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
  • C01F7/00—Compounds of aluminium
  • C01F7/02—Aluminium oxide; Aluminium hydroxide; Aluminates
  • C01F7/04—Preparation of alkali metal aluminates; Aluminium oxide or hydroxide therefrom
  • C01F7/14—Aluminium oxide or hydroxide from alkali metal aluminates
  • C01F7/144—Aluminium oxide or hydroxide from alkali metal aluminates from aqueous aluminate solutions by precipitation due to cooling, e.g. as part of the Bayer process
  • C01F7/145—Aluminium oxide or hydroxide from alkali metal aluminates from aqueous aluminate solutions by precipitation due to cooling, e.g. as part of the Bayer process characterised by the use of a crystal growth modifying agent other than aluminium hydroxide seed
• • 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

Definitions

• the present disclosure relates generally to compounds, compositions, and methods that improve recovery of aluminum values from aluminum hydroxide production processes such as the Bayer process, and more particularly, to compounds and compositions that increase particle size of aluminum hydroxide crystals, or crystalline aggregates.
• Aluminum hydroxide is produced on an industrial scale by well- established methods such as the Bayer process.
• the precipitation process operators optimize their methods so as to produce the greatest possible yield from the aluminate process liquors while trying to achieve a particular crystal size distribution of aluminum hydroxide product. It is desirable in most instances to obtain the product of relatively large crystal size and to correspondingly limit the amount of very fine crystals, since this is beneficial in subsequent processing steps required to produce aluminum metal. Production is often limited by processing conditions under which the crystallization and precipitation is conducted. These processing conditions vary from one plant to the next and include, but are not limited to, temperature profiles, seed charge, seed crystal surface area, purge of carbon dioxide or flue gases, liquor loading, liquor purity, and the like.
• a method of increasing the particle size of aluminum hydroxide crystals precipitated from a Bayer process liquor including adding to the Bayer process liquor a composition comprising a phenolic-aldehyde condensate; and recovering aluminum hydroxide crystals precipitated from the Bayer process liquor.
• the phenolic-aldehyde condensate comprises repeating units of formula (I),
• R 1 at each occurrence, is independently selected from the group consisting of hydrogen, alkyl, alkenyl, alkynyl, aryl, heteroaryl, heterocyclyl, and cycloalkyl;
• R at each occurrence, is independently selected from the group consisting of alkyl, alkenyl, alkynyl, aryl, heteroaryl, heterocyclyl, cycloalkyl, halogen, cyano, nitro, and -OR ;
• R at each occurrence, is independently selected from the group consisting of hydrogen, alkyl, alkenyl, alkynyl, aryl, heteroaryl, heterocyclyl, and cycloalkyl;
• L is -C(R a )(R b )- or -0-C(R c )(R d )-;
• R a , R b , R c , and R d are, at each occurrence, independently selected from the group consisting of hydrogen, alkyl, alkenyl, alkynyl, aryl, heteroaryl, heterocyclyl, and cycloalkyl;
• n is an integer independently selected from the group consisting of 0, 1, 2, and 3;
• n is > 1;
• the phenolic-aldehyde repeating units have formula (I- a),
• R 1 , R 2 , L, m, and n are as defined above.
• the phenolic-aldehyde repeating units have formula (I-b),
• R 1 , R 2 , L, m, and n are as defined above.
• the phenolic-aldehyde repeating units have formula (I-c),
• R 1 , R 2 , L, and n are as defined above.
• the phenolic-aldehyde condensate comprises repeating units of formula (I), wherein R 1 is hydrogen at each occurrence; and R 2 , at each occurrence, is independently selected from -OH and C Cg substituted or unsubstituted alkyl.
• L is -CH 2 - at each occurrence. In certain embodiments, L is -0-CH 2 - at each occurrence.
• the phenolic-aldehyde condensate has formula ( ⁇ ), wherein,
• R 1 at each occurrence, is independently selected from the group consisting of hydrogen, alkyl, alkenyl, alkynyl, aryl, heteroaryl, heterocyclyl, and cycloalkyl;
• R at each occurrence, is independently selected from the group consisting of alkyl, alkenyl, alkynyl, aryl, heteroaryl, heterocyclyl, cycloalkyl, halogen, cyano, nitro, and -OR ;
• R at each occurrence, is independently selected from the group consisting of hydrogen, alkyl, alkenyl, alkynyl, aryl, heteroaryl, heterocyclyl, and cycloalkyl;
• R 4 at each occurrence, is independently selected from the group consisting of alkyl, alkenyl, alkynyl, aryl, heteroaryl, heterocyclyl, cycloalkyl, halogen, cyano, nitro, and -OR 6 ;
• R 5 at each occurrence, is independently selected from the group consisting of alkyl, alkenyl, alkynyl, aryl, heteroaryl, heterocyclyl, cycloalkyl, halogen, cyano, nitro, and -OR ;
• R 6 and R 7 are each independently selected from the group consisting of hydrogen, alkyl, alkenyl, alkynyl, aryl, heteroaryl, heterocyclyl, and cycloalkyl;
• L is -C(R a )(R b )- or -0-C(R c )(R d )-;
• R a , R b , R c , and R d are each independently selected from the group consisting of hydrogen, alkyl, alkenyl, alkynyl, aryl, heteroaryl, heterocyclyl, and cycloalkyl;
• n is an integer independently selected from the group consisting of 0, 1, 2, and 3;
• n is > 1;
• p is 1, 2, 3, 4, or 5;
• q is 1, 2, 3, 4, or 5; wherein said alkyl, alkenyl, alkynyl, aryl, heteroaryl, heterocyclyl, and cycloalkyl are each independently, at each occurrence, substituted or unsubstituted with one or more suitable substituents.
• the phenolic-aldehyde condensate has formula (Il-a),
• R 1 , R 2 , R 4 , R 5 , L, m, n, p, and q are as defined above.
• the phenolic-aldehyde condensate has formula
• R 1 , R 2 , R 4 , R 5 , L, m, n, p, and q are as defined above.
• the phenolic-aldehyde condensate has formula
• R 1 , R 2 , R 4 , R 5 , L, n, p, and q are as defined above.
• the phenolic-aldehyde condensate has formula
• R 1 is hydrogen at each occurrence;
• R 2 at each occurrence, is independently selected from -OH and Q-Cg substituted or unsubstituted alkyl;
• p is 1 or 2 wherein at least one R 4 is -OH and the other optional R 4 is selected from -OH and C C 8 substituted or unsubstituted alkyl;
• q is 1 or 2 wherein at least one R 5 is -OH and the other optional R 5 is selected from -OH and Q-Cg substituted or unsubstituted alkyl.
• L is -CH 2 - at each occurrence.
• L is -0-CH 2 - at each occurrence.
• the phenolic-aldehyde condensate is selected from the group consisting of: a butylphenol formaldehyde resin formed under acidic conditions; a butylphenol formaldehyde resin formed under basic conditions; a resorcinol formaldehyde resin formed under acidic conditions; a resorcinol formaldehyde resin formed under basic conditions; a phenol formaldehyde resin formed under acidic conditions; a phenol formaldehyde resin formed under basic conditions; a cresol formaldehyde resin formed under acidic conditions; a cresol formaldehyde resin formed under basic conditions; an octylphenol formaldehyde resin formed under acidic conditions; and an octylphenol formaldehyde resin formed under basic conditions.
• the composition further comprises a solvent selected from the group consisting of ethoxylated and propoxylated alkyl ethers or alcohols, fatty acid esters, low aromatic hydrocarbon oils, kerosene, heavy aromatic naphtha ("HAN”), propylene glycol monomethyl ether, n-butanol, isobutanol, and combinations thereof.
