US20220153602A9 - Method of producing magnesium hydroxide - Google Patents
Method of producing magnesium hydroxide Download PDFInfo
- Publication number
- US20220153602A9 US20220153602A9 US17/259,247 US201917259247A US2022153602A9 US 20220153602 A9 US20220153602 A9 US 20220153602A9 US 201917259247 A US201917259247 A US 201917259247A US 2022153602 A9 US2022153602 A9 US 2022153602A9
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- US
- United States
- Prior art keywords
- containing material
- magnesium hydroxide
- magnesium
- less
- hydration
- Prior art date
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- VTHJTEIRLNZDEV-UHFFFAOYSA-L magnesium dihydroxide Chemical compound [OH-].[OH-].[Mg+2] VTHJTEIRLNZDEV-UHFFFAOYSA-L 0.000 title claims abstract description 86
- 239000000347 magnesium hydroxide Substances 0.000 title claims abstract description 85
- 229910001862 magnesium hydroxide Inorganic materials 0.000 title claims abstract description 85
- 238000000034 method Methods 0.000 title claims abstract description 44
- 239000000463 material Substances 0.000 claims abstract description 101
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 claims abstract description 65
- 239000000395 magnesium oxide Substances 0.000 claims abstract description 57
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 claims abstract description 49
- 229920000642 polymer Polymers 0.000 claims abstract description 19
- 238000002156 mixing Methods 0.000 claims abstract description 14
- 239000003063 flame retardant Substances 0.000 claims abstract description 11
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 claims abstract description 10
- 230000036571 hydration Effects 0.000 claims description 37
- 238000006703 hydration reaction Methods 0.000 claims description 37
- 239000002245 particle Substances 0.000 claims description 35
- 238000003801 milling Methods 0.000 claims description 20
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 claims description 18
- 239000011777 magnesium Substances 0.000 claims description 18
- 229910052749 magnesium Inorganic materials 0.000 claims description 18
- 238000006243 chemical reaction Methods 0.000 claims description 15
- 238000001035 drying Methods 0.000 claims description 14
- 238000009826 distribution Methods 0.000 claims description 9
- 230000000887 hydrating effect Effects 0.000 claims description 7
- 238000001354 calcination Methods 0.000 claims description 4
- 239000003607 modifier Substances 0.000 claims description 3
- 230000008569 process Effects 0.000 abstract description 16
- 230000001939 inductive effect Effects 0.000 abstract description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-M hydroxide Chemical compound [OH-] XLYOFNOQVPJJNP-UHFFFAOYSA-M 0.000 abstract 1
- 235000012254 magnesium hydroxide Nutrition 0.000 description 71
- 235000012245 magnesium oxide Nutrition 0.000 description 50
- 239000007787 solid Substances 0.000 description 12
- 239000000725 suspension Substances 0.000 description 10
- 230000001965 increasing effect Effects 0.000 description 9
- TWRXJAOTZQYOKJ-UHFFFAOYSA-L Magnesium chloride Chemical compound [Mg+2].[Cl-].[Cl-] TWRXJAOTZQYOKJ-UHFFFAOYSA-L 0.000 description 8
- 238000001914 filtration Methods 0.000 description 7
- 239000002002 slurry Substances 0.000 description 7
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical compound O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 7
- -1 chlorine ions Chemical class 0.000 description 6
- 239000012153 distilled water Substances 0.000 description 6
- 239000012535 impurity Substances 0.000 description 6
- YIXJRHPUWRPCBB-UHFFFAOYSA-N magnesium nitrate Chemical compound [Mg+2].[O-][N+]([O-])=O.[O-][N+]([O-])=O YIXJRHPUWRPCBB-UHFFFAOYSA-N 0.000 description 6
- 238000000643 oven drying Methods 0.000 description 5
- NLXLAEXVIDQMFP-UHFFFAOYSA-N Ammonia chloride Chemical compound [NH4+].[Cl-] NLXLAEXVIDQMFP-UHFFFAOYSA-N 0.000 description 4
- 239000000654 additive Substances 0.000 description 4
- 229910052500 inorganic mineral Inorganic materials 0.000 description 4
- 238000002386 leaching Methods 0.000 description 4
- 229910001629 magnesium chloride Inorganic materials 0.000 description 4
- 235000011147 magnesium chloride Nutrition 0.000 description 4
- 235000010755 mineral Nutrition 0.000 description 4
- 239000011707 mineral Substances 0.000 description 4
- 239000000243 solution Substances 0.000 description 4
- QTBSBXVTEAMEQO-UHFFFAOYSA-N Acetic acid Chemical compound CC(O)=O QTBSBXVTEAMEQO-UHFFFAOYSA-N 0.000 description 3
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 3
- 230000008901 benefit Effects 0.000 description 3
- 239000006227 byproduct Substances 0.000 description 3
- KRKNYBCHXYNGOX-UHFFFAOYSA-N citric acid Chemical compound OC(=O)CC(O)(C(O)=O)CC(O)=O KRKNYBCHXYNGOX-UHFFFAOYSA-N 0.000 description 3
- 239000013078 crystal Substances 0.000 description 3
- ZLNQQNXFFQJAID-UHFFFAOYSA-L magnesium carbonate Chemical compound [Mg+2].[O-]C([O-])=O ZLNQQNXFFQJAID-UHFFFAOYSA-L 0.000 description 3
