US2318555A - Cleansing agent and the - Google Patents
Cleansing agent and the Download PDFInfo
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- US2318555A US2318555A US2318555DA US2318555A US 2318555 A US2318555 A US 2318555A US 2318555D A US2318555D A US 2318555DA US 2318555 A US2318555 A US 2318555A
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- 239000003599 detergent Substances 0.000 title description 76
- 239000000463 material Substances 0.000 description 84
- 239000007789 gas Substances 0.000 description 72
- 239000007787 solid Substances 0.000 description 52
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 42
- 239000002245 particle Substances 0.000 description 40
- 239000000376 reactant Substances 0.000 description 34
- 238000004519 manufacturing process Methods 0.000 description 30
- 229910052910 alkali metal silicate Inorganic materials 0.000 description 28
- 239000000203 mixture Substances 0.000 description 28
- 239000000047 product Substances 0.000 description 26
- CDBYLPFSWZWCQE-UHFFFAOYSA-L sodium carbonate Chemical compound [Na+].[Na+].[O-]C([O-])=O CDBYLPFSWZWCQE-UHFFFAOYSA-L 0.000 description 24
- 238000000034 method Methods 0.000 description 22
- 238000005296 abrasive Methods 0.000 description 20
- 229910052938 sodium sulfate Inorganic materials 0.000 description 18
- 239000000725 suspension Substances 0.000 description 18
- 238000006243 chemical reaction Methods 0.000 description 16
- 239000007795 chemical reaction product Substances 0.000 description 16
- 238000004140 cleaning Methods 0.000 description 16
- OKTJSMMVPCPJKN-UHFFFAOYSA-N carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 14
- 239000000567 combustion gas Substances 0.000 description 14
- PMZURENOXWZQFD-UHFFFAOYSA-L na2so4 Chemical compound [Na+].[Na+].[O-]S([O-])(=O)=O PMZURENOXWZQFD-UHFFFAOYSA-L 0.000 description 14
- 239000004576 sand Substances 0.000 description 14
- 239000001187 sodium carbonate Substances 0.000 description 14
- 229910000029 sodium carbonate Inorganic materials 0.000 description 14
- 235000011152 sodium sulphate Nutrition 0.000 description 14
- 239000011248 coating agent Substances 0.000 description 12
- 238000000576 coating method Methods 0.000 description 12
- HEMHJVSKTPXQMS-UHFFFAOYSA-M sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 12
- 229910052783 alkali metal Inorganic materials 0.000 description 10
- 230000001747 exhibiting Effects 0.000 description 10
- 239000000377 silicon dioxide Substances 0.000 description 10
- 239000004115 Sodium Silicate Substances 0.000 description 8
- NTHWMYGWWRZVTN-UHFFFAOYSA-N Sodium silicate Chemical class [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 description 8
- 229910000288 alkali metal carbonate Inorganic materials 0.000 description 8
- 150000008041 alkali metal carbonates Chemical class 0.000 description 8
- 238000002485 combustion reaction Methods 0.000 description 8
- 230000005484 gravity Effects 0.000 description 8
- 238000010438 heat treatment Methods 0.000 description 8
- 230000004048 modification Effects 0.000 description 8
- 238000006011 modification reaction Methods 0.000 description 8
- 239000003208 petroleum Substances 0.000 description 8
- 230000001603 reducing Effects 0.000 description 8
- 238000000926 separation method Methods 0.000 description 8
- 235000019351 sodium silicates Nutrition 0.000 description 8
- 150000001340 alkali metals Chemical class 0.000 description 6
- 229910052799 carbon Inorganic materials 0.000 description 6
- 239000003795 chemical substances by application Substances 0.000 description 6
- 239000000446 fuel Substances 0.000 description 6
- 229910052751 metal Inorganic materials 0.000 description 6
- 239000002184 metal Substances 0.000 description 6
- 238000002156 mixing Methods 0.000 description 6
- 239000002006 petroleum coke Substances 0.000 description 6
- 239000011541 reaction mixture Substances 0.000 description 6
- 150000004760 silicates Chemical class 0.000 description 6
- 239000000344 soap Substances 0.000 description 6
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 6
- 229910000851 Alloy steel Inorganic materials 0.000 description 4
- KKCBUQHMOMHUOY-UHFFFAOYSA-N Sodium oxide Chemical compound [O-2].[Na+].[Na+] KKCBUQHMOMHUOY-UHFFFAOYSA-N 0.000 description 4
- 229910000831 Steel Inorganic materials 0.000 description 4
- 239000003082 abrasive agent Substances 0.000 description 4
- 229910052936 alkali metal sulfate Inorganic materials 0.000 description 4
- 239000011449 brick Substances 0.000 description 4
- 239000006229 carbon black Substances 0.000 description 4
- 239000003575 carbonaceous material Substances 0.000 description 4
- 239000003245 coal Substances 0.000 description 4
- 150000001875 compounds Chemical class 0.000 description 4
- 230000004927 fusion Effects 0.000 description 4
- 238000007429 general method Methods 0.000 description 4
- 239000007788 liquid Substances 0.000 description 4
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 4
- 239000003345 natural gas Substances 0.000 description 4
- 239000008262 pumice Substances 0.000 description 4
- 239000011734 sodium Substances 0.000 description 4
- 229910052708 sodium Inorganic materials 0.000 description 4
- 239000011780 sodium chloride Substances 0.000 description 4
- 150000003388 sodium compounds Chemical class 0.000 description 4
- 229910001948 sodium oxide Inorganic materials 0.000 description 4
- 239000010959 steel Substances 0.000 description 4
- QAOWNCQODCNURD-UHFFFAOYSA-L sulfate Chemical compound [O-]S([O-])(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-L 0.000 description 4
- BVKZGUZCCUSVTD-UHFFFAOYSA-L Carbonate dianion Chemical compound [O-]C([O-])=O BVKZGUZCCUSVTD-UHFFFAOYSA-L 0.000 description 2
- 229940108066 Coal Tar Drugs 0.000 description 2
- 101700080604 INVE Proteins 0.000 description 2
- 239000005909 Kieselgur Substances 0.000 description 2
- 229910001209 Low-carbon steel Inorganic materials 0.000 description 2
- 210000003800 Pharynx Anatomy 0.000 description 2
- 101700050571 SUOX Proteins 0.000 description 2
- PFUVRDFDKPNGAV-UHFFFAOYSA-N Sodium peroxide Chemical compound [Na+].[Na+].[O-][O-] PFUVRDFDKPNGAV-UHFFFAOYSA-N 0.000 description 2
- ASCUXPQGEXGEMJ-GPLGTHOPSA-N [(2R,3S,4S,5R,6S)-3,4,5-triacetyloxy-6-[[(2R,3R,4S,5R,6R)-3,4,5-triacetyloxy-6-(4-methylanilino)oxan-2-yl]methoxy]oxan-2-yl]methyl acetate Chemical compound CC(=O)O[C@@H]1[C@@H](OC(C)=O)[C@@H](OC(C)=O)[C@@H](COC(=O)C)O[C@@H]1OC[C@@H]1[C@@H](OC(C)=O)[C@H](OC(C)=O)[C@@H](OC(C)=O)[C@H](NC=2C=CC(C)=CC=2)O1 ASCUXPQGEXGEMJ-GPLGTHOPSA-N 0.000 description 2
