies partial saponification (50-80% conversion) after chromic acid oxidation to reduce the acid number from high levels (130-160 mg KOH/g) to controlled levels (20-60 mg KOH/g), while maintaining the light color achieved through oxidation. This partial action principle allows selective reduction of excess acid without completely reversing the beneficial oxidation effects.
Solution Approach 2:
The patent changes the chemical state of free wax acids by converting them to salts through saponification with basic metal salts, thereby transforming the harmful high acid number into a controlled parameter range while preserving the light color property achieved during oxidation.
2Adaptability or versatility
If esterification with polyvalent alcohols is performed to adapt products, then desired property profile is achieved, but process complexity increases due to additional steps
Solution Approach 1:
The patent performs saponification as a preliminary action after oxidation and before final product formulation. This preliminary saponification step prepares the wax oxidate with controlled acid number and improved properties, eliminating or reducing the need for subsequent esterification steps with polyvalent alcohols, thereby simplifying the overall process.
Solution Approach 2:
The patent extracts or removes the need for complex esterification steps by using saponification to achieve the desired property profile directly. The saponification process alone can adapt the product properties without requiring additional esterification with polyvalent alcohols, thus taking out the unnecessary process steps.
3Quantity of substance
If complete saponification is performed to reduce acid number, then acid number decreases, but genuine ester content decreases and product quality becomes inconsistent
Solution Approach 1:
The patent applies partial saponification with controlled conversion rates of 50-80%, which is optimal for reducing acid number to 20-60 mg KOH/g while preserving 30-70% genuine esters. This partial action avoids complete saponification that would destroy genuine esters, maintaining both low acid number and high genuine ester content for consistent product quality.
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 results in partly saponified rice bran wax oxidates with high thermal stability, consistent quality, and a light color, suitable for various applications without the need for additional esterification steps.
Implementation Method 1
The oxidation of fossil and nonfossil natural waxes with chromosulfuric acid has been known since the early 20th century... Oxidation with chromic acid results essentially in cleavage of the wax esters and in situ oxidation of the wax alcohols formed to give wax acids.
Implementation Method 2
saponifying the rice bran wax oxidate (O), optionally in purified form, by reacting it with a basic salt, preferably a basic metal salt... The acid number level is a measure of the content of free wax acids.
Data Source
AI summary
The invention relates to partially saponified rice bran wax oxidates, to a process for the production of these products and to their use for agriculture or forestry purposes, as an additive in plastics processing, in care products, in printing inks and/or in paints.