BR112020019796A2 - METHOD TO DISINTEGRATE THE CASTING MOLD, COMPOSITION, AND, USE OF THE COMPOSITION - Google Patents

Abstract

method for disintegrating the casting mold, composition, and, use of the composition the present invention relates to a method of disintegrating a casting mold comprising sand and a polyurethane binder. the present invention further relates to a method of disintegrating a casting mold by contact with a composition comprising at least one carboxylic acid amide and at least one alkanolamine.

Description

1/44 METHOD TO DISINTEGRATE THE CASTING MOLD, COMPOSITION, AND, USE OF THE COMPOSITION

FIELD OF THE INVENTION

[001] The present invention relates to a method of disintegrating a foundry mold that comprises sand and a polyurethane binder. The present invention also relates to a method of disintegrating a casting mold by contact with a composition comprising at least one carboxylic acid amide and at least one alkanolamine.

BACKGROUND OF THE INVENTION

[002] All foundries produce castings by pouring molten metal into molds. The most common type of casting process is known as sand casting. Sand is used in two different ways in metal casting: as a molding material, which forms the outer shape of the casting, and as taps, which form internal voids in products such as engine blocks. Since the grains of sand do not naturally adhere to each other, binders must be introduced to make the sand stick and maintain its shape during the introduction of the molten metal into the mold and the cooling of the melt.

[003] Sand casting involves manufacturing a pattern of the component to be cast and compacting sand around the pattern to produce a hollow mold. The molds are usually made in two halves to facilitate the removal of the pattern, and then the molds are assembled to form a “cavity” that matches the pattern's shape. Males made of compacted sand with special binders can be inserted into a mold, prior to assembly, to form interior surfaces for complex shapes. The molten metal is poured into the mold cavity and allowed to solidify and cool. The foundry is shaken from the sand mold using

2/44 vibrating machines, mechanically cleaned of foreign metals by cutting or grinding and blasting cleaning to remove molten sand and other contaminants from the surface. The foundry industry generates a series of by-products, of which the largest volume is “spent sand” consisting of sand with binder residues. In addition, sand casting generates metal melting and casting waste and molding processes. It is standard practice for the foundry to reuse molding sands and cores. Residual sand is routinely filtered and returned to the system for reuse.

[004] Various methods are employed to clean the molten metal in sand molds that involves both mechanical and chemical actions. The first category includes abrasive cleaning methods, such as sandblasting. Chemical cleaning methods that are available to the industry, however, produce cleaner castings than previous mechanical procedures. This is because a large number of problems are caused by the retention of granular sand in the foundry due to the adhesive properties of the decomposition products of organic binders. In such cases, adherent sand particles are immune to removal by abrasive cleaning methods and can only be removed by attacking and dissolving the residual siliceous particles with a chemical reagent. In addition, in the event that the sand molds are maintained by the binders, the sand molds can be disintegrated by treating them with the compositions or chemicals that dissolve the synthetic binders, and the sand can then be processed and reused.

[005] US 2,666,001 describes the removal of residual sand from the mold by immersion in a liquid bath comprising a strongly acidic solution of fluorophosphoric acid followed by neutralization. Fluorophosphoric acid being highly toxic and corrosive is difficult to implement the process on a large scale.

[006] US 2,766,496 describes a cleaning process

3/44 of used foundry sand which comprises the steps of sifting the sand in the presence of water to remove oversized adventitious material, fluidizing the sand with a jet of water and passing it to relatively quiescent sedimentation zones where loose carbonaceous impurities float out. The disadvantage of the process is that large volumes of water waste are generated.

[007] US 4,411,709 describes the removal of resin-bonded sand molds and sand cores and the reconditioning of sand for reuse by heating the resin-bonded molding sand and core sand to a temperature sufficient to be capable of pyrolyzing resin binders in sand. However, the process leads to the generation of carbonaceous residues that are difficult to remove.

[008] Therefore, it is an objective of the present invention, while avoiding the above mentioned disadvantages and other disadvantages, to provide a method that is acceptable in both technical and economic aspects for the reconditioning of used sand (foundry). It is also an object of the present invention to provide a method for disintegrating the sand present in the form of a sand mold and / or sand core from a metal foundry, in order to recover the sand for later use.

SUMMARY OF THE INVENTION

[009] Surprisingly, it was found that the goals could be achieved by treating the casting mold with a composition comprising a carboxylic acid amide and an alkanolamine. The sand obtained by this method can be reused with minimal steps for further processing.

[0010] Thus, in one aspect, the presently claimed invention is directed to a method for disintegrating a foundry mold comprising sand and a polyurethane binder comprising the step of

4/44 (i) contacting the casting mold with a composition comprising (a) at least one carboxylic acid amide of general formula (I) in which R1 denotes straight or branched C2-C22 alkyl, unsubstituted or substituted with hydroxy R2 and R3, independently of each other, denote H or straight or branched C1-C12 alkyl, unsubstituted or substituted; and (b) at least one alkanolamine of general formula (II) in which AO is identical or different selected from the group consisting of CH2-CH2-O, CH (CH3) -CH2-O, CH2-CH (CH3) -O, CH (C2H5) -CH- O, C (CH3) 2-CH2-O, CHC (CH3) 2-O and CH2-CH (C2H5) -, m is 1, 2, 3, 4, 5, 6 or 7, ex, y, independently of each other, are 0 or 1 to obtain a mixture of the sand and the polyurethane binder.

[0011] In another aspect, the presently claimed invention is directed to a composition comprising (a) 2-hydroxypropanamide; and (b) monoethanolamine

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[0012] In another aspect, the presently claimed invention is directed to a composition comprising (a) at least one carboxylic acid amide of general formula (I) in which R1 denotes straight or branched, unsubstituted C2-C12 alkyl R2 and R3 denote methyl; and (b) monoethanolamine.

[0013] In yet another aspect, the invention currently claimed is directed to the use of the composition comprising (a) 2-hydroxypropanamide; and (b) monoethanolamine to disintegrate the casting mold.

[0014] In yet another aspect, the presently claimed invention is directed to a method for disintegrating the foundry mold comprising sand and a polyurethane binder comprising the step of (i) contacting the foundry mold with a composition comprising (a) ) 2-hydroxypropanamide; and (b) monoethanolamine; to obtain a mixture of the sand and the polyurethane binder.

DETAILED DESCRIPTION OF THE INVENTION

[0015] Before the present compositions and formulations of the invention

6/44 are described, it should be understood that this invention is not limited to the particular compositions and formulations described, since such compositions and formulations can, of course, vary. It should also be understood that the terminology used here is not intended to be limiting, since the scope of the present invention will be limited only by the appended claims.

[0016] If from now on a group is defined as comprising at least a certain number of modalities, this also includes a group which, preferably, consists only of those modalities. In addition, the terms "first", "second", "third" or "(a)", "(b)", "(c)", "(d)" etc. and similar in the specification and in the claims, are used to distinguish between similar elements and not necessarily to describe a sequential or chronological order. It should be understood that the terms thus used are interchangeable in appropriate circumstances and that the modalities of the invention described herein are capable of operating in sequences other than those described or illustrated here. In the case of the terms "first", "second", "third" or "(A)", "(B)", "(C)" or "(a)", "(b)", "(c) ”,“ (D) ”,“ i ”,“ ii ”etc. refer to the steps of a method or use or test, there is no consistency of time or time interval between the steps, that is, the steps can be performed simultaneously or there may be time intervals of seconds, minutes, hours, days, weeks, months or even years between these steps, unless otherwise indicated in the order as set out above or below.

[0017] In the following passages, different aspects of the invention are defined in more detail. Each aspect thus defined can be combined with any other aspect or aspects, unless clearly indicated to the contrary. In particular, any characteristic indicated as being preferred or advantageous can be combined with any other characteristic or characteristics indicated as being preferred or advantageous.

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[0018] The reference throughout this specification to "a modality" or "a modality" means that a particular resource, structure or feature described in connection with the modality is included in at least one modality of the present invention. Thus, the appearance of the phrases "in one modality" or "in one modality" or "in another modality" in various places throughout this specification does not necessarily refer to the same modality, but it can. In addition, particular features, structures or characteristics can be combined in any suitable manner, as would be apparent to one skilled in the art from this description, in one or more modalities. In addition, although some modalities described herein include some, but not other characteristics included in other modalities, combinations of characteristics of different modalities must be within the scope of the invention and form different modalities, as would be understood by those in the art.

