Emulsifier particles and methods for making and using same

Abstract

Emulsifier particles and methods for making and using same. The emulsifier particles can include an alkali metal salt or an alkaline earth metal salt of a carboxylic acid terminated fatty amine condensate, an alkali metal salt or an alkaline earth metal salt of a modified tall oil, or a blend of an alkali metal salt or an alkaline earth metal salt of a carboxylic acid terminated fatty amine condensate and an alkali metal salt or an alkaline earth metal salt of a modified tall oil. The emulsifier particles can have a BET specific surface area of about 0.3 m 2 /g to about 1 m 2 /g. The method for making the emulsifier particles can include reducing a size of an emulsifier solid via a mechanical attrition process to produce the emulsifier particles.

What is claimed is: 
     
         1 . Emulsifier particles, comprising: (1) an alkali metal salt or an alkaline earth metal salt of a carboxylic acid terminated fatty amine condensate, (2) an alkali metal salt or an alkaline earth metal salt of a modified tall oil, or (3) a blend of an alkali metal salt or an alkaline earth metal salt of a carboxylic acid terminated fatty amine condensate and an alkali metal salt or an alkaline earth metal salt of a modified tall oil, wherein the emulsifier particles have a BET specific surface area of about 0.3 m 2 /g to about 1 m 2 /g. 
     
     
         2 . The emulsifier particles of  claim 1 , wherein the emulsifier particles have a BET pore volume of at least 0.001 cm 3 /g to about 0.005 cm 3 /g. 
     
     
         3 . The emulsifier particles of  claim 1 , wherein the emulsifier particles have a BET specific surface area of about 0.5 m 2 /g to about 1 m 2 /g. 
     
     
         4 . The emulsifier particles of  claim 1 , wherein the emulsifier particles have a bulk density of about 0.3 g/cm 3  to about 0.6 g/cm 3 . 
     
     
         5 . The emulsifier particles of  claim 1 , wherein the emulsifier particles have a Krumbein roundness of 0.1 to less than 0.8 and a Krumbein sphericity of 0.1 to less than 0.8. 
     
     
         6 . The emulsifier particles of  claim 1 , wherein the emulsifier particles have a weight average particle size of about 5 μm to less than 80 μm. 
     
     
         7 . The emulsifier particles of  claim 1 , wherein the emulsifier particles have a BET pore volume of at least 0.0012 cm 3 /g to about 0.002 cm 3 /g. 
     
     
         8 . The emulsifier particles of  claim 1 , wherein the emulsifier particles have a BET average pore width of about 50 angstroms to about 150 angstroms. 
     
     
         9 . The emulsifier particles of  claim 1 , wherein the emulsifier particles have a BET specific surface area of about 0.5 m 2 /g to about 1 m 2 /g, a BET pore volume of at least 0.0012 cm 3 /g to about 0.002 cm 3 /g, and a BET average pore width of about 50 angstroms to about 150 angstroms. 
     
     
         10 . The emulsifier particles of  claim 1 , wherein the emulsifier particles have a BET specific surface area of at least 0.5 m 2 /g to about 1 m 2 /g, a BET pore volume of at least 0.0012 cm 3 /g to about 0.002 cm 3 /g, a BET average pore width of about 50 angstroms to less than 100 angstroms, a weight average particle size of about 5 μm to less than 27 μm, an average Krumbein roundness of 0.1 to 0.7, and a bulk density of about 0.3 g/cm 3  to about 0.6 g/cm 3 . 
     
     
         11 . The emulsifier particles of  claim 1 , wherein:
 the emulsifier particles comprise the alkali metal salt or the alkaline earth metal salt of the modified tall oil,   the alkali metal salt or the alkaline earth metal salt of the modified tall oil is produced by adding an alkali metal hydroxide, an alkaline earth metal hydroxide, an alkali metal oxide, an alkaline earth metal oxide, or any mixture thereof to a modified tall oil, and   the modified tall oil comprises a reaction product of a tall oil distillate component and an unsaturated polycarboxylic acid, a carboxylic anhydride, or a mixture of an unsaturated polycarboxylic acid and a carboxylic anhydride.   
     