- VUTSITSGGYCKFP-UHFFFAOYSA-J [C+4].[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O Chemical compound [C+4].[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O VUTSITSGGYCKFP-UHFFFAOYSA-J 0.000 description 2
- 238000005299 abrasion Methods 0.000 description 2
- 230000001464 adherent Effects 0.000 description 2
- 239000003513 alkali Substances 0.000 description 2
- 150000008044 alkali metal hydroxides Chemical class 0.000 description 2
- -1 alkali metal salt Chemical class 0.000 description 2
- 238000004458 analytical method Methods 0.000 description 2
- 230000001174 ascending Effects 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 239000011280 coal tar Substances 0.000 description 2
- 239000000571 coke Substances 0.000 description 2
- 238000004891 communication Methods 0.000 description 2
- 238000010924 continuous production Methods 0.000 description 2
- 239000010431 corundum Substances 0.000 description 2
- 229910052593 corundum Inorganic materials 0.000 description 2
- 235000011180 diphosphates Nutrition 0.000 description 2
- 238000009826 distribution Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000004534 enameling Methods 0.000 description 2
- 238000005755 formation reaction Methods 0.000 description 2
- 238000007499 fusion processing Methods 0.000 description 2
- 239000004519 grease Substances 0.000 description 2
- 150000002430 hydrocarbons Chemical class 0.000 description 2
- 230000003993 interaction Effects 0.000 description 2
- 235000013379 molasses Nutrition 0.000 description 2
- 230000001590 oxidative Effects 0.000 description 2
- MYMOFIZGZYHOMD-UHFFFAOYSA-N oxygen Chemical compound O=O MYMOFIZGZYHOMD-UHFFFAOYSA-N 0.000 description 2
- 229910052760 oxygen Inorganic materials 0.000 description 2
- 239000001301 oxygen Substances 0.000 description 2
- 238000010422 painting Methods 0.000 description 2
- 230000002093 peripheral Effects 0.000 description 2
- 239000011295 pitch Substances 0.000 description 2
- 239000010453 quartz Substances 0.000 description 2
- 229910052904 quartz Inorganic materials 0.000 description 2
- 239000011044 quartzite Substances 0.000 description 2
- 230000035484 reaction time Effects 0.000 description 2
- 230000001172 regenerating Effects 0.000 description 2
- 230000001105 regulatory Effects 0.000 description 2
- 150000003839 salts Chemical class 0.000 description 2
- KEAYESYHFKHZAL-UHFFFAOYSA-N sodium Chemical compound [Na] KEAYESYHFKHZAL-UHFFFAOYSA-N 0.000 description 2
- 159000000000 sodium salts Chemical class 0.000 description 2
- 239000004449 solid propellant Substances 0.000 description 2
- 238000005507 spraying Methods 0.000 description 2
- 238000010025 steaming Methods 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 239000000758 substrate Substances 0.000 description 2
Images
Classifications
-
- C—CHEMISTRY; METALLURGY
- C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
- C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
- C11D3/00—Other compounding ingredients of detergent compositions covered in group C11D1/00
- C11D3/02—Inorganic compounds ; Elemental compounds
- C11D3/12—Water-insoluble compounds
- C11D3/14—Fillers; Abrasives ; Abrasive compositions; Suspending or absorbing agents not provided for in one single group of C11D3/12; Specific features concerning abrasives, e.g. granulometry or mixtures
Definitions
- This invention relates to an abrasive detergent and a process for the manufacture thereof. More particularly, this invention relates to a material having a combined detergent and abrasive action and a process for fthe manufacture thereof. Specifically, this invention relates to a material comprising a superficial iayer of alkali metal silicates formed upon the surface of a siliceous particle and a process for the manufacture thereof, said material exhibiting a combined abrasive and detergent action.
- One object of the instant invention is to provide an improved cleansing agent and a method for producing the same.
- a further object. of this invention is to provide a cleansing agent exhibiting initially a high detergent action which progressively declines during use and a method for producing the'same.
- Another object of this invention is to provide a cleansing agent exhibiting 'initially a low abrasive action which progressively increases during use and a method for producing the same.
- An additional object of this invention is to provide a cleansing agent exhibiting an initially high detergent action which progressively declines during use and is simultaneously replaced by a progressively increasing abrasive action and a method for producing the same.
- Another object of this invention is to particleslincreases. so that while Ithev detergent provide an improved cleansing agent by a continuous process. Further objects of this invention will become evident from a perusal of the instant specification.
- my invention embraces a material comprising a siliceous core with a superficial coating orv glaze of alkali metal silicates formed thereon s and a method for producing such a material.
- alkali metal silicates may be prepared by fusing a mixture of siliceous material and alkali metal carbonate or a mixture of siliceous material, a1- kaii metal sulfate, and carbon at high temperatures.
- alkali metal silicates of varying alkali'metal oxide-silicate ratios may be prepared. When sodium compounds are used.
- sodium silicates having ratios of from 1:1 to 1:4.2, more or less, may be formed, material having a ratio of 1:3.4 being especially common and widely used.
- discrete particles of siliceous material are reacted by a method -and means to-be described in detail subsequently so that.
- the reaction product comprises discreteparticles. each taking the form of a core of siliceous material bearing a layer or glaze of alkali metal silicates formed thereon.
- the outermost layers of the resulting particles consist of highly alkaline silicates; -the alkalinity decreases progressively as the center of the particle is approached until the unchanged siliceous core is reached. It is obvious that when these discrete particles are used in conjunction with water to clean surfaces by the well known techniques employed with cleansing powdersof the prior art, a gradual change in action is exhibited. Initially, by solution of the outermost layers, a highly alkaline detergent solutionls produced, but due to the softness of the outer surfaces of the discrete particles the abrasive action is nil or practically so. As the cleaning operation is continued, the
- silicates removed from the surfaces of the discrete particles become progressively less alkaline, but simultaneously the surface hardness of these action decreases the abrasive action increases.