[0019] In one aspect, the invention currently claimed relates to a method for disintegrating the foundry mold comprising sand and a polyurethane binder comprising the step of (i) contacting the foundry mold with a composition comprising (a ) at least one carboxylic acid amide of general formula (I) in which R1 denotes straight or branched C2-C22 alkyl, unsubstituted or substituted with hydroxy

8/44 R2 and R3, independently of each other, denote H or straight or branched C1-C12 alkyl, unsubstituted or substituted; and (b) at least one alkanolamine of general formula (II) in which AO is identical or different selected from the group consisting of CH2-CH2-O, CH (CH3) -CH2-O, CH2-CH (CH3) -O, CH (C2H5) -CH- O, C (CH3) 2-CH2-O, CHC (CH3) 2-O and CH2-CH (C2H5) -O m is 1, 2, 3, 4, 5, 6 or 7, ex, y, independently of each other, are 0 or 1 to obtain a mixture of the sand and the polyurethane binder.

[0020] For the purposes of the invention currently claimed, the term "disintegration" includes the cleaning of foundry molds of residual sand and binder that are left on them after the molding process. In addition, it also covers the “complete breaking of the casting mold”, in which the sand and binder are separated and the sand can be recycled. Consequently, a mixture of sand and binder refers to a mixture in which sand and binder are present in the form of discrete materials.

[0021] ‘Foundry mold’ here refers to molds made of sand and binder.

[0022] ‘Contact’ denotes the immersion of the foundry mold in the composition. It can also include adding the composition to a metal mold. When the casting mold is immersed in the composition, it disintegrates in sand and binder. In the event that the composition is added to a metal mold, it is made to clean the metal mold from the residual mixture of sand and binder after the molding process.

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[0023] For the purposes of the invention currently claimed, the term "C1-C12-alkyl" encompasses residues of saturated acyclic hydrocarbons, which can be linear or branched and not substituted or at least monosubstituted with, as in the case of C1- alkyl. C12, 1 to 12 (i.e., 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11 or 12) carbon atoms. Likewise, the term "C2-C22-alkyl" includes residues of saturated acyclic hydrocarbons, which can be linear or branched and not substituted or at least monosubstituted with, as in the case of C2-C32-alkyl, 2 to 22 (or i.e., 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21 or 22) carbon atoms. If one or more of the substituents denote an alkyl residue that is mono- or polysubstituted, it can preferably be substituted with optionally 1, 2, 3, 4 or 5, particularly preferably with 1, 2 or 3, mutually independent substituents selected from the group consisting of F, Cl, Br, I, -NO2, -CN, -OH, -SH, -NH2, -N (C1-5-alkyl) 2, -N (C1-5-OH) 2, -N (C1-5 alkyl) (phenyl), -N (C1-5 alkyl) (CH2-phenyl), -N (C1-5 alkyl) (CH2-CH2-phenyl), -C (═O ) -H, -C (═O) -C1-5alkyl, -C (═O) -phenyl, -C (═S) -C1-5alkyl, -C (═S) -phenyl, -C (═O) -OH, -C (═O) -O- C1-5alkyl) 2, -S (═O) -C1-5alkyl, -S (═O) -phenyl, -S (═ O) 2-C1-5-alkyl, -S (═O) 2-phenyl, -S (═O) 2-NH2 and -SO3H, wherein the above-mentioned C1-5-alkyl residues can be linear or branched and the phenyl residues indicated above can preferably be substituted by 1, 2, 3, 4 or 5 substituents mutually independently selected from the group consisting of F, Cl, Br, I, -CN, -CF3, -OH, -NH2, -O- CF3, -SH, -O-CH3, -O-C2H5, -O-C3H7, methyl, ethyl, n-propyl, isopropyl, n-butyl , 2-butyl, isobutyl and tert-butyl. Particularly preferred substituents can be selected mutually regardless of the group consisting of F, Cl, Br, I, -NO2, -CN, -OH, -SH, -NH2, -N (CH3) 2, -N (C2H5) 2 and - N (CH3) (C2H5). As used here, “branched” denotes a chain of atoms with one or more side chains attached to it. Branching occurs

10/44 by replacing a substituent, for example, a hydrogen atom, with a covalently bonded alkyl radical. CARBOXYLIC ACID AMIDE OF GENERAL FORMULA (I)

[0024] The carboxylic acid amide of general formula (I) has the following structure in which R1 denotes straight or branched C2-C22 alkyl, unsubstituted or substituted with hydroxy R2 and R3, independently of one another, denote H or C1 alkyl -C12 linear or branched, unsubstituted or substituted.

[0025] Preferably, R1 is selected from the group consisting of ethyl, n-propyl, n-butyl, n-pentyl, n-hexyl, n-heptyla, n-octyl, n-nonyl, n-decyl, n-undecyl, n-dodecyl, n-tridecyl, n-tetradecyl, n-pentadecyl, n-hexadecyl, n-heptadecyl, n-octadecyl, n-nonadecyl, n-eicosyl, n-heneicosila, n-docosyl, isopropyl, isobutyl, isopentyl, isohexyl, isoheptyl, isooctyl, isononyl, isodecyl, isoundecyl, isododecyl, isotridecyl, isotetradecyl, isopentadecyl, isohexadecyl, iso-heptadecyl, isoocadecyl, isoocadecyl, isonocadecyl, iso heptadecyl, isooctadecyl, isononadecyl, isoeicosyl, iso-henicosyl, isodocosyl, t-butyl, 1-hydroxyethyl, 1-hydroxypropyl, 2-hydroxypropyl, 1-hydroxybutyl, 2-hydroxybutyl, 2-hydroxybutyl, 1-hydroxypentyl, 2-hydroxypentyl, 2-hydroxypentyl, 2-hydroxypentyl, 2-hydroxy 3-hydroxypentyl, 4-hydroxypentyl, 1-hydroxyhexyl, 2-hydroxyhexyl, 3-hydroxyhexyl, 4-hydroxyhexyl and 5-hydroxyhexyl.

[0026] More preferably, R1 is selected from the group that

11/44 consists of ethyl, n-propyl, n-butyl, n-pentyl, n-hexyl, n-heptyl, n-octyl, n-nonyl, n-decyl, isooctyl, isononyl, isodecyl, isopropyl, isobutyl, isopentyl , isohexyl, isoheptyl, isodecyl, 1-hydroxyethyl, 1-hydroxypropyl, 2-hydroxypropyl, 1-hydroxybutyl, 2-hydroxybutyl, 2-hydroxybutyl, 1-hydroxypentyl, 2-hydroxypentyl, 3-hydroxypentyl, 4-hydroxypentyl, 4-hydroxypentyl , 1-hydroxyhexyl, 2-hydroxyhexyl, 3-hydroxyhexyl, 4-hydroxyhexyl and 5-hydroxyhexyl. More preferably, R1 is selected from the group consisting of n-octyl, n-nonyl, n-decyl, isooctyl, isononyl, isodecyl and 1-hydroxyethyl. Particularly preferable, R1 is 1-hydroxyethyl.

[0027] In one embodiment, R2 and R3, independently of each other, are selected from the group consisting of H, methyl, ethyl, n-propyl, n-butyl, n-pentyl, n-hexyl, n-heptyl , n-octyl, n-nonyl, n-decyl, n- undecyl, n-dodecyl, isopropyl, isobutyl, isopentyl, isohexyl, isoheptyl, isooctyl, isononyl, isodecyl, isoundecyl, isododecyl and t-butyl.

[0028] In a preferred embodiment, R2 and R3, independently of each other, are selected from the group consisting of H, methyl, ethyl, n-propyl, n-butyl, isopropyl, isobutyl and t-butyl.

[0029] More preferably, R2 and R3 independently of each other, are selected from the group consisting of methyl, ethyl and n-propyl.

[0030] In a particularly preferred embodiment, R2 and R3 are methyl.

[0031] Consequently, in one embodiment, the compound of the general formula (I) is 2-hydroxypropanamide.

[0032] Suitable carboxylic acid amides are known and are commercially available under the trade names Agnique® AMD 3L, Agnique® AMD10 and Agnique® AMD 810 from BASF SE.