- 239000001095 magnesium carbonate Substances 0.000 description 3
- 235000014380 magnesium carbonate Nutrition 0.000 description 3
- 229910000021 magnesium carbonate Inorganic materials 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- 239000004094 surface-active agent Substances 0.000 description 3
- VEXZGXHMUGYJMC-UHFFFAOYSA-M Chloride anion Chemical compound [Cl-] VEXZGXHMUGYJMC-UHFFFAOYSA-M 0.000 description 2
- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 description 2
- 239000002253 acid Substances 0.000 description 2
- 150000007513 acids Chemical class 0.000 description 2
- 235000019270 ammonium chloride Nutrition 0.000 description 2
- 238000004458 analytical method Methods 0.000 description 2
- 239000012736 aqueous medium Substances 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 2
- 229910052599 brucite Inorganic materials 0.000 description 2
- 239000003795 chemical substances by application Substances 0.000 description 2
- 239000011248 coating agent Substances 0.000 description 2
- 230000000052 comparative effect Effects 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
- 230000007613 environmental effect Effects 0.000 description 2
- 239000000945 filler Substances 0.000 description 2
- 238000010335 hydrothermal treatment Methods 0.000 description 2
- BDAGIHXWWSANSR-UHFFFAOYSA-N methanoic acid Natural products OC=O BDAGIHXWWSANSR-UHFFFAOYSA-N 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- 239000000843 powder Substances 0.000 description 2
- 238000010298 pulverizing process Methods 0.000 description 2
- 238000000746 purification Methods 0.000 description 2
- 239000007921 spray Substances 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- QIVUCLWGARAQIO-OLIXTKCUSA-N (3s)-n-[(3s,5s,6r)-6-methyl-2-oxo-1-(2,2,2-trifluoroethyl)-5-(2,3,6-trifluorophenyl)piperidin-3-yl]-2-oxospiro[1h-pyrrolo[2,3-b]pyridine-3,6'-5,7-dihydrocyclopenta[b]pyridine]-3'-carboxamide Chemical compound C1([C@H]2[C@H](N(C(=O)[C@@H](NC(=O)C=3C=C4C[C@]5(CC4=NC=3)C3=CC=CN=C3NC5=O)C2)CC(F)(F)F)C)=C(F)C=CC(F)=C1F QIVUCLWGARAQIO-OLIXTKCUSA-N 0.000 description 1
- OSWFIVFLDKOXQC-UHFFFAOYSA-N 4-(3-methoxyphenyl)aniline Chemical compound COC1=CC=CC(C=2C=CC(N)=CC=2)=C1 OSWFIVFLDKOXQC-UHFFFAOYSA-N 0.000 description 1
- 238000004438 BET method Methods 0.000 description 1
- KCXVZYZYPLLWCC-UHFFFAOYSA-N EDTA Chemical class OC(=O)CN(CC(O)=O)CCN(CC(O)=O)CC(O)=O KCXVZYZYPLLWCC-UHFFFAOYSA-N 0.000 description 1
- 229920000181 Ethylene propylene rubber Polymers 0.000 description 1
- 244000043261 Hevea brasiliensis Species 0.000 description 1
- AVXURJPOCDRRFD-UHFFFAOYSA-N Hydroxylamine Chemical compound ON AVXURJPOCDRRFD-UHFFFAOYSA-N 0.000 description 1
- GRYLNZFGIOXLOG-UHFFFAOYSA-N Nitric acid Chemical compound O[N+]([O-])=O GRYLNZFGIOXLOG-UHFFFAOYSA-N 0.000 description 1
- 229920000459 Nitrile rubber Polymers 0.000 description 1
- 239000004952 Polyamide Substances 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- VMHLLURERBWHNL-UHFFFAOYSA-M Sodium acetate Chemical compound [Na+].CC([O-])=O VMHLLURERBWHNL-UHFFFAOYSA-M 0.000 description 1
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- 229920000800 acrylic rubber Polymers 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- WYTGDNHDOZPMIW-RCBQFDQVSA-N alstonine Natural products C1=CC2=C3C=CC=CC3=NC2=C2N1C[C@H]1[C@H](C)OC=C(C(=O)OC)[C@H]1C2 WYTGDNHDOZPMIW-RCBQFDQVSA-N 0.000 description 1
- 150000003863 ammonium salts Chemical class 0.000 description 1
- 229910052925 anhydrite Inorganic materials 0.000 description 1
- 125000000129 anionic group Chemical group 0.000 description 1
- 239000007864 aqueous solution Substances 0.000 description 1
- JPNZKPRONVOMLL-UHFFFAOYSA-N azane;octadecanoic acid Chemical class [NH4+].CCCCCCCCCCCCCCCCCC([O-])=O JPNZKPRONVOMLL-UHFFFAOYSA-N 0.000 description 1
- 239000011324 bead Substances 0.000 description 1
- 229920005549 butyl rubber Polymers 0.000 description 1
- OSGAYBCDTDRGGQ-UHFFFAOYSA-L calcium sulfate Chemical compound [Ca+2].[O-]S([O-])(=O)=O OSGAYBCDTDRGGQ-UHFFFAOYSA-L 0.000 description 1
- 239000002894 chemical waste Substances 0.000 description 1
- 239000000460 chlorine Substances 0.000 description 1
- 229910052801 chlorine Inorganic materials 0.000 description 1
- 239000011362 coarse particle Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 238000013329 compounding Methods 0.000 description 1
- 238000010924 continuous production Methods 0.000 description 1
- 239000007822 coupling agent Substances 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 235000014113 dietary fatty acids Nutrition 0.000 description 1
- 239000002270 dispersing agent Substances 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 238000009837 dry grinding Methods 0.000 description 1
- 229920001971 elastomer Polymers 0.000 description 1
- 239000000806 elastomer Substances 0.000 description 1
- 239000003822 epoxy resin Substances 0.000 description 1