• a solvent selected from the group consisting of ethoxylated and propoxylated alkyl ethers or alcohols, fatty acid esters, low aromatic hydrocarbon oils, kerosene, heavy aromatic naphtha (“HAN”), propylene glycol monomethyl ether, n-butanol, isobutanol, and combinations thereof.
• the composition is selected from the group consisting of: a composition of a butylphenol formaldehyde resin formed under acidic conditions, and an ethoxylated and propoxylated alkyl ether; a composition of a butylphenol formaldehyde resin formed under acidic conditions, and kerosene; a composition of a butylphenol formaldehyde resin formed under basic conditions, and an ethoxylated and propoxylated alkyl ether; a composition of a butylphenol formaldehyde resin formed under basic conditions, and kerosene; a composition of a resorcinol formaldehyde resin, and a sodium hydroxide solution; a composition of a phenol formaldehyde resin formed under acidic conditions, and an ethoxylated and propoxylated alkyl ether; a composition of a cresol formaldehyde resin formed under basic conditions, propylene glycol monomethyl ether,
• the method provides a % increase in mean of control quantile size of at least 20%.
• crystallization aids also referred to as crystal growth modifiers.
• methods of crystallization using the compounds and compositions provide for the production of aluminum hydroxide having a significantly larger particle size than otherwise possible, and superior to that of existing crystallization aids.
• alumina refineries can be operated under conditions that will significantly boost yield while still satisfying particle size constraints.
• the compounds, compositions, and methods are also applicable to modification of the precipitation of sodium oxalate in the Bayer process; as well as to crystal growth modification for carbonate scale, gypsum, nickel hydroxide (lateritic nickel process), and trona (sodium carbonate), among others.
• suitable substituent is intended to mean a chemically acceptable functional group, preferably a moiety that does not negate the activity of the inventive compounds.
• alkyl refers to a linear or branched
• Alkyl groups include, but are not limited to, methyl, ethyl, n-propyl, isopropyl, n-butyl, iso-butyl, secondary-butyl, and tertiary-butyl. Alkyl groups may be unsubstituted or substituted by one or more suitable substituents, as defined above.
• alkenyl refers to a straight or branched hydrocarbon radical, preferably having 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 39, 30, 31, or 32 carbons, and having one or more carbon-carbon double bonds.
• Alkenyl groups include, but are not limited to, ethenyl, 1-propenyl, 2-propenyl (allyl), iso-propenyl, 2-methyl-l- propenyl, 1-butenyl, and 2-butenyl. Alkenyl groups may be unsubstituted or substituted by one or more suitable substituents, as defined above.
• alkynyl refers to a straight or branched hydrocarbon radical, preferably having 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 39, 30, 31, or 32 carbons, and having one or more carbon-carbon triple bonds.
• Alkynyl groups include, but are not limited to, ethynyl, propynyl, and butynyl. Alkynyl groups may be unsubstituted or substituted by one or more suitable substituents, as defined above.
• alkoxy refers to an alkyl group, as defined herein, appended to the parent molecular moiety through an oxygen atom.
• aryl means monocyclic, bicyclic, or tricyclic aromatic radicals such as phenyl, naphthyl, tetrahydronaphthyl, indanyl and the like; optionally substituted by one or more suitable substituents, preferably 1 to 5 suitable substituents, as defined above.
• Alkylcarbonylamino refers to groups such as acetamide.
• cycloalkyl refers to a mono, bicyclic or tricyclic carbocyclic radical (e.g., cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, cyclooctyl, cyclononyl, cyclopentenyl, cyclohexenyl,
• Cycloalkyl groups may be unsubstituted or substituted by one or more suitable substituents, preferably 1 to 5 suitable substituents, as defined above.
• halo or halogen
• halo refers to a fluoro, chloro, bromo or iodo radical.
• heteroaryl refers to a monocyclic, bicyclic, or tricyclic aromatic heterocyclic group containing one or more heteroatoms selected from O, S and N in the ring(s).
• Heteroaryl groups include, but are not limited to, pyridyl, pyrazinyl, pyrimidinyl, pyridazinyl, thienyl, furyl, imidazolyl, pyrrolyl, oxazolyl (e.g., 1,3-oxazolyl, 1,2-oxazolyl), thiazolyl (e.g., 1 ,2-thiazolyl, 1,3- thiazolyl), pyrazolyl, tetrazolyl, triazolyl (e.g., 1,2,3-triazolyl, 1,2,4-triazolyl), oxadiazolyl (e.g., 1,2,3-oxadiazolyl), thiadiazol
• heterocycle or “heterocyclyl,” as used herein, refer to a monocyclic, bicyclic, or tricyclic group containing 1 to 4 heteroatoms selected from N, O, S(0) n , NH or NR X , wherein R x is a suitable substituent. Heterocyclic groups optionally contain 1 or 2 double bonds.
• Heterocyclic groups include, but are not limited to, azetidinyl, tetrahydrofuranyl, imidazolidinyl, pyrrolidinyl, piperidinyl, piperazinyl, oxazolidinyl, thiazolidinyl, pyrazolidinyl, thiomorpholinyl,
• tetrahydrodiazinyl oxazinyl, oxathiazinyl, indolinyl, isoindolinyl, quinuclidinyl, chromanyl, isochromanyl, and benzoxazinyl.
• Examples of monocyclic saturated or partially saturated ring systems are tetrahydrofuran-2-yl, tetrahydrofuran-3-yl, imidazolidin-l-yl, imidazolidin-2-yl, imidazolidin-4-yl, pyrrolidin-l-yl, pyrrolidin- 2-yl, pyrrolidin-3-yl, piperidin-l-yl, piperidin-2-yl, piperidin-3-yl, piperazin-l-yl, piperazin-2-yl, piperazin-3-yl, l,3-oxazolidin-3-yl, isothiazolidine, l,3-thiazolidin-3- yl, l,2-pyrazolidin-2-yl, 1,3-pyrazolidin-l-yl, thiomorpholin-yl, 1,2- tetrahydrothiazin-2-yl, 1 ,3-tetrahydrothiazin-3-
• hydroxy refers to an -OH group.
• A/C refers to the alumina to caustic ratio.
• BET Brunauer-Emmett- Teller method for experimental determination of surface area. The method employs the analysis of adsorption isotherm of nitrogen or other gases on the material.
• CGM refers to a crystal growth modifier
• precipitation liquor refers to an aluminate containing liquor in an aluminum hydroxide precipitation step of an alumina production process.
• the aluminate liquor may be referred to as various terms known to those of ordinary skill in the art, for example, pregnant liquor, green liquor, and aluminum hydroxide precipitation feed.
• precipitation liquor may also include the aluminate solution directed to decomposition in a sintering- carbonate process or combined Bayer-sintering process as accomplished by methods known to those skilled in the art.
• precipitation feed liquor refers to the precipitation liquor that flows into a precipitator of an aluminum hydroxide precipitation process.
• heated precipitation liquor refers to any liquor within the aluminum hydroxide production process having a free alkalinity level above 50 g/L of Na 2 C0 3 and a temperature above ambient or 25 °C.
• pulp liquor refers to the liquor resulting from the removal of precipitated aluminum values, such as the spent liquor after the final classification stage that returns back to digestion to the Bayer process.
• Compounds of the invention include phenolic-aldehyde condensates.
• the phenolic-aldehyde condensates may serve as crystal growth modifiers to aid crystallization of aluminum hydroxide from a precipitation liquor, such as found in a Bayer process.