[0033] In a preferred embodiment, the invention currently claimed relates to a method for disintegrating the foundry mold that

12/44 comprises sand and a polyurethane binder comprising the step of (i) contacting the casting mold with a composition comprising (a) 2-hydroxypropanamide; and (b) at least one alkanolamine of general formula (II) in which AO is identical or different selected from the group consisting of CH2-CH2-O, CH (CH3) -CH2-O, CH2-CH (CH3) -O, CH (C2H5) -CH- O, C (CH3) 2-CH2-O, CHC (CH3) 2-O and CH2-CH (C2H5) -O, m is 1, 2, 3, 4, 5 , 6 or 7, ex, y independently of each other are 0 or 1; to obtain a mixture of the sand and the polyurethane binder. ALKANOLAMINE OF GENERAL FORMULA (II)

[0034] The alkanolamine of general formula (II) has the following structure in which AO is identical or different selected from the group consisting of CH2-CH2-O, CH (CH3) -CH2-O, CH2-CH (CH3 ) -O, CH (C2H5) -CH-O, C (CH3) 2-CH2-O, CHC (CH3) 2-O and CH2-CH (C2H5) -O; m is 1, 2, 3, 4, 5, 6 or 7, and x, y, independently of each other, are 0 or 1.

[0035] Preferably m is 1, 2 or 3, more preferably m is 2.

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[0036] Preferably, x and y are both 0.

[0037] Consequently, in one embodiment, the compound of general formula (II) is monoethanolamine.

[0038] In a preferred embodiment, the invention currently claimed relates to a method for disintegrating the foundry mold comprising sand and a polyurethane binder comprising the step of (i) contacting the foundry mold with a composition comprising (a) ) at least one carboxylic acid amide of general formula (I) in which R1 denotes straight or branched C2-C22 alkyl, unsubstituted or substituted with hydroxy R2 and R3, independently of one another, denote H or linear C1-C12 alkyl or branched, unsubstituted or substituted; and (b) monoethanolamine; to obtain a mixture of the sand and the polyurethane binder.

SAND

[0039] The sand is selected from the group consisting of natural silica sand, clay, green sand, quartz sand, chromite sand, olivine sand, special sands and zirconium sand.

[0040] Silica sand in the form of granular quarters is the main constituent of molding sand with sufficient refractoriness that it can

14/44 to provide resistance, stability and permeability to molding and core sand. But along with silica, small amounts of iron oxide, alumina, limestone (CaCO3), magnesia, soda and potassium are present as impurities. The chemical composition of silica sand gives an idea of impurities such as lime, magnesia, alkali, etc. gifts. The presence of excessive amounts of iron oxide, alkaline oxides and lime can decrease the melting point to a considerable extent, which is undesirable. Silica sand can be specified according to the size of the sand grain and the shape (angular, sub-angular and rounded) of the sand.

[0041] Clay sand is a mixture of natural silica sand, clay, additives and water. The clay used to make wet clay sand is bentonite clay. The compressive strength is generally 0.05 to 0.1 MPa. The water content is 3.5 to 5%.

[0042] Areia Verde is a mixture of silica sand, chromite sand or zirconia sand, bentonite (clay), inert sludge, anthracite, sometimes with a proportion of olivine, staurolite or graphite.

[0043] Quartz sand contains mainly SiO2 crystalline silica and additional mineral contents, such as feldspars, clay minerals, mica minerals, as well as carbonate and carbonaceous components. The suitability of quartz grains as a molding material is mainly determined by the SiO2 content. The higher the content, that is, the less additions of low melting point compounds, the more favorable the sand will behave in relation to high thermal loads.

[0044] Chromite sand is a naturally occurring spinel that consists mainly of chromium and iron oxides.

[0045] Olivine sand is mainly composed of silica, magnesium oxide, iron oxide and aluminum oxide. It has a low rate of thermal expansion compared to silica sand.

[0046] Special sands include natural mineral sands, products

15/44 of sintering and melting produced in granular form or transformed into granular form by breaking, grinding and classification processes, or inorganic mineral sands produced by other physical-chemical methods. Special sands are different from quartz sand, mainly due to its significantly lower thermal expansion behavior in the temperature range of 20 to 600 ° C, its thermal conductivity, refractoriness and other physical characteristics.

[0047] Preferably, the sand is silica sand or special sand.

POLYURETHANE-BASED BINDERS

[0048] Polyurethane-based binders are polyurethane-based binders that may also include, in addition to polyurethane, components such as water glass (sodium silicate) and resins such as formaldehyde phenol, formaldehyde urea and furan resins.

[0049] Polyurethanes are formed from polyhydroxylated compounds and polyisocyanates. Polyhydroxylated compounds, in turn, are commonly prepared from phenols and formaldehyde. The polyhydroxylated component can be any organic hydroxy compound having a functionality of two or more that is soluble in the employed solvents. Such polyhydroxylated compounds can include simple aliphatic polyols, amine polyols, polyether polyols, phenolic resins and mixtures thereof.

[0050] Amine polyols are normally produced as the reaction product of an alkylene oxide and an amine compound. In general, any polyol containing at least one or more tertiary amine groups is considered to be within the scope of the definition of "amine polyol". Amine compounds that react with alkylene oxides to produce amine polyols include ammonia and mono- and polyamine compounds with primary or secondary amino nitrogen. Specific examples include aliphatic amines, such as primary alkyl amines, ethylene diamine, diethylene triamine and triethylene tetramine, amines

16/44 cycloaliphatic, aromatic amines, such as ortho-, meta- and para-phenylene diamines and aniline formaldehyde resins.

[0051] The phenols used in the formation of such phenolic resins are generally any of the phenols that can be used in the formation of phenolic resins. Specific suitable phenols that can be used include phenol, o-cresol, m-cresol, p-cresol, 2,5-xylenol, 3,4-xylenol, 3,5-xylenol, 3,4,5-trimethylphenol, 2- ethylphenol, 3-ethylphenol, 3,5-diethylphenol, o-sec-butylphenol, p-butylphenol, 3,5-dibutylphenol, p-amylphenol, p-cyclohexylphenol, o-octylphenol, o-sec-decylphenol, nonylphenol, 3,5-dicyclohexylphenol, p-phenylphenol, p-crotylphenol, 2-methoxyphenol, 3,5-dimethoxyphenol, 3,4,5-trimethoxyphenol, p-ethoxyphenol, 3-methyl-4-methoxyphenol and p-phenoxyphenol.

[0052] Furan resins that are used for casting binders are generally prepared from the reaction of furfuryl alcohol with urea-formaldehyde resins, or with formaldehyde, to obtain low viscosity, soluble, fusible resins. In some cases, phenolic resins or other modifiers are added to furan resins.

[0053] The aldehyde used in the formation of the phenolic resin and furan component includes any of the aldehydes hitherto used in the formation of phenolic resins, such as formaldehyde, acetaldehyde, propionaldehyde, furfuraldehyde and benzaldehyde.

[0054] The isocyanate component that can be used in a binder can have a functionality of 2 or more. Exemplary isocyanates are organic polyisocyanates, such as tolylene-2,4-diisocyanate, tolylene-2,6-diisocyanate and mixtures thereof, and particularly their crude mixtures which are commercially available. Other typical polyisocyanates include methylene-bis- (4-phenylisocyanate), n-hexyl diisocyanate, naphthalene-1,5-diisocyanate, cyclopentylene-1,3-diisocyanate, p-phenylene diisocyanate, tolylene-2,4,6- triisocyanate and triphenylmethane-4,4 ', 4 ”-triisocyanate. Superior isocyanates are provided by the liquid reaction products of (1)

17/44 diisocyanates and (2) polyols or polyamines and the like. In addition, isothiocyanates and mixtures of isocyanates can be used. Also contemplated are the many impure or crude polyisocyanates that are commercially available. The isocyanate component may additionally contain a chlorosilane compound selected from the group consisting of trimethylchlorosilane, dimethyldichlorosilane, methyltrichlorosilane, tetrachlorosilane, dietichlorosilane, vinyltrichlorosilane and diphenyldichlorosilane.

[0055] Other commonly used additives can optionally be used in the binder. The use of such materials can increase the adhesion of the binder to the aggregate material. Examples of additives include, but are not limited to, amino silanes, epoxy silanes, mercapto silanes, hydroxysilanes and ureido silanes, such as, for example, gamma-aminopropyltrimethoxysilane, gamma-hydroxypropyltrimethoxysilane, 3-ureidopropyl triethoxysilane, gamma-mercapto-propyltrimethoxysilane gamma-glycidoxypropyltrimethoxysilane, beta- (3,4-epoxycyclohexyl) trimethoxysilane and N-beta- (aminoethyl gamma-aminopropyltrimethoxysilane.

