Processes to make phosphate salt containing products
First Claim
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1. A continuous process for producing an oil based phosphate containing product, the continuous process comprising:
- mixing a predetermined amount of water, [Y]OH, [Z]OH, and AcOH in a first mixer to create a base stream, wherein [Y] is a cation and [Z] is selected from the group consisting of NH4, NHOH and an amine;
mixing the base stream with an orthophosphoric acid using a second mixer to create a liquid phosphate salt containing solution, wherein the orthophosphoric acid is selected from the group consisting of [Y]H2PO4, [Y]HPO4, [NH4]2HPO4, and combinations thereof, wherein [Y] is a cation;
determining pH of the liquid phosphate salt containing solution and comparing the pH of the liquid phosphate salt containing solution to a predetermined liquid phosphate pH value;
providing means for adjusting the pH of the liquid phosphate salt containing solution operable to modify the pH of the liquid phosphate salt containing solution within a preselected range of the predetermined liquid phosphate pH value;
drying and granulating the liquid phosphate salt containing solution to create a water based vapor stream and a substantially water-free solid phosphoric salt product, the substantially water-free solid phosphoric salt product consisting of a plurality of particles and the plurality of particles having a size distribution of particles, a substantial amount of the particles having a diameter smaller than about 100 nanometers;
mixing the substantially water-free solid phosphoric salt product with a base stock hydrocarbon using a high shear mixer to form an oil based phosphate containing product; and
conducting all of the above steps as a continuous process.
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Abstract
The present invention provides a continuous process for producing an oil based phosphate containing product. The continuous process includes mixing water with at least one base and an orthophosphoric acid to produce a liquid phosphate salt containing solution. This solution is then dried, granulated, and mixed with a base stock hydrocarbon to form the oil based phosphate containing product.
3 Citations
18 Claims
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1. A continuous process for producing an oil based phosphate containing product, the continuous process comprising:
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mixing a predetermined amount of water, [Y]OH, [Z]OH, and AcOH in a first mixer to create a base stream, wherein [Y] is a cation and [Z] is selected from the group consisting of NH4, NHOH and an amine; mixing the base stream with an orthophosphoric acid using a second mixer to create a liquid phosphate salt containing solution, wherein the orthophosphoric acid is selected from the group consisting of [Y]H2PO4, [Y]HPO4, [NH4]2HPO4, and combinations thereof, wherein [Y] is a cation; determining pH of the liquid phosphate salt containing solution and comparing the pH of the liquid phosphate salt containing solution to a predetermined liquid phosphate pH value; providing means for adjusting the pH of the liquid phosphate salt containing solution operable to modify the pH of the liquid phosphate salt containing solution within a preselected range of the predetermined liquid phosphate pH value; drying and granulating the liquid phosphate salt containing solution to create a water based vapor stream and a substantially water-free solid phosphoric salt product, the substantially water-free solid phosphoric salt product consisting of a plurality of particles and the plurality of particles having a size distribution of particles, a substantial amount of the particles having a diameter smaller than about 100 nanometers; mixing the substantially water-free solid phosphoric salt product with a base stock hydrocarbon using a high shear mixer to form an oil based phosphate containing product; and conducting all of the above steps as a continuous process. - View Dependent Claims (2, 3, 4, 5, 6)
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7. A continuous process for producing an oil based phosphate containing product, the continuous process comprising:
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mixing a predetermined amount of water, [Y]OH, [Z]OH, and AcOH in a first mixer to create a base stream, wherein [Y] is a cation and [Z] is selected from the group consisting of NH4, NHOH and an amine; mixing the base stream with an orthophosphoric acid using a second mixer to create a liquid phosphate salt containing solution, wherein the orthophosphoric acid is selected from the group consisting of [Y]H2PO4, [Y]HPO4, [NH4]2HPO4, and combinations thereof, wherein [Y] is a cation; determining pH of the liquid phosphate salt containing solution and comparing the pH of the liquid phosphate salt containing solution to a predetermined liquid phosphate pH value; providing means for adjusting the pH of the liquid phosphate salt containing solution operable to modify the pH of the liquid phosphate salt containing solution within a preselected range of the predetermined liquid phosphate pH value; mixing the liquid phosphate salt containing solution with a base stock hydrocarbon using a wet high shear mixer to form an emulsified water-in-oil mixture; drying the emulsified water-in-oil mixture to create