• phenolic-aldehyde condensates having repeating units of formula (I),
• R at each occurrence, is independently selected from the group consisting of hydrogen, alkyl, alkenyl, alkynyl, aryl, heteroaryl, heterocyclyl, and cycloalkyl; R , at each occurrence, is independently selected from the group consisting of alkyl, alkenyl, alkynyl, aryl, heteroaryl, heterocyclyl, cycloalkyl, halogen, cyano, nitro, and -OR ;
• R at each occurrence, is independently selected from the group consisting of hydrogen, alkyl, alkenyl, alkynyl, aryl, heteroaryl, heterocyclyl, and cycloalkyl;
• L is -C(R a )(R b )- or -0-C(R c )(R d )-;
• R a , R b , R c , and R d are, at each occurrence, independently selected from the group consisting of hydrogen, alkyl, alkenyl, alkynyl, aryl, heteroaryl, heterocyclyl, and cycloalkyl;
• n is an integer independently selected from the group consisting of 0, 1, 2, and 3;
• n is > 1 ;
• alkyl, alkenyl, alkynyl, aryl, heteroaryl, heterocyclyl, and cycloalkyl are each independently, at each occurrence, substituted or unsubstituted with one or more suitable substituents.
• R 1 is hydrogen at each occurrence.
• R 1 at each occurrence, is selected from hydrogen and substituted or unsubstituted alkyl. In certain embodiments, R 1 , at each occurrence, is selected from hydrogen and substituted or unsubstituted linear C C 3 o alkyl, alkyl. In certain embodiments, R 1 , at each occurrence, is selected from hydrogen and substituted or unsubstituted branched C Cso alkyl, C C ⁇ alkyl, or Ci-Cg, alkyl.
• R 1 is selected from hydrogen, methyl, ethyl, propyl (e.g., w-propyl, isopropyl), butyl (e.g., w-butyl, isobutyl, ie/t-butyl, sec -butyl), pentyl (e.g., w-pentyl, isopentyl, ie/t-pentyl, neopentyl, sec-pentyl, 3-pentyl), hexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl, tridecyl, tetradecyl, pentadecyl, hexadecyl, heptadecyl, octadecyl, nonadecyl, eicosyl, heneicosyl, do
• R 2 at each occurrence, is selected from -OR 3 and substituted or unsubstituted alkyl.
• R at each occurrence, is selected from -OR and substituted or unsubstituted linear C C 3 o alkyl, C C ⁇ alkyl, or alkyl.
• R at each occurrence, is selected from -OR and substituted or unsubstituted branched Q-C30 alkyl, C -Cn alkyl, or
• R 2 at each occurrence, is selected from -OR 3 , methyl, ethyl, propyl (e.g., w-propyl, isopropyl), butyl (e.g., w-butyl, isobutyl, tert- butyl, sec-butyl), pentyl (e.g., w-pentyl, isopentyl, ie/t-pentyl, neopentyl, sec-pentyl, 3-pentyl), hexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl, tridecyl, tetradecyl, pentadecyl, hexadecyl, heptadecyl, octadecyl, nonadecyl, eicosyl,
• R 3 is hydrogen at each occurrence.
• L is -C(R a )(R b )-.
• R a and R b are each independently, at each occurrence, hydrogen such that L is -CH 2 -.
• R a and R b are each independently, at each occurrence, selected from hydrogen and substituted or unsubstituted linear C C ⁇ alkyl.
• R a and R b are each independently, at each occurrence, selected from hydrogen and substituted or unsubstituted branched C C ⁇ alkyl.
• R a and R b are each independently, at each occurrence, selected from hydrogen, methyl, ethyl, propyl (e.g., w-propyl, isopropyl), butyl (e.g., w-butyl, isobutyl, ie/t-butyl, sec-butyl), pentyl (e.g., w-pentyl, isopentyl, iert-pentyl, neopentyl, sec-pentyl, 3-pentyl), hexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl, tridecyl, tetradecyl, pentadecyl, hexadecyl, heptadecyl, octadecyl, nonadecyl, eicosyl, heneicosyl
• R a and R b are each independently, at each occurrence, selected from hydrogen and substituted or unsubstituted phenyl, dihydroindenyl, indenyl, naphthyl, dihydronaphthalenyl, or 5,6,7,8-tetrahydronaphthalenyl.
• R a and R b are each independently, at each occurrence, selected from hydrogen and substituted or unsubstituted cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, cyclooctyl, cyclononyl, cyclodecyl, cycloundecyl, cyclododecyl, cyclotridecyl, cyclotetradecyl, cyclopentadecyl, cyclohexadecyl, cycloheptadecyl, or
• R a and R b are each independently, at each occurrence, selected from hydrogen and substituted or unsubstituted furanyl, imidazolyl, isoxazolyl, isothiazolyl, oxadiazolyl, oxazolyl, pyridinyl, pyridazinyl, pyrimidinyl, pyrazinyl, pyrazolyl, pyrrolyl, tetrazolyl, thiadiazolyl, thiazolyl, thienyl, triazolyl, triazinyl, benzofuranyl, benzothienyl, 1,3-benzoxazolyl, benzimidazolyl, indazolyl, indolyl, isoindolyl, isoquinolinyl, naphthyridinyl, pyridoimidazolyl, or quinolinyl.
• R a and R b are each independently, at each occurrence, selected from hydrogen and substituted or unsubstituted azetidinyl, azepanyl, aziridinyl, diazepanyl, 1,3-dioxanyl, 1,3- dioxolanyl, 1,3-dithiolanyl, 1,3-dithianyl, imidazolinyl, imidazolidinyl,
• L is -0-C(R c )(R d )-.
• R c and R d are each hydrogen such that L is -0-CH 2 -.
• R c and R d are each independently, at each occurrence, selected from hydrogen and substituted or unsubstituted linear C C ⁇ alkyl.
• R c and R d are each independently, at each occurrence, selected from hydrogen and substituted or unsubstituted branched C C ⁇ alkyl.
• R c and R d are each independently, at each occurrence, selected from hydrogen, methyl, ethyl, propyl (e.g., w-propyl, isopropyl), butyl (e.g., w-butyl, isobutyl, ie/t-butyl, sec-butyl), pentyl (e.g., w-pentyl, isopentyl, ie/t-pentyl, neopentyl, sec-pentyl, 3-pentyl), hexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl, tridecyl, tetradecyl, pentadecyl, hexadecyl, heptadecyl, octadecyl, nonadecyl, eicosyl, hene
• R c and R d are each independently, at each occurrence, selected from hydrogen and substituted or unsubstituted phenyl, dihydroindenyl, indenyl, naphthyl, dihydronaphthalenyl, or 5,6,7,8-tetrahydronaphthalenyl.
• R c and R d are each independently, at each occurrence, selected from hydrogen and substituted or unsubstituted cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, cyclooctyl, cyclononyl, cyclodecyl, cycloundecyl, cyclododecyl, cyclotridecyl, cyclotetradecyl, cyclopentadecyl, cyclohexadecyl, cycloheptadecyl, or cyclooctodecyl.
• R c and R d are each independently, at each occurrence, selected from hydrogen and substituted or unsubstituted furanyl, imidazolyl, isoxazolyl, isothiazolyl, oxadiazolyl, oxazolyl, pyridinyl, pyridazinyl, pyrimidinyl, pyrazinyl, pyrazolyl, pyrrolyl, tetrazolyl, thiadiazolyl, thiazolyl, thienyl, triazolyl, triazinyl, benzofuranyl, benzothienyl, 1,3- benzoxazolyl, benzimidazolyl, indazolyl, indolyl, isoindolyl, isoquinolinyl, naphthyridinyl, pyridoimidazolyl, or quinolinyl.
• R c and R d are each independently, at each occurrence, selected from hydrogen and substituted or unsubstituted azetidinyl, azepanyl, aziridinyl, diazepanyl, 1,3-dioxanyl, 1,3- dioxolanyl, 1,3-dithiolanyl, 1,3-dithianyl, imidazolinyl, imidazolidinyl,
• n at each occurrence, is 0. In certain embodiments,
• n, at each occurrence is 1. In certain embodiments, m, at each occurrence, is 2. In certain embodiments, m, at each occurrence, is 3.