- a core of siliceous matter remains, which. while incapable of furnishing further material of detergent properties to the liquid medium, is extremely hard and has a high abrasive action.
- the improved cleansing agents of the instant invention are particularly suited for cleaning surfaces which can stand a reasonable amount of abrasion lwithout harm.
- suitable uses may be mentioned the cleaning of heavy duty floors, for example garage floors, machine shop floors, chemical plant floors and the like, the cleaning of decks, the cleaning of grease and scale from steel sheet. castings, forgings and the like prior to enameling, painting or similar treatment. the 'cleaning of metal surfaces in general, and the removal of dirt and grime from buildings, monuments and other structures.
- alkali metal silicates are largely prepared by fusing a mixture of a siliceous material and alkali metal carbonate or by fusing a mixture of siliceous material, alkali metal sulfate and carbon. These fusions are usually conducted batchwise in open hearth regenerative type furnaces, but reverberatory furnaces may be used. It is obvious that these methods may be applied to the manufacture of the improved cleansing agents of the Instant invention.
- discrete particles of siliceous material may be given a superflcial adherent layer of alkali metal carbonate or of a mixture of alkali metal sulfate and carbon, the quantity of alkali metal salt used being insufcient to react with all of the siliceous material.
- a superficial layer or glaze of alkali metal silicates forms on the surface of the siliceous material. Unless under extremely careful control, during the fusion the discrete particles fuse together and defeat the objects of this invention. If large particles of siliceous material are employed.
- this fusing together may be largely overcome by careful control of the fusion process, and by lightly crushing the reaction product the particles that have coalesced may be disrupted.
- the objects of this invention are usually accomplished only when siliceous material having a particle size larger than is ordinarily wanted is employed.
- siliceous material having a particle size within the usually desired limits is employed, a. microscopically homogeneous fused mass results.
- reactor I designates a reactor suitable for the purpose of this invention. It will be observed that this reactor takes the form of an elongated conduit having a slnuous conformation. The exact form and conformation of the reactor are largelymatters of choice; in the present instance the particular conformation lselected was chosen for the purpose of keeping the height ⁇ of the reactor Within reasonable limits.
- the reactor I is supplied with hot gases from hot gas producer 2, which are introduced into the reactor I through line 3. Hot gas producer 2 is so constructed as to enable combustion to proceed therein at moderately elevated pressures, for example, pressures in the neighborhood of 45 pounds per square'inch if desirable or necessary.
- valves I and 8 When valves I and 8 are raised, communication between 5 and 6 is cut oil while 5 is open means are provided for heating the solid re ⁇ actants in bin or hopper 4.
- this heating means takesthe form of a tubular heat exchanger in 6. Solid reactants flow through the tubes I0 in this exchanger while the tubes themselves are surrounded by suitable heated uid entering through line II and leaving through line I2.
- Solid reactants are moved from hopper or bln 4 by means of screwr conveyor I3 or other similar suitable device and are thereby conveyed to re,- actor I.
- screwr conveyor I3 By using a properly designed screw conveyor, it is not absolutely essential to divide bin or hopper 4 yinto upper and lower sections 5 and 6 separated by valve 8.
- Properly designed screw conveyors are able to seal against appreciable pressure so that I3 acts to prevent blow backs from reactor I through hopper 4.
- solid reactants may be discharged by screw I3 into a Venturi throat I4 disposed in reactor I. By this means suspension of the solid reactants in the gases entering through 3 is greatly facilitated.
- the suspension of solid reactants in the gases entering through line 3 passes through reactor I in which reaction occurs.
- the reaction products leaving reactor I are in av highly heated condition and should be cooled appreciably before being worked up. This may be accomplished by any suitable means, for example by spraying water into the suspension through line I5 or by passing the suspension over coils I6 through which water is owing 0r both.
- Reaction products are now separated from the partially cooled suspension. This separation is usually accomplished in two steps. A rough separation occurs in the rst, while the greater part of the remaining reaction products is removed iii. the second. Any suitable separation means may be employed. In the ligure the use of a gravity separator and a cyclone separator in series is shown, but other separation means, for example Cottrell precipators, may be used. In the flgure, the partially cooled suspension is shown passing to gravity separator Il through line I8. In gravity separator I'l, the velocity of the suspension is much reduced and the direction of. flow is changed several times. Separated solids may be removed through lines I9. Partially separated suspension is sent from gravity separator I'I through line 20 to cyclone separator 2
- gaseous, liquid or solid fuel may be introduced into the preheated air stream via line 28, this fuel then being partially or completely burned in hot gas producer 2.
- the suspension leaving reactor I contains appreciable sensible heat, it is advisable to recover ⁇ as much of this as possible in the form of useful work. This may be done in a number oi ways. For example, large amounts of steam may be generated in coil I8. Also, the hot gas may be used to drive a turbine, although it is preferably used for this purpose-only after the solids suspended therein have been removed. As shown in the figure, part of the heat content of the gas is recovered and used to preheat air while another part is devoted to preheating the solid reactants.
- hot gas generator 2 and reactor I As temperature conditions are very severe in hot gas producer 2 and reactor I, these must be constructed with this in mind. It has been found that an inner layer of high grade refractory brick backed by two layers of fire insulating value, the whole being surrounded with sheet steel, constitutes an economic and satisfactory method for constructing hot gas generator 2 andreactor I.
- Line I5 and coil I6 are preferably made from 18-8 or similar high temperature alloy steel. The remaining parts of the apparatus may be constructed from alloy steel or ordinary mild steel.
- the reactor shown in the ligure consists of an elongated conduit of sinuous form having three legs in which the reactants rst pass upward, then downward and then upward again, this'particular conformation is illustrative only and in no way limits the scope of this invention.
- the number of legs possessed by the reactor and the direction of flow therein are immaterial.
- equally satisfactory resultsv are obtained with reactors having one, two, four or more legs.
- Reactants if desired, may be introduced into the upper portion of a descending leg and such reactors again may have one ormore legs.
- the reactor is shown disposed vertically, equally satisfactory results have been obtained using horizontal reactors or reactors with alternating vertical and horizontal legs.
- the hot gas stream may be inert, oxidizing or reducing in its action.
- an inert hotgas stream is to be preferred; that is, the theoretical amount of air is introduced through line 21. Circulation is continued without introduction of solid reactant until the whole system is brought up to temperature, at which time screw I3 is started and the silica particles coated with sodium carbonate are introduced into the reactor at a rate of about 14.5 pounds per minute.
