Acylation Process for Starch Derivatives
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Solution Overview
Problem
The physical properties of acylated polymer compositions, such as acylated starch, are difficult to control in the acylation process, leading to inconsistent results.
Innovation Solution
The process involves pre-treating a polymer composition comprising amylose and/or amylopectin with an aqueous phase containing an acid with a pKa of 4.8 or less, an enzyme, a salt, and a polycarboxylic acid, followed by reaction with an acylating agent and additional treatment with an acid to control viscosity and degree of substitution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional acylation process is used, then acylated polymer composition is produced, but physical properties are difficult to control
Solution Approach 1:
The patent applies preliminary action by pre-treating the starch with an aqueous phase containing acid, enzyme, salt, and polycarboxylic acid before acylation. This pre-treatment modifies the starch structure in advance, creating a more reactive and accessible substrate for the subsequent acylation reaction, thereby enabling better control over the physical properties of the final product.
Solution Approach 2:
The patent utilizes parameter changes by adjusting multiple process parameters including pH (through acid addition), temperature, reaction time, and the composition of the aqueous phase. These parameter changes during pre-treatment and acylation allow precise control over the degree of substitution and viscosity of the acylated polymer composition.
2Manufacturing precision
If pre-treatment with aqueous phase is added, then viscosity control is improved, but process steps increase
Solution Approach 1:
The patent merges multiple functions into the pre-treatment step: the aqueous phase simultaneously performs swelling of starch granules, partial hydrolysis, and preparation for acylation. This combination of functions in a single step achieves viscosity control without proportionally increasing process complexity.
Solution Approach 2:
The pre-treatment step utilizes parameter changes in the aqueous phase composition (acid concentration, enzyme type, salt content, polycarboxylic acid addition) to control the swelling and partial hydrolysis of starch, thereby achieving desired viscosity characteristics before acylation occurs.
3Manufacturing precision
If multiple additives are used in pre-treatment, then degree of substitution control is improved, but manufacturing complexity increases
Solution Approach 1:
The aqueous phase serves multiple universal functions: it acts as a swelling agent, provides acidic conditions for hydrolysis, supplies ions from salts, and includes polycarboxylic acids for additional structural modification. This multi-functionality allows control over degree of substitution while consolidating multiple roles into a single treatment step.
Solution Approach 2:
The aqueous phase acts as an intermediary medium that facilitates the interaction between starch and the acylating agent. The combination of acid, enzyme, salt, and polycarboxylic acid in this intermediary phase prepares the starch in a controlled manner, enabling precise control over the degree of substitution during subsequent acylation.
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
This process effectively controls the physical properties of acylated polymer compositions, achieving a viscosity of 77 mPas or greater and a degree of substitution between 2.1 and 2.9, while also improving ethanol tolerance.
Implementation Method 1
The pre-treatment step in the process allows for efficient swelling of the polymer composition
Implementation Method 2
reacting the pre-treated polymer composition with an acylating agent to provide an acylated polymer composition
Implementation Method 3
reacting the acylated polymer with at least one acid A' with a pKa of equal to or less than 4.8 at 25°C, in the presence of water. In step (c) according to the process in of the preferred embodiment, a partial hydrolysis takes place
Data Source
AI summary
The invention concerns a process for the manufacture of an acylated polymer composition comprising amylose and/or amylopectin, comprising a pre-treatment step in the presence of an acid, a salt and a polycarboxylic acid, subsequent acylation and, preferably, a post-treatment step with an acid. The products obtained are useful as additives in inks, varnishes, lacquers, coatings, thickeners, adhesives or binders.