a water based vapor stream and a substantially water-reduced emulsified mixture, wherein the substantially water-reduced emulsified mixture contains an effective amount of water to promote water of hydration; determining the water content of the substantially water-reduced emulsified mixture using a water content analyzer and comparing the water content of the substantially water-reduced emulsified mixture to a predetermined water value; providing means for adjusting the water content of the substantially water-reduced emulsified mixture operable to modify the water content of the substantially water-reduced emulsified mixture within a preselected range of the predetermined water value; grinding the substantially water-reduced emulsified mixture to produce an oil based phosphate containing product, the oil based phosphate containing product consisting of a plurality of particles and the plurality of particles having a size distribution of particles, a substantial amount of the particles having a diameter smaller than about 100 nanometers; and conducting all of the above steps as a continuous process. - View Dependent Claims (8, 9, 10, 11, 12)
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13. A continuous process for producing an oil based phosphate containing product, the continuous process comprising:
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mixing a predetermined amount of water with salts in a first mixer to form an intermediate solution, the salts are selected from the group consisting of [Z]2B4O7, [Y]H2PO4, [Y]2HPO4, [NH4]2HPO4, [X]C2H3O2, [NR4]2HPO4, [Y]2NH4PO4, [Y][NH4]2PO4, and combinations thereof, wherein [Z] is a cation;
wherein [Y] is a cation;
[X] is selected from the group consisting of a cation, NH4, and combinations thereof; and
R is selected from the group consisting of hydrogen, alkyl groups and combinations thereof;determining pH of the intermediate mixture and comparing the pH of the intermediate mixture to a predetermined liquid phosphate pH value; providing means for adjusting the pH of the intermediate mixture operable to modify the pH of the intermediate mixture within a preselected range of the predetermined liquid phosphate pH value; drying and granulating the intermediate mixture at a temperature within a preset temperature range to create a water based vapor stream and a substantially water-free solid phosphoric salt product, the substantially water-free solid phosphoric salt product consisting of a plurality of particles and the plurality of particles having a size distribution of particles, a substantial amount of the particles having a diameter smaller than about 100 nanometers; mixing the substantially water-free solid phosphoric salt product with a base stock hydrocarbon using a high shear mixer to form an oil based phosphate containing product; and conducting all of the above steps as a continuous process. - View Dependent Claims (14, 15)
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16. A continuous process for producing an oil based phosphate containing product, the continuous process comprising:
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mixing a predetermined amount of water with salts to form an intermediate solution, the salts are selected from the group consisting of [Z]2B4O7, [Y]H2PO4, [Y]2HPO4, [NH4]2HPO4, [X]C2H3O2, [NR4]2HPO4, [Y]2NH4PO4, [Y][NH4]2PO4, and combinations thereof, wherein [Z] is a cation;
wherein [Y] is a cation;
[X] is selected from the group consisting of a cation, NH4, and combinations thereof; and
R is selected from the group consisting of hydrogen, alkyl groups and combinations thereof;determining pH of the intermediate mixture and comparing the pH of the intermediate mixture to a predetermined liquid phosphate pH value; providing means for adjusting the pH of the intermediate mixture operable to modify the pH of the intermediate mixture within a preselected range of the predetermined liquid phosphate pH value; mixing the intermediate mixture with a base stock hydrocarbon using a wet high shear mixer to form an emulsified water-in-oil mixture; drying the emulsified water-in-oil mixture at a temperature within a preset temperature range to create a water based vapor stream and a substantially water-reduced emulsified mixture, wherein the substantially water-reduced emulsified mixture contains an effective amount of water to promote water of hydration; determining the water content of the substantially water-reduced emulsified mixture using a water content analyzer and comparing the water content of the substantially water-reduced emulsified mixture to a predetermined water value; providing means for adjusting the water content of the substantially water-reduced emulsified mixture operable to modify the water content of the substantially water-reduced emulsified mixture within a preselected range of the predetermined water value; grinding the substantially water-reduced emulsified mixture to produce an oil based phosphate containing product, the oil based phosphate containing product consisting of a plurality of particles and the plurality of particles having a size distribution of particles, a substantial amount of the particles having a diameter smaller than about 100 nanometers; and conducting all of the above steps as a continuous process. - View Dependent Claims (17, 18)
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Specification