- Conditions are so regulated that the temperature in cyclone separator 2
- the re-y actor employed has a cross sectional area of one square foot. Product is removed from lines I9 and line 22.
- Hot gas circulation is continued without introduction of solid reactants until the whole system is brought up to reaction described, is introduced into reactor I at a rate of about 5.5 pounds per minute. Temperatures are similar to those described in Example 1. Product is removed from lines I9 and line 22.
- Example 3 In this example, as the hot gas is produced' the theoretical amount One hundred pounds of high grade Ottawa sand of about 20 mesh size are mixed with about 80 pounds of a 17.6 A. P. I. petroleum fraction representing 20% bottoms on Mid-Continent crude. Twenty-six pounds of sodium carbonate are added and the whole, after thorough mixing, is heated to drive off volatile matter. This may be accomplished, for example, by heating the material in an inert atmosphere in a slowly rotating kiln or similar device. The resulting material is charged to hopper or bin 4 of an appa-t ratus similar to that pictured in the figure.
- the whole apparatus is brought up to temperature by burning a suitable fuel in hot gas producer 2, following which this is gradually discontinued, solid reactants being simultaneously cut into reactor I by starting screw I3 while preheated air is added to line 3 from line 21 either by means of a bypass (not shown) or via hot gas producer 2.
- a suitable fuel in hot gas producer 2
- solid reactants being simultaneously cut into reactor I by starting screw I3 while preheated air is added to line 3 from line 21 either by means of a bypass (not shown) or via hot gas producer 2.
- the silica-carbonsodium carbonate mixture is added to reactor I at a rate about 14.5 pounds per mlnute,while preheated air is l added to line 3 at a rate of-about 175 cubic feet per minute, measured at standard conditions. Temperatures are similar to those quoted in Example l. Reaction products are removed from lines I9 and line 22.
- Example 4 hot gas is produced autogenously, so that hot gas producer 2 is not required except perhaps initially when it is Preferably used to bring the whole apparatus up to temperature.
- a bypass between line 21 and line 3 may be constructed so as to short circuit gas producer 2 when temperature has been achieved.
- One hundred pounds of high grade Ottawa sand of about 80 mesh are mixed with 110 pounds of a 17.6 A. P. I. petroleum fraction representing 20% bottoms from Mid-Continent crude. Following this, 35 pounds of sodium sulfate are added and after thorough mixing volatile matter is driven oil, for example, by heating the whole in an inert atmosphere lna slowly revolving kiln or similar device.
- the resulting material is charged to hopper or bin 4 of an apparatus similar to that shown in the ligure.
- the whole apparatus is brought up tof/temperature by burning a suitable fuel in hot gas producer 2, following which this is gradually discontinued, solid reactants being simultaneously cut into reactor I by starting screw I3 while preheated air is added to line 3 from line 21, either by means of a bypass (not shown) or via hot gas producer 2.
- the silica-carbonsodium sulfate mixture is added to reactor I at a rate of about '7 pounds per minute, while preheated air is added to line 3 at a rate of about 85 cubic feet per minute, measured at standardconditions. Temperatures are similar to those given in Example l. Reaction products are removed from lines I9 and line 22.
- ducer gas is at a temperature somewhat above 850 F. and preferably has a'low content of solids.
- Air is introduced into hot gas producer 2 through line 21 at a rate of 40-45 cubic feet per minute, measured atstandard conditions.
- the combustionvthat occurs Yin hot gas producer 2 soon brings the Whole apparatus up to temperature, at which time screw I3 is started and the sand-sodium sulfate mixture is added tothe reactor I at a rate of about 5 pounds per minute.
- Product is removed from lines I9 and line 22. Temperatures are approximately as specified in Example 1.
- the solid reaction mixture is usually obtained in the form of lumps or aggregates of appreciable size. This is especially true in Examples 2, 3 and 4. Such lumps or aggregates not only are apt' to clog hopper or bin 4 and screw I3 but also they are difficult or impossible to suspend in the gas stream entering reactor I through line 3. For these reasons it is advisable to reduce these lumps or aggregates to suitable size before being introduced into hopper or bin 4. With the solid reaction mixtures formed in accord with Examples land 5, this is easily accomplished by gentle crushing, working through sieves, or by similar means.
- the solid reactant mixtures prepared in accord with Examples 2, 3 and 4 are usually obtained in the form of lumps exhibiting more or less porosity depending upon the exact conditions employed in removing volatile hydrocarbons. -These materials require crushing prior to charging to the hopper or bin 4. The exact size of the material to be charged depends upon the mesh size of the siliceous material employed and on the porosity of the carbonaceous matter. Ob-
- carbonaceous material commonly known as petroleum coke or oil coke is described in Examples 2, 3 and 4, it is obvious that other suitable forms of carbonaceous material may be used. Preferably such material should have a low ash content.
- suitable materials for the formation of carbonaceous matter in accord with the teachings of Examples 2, 3 and 4 include molasses and coal tar pitches. Also, part of all of the carbonaceous lmatter may be added to the solid reactants in other ways.
- Example 3 instead of proceeding as described, a silica-sodium carbonate mixture may be prepared in the proportions outlined in Example 1 and in the same or similar manner, and this may be mixed with about 10 pounds of petroleum coke, carbon black or low-ash coal and the whole charged to'hopper or bin 4.
- a silica-sodium sulfate-carbon mixture may be made using the proportions of Example 2 and to this may be added 12-13 pounds of petroleum coke, carbon black, or lowash coal and the whole charged, after mixing, to hopper or bin 4.
- the nature of the cleansing agent formed may be varied' appreciably by changing the contact time in reactor I. Obviously, changes in contact time can have little or no eil'ect on the analysis discrete f variable actions just of the products formed. but'it has been found that the distribution of components is affected to an appreciable extent.
- contact time is short the products formed consist largely of discrete particles having a comparatively large silica. core bearing a comparatively thin superficial layer of alkali metal silicates having high alkalinity. Such materials when used as cleansing'agents tion which rapidlychanges to a high vabrasive action.- If, on the other hand.
- the contact time is long, the products formed consist largely of particles having a comparatively small silica core bearing a comparatively thick layer of alkali metal silicates having low alkalinity.
- Such materials when used as cleansing agents exhibit an initially moderate detergent action which slowly changes into an increasingly severe abrasive action.
- a reactor of cross sectional area X and length L may give a longer contact time than calculated and in some cases a contact time manyfold longer than calculated, while a reactor of area 0.25X and length 4L may give a contact time very close to calculated.
- required contact time is a function of the material charged..
- the silica-sodium sulfate system requires a longer reaction time .than the silica-sodium carbonate.