- 229920006228 ethylene acrylate copolymer Polymers 0.000 description 1
- 238000004299 exfoliation Methods 0.000 description 1
- 239000000194 fatty acid Substances 0.000 description 1
- 229930195729 fatty acid Natural products 0.000 description 1
- 150000004665 fatty acids Chemical class 0.000 description 1
- 235000019253 formic acid Nutrition 0.000 description 1
- 238000004108 freeze drying Methods 0.000 description 1
- 229920000578 graft copolymer Polymers 0.000 description 1
- LNEPOXFFQSENCJ-UHFFFAOYSA-N haloperidol Chemical compound C1CC(O)(C=2C=CC(Cl)=CC=2)CCN1CCCC(=O)C1=CC=C(F)C=C1 LNEPOXFFQSENCJ-UHFFFAOYSA-N 0.000 description 1
- 230000000670 limiting effect Effects 0.000 description 1
- 238000011068 loading method Methods 0.000 description 1
- 230000005923 long-lasting effect Effects 0.000 description 1
- UEGPKNKPLBYCNK-UHFFFAOYSA-L magnesium acetate Chemical compound [Mg+2].CC([O-])=O.CC([O-])=O UEGPKNKPLBYCNK-UHFFFAOYSA-L 0.000 description 1
- 239000011654 magnesium acetate Substances 0.000 description 1
- 235000011285 magnesium acetate Nutrition 0.000 description 1
- 229940069446 magnesium acetate Drugs 0.000 description 1
- 159000000003 magnesium salts Chemical class 0.000 description 1
- 230000014759 maintenance of location Effects 0.000 description 1
- 229920003052 natural elastomer Polymers 0.000 description 1
- 229920001194 natural rubber Polymers 0.000 description 1
- 229910017604 nitric acid Inorganic materials 0.000 description 1
- 238000010951 particle size reduction Methods 0.000 description 1
- 238000005453 pelletization Methods 0.000 description 1
- 229920001200 poly(ethylene-vinyl acetate) Polymers 0.000 description 1
- 229920000058 polyacrylate Polymers 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 229920001225 polyester resin Polymers 0.000 description 1
- 239000004645 polyester resin Substances 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 229920002959 polymer blend Polymers 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 229920000915 polyvinyl chloride Polymers 0.000 description 1
- 239000002244 precipitate Substances 0.000 description 1
- 238000001556 precipitation Methods 0.000 description 1
- 238000000197 pyrolysis Methods 0.000 description 1
- 230000009257 reactivity Effects 0.000 description 1
- 238000004064 recycling Methods 0.000 description 1
- 230000002829 reductive effect Effects 0.000 description 1
- 230000001105 regulatory effect Effects 0.000 description 1
- 238000012216 screening Methods 0.000 description 1
- 238000010008 shearing Methods 0.000 description 1
- 238000007873 sieving Methods 0.000 description 1
- 238000005245 sintering Methods 0.000 description 1
- 239000001632 sodium acetate Substances 0.000 description 1
- 235000017281 sodium acetate Nutrition 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 238000001694 spray drying Methods 0.000 description 1
- 230000006641 stabilisation Effects 0.000 description 1
- 238000011105 stabilization Methods 0.000 description 1
- 230000000087 stabilizing effect Effects 0.000 description 1
- 230000003068 static effect Effects 0.000 description 1
- 229920001169 thermoplastic Polymers 0.000 description 1
- 229920001187 thermosetting polymer Polymers 0.000 description 1
- 239000004416 thermosoftening plastic Substances 0.000 description 1
- 230000009466 transformation Effects 0.000 description 1
- UKRDPEFKFJNXQM-UHFFFAOYSA-N vinylsilane Chemical class [SiH3]C=C UKRDPEFKFJNXQM-UHFFFAOYSA-N 0.000 description 1
- 238000001238 wet grinding Methods 0.000 description 1
- DXZMANYCMVCPIM-UHFFFAOYSA-L zinc;diethylphosphinate Chemical compound [Zn+2].CCP([O-])(=O)CC.CCP([O-])(=O)CC DXZMANYCMVCPIM-UHFFFAOYSA-L 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01F—COMPOUNDS OF THE METALS BERYLLIUM, MAGNESIUM, ALUMINIUM, CALCIUM, STRONTIUM, BARIUM, RADIUM, THORIUM, OR OF THE RARE-EARTH METALS
- C01F5/00—Compounds of magnesium
- C01F5/14—Magnesium hydroxide
- C01F5/16—Magnesium hydroxide by treating magnesia, e.g. calcined dolomite, with water or solutions of salts not containing magnesium
-
- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
- C01P2004/00—Particle morphology
- C01P2004/51—Particles with a specific particle size distribution
-
- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
- C01P2004/00—Particle morphology
- C01P2004/60—Particles characterised by their size
- C01P2004/61—Micrometer sized, i.e. from 1-100 micrometer
-
- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
- C01P2004/00—Particle morphology
- C01P2004/60—Particles characterised by their size
- C01P2004/62—Submicrometer sized, i.e. from 0.1-1 micrometer
-
- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
- C01P2006/00—Physical properties of inorganic compounds
- C01P2006/12—Surface area
-
- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
- C01P2006/00—Physical properties of inorganic compounds
- C01P2006/80—Compositional purity
Definitions
- Current invention relates to a process for producing magnesium hydroxide.