• n ranges from 1 to 100, 1 to 50, 1 to 30, 1 to 20, 1 to 15, or 1 to 10. In certain embodiments, n is 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, or 50.
• the phenolic-aldehyde condensates have repeating units of formula (I-a),
• R , R , L, m, and n are as defined above.
• R is hydrogen at each occurrence, and R , at each occurrence, is independently selected from -OH and Ci-Cg substituted or unsubstituted alkyl.
• the phenolic-aldehyde condensates have repeating units of formula (I-b),
• R , R , L, m, and n are as defined above.
• R is hydrogen at each occurrence, and R , at each occurrence, is independently selected from -OH and Ci-Cg substituted or unsubstituted alkyl.
• the phenolic-aldehyde condensates have repeating units of formula (I-c),
• R , R , L, and n are as defined above.
• R is hydrogen at each occurrence, and R , at each occurrence, is independently selected from -OH and Ci-Cg substituted or unsubstituted alkyl.
• the phenolic-aldehyde condensates have repeating units of formula (I-d),
• R , R , and n are as defined above.
• R is hydrogen at each occurrence, and R , at each occurrence, is independently selected from -OH and Ci-Cg substituted or unsubstituted alkyl.
• the phenolic-aldehyde condensates have repeating units of formula (I-e),
• R , R , and n are as defined above.
• R is hydrogen at each occurrence, and R , at each occurrence, is independently selected from -OH and C Cg substituted or unsubstituted alkyl.
• the phenolic-aldehyde condensates have repeating units of formula (I-f),
• R , R , L, m, and n are as defined above.
• R is hydrogen at each occurrence, and R , at each occurrence, is independently selected from -OH and C Cg substituted or unsubstituted alkyl.
• the phenolic-aldehyde condensates have repeating units of formula (I-g),
• R , R , L, and n are as defined above.
• R is hydrogen at each occurrence, and R , at each occurrence, is independently selected from -OH and Ci-Cg substituted or unsubstituted alkyl.
• the phenolic-aldehyde condensates have repeating units of formula (I-h),
• R , R , L, and n are as defined above.
• R is hydrogen at each occurrence, and R , at each occurrence, is independently selected from -OH and Ci-Cg substituted or unsubstituted alkyl.
• the phenolic-aldehyde condensates have repeating units of formula (I-i) or formula (I-j),
• R , R , and n are as defined above.
• R is hydrogen at each occurrence, and R , at each occurrence, is independently selected from -OH and C Cg substituted or unsubstituted alkyl.
• the phenolic-aldehyde condensates have repeating units of formula (I-k) or formula (1-1),
• R , R , and n are as defined above.
• R is hydrogen at each occurrence, and R , at each occurrence, is independently selected from -OH and C Cg substituted or unsubstituted alkyl.
• R 1 at each occurrence, is independently selected from the group consisting of hydrogen, alkyl, alkenyl, alkynyl, aryl, heteroaryl, heterocyclyl, and cycloalkyl;
• R at each occurrence, is independently selected from the group consisting of alkyl, alkenyl, alkynyl, aryl, heteroaryl, heterocyclyl, cycloalkyl, halogen, cyano, nitro, and -OR ;
• R at each occurrence, is independently selected from the group consisting of hydrogen, alkyl, alkenyl, alkynyl, aryl, heteroaryl, heterocyclyl, and cycloalkyl;
• R 4 at each occurrence, is independently selected from the group consisting of alkyl, alkenyl, alkynyl, aryl, heteroaryl, heterocyclyl, cycloalkyl, halogen, cyano, nitro, and -OR 6 ;
• R 5 at each occurrence, is independently selected from the group consisting of alkyl, alkenyl, alkynyl, aryl, heteroaryl, heterocyclyl, cycloalkyl, halogen, cyano, nitro, and -OR ;
• R 6 and R 7 are each independently selected from the group consisting of hydrogen, alkyl, alkenyl, alkynyl, aryl, heteroaryl, heterocyclyl, and cycloalkyl;
• L is -C(R a )(R b )- or -0-C(R c )(R d )-;
• R a , R b , R c , and R d are each independently selected from the group consisting of hydrogen, alkyl, alkenyl, alkynyl, aryl, heteroaryl, heterocyclyl, and cycloalkyl;
• n is an integer independently selected from the group consisting of 0, 1, 2, and 3;
• n is > 1;
• p is 1, 2, 3, 4, or 5;
• q is 1, 2, 3, 4, or 5; wherein said alkyl, alkenyl, alkynyl, aryl, heteroaryl, heterocyclyl, and cycloalkyl are each independently, at each occurrence, substituted or unsubstituted with one or more suitable substituents.
• R 1 is hydrogen at each occurrence.
• R 1 at each occurrence, is selected from hydrogen and substituted or unsubstituted alkyl. In certain embodiments, R 1 , at each occurrence, is selected from hydrogen and substituted or unsubstituted linear C C 3 o alkyl, C Qg alkyl, or Q-Cg alkyl. In certain embodiments, R 1 , at each occurrence, is selected from hydrogen and substituted or unsubstituted branched C Cso alkyl, Ci-Qg alkyl, or Q-Cg alkyl.
• R 1 is selected from hydrogen, methyl, ethyl, propyl (e.g., w-propyl, isopropyl), butyl (e.g., w-butyl, isobutyl, ie/t-butyl, sec -butyl), pentyl (e.g., w-pentyl, isopentyl, ie/t-pentyl, neopentyl, sec-pentyl, 3-pentyl), hexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl, tridecyl, tetradecyl, pentadecyl, hexadecyl, heptadecyl, octadecyl, nonadecyl, eicosyl, heneicosyl, do
• R 2 at each occurrence, is selected from -OR 3 and substituted or unsubstituted alkyl.
• R at each occurrence, is selected from -OR and substituted or unsubstituted linear C C 3 o alkyl, C Qg alkyl, or C Cg alkyl.
• R at each occurrence, is selected from -OR and substituted or unsubstituted branched C Cso alkyl, C -Cn alkyl, or
• R 2 at each occurrence, is selected from -OR 3 , methyl, ethyl, propyl (e.g., w-propyl, isopropyl), butyl (e.g., w-butyl, isobutyl, tert- butyl, sec-butyl), pentyl (e.g., w-pentyl, isopentyl, ie/t-pentyl, neopentyl, sec-pentyl, 3-pentyl), hexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl, tridecyl, tetradecyl, pentadecyl, hexadecyl, heptadecyl, octadecyl, nonadecyl, eicosyl,
• R 3 is hydrogen at each occurrence.
• R 4 at each occurrence, is selected from -OR 6 and substituted or unsubstituted alkyl. In certain embodiments, R 4 , at each occurrence, is selected from -OR 6 and substituted or unsubstituted linear C C 3 o alkyl, C Qg alkyl, or Q-Cg alkyl. In certain embodiments, R 4 , at each occurrence, is selected from -OR 6 and substituted or unsubstituted branched Q-C 30 alkyl, C C ⁇ alkyl, or Q-Cg alkyl.
• R 4 is selected from -OR 6 , methyl, ethyl, propyl (e.g., w-propyl, isopropyl), butyl (e.g., w-butyl, isobutyl, tert- butyl, sec-butyl), pentyl (e.g., w-pentyl, isopentyl, ie/t-pentyl, neopentyl, sec-pentyl, 3-pentyl), hexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl, tridecyl, tetradecyl, pentadecyl, hexadecyl, heptadecyl, octadecyl, nonadecyl, eicosyl, heneicosyl,
• R 6 is hydrogen at each occurrence.