SURFACES

[0056] In one embodiment, the composition that is used according to the invention currently claimed further comprises at least one surfactant. The at least one surfactant is selected from the group consisting of anionic surfactant, cationic surfactant, non-ionic surfactant and amphoteric surfactant.

[0057] Suitable anionic surfactants are selected from the group consisting of alkyl sulfate salt, alkyl ether sulfate, α-olefin sulfonate and linear alkyl benzene sulfonate.

[0058] Alkyl sulfates are composed of the formula: ROSO3-M + where

18/44 R denotes straight or branched С6-С22 alkyl, unsubstituted, М denotes alkali metal or ammonium cation

[0059] For the purposes of the invention currently claimed, the term "C6-C22-alkyl" embraces residues of saturated acyclic hydrocarbons, which can be linear or branched and not substituted with 6 to 22 carbon atoms.

[0060] Alkyl sulfates are obtained by sulfating the upper alcohols (carbon atoms C6-C22) produced from tallow glycerides, coconut oil, suitable vegetable oil or synthetic alcohols followed by neutralization with alkaline hydroxide. Thus, alkyl sulfates also contain by-products of the reaction, such as free salt (eg, sodium chloride is the by-product of free salt, when the neutralizing agent is sodium hydroxide), free fatty alcohol, fatty alcohol salt. Therefore, the solid content of the alkyl sulfate will be different from the active content. The active content denotes "the amount of alkyl sulfate" present in the composition, while the solid content denotes "a total of alkyl sulfate, fatty alcohol, fatty alcohol salt and free salt" in the composition. “Free” here denotes that the salt is not linked to fatty alcohol / alkyl sulfate by any type of chemical bond.

[0061] Alkyl ether sulfates are composed of the formula R'-О- (С2Н4О) n-SОзМ where R 'denotes straight or branched С6-С22 alkyl, unsubstituted, n is 1 to 20 М denotes alkali metal or ammonium cation

[0062] Alkyl ether sulfates are produced by the ethoxylation of fatty alcohol and therefore will generally be obtained in the form of mixtures comprising various lengths of alkyl chain and varying degrees of ethoxylation. Often, such mixtures will inevitably contain some non-ethoxylated alkyl sulfates.

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[0063] α-olefin sulfonates are generally produced by α-olefin sulfonation. Α-olefins, which are sulfonated to form the surfactants used in the compositions of the present invention, can contain from about 10 to 22 carbon atoms and preferably 12 to 18 carbon atoms. They can be derived from a variety of processes, such as, for example, by cracking the wax, forming ethylene or dehydrating the corresponding primary alcohol. Exemplary alpha-olefins are 1-decene, 1-undecene, 1-dodcene, 1-tridecene, 1-tetradecene, 1-pentadecene, 1-hexadecene, 1-heptadecene, 1-octadecene and the like and mixtures of the above. Sulphonation of these long-chain olefins is usually carried out using sulfur trioxide mixed with a diluent. After the sulfonation is complete, the neutralization and hydrolysis of the acid mixture is carried out so that any by-products of sultones that are formed are converted into the corresponding hydroxyalkanesulfonates. Thus, as is well known in the art, the term α-olefin sulfonates, as used herein, includes not only the alkenesulfonate itself, but also mixtures of the same formed as a result of the usual sulfonation neutralization and hydrolysis procedure with substantial proportions of corresponding water-soluble hydroxyalkane sulfonates.

[0064] Linear alkyl benzene sulfonate (LABS) is produced by sulfonation of linear alkyl benzene (LAB) and subsequent neutralization of the corresponding sulfonic acid (HLAS). Linear alkylbenzene is synthesized by the alkylation of benzene with linear olefins. Traditional processes for alkylating aromatic compounds use Friedel-Craft type catalysts, for example, hydrofluoric acid, aluminum trichloride and the like.

[0065] The anionic surfactant may also include alkylamide sulfates of formula R4CONHR5OSO3M where

20/44 R4 denotes a C2-C22 alkyl R5 radical C2-C3 alkyl, M is a hydrogen atom or an alkali metal cation or ethoxylenated (EO) and / or propoxylenated (PO) derivatives thereof, containing an average of 0 , 5 to 60 EO and / or PO units;

[0066] Other anionic surfactants are, salts of C8-C24 fatty acids, saturated or unsaturated, alkyl glyceryl sulfonates, paraffin sulfonates, N-acyl N-alkyltaurates, alkyl phosphates, isethionates, alkyl succinamates, alkyl sulfosuccinates, sulfosuccinate monoesters or diesters, N-acyl sarcosinates, alkyl glycoside sulfates, polyethoxycarboxylates, the cation being an alkali metal (sodium, potassium or lithium), a substituted or unsubstituted ammonium residue (methyl-, dimethyl-, trimethyl- or tetramethylammonium, dimethylpiperidinium, etc.) or an alkanolamine derivative (monoethanolamine, diethanolamine, triethanolamine, etc.) and alkyl or alkylaryl phosphate esters.

[0067] Cationic surfactants are a well-known group of surfactant compounds that have at least one active cationic constituent (positive ion). As the cationic surfactant, quaternary ammonium hydroxides such as octltrimethylammonium hydroxide, dodecyltrimethylammonium hydroxide, hexadecyltrimethylammonium hydroxide, octyldimethylbutylammonium hydroxide, dihydimethyl hydroxide, dihydroethyl hydroxide, dihydroethyl hydroxide, dihydroxy hydroxide trimethylammonium from coconut oil, and its salts can be exemplified.

[0068] Examples of amphoteric surfactants include betaines, sulfobetaines and carboxylates and sulfonates of fatty acids and imidazole, such as alkyldimethylbetaines, alkylamidopropyl dimethylbetaines, alkyldimethylsulfobetaines or alkylamidopropyl dimethylsulfobetaines, such as the products by Mirataine

21/44 condensation of fatty acids and protein hydrolysates; alkyl amphacetates or alkyl amphodiacetates in which the alkyl group contains 6 to 20 carbon atoms; amphoteric alkyl polyamine derivatives, such as Amphionic XL® sold by Rhodia and Ampholac 7T / X® and Ampholac 7C / X® sold by Berol Nobel.

[0069] The at least one surfactant is preferably a non-ionic surfactant.

[0070] The at least one nonionic surfactant is selected from the group consisting of mono- (C8-C22) -alkyl ether of poly (C2-C4) alkylene glycol, ester of mono- (C8-C22) -carboxylic acid poly (C2-C4) alkylene glycol, alkoxylated oil and alkoxylated alkylamine.

[0071] The mono- (C8-C22) -alkyl ether of poly (C2-C4) alkylene glycol is preferably mono- (C8-C22) -alkyl ether of poly (C2-C3) alkylene glycol.

Preferred mono- (C8-C22) -alkyl poly (C2-C3) alkylene glycol ethers are preferably compounds of the formula R6- (O-CH2-CH2) q (O-CH (CH3) -CH2) r-OH where R6 is straight or branched C8-C22-alkyl; q is a natural number from 1 to 50; and r is 0 or is a natural number from 1 to 30, with the proviso that 2 ≤ q + r ≤ 50.

[0073] In a preferred embodiment, the mono- (C8-C22) -alkyl ether of poly (C2-C3) alkylene glycol are preferably compounds of the formula R6- (O-CH2-CH2) q (O-CH (CH3) -CH2) r-OH where R6 is straight or branched C8-C22-alkyl; q is a natural number from 1 to 15; and r is 0 or is a natural number from 1 to 20, with the proviso that 2 ≤ q + r ≤ 30.

22/44

[0074] In the context of the present invention, the term "alkyl", as used herein, refers to acyclic saturated aliphatic residues, including straight or branched alkyl residues. In addition, the alkyl residue is unsubstituted and includes, as in the case of C8-C22 alkyl, 8 to 22 carbon atoms.

[0075] Representative examples of straight and branched C8-C22 alkyl include, but are not limited to, n-octyl, n-nonyl, n-decyl, n-undecyl, n-dodecyl, n-tridecyl, n-tetradecyl, n -pentadecyl, n-hexadecyl, n-heptadecyl, n-octadecyl, n-nonadecyl, n-eicosyl, n-henicosyl, n-docosyl, 2-ethylhexyl, 2-propylheptyla, 2-butyl-1-octyl , 2-pentyl-1-nonyl, isooctyl, isodecyl, isoundecyl, isododecyl, isotridecyl, isotetradecyl, isopentadecyl, isohexadecyl, isoheptadecyl, isooctadecyl, isononadecyl, isoeicosyl, isohydylates, and isohydyls.