- the contact time required to produce a cleansing agent of any desired set of properties also depends upon the size of the silica par ticles charged. While it is impossible to give any definite figures, it may be stated .that under the conditions outlined in Example l, a cleansing agent of average properties was obtained at a calculated contact time of 3 seconds.
- silica material and sodium salt are so proportioned as to give an overall exhibit an initially high detergent acgive definite contact times4 prior to use.
- the cleansing agents of this invention are primarily for useln what may be termed heavy duty cleaning. Theoretically it should be possible to make these improved cleansing agents with the inertfsiiica core as small as desired, .so that the materials can e used in cleansing operations of higher order. Actually. however, this has been found diilicult to accomplish, due toa few unreacted or only partially reacted silica particles that are usually formed simultaneously with the desired y product.
- -products of this invention may be incorporated with other detergent and/or abrasive materials
- suitable additional detergent agents may be mentioned soaps, alkali metal carbonates, alkali metal hydroxides, alkali metal pyrophosphates, alkali metal metaphosphates. and the like.
- abrasives may be mentioned pumice, sand, corundum, and the like.
- inert materials may be added.
- a particularly effective cleansing agent may be made by coating the products formed according to the teachings of thisy invention with sodium hydroxide or with soap.
- a process for the manufacture of a cleansing agent composed of silica particles coated with an autogenous layer of alkali metal silicates consisting of suspending, silica particles coated with alkali metals in a stream of combustion gases at elevated temperature for a time suiiicient to effect reaction between the selected coating mafalling Lin the approximatev of combustion gases.
- a process for the manufacture of a cleansl5 ing agent composed oi' silica particles coated with an autogenous layer of sodium silicates consisting of suspending silica particles coated with sodium sulfate in a stream of combustion gases at elevated temperatures for a time sumcient to eil'ect reaction between said sodium sulfate and the peripheral portions of the silica particles and separating the resulting product from said stream of combustion gases.
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- Chemical & Material Sciences (AREA)
- Inorganic Chemistry (AREA)
- Life Sciences & Earth Sciences (AREA)
- Engineering & Computer Science (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Oil, Petroleum & Natural Gas (AREA)
- Wood Science & Technology (AREA)
- Organic Chemistry (AREA)
- Compounds Of Alkaline-Earth Elements, Aluminum Or Rare-Earth Metals (AREA)
Description
May 4, 1943- R. F. RUTHRUFF 2,318,555
CLEANSING AGENT AND THE MANUFACTURE THEREOF Filed Jan. l5, 1940 CYCL 0/14.F 5MM/Wm INVE R Patented Mey 4, 1943 CLEANSING AGENT AND MANUFACTURE THEREOF I tobert F. Ruthmfl, Chicago,'lll. Application January 15, 1940, Serial No. 313,899
7 Claims.
This invention relates to an abrasive detergent and a process for the manufacture thereof. More particularly, this invention relates to a material having a combined detergent and abrasive action and a process for fthe manufacture thereof. Specifically, this invention relates to a material comprising a superficial iayer of alkali metal silicates formed upon the surface of a siliceous particle and a process for the manufacture thereof, said material exhibiting a combined abrasive and detergent action. Y
The detergent action of various alkali metal silicates has been known for a number of years. For example. various alkali metal silicates have been employed in the compounding of soaps for at least 75 years. Similarly, the addition of abray sive agents such as finely divided pumice iodetergents to increase the effectiveness of the latter is well known in the art. However, as far as I am aware, no one has previously suggested an abrasive-detergent combination in which these two elements are combined in a single whole that initially exhibits a high detergent action which as it declines is gradually replaced by an increasingly severe abrasive action.
One object of the instant invention is to provide an improved cleansing agent and a method for producing the same. A further object. of this invention is to provide a cleansing agent exhibiting initially a high detergent action which progressively declines during use and a method for producing the'same. Another object of this invention is to provide a cleansing agent exhibiting 'initially a low abrasive action which progressively increases during use and a method for producing the same. An additional object of this invention is to provide a cleansing agent exhibiting an initially high detergent action which progressively declines during use and is simultaneously replaced by a progressively increasing abrasive action and a method for producing the same. Another object of this invention is to particleslincreases. so that while Ithev detergent provide an improved cleansing agent by a continuous process. Further objects of this invention will become evident from a perusal of the instant specification.
Briey, my invention embraces a material comprising a siliceous core with a superficial coating orv glaze of alkali metal silicates formed thereon s and a method for producing such a material. As is well known to those skilled in the art, alkali metal silicates may be prepared by fusing a mixture of siliceous material and alkali metal carbonate or a mixture of siliceous material, a1- kaii metal sulfate, and carbon at high temperatures. By this means alkali metal silicates of varying alkali'metal oxide-silicate ratios may be prepared. When sodium compounds are used. sodium silicates having ratios of from 1:1 to 1:4.2, more or less, may be formed, material having a ratio of 1:3.4 being especially common and widely used. In accord with the teachings of my invention, discrete particles of siliceous material are reacted by a method -and means to-be described in detail subsequently so that.
the reaction product comprises discreteparticles. each taking the form of a core of siliceous material bearing a layer or glaze of alkali metal silicates formed thereon. The outermost layers of the resulting particles consist of highly alkaline silicates; -the alkalinity decreases progressively as the center of the particle is approached until the unchanged siliceous core is reached. It is obvious that when these discrete particles are used in conjunction with water to clean surfaces by the well known techniques employed with cleansing powdersof the prior art, a gradual change in action is exhibited. Initially, by solution of the outermost layers, a highly alkaline detergent solutionls produced, but due to the softness of the outer surfaces of the discrete particles the abrasive action is nil or practically so. As the cleaning operation is continued, the
silicates removed from the surfaces of the discrete particles become progressively less alkaline, but simultaneously the surface hardness of these action decreases the abrasive action increases. Theoretically, when all alkali metal silicate has been 'removed from the outer surfaces of the discrete particles, a core of siliceous matter remains, which. while incapable of furnishing further material of detergent properties to the liquid medium, is extremely hard and has a high abrasive action.
The improved cleansing agents of the instant invention are particularly suited for cleaning surfaces which can stand a reasonable amount of abrasion lwithout harm. Among such suitable uses may be mentioned the cleaning of heavy duty floors, for example garage floors, machine shop floors, chemical plant floors and the like, the cleaning of decks, the cleaning of grease and scale from steel sheet. castings, forgings and the like prior to enameling, painting or similar treatment. the 'cleaning of metal surfaces in general, and the removal of dirt and grime from buildings, monuments and other structures.
