Polypropylene Glycol and Phenyl Ether Blend for Mining Foam Control
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Solution Overview
Problem
Excessive foaming in mining flotation processes is a challenge due to the use of highly viscous and flammable volatile organic solvents, which negatively impacts efficiency, safety, and environmental sustainability.
Innovation Solution
A blend of polypropylene glycols with weight average molecular weights between 3000 to 5000 grams/mole and dipropylene glycol phenyl ethers or diethylene glycol phenyl ethers, with viscosities below 400 cSt at 25°C and 200 cSt at 40°C, and a flash point above 60.5°C, providing non-flammable foam control properties for mining processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If highly viscous polypropylene glycol is used to control foam, then foam control performance is improved, but viscosity becomes too high for practical use
Solution Approach 1:
The patent divides the single high molecular weight polypropylene glycol into multiple segments with different molecular weights (300-1000, 1000-3000, and 3000-5000 g/mol ranges). This segmentation allows the blend to achieve both high foam control performance and acceptable viscosity by combining the advantages of different molecular weight fractions.
Solution Approach 2:
The patent changes the molecular weight parameters of the polypropylene glycol components, specifying weight average molecular weights in the range of 3000-5000 g/mol and blending ratios that result in viscosity ≤400 cSt at 25°C. This parameter optimization resolves the contradiction between foam control efficacy and operational ease.
2Ease of operation
If volatile organic solvents are used to dilute polypropylene glycol, then viscosity is reduced for easier handling, but flammability and safety risks increase
Solution Approach 1:
The patent converts the harmful flammability of organic solvents into a benefit by using the phenyl ether group's natural fire-resistant properties. The phenyl ether-containing compound serves as both a viscosity reducer and a flame retardant, eliminating the need for flammable diluents while maintaining handling ease.
Solution Approach 2:
The patent changes the chemical composition parameters by incorporating phenyl ether groups (specifically dipropylene glycol phenyl ether or diethylene glycol phenyl ether) into the blend formulation. This compositional change achieves the desired viscosity reduction while simultaneously eliminating flammability, as the blend attains a flash point >60.5°C.
3Reliability
If high molecular weight polypropylene glycol is used, then foam control efficacy is improved, but handling and safety become more difficult
Solution Approach 1:
The patent segments the high molecular weight polypropylene glycol into a blend of multiple fractions with weight average molecular weights specifically in the 3000-5000 g/mol range. This segmentation maintains the foam control efficacy of high molecular weight polymers while reducing the viscosity to ≤400 cSt at 25°C, thereby improving handling properties.
Solution Approach 2:
The patent creates a composite material system by blending polypropylene glycol with phenyl ether-containing compounds. This composite approach combines the foam control benefits of high molecular weight polypropylene glycol with the flow improvement and fire resistance of phenyl ethers, achieving both effective foam control and ease of handling.
Data Source
AI summary
A blend comprising from 1 to 99 weight percent one or more polypropylene glycols wherein each polypropylene glycol has a weight average molecular weight of greater than or equal to 1000 grams/mole and from 1 to 99 weight percent one or more dipropylene glycol phenyl ethers and/or diethylene glycol phenyl ethers wherein the blend has a viscosity (ASTM D445, @ 25 °C) of less than or equal to 400 cSt and viscosity (ASTM D445, @ 40 °C) of less than or equal to 200 cSt, is provided. Processes using the blend in mining applications are also provided.