     
         12 . The emulsifier particles of  claim 11 , wherein:
 the tall oil distillate component comprises tall oil fatty acids, tall oil rosin acids, or a mixture thereof,   the unsaturated polycarboxylic acid comprises maleic acid, fumaric acid, phthalic acid, trans-2-hexenedioic acid, trans-3-hexenedioic acid, cis-3-octenedioic acid, cis-4-octenedioic acid, trans-3-octenedioic acid, succinic acid, or any mixture thereof, and   the carboxylic anhydride comprises maleic anhydride, succinic anhydride, or a mixture thereof.   
     
     
         13 . The emulsifier particles of  claim 1 , wherein:
 the emulsifier particles comprise the alkali metal salt or the alkaline earth metal salt of the carboxylic acid terminated fatty amine condensate,   the alkali metal salt or the alkaline earth metal salt of the carboxylic acid terminated fatty amine condensate is produced by adding an alkali metal hydroxide, an alkaline earth metal hydroxide, an alkali metal oxide, an alkaline earth metal oxide, or any mixture thereof to a carboxylic acid terminated fatty amine condensate, and   the carboxylic acid terminated fatty amine condensate comprises a reaction product of a fatty acid amine condensate and a polycarboxylic acid, a carboxylic anhydride, or a mixture of a polycarboxylic acid and a carboxylic anhydride.   
     
     
         14 . Emulsifier particles, comprising a neutralized carboxylic acid terminated fatty amine condensate, a neutralized modified tall oil, or a blend thereof, wherein the emulsifier particles have a BET specific surface area of about 0.3 m 2 /g to about 1 m 2 /g, a BET pore volume of at least 0.001 cm 3 /g to about 0.005 cm 3 /g, and a BET average pore width of about 50 angstroms to about 200 angstroms. 
     
     
         15 . The emulsifier particles of  claim 14 , wherein the emulsifier particles comprise the neutralized carboxylic acid terminated fatty amine condensate, and wherein the neutralized carboxylic acid terminated fatty amine condensate comprises an alkali metal salt or an alkaline earth metal salt of a carboxylic acid terminated fatty amine condensate. 
     
     
         16 . The emulsifier particles of  claim 14 , wherein:
 the emulsifier particles comprise the neutralized modified tall oil,   the neutralized modified tall oil comprises an alkali metal salt or an alkaline earth metal salt of a modified tall oil,   the alkali metal salt or the alkaline earth metal salt of the modified tall oil is produced by adding an alkali metal hydroxide, an alkaline earth metal hydroxide, an alkali metal oxide, an alkaline earth metal oxide, or any mixture thereof to a modified tall oil, and   the modified tall oil comprises a reaction product of a tall oil distillate component and an unsaturated polycarboxylic acid, a carboxylic anhydride, or a mixture of an unsaturated polycarboxylic acid and a carboxylic anhydride.   
     
     
         17 . A method for making emulsifier particles, comprising reducing a size of an emulsifier solid via a mechanical attrition process to produce emulsifier particles, wherein the emulsifier solid comprises: (1) an alkali metal salt or an alkaline earth metal salt of a carboxylic acid terminated fatty amine condensate, (2) an alkali metal salt or an alkaline earth metal salt of a modified tall oil, or (3) a blend of an alkali metal salt or an alkaline earth metal salt of a carboxylic acid terminated fatty amine condensate and an alkali metal salt or an alkaline earth metal salt of a modified tall oil, and wherein the emulsifier particles have a BET specific surface area of about 0.3 m 2 /g to about 1 m 2 /g. 
     
     
         18 . The method of  claim 17 , wherein the emulsifier particles have a BET specific surface area of about 0.5 m 2 /g to about 1 m 2 /g, a BET pore volume of at least 0.0012 cm 3 /g to about 0.003 cm 3 /g, and a BET average pore width of about 50 angstroms to about 150 angstroms. 
     
     
         19 . The method of  claim 18 , wherein the emulsifier particles have a Krumbein roundness of 0.1 to less than 0.8 and a Krumbein sphericity of 0.1 to less than 0.8. 
     
     
         20 . The method of  claim 18 , wherein the emulsifier particles have a bulk density of about 0.3 g/cm 3  to about 0.6 g/cm 3 , a BET pore volume of at least 0.0012 cm 3 /g to about 0.002 cm 3 /g, and a BET average pore width of about 50 angstroms to less than 100 angstroms.