As has been mentioned previously, alkali metal silicates are largely prepared by fusing a mixture of a siliceous material and alkali metal carbonate or by fusing a mixture of siliceous material, alkali metal sulfate and carbon. These fusions are usually conducted batchwise in open hearth regenerative type furnaces, but reverberatory furnaces may be used. It is obvious that these methods may be applied to the manufacture of the improved cleansing agents of the Instant invention. For example, discrete particles of siliceous material may be given a superflcial adherent layer of alkali metal carbonate or of a mixture of alkali metal sulfate and carbon, the quantity of alkali metal salt used being insufcient to react with all of the siliceous material. On fusing such a reaction mixture as above described, a superficial layer or glaze of alkali metal silicates forms on the surface of the siliceous material. Unless under extremely careful control, during the fusion the discrete particles fuse together and defeat the objects of this invention. If large particles of siliceous material are employed. this fusing together may be largely overcome by careful control of the fusion process, and by lightly crushing the reaction product the particles that have coalesced may be disrupted. However, by using the apparatus of the prior art, the objects of this invention are usually accomplished only when siliceous material having a particle size larger than is ordinarily wanted is employed. When siliceous material having a particle size within the usually desired limits is employed, a. microscopically homogeneous fused mass results.
For the above reasons it is usually advisable to employ the method and apparatus now to be described, or suitable modifications thereof, in the manufacture of the improved cleansing agents of the instant invention. Briey, discrete particles of siliceous material of the desired particle size are given a superflcial coating of a sufficient amount ol material or materials capable of reacting at elevated temperatures with the siliceous substrate to form a superficial glaze or coating of alkali metal silicates thereon. The resulting material is suspended in a moving stream of highly heated gas for a period sufflcient for such interaction to occur. If necessary for the reaction, the highly heated gas may have a reducing action. After reaction, the products are separated from the gas stream by known wherein the gure is a diagrammatic representation, partly in section and partly in elevation, of a suitable apparatus for carrying out the process' of this invention.
In the figure, numeral I designates a reactor suitable for the purpose of this invention. It will be observed that this reactor takes the form of an elongated conduit having a slnuous conformation. The exact form and conformation of the reactor are largelymatters of choice; in the present instance the particular conformation lselected was chosen for the purpose of keeping the height `of the reactor Within reasonable limits. In the particular embodiment pictured, the reactor I is supplied with hot gases from hot gas producer 2, which are introduced into the reactor I through line 3. Hot gas producer 2 is so constructed as to enable combustion to proceed therein at moderately elevated pressures, for example, pressures in the neighborhood of 45 pounds per square'inch if desirable or necessary.
When valves I and 8 are raised, communication between 5 and 6 is cut oil while 5 is open means are provided for heating the solid re` actants in bin or hopper 4. In the figure, this heating means takesthe form of a tubular heat exchanger in 6. Solid reactants flow through the tubes I0 in this exchanger while the tubes themselves are surrounded by suitable heated uid entering through line II and leaving through line I2.
Solid reactants are moved from hopper or bln 4 by means of screwr conveyor I3 or other similar suitable device and are thereby conveyed to re,- actor I. By using a properly designed screw conveyor, it is not absolutely essential to divide bin or hopper 4 yinto upper and lower sections 5 and 6 separated by valve 8. Properly designed screw conveyors are able to seal against appreciable pressure so that I3 acts to prevent blow backs from reactor I through hopper 4. However, as a safety precaution, it is well to design hopper or bin 4 as described or in a similar fashion. If desired, solid reactants may be discharged by screw I3 into a Venturi throat I4 disposed in reactor I. By this means suspension of the solid reactants in the gases entering through 3 is greatly facilitated.
The suspension of solid reactants in the gases entering through line 3 passes through reactor I in which reaction occurs. The reaction products leaving reactor I are in av highly heated condition and should be cooled appreciably before being worked up. This may be accomplished by any suitable means, for example by spraying water into the suspension through line I5 or by passing the suspension over coils I6 through which water is owing 0r both.
Reaction products are now separated from the partially cooled suspension. This separation is usually accomplished in two steps. A rough separation occurs in the rst, while the greater part of the remaining reaction products is removed iii. the second. Any suitable separation means may be employed. In the ligure the use of a gravity separator and a cyclone separator in series is shown, but other separation means, for example Cottrell precipators, may be used. In the flgure, the partially cooled suspension is shown passing to gravity separator Il through line I8. In gravity separator I'l, the velocity of the suspension is much reduced and the direction of. flow is changed several times. Separated solids may be removed through lines I9. Partially separated suspension is sent from gravity separator I'I through line 20 to cyclone separator 2|, where practically complete removal of solid reaction products occurs. these being removed through line 22.
'The practically solid-free gas leaves cyclone separator 2l through line 23 and passes to air preheater 24, leaving through line 25. Part of the stream in line 23 may be diverted through line Ib to preheat solid reactants as previously described. Air enters air preheater 24 through line 26 and leaves through line 21, passing to` hot gas generator 2.
45 pounds per square inch. If desired or necessary, a suitable amount of gaseous, liquid or solid fuel may be introduced into the preheated air stream via line 28, this fuel then being partially or completely burned in hot gas producer 2.
As the suspension leaving reactor I contains appreciable sensible heat, it is advisable to recover` as much of this as possible in the form of useful work. This may be done in a number oi ways. For example, large amounts of steam may be generated in coil I8. Also, the hot gas may be used to drive a turbine, although it is preferably used for this purpose-only after the solids suspended therein have been removed. As shown in the figure, part of the heat content of the gas is recovered and used to preheat air while another part is devoted to preheating the solid reactants.
As temperature conditions are very severe in hot gas producer 2 and reactor I, these must be constructed with this in mind. It has been found that an inner layer of high grade refractory brick backed by two layers of fire insulating value, the whole being surrounded with sheet steel, constitutes an economic and satisfactory method for constructing hot gas generator 2 andreactor I. Line I5 and coil I6 are preferably made from 18-8 or similar high temperature alloy steel. The remaining parts of the apparatus may be constructed from alloy steel or ordinary mild steel.
While the reactor shown in the ligure consists of an elongated conduit of sinuous form having three legs in which the reactants rst pass upward, then downward and then upward again, this'particular conformation is illustrative only and in no way limits the scope of this invention. The number of legs possessed by the reactor and the direction of flow therein are immaterial. For example. instead of the reactor shown, equally satisfactory resultsv are obtained with reactors having one, two, four or more legs. Also, it is not necessary to introduce the reactants into an ascending leg of the reactor. Reactants, if desired, may be introduced into the upper portion of a descending leg and such reactors again may have one ormore legs. Also, while in the figure the reactor is shown disposed vertically, equally satisfactory results have been obtained using horizontal reactors or reactors with alternating vertical and horizontal legs.