• R 5 at each occurrence, is selected from -OR 7 and substituted or unsubstituted alkyl. In certain embodiments, R 5 , at each occurrence, is selected from -OR and substituted or unsubstituted linear alkyl, C Qg alkyl, or C ⁇ -C % alkyl. In certain embodiments, R 5 , at each occurrence, is selected from -OR and substituted or unsubstituted branched C C 3 o alkyl, C ⁇ -C ⁇ % alkyl, or
• R 5 is selected from -OR 7 , methyl, ethyl, propyl (e.g., w-propyl, isopropyl), butyl (e.g., w-butyl, isobutyl, tert- butyl, sec-butyl), pentyl (e.g., w-pentyl, isopentyl, ie/t-pentyl, neopentyl, sec-pentyl, 3-pentyl), hexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl, tridecyl, tetradecyl, pentadecyl, hexadecyl, heptadecyl, octadecyl, nonadecyl, eicosyl,
• R 7 is hydrogen at each occurrence.
• L is -C(R a )(R b )-.
• R a and R b are each independently, at each occurrence, hydrogen such that L is -CH 2 -.
• R a and R b are each independently, at each occurrence, selected from hydrogen and substituted or unsubstituted linear C Qg alkyl.
• R a and R b are each independently, at each occurrence, selected from hydrogen and substituted or unsubstituted branched C Qg alkyl.
• R a and R b are each independently, at each occurrence, selected from hydrogen, methyl, ethyl, propyl (e.g., w-propyl, isopropyl), butyl (e.g., w-butyl, isobutyl, ie/t-butyl, sec-butyl), pentyl (e.g., w-pentyl, isopentyl, iert-pentyl, neopentyl, sec-pentyl, 3-pentyl), hexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl, tridecyl, tetradecyl, pentadecyl, hexadecyl, heptadecyl, octadecyl, nonadecyl, eicosyl, heneicosyl
• R a and R b are each independently, at each occurrence, selected from hydrogen and substituted or unsubstituted phenyl, dihydroindenyl, indenyl, naphthyl, dihydronaphthalenyl, or 5,6,7,8-tetrahydronaphthalenyl.
• R a and R b are each independently, at each occurrence, selected from hydrogen and substituted or unsubstituted cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, cyclooctyl, cyclononyl, cyclodecyl, cycloundecyl, cyclododecyl, cyclotridecyl, cyclotetradecyl, cyclopentadecyl, cyclohexadecyl, cycloheptadecyl, or
• R a and R b are each independently, at each occurrence, selected from hydrogen and substituted or unsubstituted furanyl, imidazolyl, isoxazolyl, isothiazolyl, oxadiazolyl, oxazolyl, pyridinyl, pyridazinyl, pyrimidinyl, pyrazinyl, pyrazolyl, pyrrolyl, tetrazolyl, thiadiazolyl, thiazolyl, thienyl, triazolyl, triazinyl, benzofuranyl, benzothienyl, 1,3-benzoxazolyl, benzimidazolyl, indazolyl, indolyl, isoindolyl, isoquinolinyl, naphthyridinyl, pyridoimidazolyl, or quinolinyl.
• R a and R b are each independently, at each occurrence, selected from hydrogen and substituted or unsubstituted azetidinyl, azepanyl, aziridinyl, diazepanyl, 1,3-dioxanyl, 1,3- dioxolanyl, 1,3-dithiolanyl, 1,3-dithianyl, imidazolinyl, imidazolidinyl,
• L is -0-C(R c )(R d )-.
• R c and R d are each hydrogen such that L is -0-CH 2 -.
• R c and R d are each independently, at each occurrence, selected from hydrogen and substituted or unsubstituted linear Ci-Cis alkyl.
• R c and R d are each independently, at each occurrence, selected from hydrogen and substituted or unsubstituted branched C C ⁇ alkyl.
• R c and R d are each independently, at each occurrence, selected from hydrogen, methyl, ethyl, propyl (e.g., w-propyl, isopropyl), butyl (e.g., w-butyl, isobutyl, ie/t-butyl, sec-butyl), pentyl (e.g., w-pentyl, isopentyl, ie/t-pentyl, neopentyl, sec-pentyl, 3-pentyl), hexyl, heptyl, octyl, nonyl, decyl, undecyl, dodecyl, tridecyl, tetradecyl, pentadecyl, hexadecyl, heptadecyl, octadecyl, nonadecyl, eicosyl, hene
• R c and R d are each independently, at each occurrence, selected from hydrogen and substituted or unsubstituted phenyl, dihydroindenyl, indenyl, naphthyl, dihydronaphthalenyl, or 5,6,7,8-tetrahydronaphthalenyl.
• R c and R d are each independently, at each occurrence, selected from hydrogen and substituted or unsubstituted cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, cyclooctyl, cyclononyl, cyclodecyl, cycloundecyl, cyclododecyl, cyclotridecyl, cyclotetradecyl, cyclopentadecyl, cyclohexadecyl, cycloheptadecyl, or cyclooctodecyl.
• R c and R d are each independently, at each occurrence, selected from hydrogen and substituted or unsubstituted furanyl, imidazolyl, isoxazolyl, isothiazolyl, oxadiazolyl, oxazolyl, pyridinyl, pyridazinyl, pyrimidinyl, pyrazinyl, pyrazolyl, pyrrolyl, tetrazolyl, thiadiazolyl, thiazolyl, thienyl, triazolyl, triazinyl, benzofuranyl, benzothienyl, 1,3- benzoxazolyl, benzimidazolyl, indazolyl, indolyl, isoindolyl, isoquinolinyl, naphthyridinyl, pyridoimidazolyl, or quinolinyl.
• R c and R d are each independently, at each occurrence, selected from hydrogen and substituted or unsubstituted azetidinyl, azepanyl, aziridinyl, diazepanyl, 1,3-dioxanyl, 1,3- dioxolanyl, 1,3-dithiolanyl, 1,3-dithianyl, imidazolinyl, imidazolidinyl,
• n at each occurrence, is 0. In certain embodiments,
• n, at each occurrence is 1. In certain embodiments, m, at each occurrence, is 2. In certain embodiments, m, at each occurrence, is 3.
• p is 1. In certain embodiments, p is 2. In certain embodiments, p is 3. In certain embodiments, p is 4. In certain embodiments, p is 5.
• q is 1. In certain embodiments, q is 2. In certain embodiments, q is 3. In certain embodiments, q is 4. In certain embodiments, q is 5.
• n ranges from 1 to 100, 1 to 50, 1 to 30, 1 to 20, 1 to 15, or 1 to 10. In certain embodiments, n is 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, or 50.
• the phenolic-aldehyde condensates have formula (Il-a),
• R 1 , R 2 , R 4 , R 5 , L, m, n, p, and q are as defined above.
• R 1 is hydrogen at each occurrence;
• R 2 at each occurrence, is independently selected from -OH and Q-Cg substituted or unsubstituted alkyl;
• p is 1 or 2 wherein at least one R 4 is -OH and the other optional R 4 is selected from -OH and C C 8 substituted or unsubstituted alkyl;
• q is 1 or 2 wherein at least one R 5 is -OH and the other optional R 5 is selected from -OH and Q-Cg substituted or unsubstituted alkyl.
• the phenolic-aldehyde condensates have formula (Il-b),
• R 1 , R 2 , R 4 , R 5 , L, m, n, p, and q are as defined above.
• R 1 is hydrogen at each occurrence;
• R 2 at each occurrence, is independently selected from -OH and Q-Cg substituted or unsubstituted alkyl;
• p is 1 or 2 wherein at least one R 4 is -OH and the other optional R 4 is selected from -OH and Ci-Cg substituted or unsubstituted alkyl;
• q is 1 or 2 wherein at least one R 5 is -OH and the other optional R 5 is selected from -OH and Q-Cg substituted or unsubstituted alkyl.