- this invention is directed to a method of producing magnesium hydroxide suitable for mixing with polymers.
- Said magnesium hydroxide is especially appropriate for inducing flame retardant properties in polymeric compounds being at the same time an environmental friendly filler.
- EP 0 599 085 discloses a process for producing magnesium hydroxide by wet-pulverizing a light burned magnesia followed by its hydration in presence of an alkaline aqueous medium at a temperature of not less than 70° C. and preferably below 120° C.
- the pH of the reaction is not less than 11.
- light burned magnesia bears increased porosity and on the other hand, the extended wet-pulverizing during hydration may create further uneven particle surfaces putting at stake desirable flame retardant crystal structures.
- EP 0 568 488 presents a particulate magnesium hydroxide with specific surface (BET) of 13-30 m 2 /gr and average particle size 0.3-1.0 ⁇ m. These flame retardant have been produced by the calcination of a magnesium feedstock, which has a specific surface of 3-10 m 2 /gr, followed by its hydration and milling for achieving the desirable particle size.
- BET specific surface
- magnesium hydroxide with BET values above 13 m 2 /gr is expected to induce difficulties in mixing with polymers increasing the viscosity of the compound.
- CA 2 032 470 presents a magnesium hydroxide of average grain size less than 10 ⁇ m and low content of impurities within the magnesia suitable for flame retardant applications.
- the claimed process is energy intensive involving apart from leaching with strong acids, spray roasting of a magnesium chloride solution, as well as, subsequent post-washes.
- U.S. Pat. No. 4,098,762 refers to magnesium hydroxide particles coated with an anionic surface active agent. These particles have a specific surface of less than 20 m 2 /gr. Said magnesium hydroxide has been produced by hydrothermal treatment at elevated temperature and pressure of basic magnesium chloride or magnesium nitrate in an aqueous medium. Besides the prerequisite of a coating agent for producing said particles, above method involves extended retention time of the solution within the autoclave in order to bring the properties at the desired level.
- U.S. Pat. No. 5,843,389 describes a process for producing magnesium hydroxide of low particle size and specific surface from solution by precipitation. Said process includes subsequent stages of leaching a magnesium-containing ore, purification, filtration and hydrothermal treatment in an autoclave. Special care has been taken for the handling and recycling of the chemical by-products formed due to leaching.
- GR 20080100407 discloses the production of magnesium hydroxide from hard burned magnesia. Said process involves at least two stages of hydration at a temperature of 50-100° C. for 15-24 hours each, in order to obtain the desired properties for flame retardant applications. Apart from the long lasting hydration process, said method demands the presence of magnesium salts.
- Prior art relates either to energy-intensive procedures and time-consuming methods or to necessary additives and by-product handling concerns, which all complicate magnesium hydroxide production, raise environmental issues and increase cost.
- the object of the present invention is to overcome the problems mentioned above.
- a method of producing magnesium hydroxide comprising hydrating a magnesium oxide containing material at high temperatures and pressures, resulting in a magnesium hydroxide containing material.
- the magnesium oxide containing material has a specific surface of more than 0.1 m 2 /gr and lower than 25 m 2 /gr.
- the method comprising the steps of (i) hydrating a magnesium oxide containing material at high temperatures and pressures, resulting in a magnesium hydroxide containing material, (ii) drying the magnesium hydroxide containing material, and (iii) milling.
- hydration is taking place at a temperature between 120° C. and 350° C. and a pressure between 2 bar and 165 bar.
- the magnesium hydroxide containing material comprising particles, wherein said particles present a specific surface of more than 1 m 2 /gr and less than 20 m 2 /gr.
- the magnesium hydroxide comprising particles of d 50 of more than 0.5 ⁇ m and less than 20 ⁇ m.
- the magnesium hydroxide containing material is suitable for mixing with polymers and presents flame retardant properties.
- the magnesium containing material which will be used for receiving the magnesium oxide containing material of the present invention is any available magnesium source.
- said magnesium containing material is any mineral known in the art such as magnesium carbonate, periclase, brucite and the like.
- the initial magnesium containing material is a mixture of various chemical structures.