The figure and the above'description relating thereto cover one embodiment of an apparatus suitable for the present invention. Further details, including quantities, temperatures, rates and the like, as well as a few of the many possible modifications of the apparatus shown and described will be outlined in the five examples to follow.
Eample 1 On hundred pounds of a high grade Ottawa sand of about 20 mesh size are uniformly coated with a strong solution containing 26 pounds of If desired, this air may be under low superatmospheric pressure, for example up to i between 2400 Fand brick of high sodium carbonate. 'I'he resulting mixture is slowly dried, preferably while being stirred, and is then charged into bin or hopper 4 of a semicommercial unit similar to that shown in the ligure. A natural gas comprising essentially methane is charged to the hot gas producer 2 through line 28 at a rate of about 17 cubic feet per minute: this-gas is burner in air introduced through line 21. In this modification of the general method for producing cleansing agents in accord with this invention, the hot gas stream may be inert, oxidizing or reducing in its action. For heat economy an inert hotgas stream is to be preferred; that is, the theoretical amount of air is introduced through line 21. Circulation is continued without introduction of solid reactant until the whole system is brought up to temperature, at which time screw I3 is started and the silica particles coated with sodium carbonate are introduced into the reactor at a rate of about 14.5 pounds per minute. Conditions are so regulated that the temperature in cyclone separator 2| is somewhat above 1000 F., while the temperature of the air in line 21 and the solid introduced into reactor I is somewhat above 850 F. As far as can be measured, the temperature in reactor I varies 2700 F., but little reliance can be placed on these determinations. The re-y actor employed has a cross sectional area of one square foot. Product is removed from lines I9 and line 22.
otherwise a slight deciency of air should be used to insure that the hot combustion gases contain no oxygen. Hot gas circulation is continued without introduction of solid reactants until the whole system is brought up to reaction described, is introduced into reactor I at a rate of about 5.5 pounds per minute. Temperatures are similar to those described in Example 1. Product is removed from lines I9 and line 22.
Example 3 In this example, as the hot gas is produced' the theoretical amount One hundred pounds of high grade Ottawa sand of about 20 mesh size are mixed with about 80 pounds of a 17.6 A. P. I. petroleum fraction representing 20% bottoms on Mid-Continent crude. Twenty-six pounds of sodium carbonate are added and the whole, after thorough mixing, is heated to drive off volatile matter. This may be accomplished, for example, by heating the material in an inert atmosphere in a slowly rotating kiln or similar device. The resulting material is charged to hopper or bin 4 of an appa-t ratus similar to that pictured in the figure. The whole apparatus is brought up to temperature by burning a suitable fuel in hot gas producer 2, following which this is gradually discontinued, solid reactants being simultaneously cut into reactor I by starting screw I3 while preheated air is added to line 3 from line 21 either by means of a bypass (not shown) or via hot gas producer 2. Under settled conditions the silica-carbonsodium carbonate mixture is added to reactor I at a rate about 14.5 pounds per mlnute,while preheated air is l added to line 3 at a rate of-about 175 cubic feet per minute, measured at standard conditions. Temperatures are similar to those quoted in Example l. Reaction products are removed from lines I9 and line 22.
Example 4 Again, in this example, hot gas is produced autogenously, so that hot gas producer 2 is not required except perhaps initially when it is Preferably used to bring the whole apparatus up to temperature. If desired, a bypass between line 21 and line 3 may be constructed so as to short circuit gas producer 2 when temperature has been achieved. One hundred pounds of high grade Ottawa sand of about 80 mesh are mixed with 110 pounds of a 17.6 A. P. I. petroleum fraction representing 20% bottoms from Mid-Continent crude. Following this, 35 pounds of sodium sulfate are added and after thorough mixing volatile matter is driven oil, for example, by heating the whole in an inert atmosphere lna slowly revolving kiln or similar device. The resulting material is charged to hopper or bin 4 of an apparatus similar to that shown in the ligure. The whole apparatus is brought up tof/temperature by burning a suitable fuel in hot gas producer 2, following which this is gradually discontinued, solid reactants being simultaneously cut into reactor I by starting screw I3 while preheated air is added to line 3 from line 21, either by means of a bypass (not shown) or via hot gas producer 2. Under settled conditions the silica-carbonsodium sulfate mixture is added to reactor I at a rate of about '7 pounds per minute, while preheated air is added to line 3 at a rate of about 85 cubic feet per minute, measured at standardconditions. Temperatures are similar to those given in Example l. Reaction products are removed from lines I9 and line 22.
Example One hundred pounds of high grade Ottawa sand of about 80 mesh is mixed with a strong solution containing 35 pounds of sodium sulfate. The mixture is then brought slowly to dryness,
. preferably with agitation, and is then charged ducer gas is at a temperature somewhat above 850 F. and preferably has a'low content of solids. Air is introduced into hot gas producer 2 through line 21 at a rate of 40-45 cubic feet per minute, measured atstandard conditions. The combustionvthat occurs Yin hot gas producer 2 soon brings the Whole apparatus up to temperature, at which time screw I3 is started and the sand-sodium sulfate mixture is added tothe reactor I at a rate of about 5 pounds per minute. Product is removed from lines I9 and line 22. Temperatures are approximately as specified in Example 1.
It is obvious that in all the above examples, once the unit is on stream operation is continuous. While in each of the above examples a suitable starting up procedure is described, it is to be understood that this is resorted to only on bringing a new apparatus on stream or when a new run is begun after a protracted shut-down for repairs, reconditioning or other reasons.
In each of the ve examples considered above, the solid reaction mixture is usually obtained in the form of lumps or aggregates of appreciable size. This is especially true in Examples 2, 3 and 4. Such lumps or aggregates not only are apt' to clog hopper or bin 4 and screw I3 but also they are difficult or impossible to suspend in the gas stream entering reactor I through line 3. For these reasons it is advisable to reduce these lumps or aggregates to suitable size before being introduced into hopper or bin 4. With the solid reaction mixtures formed in accord with Examples land 5, this is easily accomplished by gentle crushing, working through sieves, or by similar means. The solid reactant mixtures prepared in accord with Examples 2, 3 and 4 are usually obtained in the form of lumps exhibiting more or less porosity depending upon the exact conditions employed in removing volatile hydrocarbons. -These materials require crushing prior to charging to the hopper or bin 4. The exact size of the material to be charged depends upon the mesh size of the siliceous material employed and on the porosity of the carbonaceous matter. Ob-
"vio/usly, the ideal is aggregates each of which contains one silica particle.