• the phenolic-aldehyde condensates have formula (II-c),
• R 1 is hydrogen at each occurrence;
• R 2 at each occurrence, is independently selected from -OH and Q-Cg substituted or unsubstituted alkyl;
• p is 1 or 2 wherein at least one R 4 is -OH and the other optional R 4 is selected from -OH and Ci-Cg substituted or unsubstituted alkyl;
• q is 1 or 2 wherein at least one R 5 is -OH and the other optional R 5 is selected from -OH and Q-Cg substituted or unsubstituted alkyl.
• the phenolic-aldehyde condensates have formula (Il-d),
• R 1 is hydrogen at each occurrence;
• R 2 at each occurrence, is independently selected from -OH and Q-Cg substituted or unsubstituted alkyl;
• p is 1 or 2 wherein at least one R 4 is -OH and the other optional R 4 is selected from -OH and Ci-Cg substituted or unsubstituted alkyl;
• q is 1 or 2 wherein at least one R 5 is -OH and the other optional R 5 is selected from -OH and Q-Cg substituted or unsubstituted alkyl.
• the phenolic-aldehyde condensates have formula (Il-e),
• R 1 , R 2 , R 4 , R 5 , n, p, and q are as defined above.
• R 1 is hydrogen at each occurrence;
• R 2 at each occurrence, is independently selected from -OH and Q-Cg substituted or unsubstituted alkyl;
• p is 1 or 2 wherein at least one R 4 is -OH and the other optional R 4 is selected from -OH and C Cg substituted or unsubstituted alkyl;
• q is 1 or 2 wherein at least one R 5 is -OH and the other optional R 5 is selected from -OH and C Cg substituted or unsubstituted alkyl.
• the phenolic-aldehyde condensates have formula (Il-f),
• R 1 , R 2 , R 4 , R 5 , L, m, n, p, and q are as defined above.
• R 1 is hydrogen at each occurrence;
• R 2 at each occurrence, is independently selected from -OH and C Cg substituted or unsubstituted alkyl;
• p is 1 or 2 wherein at least one R 4 is -OH and the other optional R 4 is selected from -OH and Ci-Cg substituted or unsubstituted alkyl;
• q is 1 or 2 wherein at least one R 5 is -OH and the other optional R 5 is selected from -OH and Q-Cg substituted or unsubstituted alkyl.
• the phenolic-aldehyde condensates have formula (II-g),
• R 1 is hydrogen at each occurrence;
• R 2 at each occurrence, is independently selected from -OH and Q-Cg substituted or unsubstituted alkyl;
• p is 1 or 2 wherein at least one R 4 is -OH and the other optional R 4 is selected from -OH and C Cg substituted or unsubstituted alkyl;
• q is 1 or 2 wherein at least one R 5 is -OH and the other optional R 5 is selected from -OH and C Cg substituted or unsubstituted alkyl.
• the phenolic-aldehyde condensates have formula (Il-h),
• R 1 , R 2 , R 4 , R 5 , L, n, p, and q are as defined above.
• R 1 is hydrogen at each occurrence;
• R 2 at each occurrence, is independently selected from -OH and CrCg substituted or unsubstituted alkyl;
• p is 1 or 2 wherein at least one R 4 is -OH and the other optional R 4 is selected from -OH and C Cg substituted or unsubstituted alkyl;
• q is 1 or 2 wherein at least one R 5 is -OH and the other optional R 5 is selected from -OH and C Cg substituted or unsubstituted alkyl.
• the phenolic-aldehyde condensates have formula (Il-i) or formula (Il-j),
• R 1 is hydrogen at each occurrence;
• R 2 at each occurrence, is independently selected from -OH and Q-Cg substituted or unsubstituted alkyl;
• p is 1 or 2 wherein at least one R 4 is -OH and the other optional R 4 is selected from -OH and C C 8 substituted or unsubstituted alkyl;
• q is 1 or 2 wherein at least one R 5 is -OH and the other optional R 5 is selected from -OH and Q-Cg substituted or unsubstituted alkyl.
• the phenolic-aldehyde condensates have formula (Il-k) or formula (II-
• R 1 is hydrogen at each occurrence;
• R 2 at each occurrence, is independently selected from -OH and Q-Cg substituted or unsubstituted alkyl;
• p is 1 or 2 wherein at least one R 4 is -OH and the other optional R 4 is selected from -OH and Ci-Cg substituted or unsubstituted alkyl;
• q is 1 or 2 wherein at least one R 5 is -OH and the other optional R 5 is selected from -OH and substituted or unsubstituted alkyl.
• the phenolic-aldehyde condensates may contain asymmetric centers and can thus occur as racemates and racemic mixtures, single enantiomers,
• phenolic-aldehyde condensates produced by an acid catalyzed or base catalyzed reaction between an aldehyde (e.g., formaldehyde, or paraformaldehyde) and a mixture of one or more phenols.
• the phenolic-aldehyde condensates are products produced by an acid catalyzed or base catalyzed reaction between an aldehyde (e.g.,
• the phenol is selected from the group consisting of phenol, resorcinol, butylphenol, cresol, and octylphenol.
• Specific embodiments of the invention include, but are not limited to: a butylphenol formaldehyde resin formed under acidic conditions; a butylphenol formaldehyde resin formed under basic conditions; a resorcinol formaldehyde resin formed under acidic conditions; a resorcinol formaldehyde resin formed under basic conditions; a phenol formaldehyde resin formed under acidic conditions; a phenol formaldehyde resin formed under basic conditions; a cresol formaldehyde resin formed under acidic conditions; a cresol formaldehyde resin formed under basic conditions; an octylphenol formaldehyde resin formed under acidic conditions; and an octylphenol formaldehyde resin formed under basic conditions.
• compositions disclosed herein include at least one compound as described above.
• a composition of the invention contains a pure composition of a phenolic-aldehyde condensate having repeating units of formula (I). In other embodiments, a composition of the invention contains a mixture of two or more structurally distinct phenolic-aldehyde condensates having repeating units of formula (I).
• a composition of the invention may comprise a mixture of the phenolic-aldehyde condensates wherein n is variable, and/or wherein R 1 is variable, and/or wherein R 2 is variable, and/or wherein L is variable, and/or wherein m is variable, and/or wherein the pattern of linkage to the repeating aryl varies (e.g., para, ortho, or meta with respect to the linking L groups).
• a composition of the invention may comprise a mixture of phenolic-aldehyde condensates having repeating units of formula (I), wherein n is variable.
• a composition of the invention may comprise a mixture of phenolic-aldehyde condensates wherein n is variable, and the remaining variables R 1 , R 2 , L, and m are the same across the repeating units of formula (I) in the composition.
• Such a composition may be characterized by a weight average molecular weight and a polydispersity.
• a composition of the invention may comprise a mixture of phenolic-aldehyde condensates having repeating units of formula (I), wherein n is variable; R 1 is hydrogen at each occurrence; R 2 , at each occurrence, is independently selected from is -OH and Ci-Cg substituted or unsubstituted alkyl; L, at each occurrence, is -CH 2 -; and m, at each occurrence, is 1.
• formula (I) wherein n is variable; R 1 is hydrogen at each occurrence; R 2 , at each occurrence, is independently selected from is -OH and Ci-Cg substituted or unsubstituted alkyl; L, at each occurrence, is -CH 2 -; and m, at each occurrence, is 1.
• R is unsubstituted C Cg alkyl at each occurrence.
• a composition of the invention may comprise a mixture of phenolic-aldehyde condensates having repeating units of formula (I), wherein n is variable; R 1 is hydrogen at each occurrence; R 2 , at each occurrence, is independently selected from is -OH and C Cg substituted or unsubstituted alkyl; L, at each occurrence, is -0-CH 2 -; and m, at each occurrence, is 1.