- the magnesium containing material is a natural ore such as magnesite, serpentine, brucite and the like.
- the magnesium oxide containing material of said invention has been produced by agglomerating, pelletizing or briquetting mixtures of powders of magnesium containing materials with known means in the art.
- the magnesium oxide content in the magnesium oxide containing material is more than 80% (loss-free—XRF analysis) or more than 85%, preferably more than 90% most preferably more than 92% such as 94%, 97%, 95% and the like.
- the magnesium oxide containing material used for the present invention can be produced by known means in the art such as muffle furnace, multiple-hearth furnace, rotary kiln, electro-fusion, shaft kiln, and the like.
- the magnesium oxide containing material used for the present invention has been produced by calcining said magnesium containing material at a temperature higher than 700° C. and lower than 2000° C.
- the temperature was higher than 900° C. and lower than 1900° C. and most preferably the temperature was higher than 1100° C. and lower than 1800° C.
- the calcination temperature was higher than 1300° C. or higher than 1500° C.
- the magnesium oxide used for the present invention has not been produced by hydro-pyrolysis, magnesium chloride or magnesium nitrate sources.
- the magnesium oxide crystal is increased. Furthermore, its specific surface and reactivity are decreased, accordingly. More specifically, the specific surface as measured by BET method, is more than 0.1 m 2 /gr and less than 25 m 2 /gr, such as 15 m 2 /gr, 19 m 2 /gr, 22 m 2 /gr, 12 m 2 /gr, 4 m 2 /gr, 9 m 2 /gr and the like. Preferably specific surface is more than 0.2 m 2 /gr and less than 10 m 2 /gr.
- the specific surface is more than 0.2 m 2 /gr and less than 7.5 m 2 /gr, preferably more than 0.2 m 2 /gr and less than 5 m 2 /gr. In special embodiments the specific surface is more than 0.3 m 2 /gr and less than 3 m 2 /gr. It is not obvious for someone ordinary skilled in the art to use hard burned magnesium oxide of low specific surface for hydration due to the fact that it would increase considerably the hydration time, would deliver low productivity and would require additives for improving process.
- the BET value of magnesium oxide used for hydration in the present invention is lower than 2.9 m 2 /gr such as 2.0 m 2 /gr, 0.5 m 2 /gr, 1.5 m 2 /gr and the like.
- the magnesium oxide containing material of the present invention presents 0-10 mm particle size distribution.
- said magnesium oxide containing material has a 0-5 mm particle size distribution, preferably 0-2 mm, more preferably 0-1.5 mm, most preferably 0-1 mm.
- said magnesium oxide containing material presents 0-0.8 mm particle size distribution and most specifically 0-0.5 mm particle size distribution.
- said magnesium oxide containing material has d 50 less than 300 ⁇ m, such as 100 ⁇ m, 200 ⁇ m, 75 ⁇ m, 150 ⁇ m, 25 ⁇ m, 35 ⁇ m and the like.
- said particles pass through a 120 mesh screen.
- the magnesium oxide containing material of the present invention has d 10 more than 0.5 ⁇ m, preferably more than 1 ⁇ m.
- said d 10 is more than 3 ⁇ m or more than 5 ⁇ m.
- said magnesium oxide containing material has d 50 more than 10 ⁇ m, preferably more than 15 ⁇ m.
- said magnesium oxide containing material has d 50 more than 20 ⁇ m.
- current invention works also with coarse particles without special limitations on particle size distribution or need of surfactants. Current invention does not require slurry stabilization. In the art, specific and well-defined viscosity ranges are usually required for the suspension, which is going to be processed. In many cases, said suspensions proposed in the art require surfactants for achieving processing. In these cases, wet milling has been suggested for stabilizing the slurry.
- the hydration of said magnesium oxide is taking place preferably at high temperatures and pressures. It is preferred a temperature of more than 110° C. and less than 350° C., preferably more than 130° C. and less than 330° C. or even 320° C., preferably more than 140° C. and less than 300° C. and most preferably more than 150° C. and less than 290° C. In preferred embodiments the hydration temperature is more than 160° C. and less than 280° C. or even 270° C. In special embodiments the hydration temperature is more than 170° C. or more than 180° C. and less than 260° C. The pressure is regulated by the water vapor, accordingly.
- pressure is more than 2 bar, preferably more than 5 bar, most preferably more than 11 bar.
- the pressure in the reactor is further increased by external methods such as pressurized gas. Hydration pressure is preferably lower than 165 bar such as 90 bar, 30 bar, 60 bar and the like. In special cases the internal pressure is increased by the use of suitable solvents.
- the in weight content of the magnesium oxide containing material in the aqueous solution is more than 1% and less than 100%.
- said solid content is more than 2% and less than 70% in weight, more preferably more than 5% and less than 50% in weight, such as 25%, 40% and the like.
- the required time of hydration within the reactor is less than 12 h, preferably less than 8 h, preferably less than 6 h, preferably less than 4 h, more preferably less than 3 h, most preferably less than 2 h such as 30 min, 1 h, 15 min, 5 min and the like. Hydration is taking place either in batch reactor or at continuous process. In special cases, hydration is taking place in combinations thereof.