[0076] The mono- (C8-C22) alkyl ether of poly (C2-C4) alkylene glycol has a molecular weight of 300 g / mol to 2000 g / mol determined by 1 H-NMR spectroscopy using, for example, a spectrometer 400 MHz per Bruker. The molecular weight can be determined by integrating the signals from the poly (C2-C4) alkylene glycol structure and by comparing this integral with the integral of the mono- (C8-C22) -alkyl signals.

[0077] Poly (C2-C4) alkylene glycol mono- (C8-C22) -alkyl ether can be prepared by alkoxylation of fatty alcohol. When the fatty alcohol R1-OH which is used for the synthesis of mono- (C8-C22) -alkyl ether of poly (C2-C4) alkylene glycol is derived from a natural source, it is common to have mixtures, for example, alcohols C16 and C18 or C12 and C14 alcohols. Fatty alcohol R1-OH can also be synthesized (for example, by oxo process) from mixtures of olefins and, in this case, it is common to have mixtures, for example, of C13 and C15 alcohols.

[0078] Suitable mono- (C8-C22) -alkyl ether of suitable poly (C2-C4) alkylene glycol is known and commercially available, for example,

23/44 Lutensol® XL from BASF SE.

[0079] The mono- (C8-C22) -carboxylic acid ester of poly (C2-C4) alkylene glycol are preferably compounds of the formula R6-CO- (O-CH2-CH2) q (O-CH (CH3) - CH2) r-R7 where R6 is straight or branched C8-C22 alkyl; R7 is H or straight or branched C1-C8 alkyl; q is a natural number from 1 to 50; and r is 0 or is a natural number from 1 to 30, with the proviso that 2 ≤ q + r ≤ 50

[0080] Representative examples of straight or branched C8-C22 alkyl include, but are not limited to, n-octyl, n-nonyl, n-decyl, n-undecyl, n-dodecyl, n-tridecyl, n-tetradecyl, n -pentadecyl, n-hexadecyl, n-heptadecyl, n-octadecyl, n-nonadecyl, n-eicosyl, n-henicosyl, n-docosyl, 2-ethylhexyl, 2-propylheptyla, 2-butyl-1-octyl , 2-pentyl-1-nonyl, isooctyl, isodecyl, isoundecyl, isododecyl, isotridecyl, isotetradecyl, isopentadecyl, isohexadecyl, iso-heptadecyl, isooctadecyl, isononadecyl, isoeicosyl, isodicyl, and isoeneic.

[0081] Representative examples of straight or branched C1-C8 alkyl include, but are not limited to, methyl, ethyl, n-propyl, n-butyl, n-pentyl, n-hexyl, n-heptyl, n-octyl, isopropyl , isobutyl, isopentyl, isohexyl, isoheptyl, isooctyl, t-butyl, 2-ethylhexyl and isomers thereof.

[0082] The mono- (C8-C22) -carboxylic acid esters of poly (C2-C4) alkylene glycol have a molecular weight of 300 to 2000 determined by 1 H-NMR spectroscopy using, for example, a 400 MHz spectrometer Bruker. The molecular weight can be determined by integrating the poly (C2-C4) alkylene glycol backbone signals and by comparing this integral with the integral of the mono- (C8-C22) -alkyl signals.

[0083] The alkoxylated oil is preferably an ethoxylated oil, more

24/44 preferably an ethoxylated derivative of castor oil with a hydrophilic / lipophilic balance of about 14 (HLB 14), such as Emulan® EL.

[0084] Alkoxylated alkylamines are preferably compounds of the formula wherein R is straight or branched, substituted or unsubstituted C8-C22-alkyl or straight or branched, substituted or unsubstituted C8-C22-alkenyl; AO is identical or different selected from the group consisting of CH2-CH2-O, CH (CH3) -CH2-O, CH2-CH (CH3) -O, CH (C2H5) -CH- O, C (CH3) 2-CH2-O, CHC (CH3) 2-O and CH2-CH (C2H5) -O, a is a natural number from 1 to 20; and b is a natural number from 1 to 20, with the proviso that 2 ≤ a + b ≤ 40.

[0085] For the purpose of the invention currently claimed, the term "alkenyl" encompasses unsaturated acyclic hydrocarbon residues, which can be linear or branched and unsubstituted or at least monosubstituted and comprise at least one double bond, preferably 1, 2 or 3 double bonds, with, as in the case of C8-C22 alkenyl, 8 to 22 (ie 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21 , 22) carbon atoms. If one or more of the substituents denote an alkenyl residue that is mono- or polysubstituted, it can preferably be substituted with optionally 1, 2, 3, 4 or 5, particularly preferably with 1, 2 or 3, mutually independently selected substituents from group consisting of F, Cl, Br, I, -NO2, -CN, -OH, -SH, -NH2, -N (C1-5alkyl) 2, -N (C1-5alkyl) (phenyl ), -N (C1-5alkyl) (CH2-phenyl), -N (C1-5alkyl)

25/44 (CH2-CH2-phenyl), -C (═O) -H, -C (═O) -C1-5alkyl, -C (═O) -phenyl, -C (═S) - alkyl -C1-5, -C (═S) -phenyl, -C (═O) -OH, -C (═O) -O-C1-5 alkyl, -C (═O) -O- phenyl, - C (═O) -NH2, -C (═O) -NH-C1-5 alkyl, -C (═O) -N (C1-5 alkyl) 2, - S (═O) -C1 alkyl -5, -S (═O) -phenyl, -S (═O) 2-C1-5-alkyl, -S (═O) 2-phenyl, - S (═O) 2-NH2 and -SO3H, in that the aforementioned C1-5 alkyl residues can in each case be linear or branched and the phenyl residues indicated above can preferably be substituted by 1, 2, 3, 4 or 5 substituents mutually independently selected from the group consisting of in F, Cl, Br, I, -CN, -CF3, -OH, -NH2, -O- CF3, -SH, -O-CH3, -O-C2H5, -O-C3H7, methyl, ethyl, n- propyl, isopropyl, n-butyl, 2-butyl, isobutyl and tert-butyl. Particularly preferred substituents can be selected mutually regardless of the group consisting of F, Cl, Br, I, -NO2, -CN, -OH, -SH, -NH2, -N (CH3) 2, -N (C2H5) 2 and -N (CH3) (C2H5).

[0086] Preferably, R is linear unsubstituted C8-C22 alkenyl; AO is CH2-CH2-O, a is a natural number from 1 to 10; b is a natural number from 1 to 10, with the proviso that 5 ≤ a + b ≤ 20.

[0087] More preferably, alkoxylated alkylamine is ethoxylated alkylamine and more preferably oleylamine ethoxylated.

[0088] Suitable alkoxylated alkylamine is known and commercially available, for example, Lutensol® FA12 from BASF SE.

[0089] Particularly preferred, the non-ionic surfactant is selected from polyethylene glycol alkyl ether, ethoxylated castor oil and oleylamine ethoxylate.

[0090] In a preferred embodiment, the invention currently claimed relates to a method for disintegrating the foundry mold comprising sand and a polyurethane binder comprising the step of (i) contacting the foundry mold with a composition comprising ( a) at least one carboxylic acid amide of the formula

26/44 general (I) in which R1 denotes straight or branched C2-C22 alkyl, unsubstituted or substituted with hydroxy R2 and R3, independently of one another, denote H or straight or branched, unsubstituted C1-C12 alkyl replaced; (b) at least one alkanolamine of general formula (II) in which AO is identical or different selected from the group consisting of CH2-CH2-O, CH (CH3) -CH2-O, CH2-CH (CH3) - O, CH (C2H5) -CH- O, C (CH3) 2-CH2-O, CHC (CH3) 2-O and CH2-CH (C2H5) -O, m is 1, 2, 3, 4, 5, 6 or 7, ex, y independently of each other are 0 or 1; and (c) at least one non-ionic surfactant; to obtain a mixture of the sand and the polyurethane binder.