• R is unsubstituted Ci-C% alkyl at each occurrence.
• a composition of the invention may comprise a mixture of phenolic-aldehyde condensates having repeating units of formula (I), wherein the pattern of linkage of the L groups to the repeating aryl varies.
• a composition of the invention may comprise a mixture of phenolic- aldehyde condensates having repeating units of formula (I), wherein the pattern of linkage of the L groups to the repeating aryl varies, and wherein the n variable varies across the phenolic-aldehyde condensates in the composition.
• a composition of the invention contains a mixture of phenolic-aldehyde condensates having repeating units of formula (I), wherein R a and/or R b vary, particularly where different aldehydes have been used to prepare the compounds.
• a composition of the invention contains a mixture of phenolic-aldehyde condensates having repeating units of formula (I), wherein R 1 and/or R and/or m vary, particularly where different phenols have been used to prepare the compounds.
• a composition of the invention contains a pure composition of a phenolic-aldehyde condensate of formula (II).
• a composition of the invention contains a mixture of two or more structurally distinct phenolic-aldehyde condensates of formula (II).
• a composition of the invention may comprise a mixture of the phenolic-aldehyde condensates wherein n is variable, and/or wherein R 1 is variable, and/or wherein R 2 is variable, and/or wherein R 4 is variable, and/or wherein R 5 is variable, and/or wherein L is variable, and/or wherein m is variable, and/or wherein p is variable, and/or wherein q is variable, and/or wherein the pattern of linkage to the repeating aryl varies (e.g., para, ortho, or meta with respect to the linking L groups).
• a composition of the invention may comprise a mixture of phenolic-aldehyde condensates of formula (II), wherein n is variable.
• a composition of the invention may comprise a mixture of phenolic-aldehyde condensates wherein n is variable, and the remaining variables R 1 , R 2 , R 4 , R 5 , L, m, p, and q are the same across the compounds of formula (II) in the composition.
• Such a composition may be characterized by a weight average molecular weight and a polydispersity.
• a composition of the invention may comprise a mixture of phenolic-aldehyde condensates of formula (II), wherein n is variable; R 1 is hydrogen at each occurrence; R 2 , R 4 , and R 5 , at each occurrence, are each independently selected from -OH and Q-Cg substituted or unsubstituted alkyl; L, at each occurrence, is -CH 2 -; and m, p, and q, at each occurrence, are each 1.
• R 2 , R 4 , and R 5 are unsubstituted Q-Cg alkyl at each occurrence.
• a composition of the invention may comprise a mixture of phenolic-aldehyde condensates of formula (II), wherein n is variable; R 1 is hydrogen at each occurrence; R 2 , R 4 , and R 5 , at each occurrence, are each independently selected from -OH and Q-Cg substituted or unsubstituted alkyl; L, at each occurrence, is -0-CH 2 -; and m, p, and q, at each occurrence, are each 1. In certain embodiments, R is unsubstituted Q-Cg alkyl at each occurrence.
• a composition of the invention may comprise a mixture of phenolic-aldehyde condensates of formula (II), wherein the pattern of linkage of the L groups to the repeating aryl varies.
• a composition of the invention may comprise a mixture of phenolic-aldehyde condensates of formula (II), wherein the pattern of linkage of the L groups to the repeating aryl varies, and wherein the n variable varies across the phenolic -aldehyde condensates in the composition.
• a composition of the invention contains a mixture of phenolic-aldehyde condensates of formula (II), wherein R a and/or R b vary, particularly where different aldehydes have been used to prepare the compounds.
• a composition of the invention contains a mixture of phenolic-aldehyde condensates of formula (II), wherein R 1 and/or R2 and/or R 4 and/or R 5 and/or m and/or p and/or q vary, particularly where different phenols have been used to prepare the compounds.
• compositions of the invention can optionally include one or more solvents.
• suitable solvents include, but are not limited to, ethoxylated and propoxylated alkyl ethers or alcohols, fatty acid esters, low aromatic hydrocarbon oils, kerosene, heavy aromatic naphtha ("HAN”), propylene glycol monomethyl ether, n-butanol, isobutanol, and combinations thereof.
• Specific embodiments of the invention include, but are not limited to: a formulation comprising a butylphenol formaldehyde resin formed under acidic conditions, and an ethoxylated and propoxylated alkyl ether; a formulation comprising a butylphenol formaldehyde resin formed under acidic conditions, and kerosene; a formulation comprising a butylphenol formaldehyde resin formed under basic conditions, and an ethoxylated and propoxylated alkyl ether; a formulation comprising a butylphenol formaldehyde resin formed under basic conditions, and kerosene; a formulation comprising a resorcinol formaldehyde resin, and a sodium hydroxide solution; a formulation comprising a phenol formaldehyde resin formed under acidic conditions, and an ethoxylated and propoxylated alkyl ether; a formulation comprising a cresol formaldehyde resin formed under basic conditions, propylene glycol mono
• Phenolic-aldehyde condensates of the invention can be prepared as described in Scheme 1, wherein R 1 , R 2 , m, and n are as defined above, and where L is -CH 2 -.
• Treatment of a phenol of formula (1), optionally in excess, with an aldehyde (2) (e.g., formaldehyde, paraformaldehyde) in the presence of an acid (3) will provide phenolic-aldehyde condensates of formula (4).
• Scheme 1 depicts phenolic-aldehyde condensates formed under acidic conditions, and in particular, where L is -CH 2 -.
• phenolic-aldehyde condensates of the invention can be prepared as described in Scheme 2, wherein R 1 , R 2 , m, and n are as defined above, and where L is -0-CH 2 -.
• Treatment of a phenol of formula (1), optionally in excess, with an aldehyde (2) (e.g., formaldehyde, paraformaldehyde) in the presence of a base (5) will provide a compound of formula (6), which undergoes further reaction with aldehyde of formula (2) and base of formula (5) to provide phenolic-aldehyde condensates of formula (4).
• Scheme 2 depicts phenolic-aldehyde condensates formed under basic conditions, and in particular, where L is -0-CH 2 -.
• compositions of the invention may be used to aid crystallization of aluminum hydroxide, and in particular, aluminum hydroxide from a precipitation liquor.
• the phenolic-aldehyde resins may be applied neat, or depending on the solubility, as solutions in hydrocarbon oils, ethoxylated or propoxylated alkyl ethers or alcohols, fatty acid esters, or combinations thereof.
• the precipitation liquor may be located in a Bayer process.
• the crystal growth modifiers may be introduced into the precipitation liquor via various routes.
• the phenolic-aldehyde condensates may be added to the pregnant liquor or anywhere in the crystallization circuit, including the seed and in any of the tanks in the crystallization train.
• the compounds and compositions can be introduced to the precipitation liquor at the following steps of a Bayer process: a) to a precipitation feed liquor, b) to a seed slury, c) directly into a precipitation tank, or d) any combination thereof.
• the compounds and compositions can be added to a precipitation liquor via various modes of addition, such as in-line injection.
• a method of the invention may include addition of a compound or composition of the invention to a Bayer process liquor.
• the method may include a reduced formation of product fines concurrent with an upward shift in particle size distribution of aluminum hydroxide.
• a method of the invention may include a Bayer process for the formation of aluminum hydroxide crystals, said process comprising crystallization of dissolved aluminum hydroxide as gibbsite from a filtrate to produce gibbsite crystals, wherein the crystallization is aided by a crystal growth modifier of the invention, said crystal growth modifier added to the filtrate before, during, or both before and during, the crystallization, the gibbsite crystals produced in the process being courser than when crystallization occurs from an otherwise identical filtrate that contains no crystal growth modifier as disclosed herein.