- Hydration at high temperature and pressure compared to atmospheric conditions for a magnesium oxide containing material assist the finalization of the hydration within a reasonable timeframe. Surprisingly, the increased temperature and pressure assist the production of magnesium hydroxides of low BET values without the absolute need of additives during hydration.
- Current invention does not require presence of chloride ions.
- chlorine ions are lower than 0.02 wt. % of the dry magnesium oxide containing material such as 0.01 wt %, 0.001 wt.%, 0.005 wt. % and the like.
- Chloride ions are known to be corrosive.
- hydration of a magnesium containing solution in an autoclave requires extended time for creating adequate magnesium hydroxide material particles of low BET values suitable for mixing with polymers.
- Current invention solves this issue by hydrating a magnesium oxide containing material particles, which initially have low BET value and transform them to a magnesium hydroxide of low BET value in suspension.
- the magnesia of the present invention when hydrated in an autoclave produces magnesium hydroxide, which succeeds low BET values and particle sizes.
- magnesia with BET values higher than 25 m 2 /gr even when hydrated in reactor does not produce the magnesium hydroxide with the desired characteristics described in current invention.
- the hydration of the magnesium oxide of the present invention does not require any hydrating agent.
- said hydration can be performed in presence of hydrating agents such as hydrochloric acid, nitric acid, acetic acid, citric acid, formic acid, magnesium nitrate, magnesium chloride, ammonium chloride, magnesium acetate, sodium acetate and the like.
- hydrating agents such as hydrochloric acid, nitric acid, acetic acid, citric acid, formic acid, magnesium nitrate, magnesium chloride, ammonium chloride, magnesium acetate, sodium acetate and the like.
- present invention does not exploit sodium hydroxide during hydration.
- current invention does not require the presence of ammonium chloride.
- the process of the present invention involves drying by any mean that does not increase the specific surface of the magnesium hydroxide by more than 40%, not more than 30%, preferably not more than 20%, preferably not more than 10%. in preferred embodiments, drying does not increase the specific surface of the magnesium hydroxide.
- the initial reference specific surface of the magnesium hydroxide is measured by taking part of the precipitated suspension after hydration and drying it in an oven at 120° C. under static conditions. It has been disclosed that drying in a long gap mill increased the BET value of the magnesium hydroxide up to 40% compared to the initial BET value in the slurry.
- the drying process can be performed by any mean in the art and combinations thereof, such as vacuum filter, pressure filter, spray dryer, paddle dryer, drum dryer, freeze dryer, fluidized-bed dryers and the like. In preferred cases, drying does not include crushing or milling at the same time. In specific embodiments, current invention does not involve drying in a long gap mill.
- the magnesium hydroxide containing material, which is directed to drying can be in slurry or cake form.
- the drying process of the present invention does not involve spray drying of the magnesium hydroxide slurry. This latter drying method performs low-yield and it is energy-intensive. Present invention has advantages over prior art as it does not require the use of dispersing agents and well-defined range of particle size distribution in the slurry.
- the magnesium hydroxide containing material of the present invention holds the majority of the impurities of the magnesium oxide containing material.
- the process of the present invention does not require filtering for removing impurities.
- Impurities are mostly encapsulated in the magnesium hydroxide containing material without affecting adversely the hydration process.
- Impurities are less than 20% and more than 0.5% (loss-free—XRF analysis), preferably less than 10% and more than 1%, such as 8%, 4%, 6%, 2% and the like.
- optional conventional beneficiation processes are combined with present invention if purity increase is required.
- present invention does not include complex formers during hydration for improving purity.
- Additives such as hydroxylamine, ammonium salts, ethylenediaminetetraacetic acids or nitryltriacetic acids are not required for current invention.
- other methods presented in prior art, which involve leaching must include plenty of post washes, purifications and filtering to remove the dissolved impurities and the by-products in order to produce a magnesium hydroxide suitable for mixing with polymers. It is obvious that all these steps burden the environment with chemical waste management. Current invention successfully overcomes these problems.
- the process of the present invention involves milling by any mean that does not increase the specific surface of the magnesium containing material by more than 100%, 50%, 40% or 30%, preferably not more than 20%, preferably not more than 10%.
- Each reference specific surface value of the magnesium containing material is measured each time by taking part of the dried magnesium containing material before each fine milling step.
- the magnesium containing material can be magnesium oxide, magnesium carbonate, magnesium hydroxide and the like.
- the process of the present invention involves milling by any mean that does not increase the specific surface of the magnesium hydroxide by more than 40%, not more than 30%, preferably not more than 20%, preferably not more than 10%. Preferably, milling does not increase the specific surface of the magnesium hydroxide.
- the specific surface of the grinded magnesium hydroxide is lower than prior its milling. Drying and milling in a long gap mill as presented in WO 2008/146089 increased the BET value of the magnesium hydroxide up to 40% compared to the initial BET value in the slurry.
- the milling can be performed in wet or dry conditions, exploiting equipment such as ball mill, agitated bead mil, jet mill, long gap mill, pin mill, pendulum roller mill, disk mill and the like.
- milling is performed at the dried magnesium hydroxide containing material. In other embodiments, milling is performed at the wet magnesium hydroxide containing material.
- milling is performed at both the wet and the dry magnesium hydroxide containing material.