[0091] In another preferred embodiment, the invention currently claimed relates to a method for disintegrating the foundry mold comprising sand and a polyurethane binder comprising the step of (i) contacting the foundry mold with a composition comprising ( a) at least one carboxylic acid amide of general formula (I)

27/44 where R1 denotes straight or branched C2-C22 alkyl, unsubstituted or substituted with hydroxy R2 and R3, independently of each other, denote H or straight or branched C1-C12 alkyl, unsubstituted or substituted; (b) at least one alkanolamine of general formula (II) in which AO is identical or different selected from the group consisting of CH2-CH2-O, CH (CH3) -CH2-O, CH2-CH (CH3) - O, CH (C2H5) -CH- O, C (CH3) 2-CH2-O, CHC (CH3) 2-O and CH2-CH (C2H5) -O, m is 1, 2, 3, 4, 5, 6 or 7, ex, y independently of each other are 0 or 1; and (c) at least one nonionic surfactant selected from the group consisting of poly (C8-C22) -alkyl poly (C2-C4) alkylene glycol ether, poly- (C8-C22) -carboxylic acid ester (C2-C4) alkylene glycol, alkoxylated oil and alkoxylated alkylamine; to obtain a mixture of the sand and the polyurethane binder.

WATER

[0092] In a preferred embodiment, the composition that is used according to the present invention does not contain water. In another preferred embodiment, water is added to the composition. The amount of water, if

28/44 added to the composition, is in the range of 0.1% by weight to 12.0% by weight, based on the total weight of the composition. The disintegration of the casting mold takes longer, in the range of 100 minutes to 180 minutes when the composition contains water, compared to the composition without water.

ADDITIONS

[0093] The casting mold may also comprise at least one additive. Additives are the materials usually added to the mixture of sand and binder to develop some special properties in the sand. Some additives commonly used to improve the molding properties and core sands are coal dust, corn flour, dextrin, marine coal, tar, wood flour, silica flour.

COAL POWDER

[0094] The coal dust is added mainly to produce a reducing atmosphere during the casting process. This reducing atmosphere causes any oxygen at the poles to become chemically bonded, so that it cannot oxidize the metal. It is usually added to the molding sands to make molds for the production of gray cast iron and malleable castings.

CORNFLOUR

[0095] Corn flour belongs to the starch family of carbohydrates and is used to increase the ability to collapse from molding sand and core. It is completely volatilized by the heat in the sand mold, leaving space between the sand grains. This allows the free movement of the sand grains, which finally gives rise to the movement of the mold wall and reduces the expansion of the mold and, therefore, defects in the castings. Corn sand, if added to molding sand and core sand, significantly improves mold and core strength.

DEXTRIN

[0096] Dextrin also belongs to the carbohydrate family of

29/44 starch, which also behaves similarly to corn flour. Dextrin increases the dry resistance of molds.

MARINE COAL

[0097] Marine coal is a fine-powdered bituminous coal that positions its place between the pores of the silica sand grains in the molding sand and in the male sand. When heated, marine coal becomes coke, which fills pores and is unaffected by water. Because of this, the grains of sand are restricted and cannot move in a dense packaging pattern. Thus, marine coal reduces the movement of the mold wall and the permeability in the sand of the mold and core and therefore makes the surface of the mold and core clean and smooth.

PICHE

[0098] Tar is a distilled form of soft charcoal. 0.02% to 2% can be added in mold and core sand. The pitch increases the hot resistances, the surface finish on the mold surfaces and behaves exactly the same way as marine coal.

WOOD FLOUR

[0099] Wood flour is a fibrous material mixed with a granular material such as sand. Wood flour is made up of relatively long fine fibers that prevent grains of sand from coming into contact with each other. Wood flour can be added between 0.05% to 2% in the mold and in the male's sand. The wood flour volatilizes when heated, thus allowing the sand grains to expand. Wood flour will increase the movement of the mold wall and decrease expansion defects. Wood flour also increases the ability to collapse from the mold and core.

SPRAYED SILICA OR SILICA FLOUR

[00100] Silica flour is called powdered silica. Powdered silica can be easily added up to 3%, which increases the

30/44 resistance to hot and finishing surfaces of molds and cores. It also reduces metal penetration into mold and core walls.

[00101] In another aspect, the presently claimed invention is directed to a composition comprising (a) 2-hydroxypropanamide; and (b) monoethanolamine.

[00102] In another embodiment, the invention currently claimed is directed to a composition comprising (a) 2-hydroxypropanamide; (b) monoethanolamine; and (c) at least one non-ionic surfactant;

[00103] In another embodiment, the invention currently claimed is directed to a composition comprising (a) 2-hydroxypropanamide; (b) monoethanolamine; and (c) at least one nonionic surfactant selected from the group consisting of poly (C8-C22) alkyl poly (C2-C4) alkylene glycol ether, mono- (C8-C22) poly (C2) carboxylic acid ester -C4) alkylene glycol, alkoxylated oil and alkoxylated alkylamine.

[00104] In yet another aspect, the presently claimed invention is directed to the use of the composition comprising (a) 2-hydroxypropanamide; and (b) monoethanolamine to disintegrate the casting mold.

[00105] In another embodiment, the invention currently claimed is directed to the use of the composition comprising (a) 2-hydroxypropanamide; (b) monoethanolamine; and (c) at least one non-ionic surfactant;

31/44 to disintegrate the casting mold.

[00106] In another embodiment, the invention currently claimed is directed to the use of the composition comprising (a) 2-hydroxypropanamide; (b) monoethanolamine; and (c) at least one nonionic surfactant selected from the group consisting of poly (C8-C22) -alkyl poly (C2-C4) alkylene glycol ether, mono- (C8-C22) carboxylic acid ester of poly ( C2-C4) alkylene glycol, alkoxylated oil and alkoxylated alkylamine; to disintegrate the casting mold.

[00107] In yet another aspect, the presently claimed invention is directed to a method for disintegrating the foundry mold comprising sand and a polyurethane binder comprising the step of (i) contacting the foundry mold with a composition comprising ( a) 2-hydroxypropanamide; and (b) monoethanolamine; to obtain a mixture of the sand and the polyurethane binder.

[00108] In one embodiment, the presently claimed invention is directed to a method for disintegrating the foundry mold comprising sand and a polyurethane binder comprising the step of (i) contacting the foundry mold with a composition comprising (a ) 2-hydroxypropanamide; (b) monoethanolamine; and (c) at least one non-ionic surfactant; to obtain a mixture of the sand and the binder of

32/44 polyurethane.

[00109] In another embodiment, the invention currently claimed is directed to a method for disintegrating the foundry mold comprising sand and a polyurethane binder comprising the step of (i) contacting the foundry mold with a composition comprising (a ) 2-hydroxypropanamide; (b) monoethanolamine; and (c) at least one nonionic surfactant selected from the group consisting of poly (C8-C22) -alkyl poly (C2-C4) alkylene glycol ether, poly (C8-C22) carboxylic acid ester ( C2-C4) alkylene glycol, alkoxylated oil and alkoxylated alkylamine; to obtain a mixture of the sand and the polyurethane binder.

[00110] In another aspect, the invention presently claimed is directed to a composition comprising (a) at least one carboxylic acid amide of general formula (I) in which R1 denotes straight or branched, unsubstituted C2-C12 alkyl; R2 and R3 denote methyl; and (b) monoethanolamine.

[00111] In another embodiment, the presently claimed invention is directed to a composition comprising (a) at least one carboxylic acid amide of formula

33/44 general (I) where R1 denotes straight or branched C2-C12 alkyl; R2 and R3 denote methyl; (b) monoethanolamine; and (c) at least one nonionic surfactant.

[00112] In another embodiment, the invention presently claimed is directed to a composition comprising (a) at least one carboxylic acid amide of general formula (I) in which R1 denotes straight or branched, unsubstituted C2-C12 alkyl; R2 and R3 denote methyl; (b) monoethanolamine; and (c) at least one nonionic surfactant selected from the group consisting of poly (C8-C22) -alkyl poly (C2-C4) alkylene glycol ether, poly (C8-C22) carboxylic acid ester ( C2-C4) alkylene glycol, alkoxylated oil and alkoxylated alkylamine.

[00113] In yet another aspect, the presently claimed invention is directed to the use of the composition comprising (a) at least one carboxylic acid amide of general formula (I)

34/44 where R1 denotes straight or branched C2-C12 alkyl, unsubstituted; R2 and R3 denote methyl; and (b) monoethanolamine, to disintegrate the casting mold.

[00114] In another embodiment, the invention presently claimed is directed to the use of the composition comprising (a) at least one carboxylic acid amide of general formula (I) in which R1 denotes straight or branched, unsubstituted C2-C12 alkyl ; R2 and R3 denote methyl; and (b) monoethanolamine; and (c) at least one non-ionic surfactant; to disintegrate the casting mold.