• the amount of crystal growth modifier required to produce a desirable effect depends upon the precipitation process parameters. Most often, this amount is determined by the surface area of available hydrated alumina solids in the precipitation liquor.
• the solids comprise the aluminum hydroxide introduced as seed or originated as new crystals or agglomerates during the decomposition of precipitation liquor.
• the suitable amount of crystal growth modifier may range from about 0.01 to about 30 mg per square meter of the available aluminum hydroxide seed area, and preferably, from about 0.1 to about 15 mg per square meter. Commonly, less than about 8 mg/m of CGM can be used.
• the precipitation operators can dose the crystal growth modifier by volume.
• the crystal growth modifier amount may range from about 0.01 to about 400 mg/liter of precipitation liquor, preferably from about 0.05 to about 200 mg/liter of precipitation liquor. Commonly less than about 100 mg/liter of CGM can be used.
• the addition of the crystal growth modifier results in at least half of the recovered crystals by weight exceed 325 mesh (44-45 microns). In certain embodiments, the addition of the crystal growth modifier results in at least half of the recovered crystals by weight exceed at least 40 microns, at least 45 microns, at least 50 microns, at least 55 microns, at least 60 microns, at least 65 microns, at least 70 microns, at least 75 microns, at least 80 microns, at least 85 microns, at least 90 microns, or at least 95 microns.
• the addition of the crystal growth modifier results in at least half of the recovered crystals by weight exceed 40 microns, 41 microns, 42 microns, 43 microns, 44 microns, 45 microns, 46 microns, 47 microns, 48 microns, 49 microns, 50 microns, 51 microns, 52 microns, 53 microns, 54 microns, 55 microns, 56 microns, 57 microns, 58 microns, 59 microns, 60 microns, 61 microns, 62 microns, 63 microns, 64 microns, 65 microns, 66 microns, 67 microns, 68 microns, 69 microns, 70 microns, 71 microns, 72 microns, 73 microns, 74 microns, 75 microns, 76 microns, 77 microns, 78 microns, 79 microns, 80 microns, 81 microns, 82
• the crystal growth modifiers provide a % increase in mean of control quantile size of at least 5%, at least 10%, at least 15%, at least 20%, at least 25%, or at least 30%. In certain embodiments, the crystal growth modifiers provide a % increase in mean of control quantile size of 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, or 35% for any of d(0.1), d(0.5), or d(0.9).
• an upward shift in oxalate ball size also occurs.
• oxalate balls precipitate to a size in the range of from about 200 to about 10,000 ⁇ . In certain embodiments, oxalate balls precipitate to a size in the range of about 300 ⁇ .
• crystal growth modifier also provides a more effective Bayer process wherein the yield of coarser alumina trihydrate particles is increased, and the separation and collection of alumina trihydrate from the alkaline liquor is improved.
• An exemplary test procedure for evaluating crystal growth modifiers can be conducted as follows. Tests are run using fresh pregnant liquor, obtained from the reconstitution of plant spent liquor. A desired weight of spent liquor is measured into a stainless steel beaker and the volume reduced by evaporation to about 30%. To this a set weight of aluminum hydroxide solid is added and the mixture stirred until it is dissolved. This solution is removed from the hot plate and placed on a weighing balance and de-ionized water added until a desired weight is attained. The pregnant liquor is filtered to remove any insoluble material.
• Precipitation tests are performed in 250-mL Nalgene® bottles rotated end- over-end, at 10 rpm, in an Intronics temperature-controlled water bath.
• the crystal growth modifier is dosed, with respect to the total surface area of the seed crystals (mg/m ) (e.g., 2 mg or 4 mg), to the lid of the appropriate bottles using a micro-syringe and the bottles are then placed in the rotating bath for equilibration at 72 °C (20 minutes).
• the bottles are removed, quickly charged with the required quantity of seed (50 g/L, based on liquor volume) and immediately returned to the water bath.
• the temperature of the water bath is set to 72 °C, for example.
• the bottles are rotated overnight for 15 hours.
• the bottles are removed and for each bottle a 20-mL sample of the slurry is filtered through a syringe filter and submitted for liquor analysis.
• 10 mL of a sodium gluconate solution (400 g/L) is added to the remaining slurry and mixed well.
• the solids are collected by vacuum filtration and are thoroughly washed with hot deionized water and dried at 110° C.
• the particle size distribution and specific surface area are determined on a Malvern Particle Sizer, which is well known in the art.
• the particle size distribution is given by three quantiles, d(0.1), d(0.5) and d(0.9). These represent the particle size at which the total particle volume (or mass) is less than about 10%, 50% and 90% respectively.
• a butylphenol formaldehyde resin obtained from commercial sources was evaluated for coarsening effects.
• Two formulations comprising the resin were prepared:
• Formulation A butylphenol formaldehyde resin formed under acidic conditions, dispersed in an ethoxylated and propoxylated ether at a concentration of 100 g/L;
• Formulation A* butylphenol formaldehyde resin formed under acidic conditions, dispersed in kerosene at a concentration of 50 g/L.
• Tables 1 and 2 show the effects of the butylphenol aldehyde formulations on particle size of Bayer aluminum hydroxide at 72 °C and 68 °C, respectively.
• the particle size distribution is given by the three quantiles, d(0.1), d(0.5) and d(0.9). Thus, 10%, 50% and 90%, respectively, of the total particle volume (or mass) is less than the size given in the tables.
• the d(0.5) is just the medium size.
• the percent (%) increase over the control quantile particle size is the difference between the quantiles particle sizes obtained in the tests with a crystal growth modifier and control divided by the control quantile particle size.
• the existing commercial crystal growth modifier incorporates fatty acids with chains of greater than ten carbons, and is referred to herein as the "Incumbent.”
• Formulation A butylphenol formaldehyde resin formed under acidic conditions with excess butylphenol, solvated in an ethoxylated and propoxylated ether at a concentration of 100 g/L;
• Formulation A* butylphenol formaldehyde resin formed under acidic conditions with excess butylphenol, solvated in kerosene at a concentration of 50 g/L;
• Formulation B resorcinol formaldehyde resin dissolved in a 15 g/L NaOH solution at a concentration of 100 g/L;
• Formulation C butylphenol formaldehyde resin formed under alkaline conditions, with a large excess of formaldehyde, solvated in an ethoxylated and propoxylated alkyl ether at a concentration of 100 g/L;
• Formulation C* butylphenol formaldehyde resin formed under alkaline conditions, with a large excess of formaldehyde, solvated in kerosene at a concentration of 25 g/L;
• Formulation D phenol formaldehyde resin formed under acidic conditions, with excess phenol, solvated in an ethoxylated and propoxylated alkyl ether at a concentration of 25 g/L;
• Formulation E cresol formaldehyde resin, formed under alkaline conditions, with a large excess of formaldehyde, supplied as a solution in propylene glycol monomethyl ether, n-butanol, and isobutanol, at a concentration of 50 wt%;
• Formulation F octylphenol formaldehyde resin formed under acidic conditions, with excess octylphenol, solvated in kerosene at a concentration of 50 g/L.
• Tables 3 and 4 show the effects of the formulations on particle size of Bayer aluminum hydroxide at 72 °C and 68 °C, respectively.
• the particle size distribution is given by the three quantiles, d(0.1), d(0.5) and d(0.9). Thus, 10%, 50% and 90%, respectively, of the total particle volume (or mass) is less than the size given in the tables.
• the d(0.5) is just the medium size.
• the percent (%) increase over the control quantile particle size is the difference between the quantiles particle sizes obtained in the tests with a crystal growth modifier and control divided by the control quantile particle size.
• the increase in particle size afforded by an existing commercial crystal growth modifier is also listed in Tables 3 and 4.
• the existing commercial crystal growth modifier incorporates fatty acids with chains of greater than ten carbons, and is referred to herein as the

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