- current invention does not involve milling in a long gap mill.
- the extended milling time which is applied in order to reduce the particle size, induces a considerable increase of the specific surface of the mineral.
- current invention exploits short time for milling with enhanced particle-to-particle attrition, thus balancing the specific surface increase of the mineral.
- milling is performed at the magnesium oxide containing material prior to hydration.
- milling is performed both at the magnesium oxide containing material prior to hydration and the magnesium hydroxide containing material after hydration.
- the particle size reduction that is taking place during hydration in reactor is likely due to crystal transformation, shearing and platelet exfoliation.
- hydro-cyclones, screening, sieving, air-cyclones, sorters, classifiers and the like are equipment that can be combined with current invention.
- a method of producing magnesium hydroxide comprising the steps of (i) hydrating a magnesium oxide containing material at a temperature between 120° C. and 350° C. resulting in magnesium hydroxide containing material, (ii) drying the magnesium hydroxide containing material, (iii) milling the magnesium containing material.
- the steps of the invention are not necessarily executed in that particular order.
- the dried magnesium hydroxide containing material has particles with d 90 of more than 1.5 and less than 50 ⁇ m, preferably more than 2.0 ⁇ m and less than 30 ⁇ m, preferably more than 2.2 ⁇ m and less than 20 ⁇ m. In special embodiments d 90 is less than 10 ⁇ m, less than 8.0 ⁇ m or less than 6.0 ⁇ m.
- the dried magnesium hydroxide containing material of present invention has particles with d 50 of more than 0.5 and less than 20 ⁇ m, preferably more than 1.0 ⁇ m and less than 15 ⁇ m, most preferably more than 1.1 ⁇ m and less than 10 ⁇ m or even 8 ⁇ m.
- d 50 is more than 1.3 ⁇ m or more than 1.5 ⁇ m and less than 5.0 ⁇ m or less than 3.5 ⁇ m.
- particles with d 50 of more than 10 ⁇ m are produced such as 20 ⁇ m, 30 ⁇ m, 25 ⁇ m, 18 ⁇ m, 35 ⁇ m and the like.
- the average particle size of said dried magnesium hydroxide containing material is more than 1.5 ⁇ m and less than 20 ⁇ m.
- a low average particle size is required for mixing with polymers.
- a great presence of fines lower than 1.0 ⁇ m makes harder the compounding with polymers as the viscosity during melt mixing increases.
- the d 10 of the magnesium hydroxide containing material of the present invention as measured by laser diffraction in suspension (Malvern Mastersizer equipment) is more than 0.3 ⁇ m and less than 5.0 ⁇ m, preferably more than 0.5 ⁇ m and less than 3.0 ⁇ m. In specific embodiments, d 10 is more than 0.7 ⁇ m, such as 1.1 ⁇ m, 0.9 ⁇ m, 1.0 ⁇ m and the like. It is an advantage of the current invention compared to other methods in the art that produces a low amount of fines.
- the magnesium hydroxide containing material of the present invention has a narrow particle size distribution suitable for mixing with polymers.
- the dried magnesium hydroxide containing material comprising particles presenting a specific surface (BET) of more than 0.5 m 2 /gr and less than 20 m 2 /gr, preferably more than 1 m 2 /gr and less than 18 m 2 /gr, preferably more than 2 m 2 /gr and less than 15 m 2 /gr, more preferably more than 3 m 2 /gr and less than 13 m 2 /gr.
- BET specific surface
- said specific surface is less than 12.9 m 2 /gr, such as 5 m 2 /gr, 10 m 2 /gr, 12 m 2 /gr, 12.5 m 2 /gr, 4 m 2 /gr, 7.5 m 2 /gr and the like.
- a low BET value of said dried magnesium hydroxide containing material is appropriate for mixing with polymers enabling better dispersion and high filler loadings.
- the degree of conversion of magnesium oxide containing material to magnesium hydroxide containing material should be appropriately adequate for each application.
- the degree of conversion should be more than 70%, preferably more than 80%, such as 85%, 91%, 88%, 96% and the like. Most preferably the degree of conversion is more than 90%.
- the degree of conversion is calculated as the percentage of the MgO (measured in XRF) in the magnesium oxide containing material that has been converted to magnesium hydroxide.
- the magnesium hydroxide containing material according to the present invention can be coated with surface modifiers such as fatty acids, amino-, alkyl- or vinyl- silanes, siloxanes, stearates, titanate or zirconate coupling agents, maleic anhydrite grafted polymers and the like.
- the coating can be applied in wet or dry conditions by any method known in the art.
- the BET value of the magnesium hydroxide can be further reduced compared to the uncoated material due to the presence of surface modifiers.
- the magnesium hydroxide containing material of the present invention is suitable for mixing with polymers.
- said magnesium hydroxide containing material contains already a high amount of magnesium hydroxide (e.g. degree of conversion more than 70%, preferably more than 85%, most preferably more than 90%) prior its mixing with the polymers.
- the range of polymers includes both synthetic and natural ones involving thermoplastics, thermosets and elastomers.