[00115] In another embodiment, the invention currently claimed is directed to the use of the composition comprising (a) at least one carboxylic acid amide of general formula (I)

35/44 where R1 denotes straight or branched C2-C12 alkyl, unsubstituted; R2 and R3 denote methyl; and (b) monoethanolamine; and (c) at least one nonionic surfactant selected from the group consisting of poly (C8-C22) -alkyl poly (C2-C4) alkylene glycol ether, poly (C8-C22) carboxylic acid ester ( C2-C4) alkylene glycol, alkoxylated oil and alkoxylated alkylamine; to disintegrate the casting mold.

[00116] In yet another aspect, the presently claimed invention is directed to a method for disintegrating the foundry mold comprising sand and a polyurethane binder comprising the step of (i) contacting the foundry mold with a composition comprising ( a) at least one carboxylic acid amide of general formula (I) in which R1 denotes straight or branched C2-C12-alkyl; R2 and R3 denote methyl; and (b) monoethanolamine;

36/44 to obtain a mixture of sand and polyurethane binder.

[00117] In one embodiment, the invention currently claimed is directed to a method for disintegrating the foundry mold comprising sand and a polyurethane binder comprising the step of (i) contacting the foundry mold with a composition comprising (a ) at least one carboxylic acid amide of general formula (I) in which R1 denotes straight or branched C2-C12 alkyl; R2 and R3 denote methyl; and (b) monoethanolamine; and (c) at least one non-ionic surfactant; to obtain a mixture of the sand and the polyurethane binder.

[00118] In another embodiment, the invention currently claimed is directed to a method for disintegrating the foundry mold comprising sand and a polyurethane binder comprising the step of (i) contacting the foundry mold with a composition comprising (a ) at least one carboxylic acid amide of general formula (I)

37/44 where R1 denotes unsubstituted straight or branched C2-C12 alkyl; R2 and R3 denote methyl; and (b) monoethanolamine; and (c) at least one nonionic surfactant selected from the group consisting of poly (C8-C22) -alkyl poly (C2-C4) alkylene glycol ether, poly (C8-C22) carboxylic acid ester ( C2-C4) alkylene glycol, alkoxylated oil and alkoxylated alkylamine, alkoxylated oil and alkoxylated alkylamine; to obtain a mixture of the sand and the polyurethane binder.

[00119] In another preferred embodiment, the invention currently claimed relates to a method for disintegrating the foundry mold comprising sand and a polyurethane binder comprising the steps of (i) contacting the foundry mold with a composition comprising (a) at least one carboxylic acid amide of general formula (I) in which R1 denotes straight or branched C2-C22-alkyl, unsubstituted or substituted with hydroxy R2 and R3, independently of one another, denote H or

38/44 straight or branched C1-C12 alkyl, unsubstituted or substituted; (b) at least one alkanolamine of general formula (II) in which AO is identical or different selected from the group consisting of CH2-CH2-O, CH (CH3) -CH2-O, CH2-CH (CH3) - O, CH (C2H5) -CH- O, C (CH3) 2-CH2-O, CHC (CH3) 2-O and CH2-CH (C2H5) -O, m is 1, 2, 3, 4, 5, 6 or 7, ex, y independently of each other are 0 or 1, to obtain a mixture of the sand and the polyurethane binder; (ii) separating the sand from the mixture obtained in step (i); and (iii) drying the sand obtained in step (ii).

[00120] The sand is separated from the mixture of sand and polyurethane binder by one or more methods known in the art, that is, reconditioning, thermal methods, dry methods, etc. The reconditioning only contemplates that the used sand is passed on magnetic pulleys, through breakers and sieves and then sanded to remove fine particles. Heat treatment methods include a roasting oven, a fluid bed oven and a rotary oven. The thermal calcination system subjects the sand to temperatures in the range of 1200 ° -1500 ° in the presence of excess oxygen, thus removing carbonaceous additives. The drying method includes mechanical methods that understand the impact of sand grains to fracture the “shells” of old connections of individual grains. There are several modes that would fall into the category of being dry, including (a) centrifuging the sand against a fence; (b) pneumatically shooting sand at a target, or, in addition,

39/44 that two separate streams of sand cross to rub; and (c) mulling at low levels of kinetic energy to compress the grains of sand under the pressure of a wheel.

[00121] The sand is dried by processes known to one skilled in the art. The sand is passed through a fluid bed furnace. The hot sand is then passed through a cooling drum where the sand is subsequently cleaned and cooled to room temperature by means of cooling air. The sand obtained after drying is routinely sieved and returned to the system for reuse. Sand can be recycled and reused in the smelter to make smelting molds for various cycles.

[00122] However, as the sand is used repeatedly, the particles eventually become too fine for the molding process; and therefore can also be put in another application, if this sand cannot be used for molding, such as:

1. Asphalt Concrete: Replacement of up to 15% of used sand with fine aggregate of conventional asphalt concrete.

[00123] 2. Compost additive: Bulking agent for composted yard waste, to produce topsoil or topsoil additive.

[00124] 3. Concrete: Replacement by regular sand in structural grade concrete, in low percentages.

[00125] 4. Bricks and paving: Encapsulation in a proprietary high-pressure pozzolanic process that can encapsulate and chemically connect various residues in grade C fly ash (a fine particulate ash produced by coal-fired power plants). The process at room temperature results in bricks that are economical and can be shaped to meet the requirements of the end user.

[00126] The present invention offers one or more of the following advantages:

40/44

1. The method of the present invention can be used for a variety of casting molds with varying sand and binder composition.

[00127] 2. A small amount of the composition is effective in disintegrating the casting mold.

[00128] In the following, specific embodiments of the present invention are described:

1. Method for disintegrating the foundry mold comprising sand and a polyurethane-based binder, comprising at least the step of (i) contacting the foundry mold with a composition comprising (a) at least one carboxylic acid amide of general formula (I) in which R1 denotes straight or branched C2-C22 alkyl, unsubstituted or substituted with hydroxy R2 and R3, independently of one another, denote H or straight or branched C1-C12 alkyl, unsubstituted or substituted ; (b) at least one alkanolamine of general formula (II) in which AO is identical or different selected from the group that

41/44 consists of CH2-CH2-O, CH (CH3) -CH2-O, CH2-CH (CH3) -O, CH (C2H5) -CH-O, C (CH3) 2-CH2-O, CHC ( CH3) 2-O and CH2-CH (C2H5) -O, m is 1, 2, 3, 4, 5, 6 or 7, ex, y independently of each other are 0 or 1, to obtain a mixture of sand and of the polyurethane binder.

[00129] 2. The method according to modality 1, in which the sand is selected from the group consisting of natural silica sand, clay, green sand, quartz sand, chromite sand, olivine sand, sands and zirconium sand.

[00130] 3. The method according to modality 1, in which the polyurethane-based binder comprises polyurethane, water glass and at least one resin that is different from polyurethane.

[00131] 4. The method according to modality 1, in which R1 is selected from the group consisting of ethyl, n-propyl, n-butyl, n-pentyl, n-hexyl, n-heptyl, n-octyl, n-nonyl, n-decyl, n-undecyl, n-dodecyl, n-tridecyl, n-tetradecyl, n-pentadecyl, n-hexadecyl, n-heptadecyl, n-octadecyl, n-nonadecyl, n-eicosyl, n- heneicosyl, n-docosyl, isopropyl, isobutyl, isopentyl, isohexyl, isoheptyl, isooctyl, isononyl, isodecyl, isoundecyl, isododecyl, isotridecyl, isotetradecyl, isopentadecyl, iso- hexadecyl, iso-hexadecyl, iso-hexadecyl, iso-hexadecyl, iso iso- hyeneicosyl, isodocosyl, t-butyl, 1-hydroxyethyl, 1-hydroxypropyl, 2-hydroxypropyl, 1-hydroxybutyl, 2-hydroxybutyl, 2-hydroxybutyl, 1-hydroxypentyl, 2-hydroxypentyl, 3-hydroxypentyl, 4-hydroxypentyl, 1-hydroxy-hexyl, 2-hydroxy-hexyl, 3-hydroxy-hexyl, 4-hydroxy-hexyl and 5-hydroxy-hexyl ..