While the use of' the carbonaceous material commonly known as petroleum coke or oil coke is described in Examples 2, 3 and 4, it is obvious that other suitable forms of carbonaceous material may be used. Preferably such material should have a low ash content. Other suitable materials for the formation of carbonaceous matter in accord with the teachings of Examples 2, 3 and 4 include molasses and coal tar pitches. Also, part of all of the carbonaceous lmatter may be added to the solid reactants in other ways. For instance, in Example 3, instead of proceeding as described, a silica-sodium carbonate mixture may be prepared in the proportions outlined in Example 1 and in the same or similar manner, and this may be mixed with about 10 pounds of petroleum coke, carbon black or low-ash coal and the whole charged to'hopper or bin 4. Similarly, in Example 4 a silica-sodium sulfate-carbon mixture may be made using the proportions of Example 2 and to this may be added 12-13 pounds of petroleum coke, carbon black, or lowash coal and the whole charged, after mixing, to hopper or bin 4.
The nature of the cleansing agent formed may be varied' appreciably by changing the contact time in reactor I. Obviously, changes in contact time can have little or no eil'ect on the analysis discrete f variable actions just of the products formed. but'it has been found that the distribution of components is affected to an appreciable extent. When contact time is short the products formed consist largely of discrete particles having a comparatively large silica. core bearing a comparatively thin superficial layer of alkali metal silicates having high alkalinity. Such materials when used as cleansing'agents tion which rapidlychanges to a high vabrasive action.- If, on the other hand. the contact time is long, the products formed consist largely of particles having a comparatively small silica core bearing a comparatively thick layer of alkali metal silicates having low alkalinity. Such materials when used as cleansing agents exhibit an initially moderate detergent action which slowly changes into an increasingly severe abrasive action.
It'is impossible to for the production of cleansing agents having the described. The proper contact times must be determined for each individual apparatus under a given set of operating conditions. This is true for several reasons. In the first place, temperature conditions are somewhat variable in the reactor and cannot be measured with any great degree of certainty. Also, the phenomenon of slip is encountered. While solid reactants may be added to the reactor at a certain constant rate, measured as pounds of solid per cubic foot of gas. the concentration of solids in the reactor space may be equal to this gure or manyfold greater depending on the gas velocity through the reactor. The solids concentration in the reactor space approaches that of the added solids at high air velocities. Thus, a reactor of cross sectional area X and length L may give a longer contact time than calculated and in some cases a contact time manyfold longer than calculated, while a reactor of area 0.25X and length 4L may give a contact time very close to calculated. Also, required contact time is a function of the material charged.. As a general rule. the silica-sodium sulfate system requires a longer reaction time .than the silica-sodium carbonate. Naturally. the contact time required to produce a cleansing agent of any desired set of properties also depends upon the size of the silica par ticles charged. While it is impossible to give any definite figures, it may be stated .that under the conditions outlined in Example l, a cleansing agent of average properties was obtained at a calculated contact time of 3 seconds.
While Ottawa sand has been specified as the siliceous material in the examples, numerous equivalents, for example, quartz, quartzite and diatomaceous earth, will readily occur to those skilled in the art. While sodium carbonate has been used in certain examples as illustrative of a material capable of reacting directly with siliceous material to form sodium silicates, many equivalents, such as sodium oxide. sodium peroxide, sodium hydroxide. and salts capable of forming one of these when thermally decomposed, may be substituted therefor. Likewise. equivalents for the sodium sulfate mentioned in some examples as illustrative of a compound that must be reduced prior to reduction with siliceous material will occur to those skilled in the art, while in the examples, sodium compounds have been cited exclusively. suitable compounds of other alkali metals may be used.
In the examples the silica material and sodium salt are so proportioned as to give an overall exhibit an initially high detergent acgive definite contact times4 prior to use.
I tate sodium `oxide-silica ratio of 1:6.8 calculated Jn the mole basis. Obviously, the instant invention is not limited to this ratio. this constant ratio being employed in the examples simply to facilicomparisons between the various processes. Ratios of `from about 1:3.5 up to 1:10 or more have been employed.
As has been previously mentioned, the cleansing agents of this invention are primarily for useln what may be termed heavy duty cleaning. Theoretically it should be possible to make these improved cleansing agents with the inertfsiiica core as small as desired, .so that the materials can e used in cleansing operations of higher order. Actually. however, this has been found diilicult to accomplish, due toa few unreacted or only partially reacted silica particles that are usually formed simultaneously with the desired y product.
After being formed it is advisable to keep the resulting products out of contact with air until used to prevent caking. his caking tendency may be reduced considerably by thoroughly steaming the products after being formed. The
-products of this invention may be incorporated with other detergent and/or abrasive materials Among suitable additional detergent agents may be mentioned soaps, alkali metal carbonates, alkali metal hydroxides, alkali metal pyrophosphates, alkali metal metaphosphates. and the like. Among abrasives may be mentioned pumice, sand, corundum, and the like. Also, if desired, inert materials may be added. A particularly effective cleansing agent may be made by coating the products formed according to the teachings of thisy invention with sodium hydroxide or with soap.
examples of various modifications thereof, it is to be understood that this apparatus and these examples are illustrative only and are included for the purpose of familiarizing those skilled in i mate range 3.5 to 1 to 10.0 to l.
2. A cleansing agent in the form of individual particles each of which consists of a silica core covered with an autogenous layer of sodium silicates, the silica to sodium oxide ratio of said individual particlesrange 3.5 to 1 to 10.0 to 1.
3. A process for the manufacture of a cleansing agent composed of silica particles coated with an autogenous layer of alkali metal silicates consisting of suspending, silica particles coated with alkali metals in a stream of combustion gases at elevated temperature for a time suiiicient to effect reaction between the selected coating mafalling Lin the approximatev of combustion gases.
5. A process in accordance with claim 4 wherein said stream of combustion gases is brought to reaction temperature by the combustion of carbonaceous matter contained in. saidcoating of sodium carbonate.
6. A process for the manufacture of a cleansl5 ing agent composed oi' silica particles coated with an autogenous layer of sodium silicates consisting of suspending silica particles coated with sodium sulfate in a stream of combustion gases at elevated temperatures for a time sumcient to eil'ect reaction between said sodium sulfate and the peripheral portions of the silica particles and separating the resulting product from said stream of combustion gases.
'7. A process in accordance with claim 6 wherey in said stream of combustion gases is brought to reaction temperature by the combustion otcarbonaceous matter contained in said coating oi' sodium sulfate.
ROBERT F. RUTHRUFF.
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