- Such polymers involve polyethylenes, polypropylenes, a-olefins, ethylene-acrylate copolymers, ethylene-vinyl acetate copolymers, polyvinyl chlorides, polyamides, epoxy resins, polyester resins, natural rubber, butyl rubber, ethylene-propylene rubber, acrylic rubber, nitrile rubber, and the like.
- the magnesium hydroxide containing material of the present invention is suitable for mixing with polymers and various polymer blends thereof.
- the magnesium hydroxide containing material according to the present invention induces flame retardant properties in the polymer compound. Beneficial on said properties is purity and high degree of conversion. Present invention exploits a broad spectrum of purities, while is able to achieve a high degree of conversion. Said magnesium hydroxide is a halogen-free flame retardant mineral.
- a magnesium oxide containing material with 91% purity which was dry grinded at d 50 of 300 ⁇ m and presenting a BET value of 2.2 m 2 /gr, was hydrated in distilled water at 10 wt. % solid content in reactor at 190° C. for 2 h.
- a magnesium oxide containing material with 93% purity which was grinded at d 50 of 28 ⁇ m and presenting a BET value of 0.7 m 2 /gr, was hydrated in distilled water at 10 wt. % solid content in reactor at 190° C. for 2 h.
- a magnesium oxide containing material with 96% purity which was dry grinded at d 50 of 55 ⁇ m and presenting a BET value of 0.8 m 2 /gr, was hydrated in distilled water at 10 wt. % solid content in reactor at 190° C. for 2 h.
- a magnesium oxide containing material with 96% purity which was dry grinded at 0-1 mm particle size distribution and presenting a BET value of 11.7 m 2 /gr, was hydrated in distilled water at 10 wt. % solid content in reactor at 190° C. for 2 h.
- a magnesium oxide containing material with 96% purity which was dry grinded at d 50 of 75 ⁇ m and presenting a BET value of 7.5 m 2 /gr, was hydrated in distilled water at 10 wt. % solid content at 80° C. for 24 h.
- a magnesium oxide containing material with 96% purity which was dry grinded at d 50 of 4.5 ⁇ m and presenting a BET value of 31.7 m 2 /gr, was hydrated in distilled water at 10 wt. % solid content in reactor at 190° C. for 2 h.
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GR20180100313 | 2018-07-12 | ||
GR20180100313A GR20180100313A (el) | 2018-07-12 | 2018-07-12 | Μεθοδος παραγωγης υδροξειδιου του μαγνησιου |
PCT/GR2019/000047 WO2020012202A1 (en) | 2018-07-12 | 2019-07-04 | Method of producing magnesium hydroxide |
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US20210300775A1 US20210300775A1 (en) | 2021-09-30 |
US20220153602A9 true US20220153602A9 (en) | 2022-05-19 |
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US (1) | US20220153602A9 (el) |
EP (1) | EP3820819A1 (el) |
AU (1) | AU2019300376B2 (el) |
BR (1) | BR112021000481A2 (el) |
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US2898194A (en) * | 1955-12-23 | 1959-08-04 | Basic Inc | Beneficiation of magnesite ores |
SU559899A1 (ru) * | 1975-05-04 | 1977-05-30 | Институт общей и неорганической химии АН Белорусской ССР | Способ получени гидроокиси магни |
GB1514081A (en) | 1975-05-30 | 1978-06-14 | Kyowa Chem Ind Co Ltd | Particulate magnesium hydroxide |
JPH0248414A (ja) * | 1988-08-09 | 1990-02-19 | Mitsubishi Mining & Cement Co Ltd | 水酸化マグネシウムの製造方法 |
AT392774B (de) * | 1989-05-05 | 1991-06-10 | Veitscher Magnesitwerke Ag | Feinpulveriges magnesiumhydroxid und verfahren zu dessen herstellung |
IE921328A1 (en) * | 1992-04-23 | 1993-11-03 | Defped Ltd | Particulate magnesium hydroxide |
US5662881A (en) | 1992-10-29 | 1997-09-02 | Daicel Abosisangyo Co. | Apparatus and method for the production of active magnesium hydroxide |
IL112385A (en) | 1994-01-21 | 1998-08-16 | Flamemag International Gie | Process for preparing magnesium hydroxide for extinguishing flames |
EP0791559B1 (de) * | 1996-02-20 | 2000-09-13 | MAGNIFIN, Magnesiaprodukte Gesellschaft mbH | Verfahren zur Herstellung eines kristallinen Magnesiumhydroxids |
EP0958243A1 (en) * | 1997-01-31 | 1999-11-24 | Solutia Inc. | Hydration of alkaline earth metal oxide to produce alkaline earth metal hydroxide |
JP5350232B2 (ja) | 2006-06-21 | 2013-11-27 | マルテインスベルク・ゲゼルシヤフト・ミツト・ベシユレンクテル・ハフツング | 水酸化アルミニウムの製造方法 |
GB0812714D0 (en) * | 2008-07-10 | 2008-08-20 | Imerys Minerals Ltd | Magnesium hydroxide |
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GR20180100313A (el) | 2020-03-18 |
US20210300775A1 (en) | 2021-09-30 |
WO2020012202A1 (en) | 2020-01-16 |
EP3820819A1 (en) | 2021-05-19 |
BR112021000481A2 (pt) | 2021-04-06 |
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