[00132] 5. The method according to modality 1, in which R1 is selected from the group comprising ethyl, n-propyl, n-butyl, n-pentyl, n-hexyl, n-heptyl, n-octyl , n-nonyl, n-decyl, isooctyl, isopropyl, isobutyl, isopentyl, isohexyl, isoheptyl, isononyl, isodecyl, 1-

42/44 hydroxyethyl, 1-hydroxypropyl, 2-hydroxypropyl, 1-hydroxybutyl, 2-hydroxybutyl, 1-hydroxypentyl, 2-hydroxypentyl, 3-hydroxypentyl, 4-hydroxypentyl, 1-hydroxyhexyl, 2-hydroxyhexyl, 3 -hydroxyhexyl, 4-hydroxyhexyl and 5-hydroxyhexyl.

[00133] 6. The method according to modality 1, in which R2 and R3, independently of each other, are selected from the group consisting of H, methyl, ethyl, n-propyl, n-butyl, n- pentyl, n-hexyl, n-heptyl, n-octyl, n-nonyl, n-decyl, n-undecyl, n-dodecyl, isopropyl, isobutyl, isopentyl, isohexyl, isoheptyl, isooctyl, isononyl, isodecyl, isoundecyl, isododecyl and t-butyl.

[00134] 7. The method according to one or more of modalities 1 to 6, in which R2 and R3 independently of each other, are selected from the group consisting of H, methyl, ethyl, n-propyl, n- butyl, isopropyl, isobutyl and t-butyl.

[00135] 8. The method according to one or more modalities from 1 to 7, in which R2 and R3 are methyl.

[00136] 9. The method according to modality 1, where m is 1, 2 or 3.

[00137] 10. The method according to modality 1, where x and y are 0.

[00138] 11. The method according to one or more modalities 1 to 10, wherein at least one carboxylic acid amide of general formula (I) and at least one alkanolamine of general formula (II) are present in a molar ratio from 5: 1 to 1: 5.

[00139] 12. The method according to modality 1, in which the contact in step (i) is obtained by immersing the casting mold at a temperature in the range ≥ 10 to ≤ 200 ℃.

[00140] 13. The method according to modality 1, in which step (i) is performed for a period of time ≥ 10 min. at ≤ 60 min.

43/44

[00141] 14. The method according to one or more of modalities 1 to 13, further comprising the step of (ii) separating the sand from the mixture obtained in step (i).

[00142] 15. The method according to one or more of modalities 1 to 14, also comprising the step of (iii) drying the sand obtained in step (ii).

[00143] 16. The method according to modality 1, in which the composition comprises at least one surfactant.

[00144] 17. Method according to modality 16, in which at least one surfactant is a non-ionic surfactant.

[00145] 18. The method according to modality 17, in which the nonionic surfactant is selected from the group consisting of mono- (C8-C22) -alkyl ether of poly (C2-C4) alkylene glycol, ester of mono- (C8-C22) carboxylic acid of poly (C2-C4) alkylene glycol, alkoxylated oil and alkoxylated alkylamine.

[00146] 19. Method according to modalities 17 or 18, in which the nonionic surfactant is selected from polyethylene glycol alkyl ether, ethoxylated castor oil and oleylamine ethoxylate.

[00147] 20. The method according to one or more of modalities 1 to 19, wherein the composition comprises water.

[00148] 21. A composition comprising (a) 2-hydroxypropanamide; and (b) monoethanolamine.

[00149] 22. Use of the composition according to modality 21 to disintegrate the casting mold.

[00150] 23. Method for disintegrating the foundry mold comprising sand and binder comprising the step of (i) contacting the foundry mold with the composition according to modality 21;

44/44 to obtain a mixture of sand and binder.

EXAMPLES

[00151] Agnique® AMD 3L Monoethanol amine compounds (N, N-Dimethyl lactamide) Lutensol® FA12 (oleylamine ethoxylate) Lutensol® XL60 (C10-Guerbet alcohol ethoxylates) Emulan® EL (castor oil ethoxylate) Agnique® AMD 10 (C10 N fatty acid, N-Dimethylamide) Agnique® AMD 810 (C8 / C10 N fatty acid, N-Dimethylamide) are available from BASF SE, Ludwigshafen, Germany.

[00152] A sample casting mold size of 9 cm x 2.2 cm x 2.2 cm, made of PU-sand composite, was prepared according to the state of the art.

GENERAL PROCEDURE

[00153] The casting mold sample was immersed (one third) in the composition as described in Examples 1 to 6, at room temperature. The sample collapse time was determined. The collapse time is the time required for the sample to disintegrate from the foundry mold, resulting in a mixture of sand and binder. Example Amino acid Amount of Alcanolami Amount of surfactant Amount of carboxylic acid Amino in the alkanolamine of surfactant carboxylic collapse (% (% by weight) (% by weight) (minutes) by weight) 1 Agnique® 75 monoethanol 25 none - 60 AMD 3L amine 2 Agnique® 25 monoethanol 25 Lutensol® 50 60 AMD 3L amine XL60 3 Agnique® 50 monoethanol 25 Lutensol® 25 60 AMD 3L amine FA12 4 Agnique® 50 monoethanol 25 Emulan® EL 25 60 AMD 3L amine 5 Agnique® 25 monoethanol 25 Lutensol ® 50 35 AMD 10 amine XL60 6 Agnique® 25 monoethanol 25 Lutensol® 50 45 AMD 810 amine XL60

Claims (15)

1. Method for disintegrating the foundry mold comprising sand and a polyurethane-based binder characterized by the fact that it comprises the step of (i) contacting the foundry mold with a composition comprising (a) at least one acid amide carboxylic acid of general formula (I) (I) in which R1 denotes straight or branched C2-C22 alkyl, unsubstituted or substituted with hydroxy R2 and R3, independently of one another, denote H or straight or branched, unsubstituted C1-C12 alkyl or replaced; and (b) at least one alkanolamine of general formula (II) in which AO is identical or different selected from the group consisting of CH2-CH2-O, CH (CH3) -CH2-O, CH2-CH (CH3) -O, CH (C2H5) -CH- O, C (CH3) 2-CH2-O, CHC (CH3) 2-O and CH2-CH (C2H5) -O, m is 1, 2, 3, 4, 5 , 6 or 7, ex, y independently of each other are 0 or 1; to obtain a mixture of the sand and the polyurethane binder. 2. Method according to claim 1, characterized by the fact that the sand is selected from the group consisting of natural silica sand, clay, green sand, quartz sand, chromite sand, olivine sand, special sands and zirconium sand. Method according to claim 1, characterized in that the polyurethane-based binder comprises polyurethane, water glass and at least one resin that is different from polyurethane. 4. Method according to claim 1, characterized by the fact that R1 is selected from the group comprising ethyl, n-propyl, n-butyl, n-pentyl, n-hexyl, n-heptyl, n-octyl, n-nonyl, n-decyl, isooctyl, isopropyl, isobutyl, isopentyl, isohexyl, isoheptyl, isononyl, isodecyl, 1-hydroxyethyl, 1-hydroxypropyl, 2-hydroxypropyl, 1-hydroxybutyl, 2-hydroxybutyl, 1- hydroxypentyl, 2-hydroxypentyl, 3-hydroxypentyl, 4-hydroxypentyl, 1-hydroxyhexyl, 2-hydroxyhexyl, 3-hydroxyhexyl, 4-hydroxyhexyl and 5-hydroxyhexyl. 5. Method according to claim 1, characterized by the fact that R2 and R3 are methyl. 6. Method according to claim 1, characterized by the fact that m is 1, 2 or 3. 7. Method according to claim 1, characterized by the fact that x and y are 0. Method according to any one of claims 1 to 7, characterized in that at least one carboxylic acid amide of general formula (I) and at least one alkanolamine of general formula (II) are present in a ratio molar ratio of 5: 1 to 1: 5. Method according to any one of claims 1 to 8, characterized in that it additionally comprises the step of (ii) separating the sand from the mixture obtained in step (i). 10. Method according to any one of claims 1 to 9, characterized in that it additionally comprises the step of (iii) dry the sand obtained in step (ii). 11. Method according to claim 1, characterized in that the composition comprises at least one surfactant. 12. Method according to claim 11, characterized by the fact that at least one surfactant is a non-ionic surfactant. 13. Method according to claim 12, characterized in that the nonionic surfactant is selected from the group consisting of mono- (C8-C22) -alkyl ether of poly (C2-C4) alkylene glycol, ester of mono- (C8-C22) -carboxylic acid of poly (C2-C4) alkylene glycol, alkoxylated oil and alkoxylated alkylamine. 14. Composition, characterized by the fact that it comprises (a) 2-hydroxypropanamide; and (b) monoethanolamine. 15. Use of the composition as defined in claim 14, characterized in that it is to disintegrate a casting mold.