Paper Processing Composition and Process of Production

Abstract

A process for improving the dry strength of the paper by applying a dry-strength enhancing composition to pulp during a paper-making process, said dry-strength enhancing composition comprising a solution comprising an acid mixed with at least one metal ion wherein the metal ion is generally provided as a metal sulfate or a solubilized sulfate to form a mixture (I), wherein the mixture generates an exothermic reaction to form a mixture (II) and wherein the mixture is cooled to form the dry-strength enhancing composition.

1 . A dry-strength enhancing composition comprising:
 a solution comprising an acid selected from the group including: phosphoric acid, fumaric acid, nitric acid, sulfurous acid, sulfonic acid, perchloric acid, acetic acid, sulfuric acid or a combination thereof, mixed with;   at least one metal ion selected from zinc, magnesium, manganese, nickel, and iron;
 wherein the metal ion is generally provided as a metal sulfate or a solubilized sulfate solution comprising water and a sulfate selected from the group including sodium sulfate, ammonium sulfate, magnesium sulfate, zinc sulfate, manganese sulfate, barium sulfate, calcium sulfate, iron sulfate, potassium sulfate, nickel sulfate, radium sulfate, strontium sulfate and dihyro-sulfate to form a mixture (i); 
 wherein the mixture generates an exothermic reaction, generating temperatures in the range of 150° F. to 950° F. to form a mixture (II); 
 wherein the mixture (II) is cooled using either an air coolant, a liquid coolant, a gas coolant, or a combination thereof to form the dry-strength enhancing composition; and 
 wherein the dry-strength enhancing composition has a pH value of less than 6.5. 
   
     
     
         2 . The dry-strength enhancing composition of  claim 1  wherein the acid is a food grade acid. 
     
     
         3 . The dry-strength enhancing composition of  claim 1  wherein the acid is of at least 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98% or 99% purity. 
     
     
         4 . The dry-strength enhancing composition of  claim 1  wherein the water is selected from the group comprising: distilled water, deionized water, purified water, filtered water, pharmaceutical grade water, medical grade water, reverse osmosis water, or a combination thereof. 
     
     
         5 . The dry-strength enhancing composition of  claim 4  wherein the water has a mega Ohm count between 5-19. 
     
     
         6 . The dry-strength enhancing composition of  claim 1  wherein the mixture generates temperatures in the range of 200° F. to 800° F., 300° F. to 800° F., 400° F. to 700° F., 500° F. to 800° F., 600° F. to 800° F., or a combination thereof. 
     
     
         7 . The dry-strength enhancing composition of  claim 1  wherein the composition is produced in a continuous process. 
     
     
         8 . A process for enhancing the dry strength of the paper by applying the dry-strength enhancing composition as defined in  claim 1  to pulp during a paper-making process. 
     
     
         9 . A dry-strength enhancing composition produced by the process of:
 providing an acid selected from the group including: phosphoric acid, fumaric acid, nitric acid, sulfurous acid, sulfonic acid, perchloric acid, acetic acid, sulfuric acid or a combination thereof;   providing a solubilized sulfate solution comprising water and a sulfate selected from the group including sodium sulfate, ammonium sulfate, magnesium sulfate, zinc sulfate, manganese sulfate, barium sulfate, calcium sulfate, iron sulfate, potassium sulfate, nickel sulfate, radium sulfate, strontium sulfate and dihyro-sulfate;   combining the acid and the solubilized sulfate within a reaction vessel to form a mixture (I);
 wherein the mixture generates an exothermic reaction, generating temperatures in the range of 150° F. to 950° F. to form a mixture (II); and 
   cooling mixture (II) within the reaction vessel using either an air coolant, a liquid coolant, a gas coolant, or a combination thereof to form the dry-strength enhancing composition; and
 wherein the dry-strength enhancing composition has a pH value of less than 6.5. 
   
     
     
         10 . The dry-strength enhancing composition of  claim 9  wherein the reaction vessel is an inline blending apparatus to which no pressure is added as the acid and the solubilized sulfate (mixture (I)) passes through the reaction vessel. 
     
     
         11 . The dry-strength enhancing composition of  claim 9  wherein the acid is a food grade acid. 
     
     
         12 . The dry-strength enhancing composition of  claim 9  wherein the acid is of at least 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98% or 99% purity. 
     
     
         13 . The dry-strength enhancing composition of  claim 9  wherein the water is selected from the group comprising: distilled water, deionized water, purified water, filtered water, pharmaceutical grade water, medical grade water, reverse osmosis water, or a combination thereof. 
     
     
         14 . A process for improving the dry strength of the paper by applying the dry-strength enhancing composition as defined in  claim 9  to pulp during a paper-making process. 
     
     
         15 . A method of producing a dry-strength enhancing composition comprising the steps of:
 providing an acid selected from the group including: phosphoric acid, fumaric acid, nitric acid, sulfurous acid, sulfonic acid, perchloric acid, acetic acid, sulfuric acid or a combination thereof;   providing a solubilized sulfate solution comprising water and a sulfate selected from the group including sodium sulfate, ammonium sulfate, magnesium sulfate, zinc sulfate, manganese sulfate, barium sulfate, calcium sulfate, iron sulfate, potassium sulfate, nickel sulfate, radium sulfate, strontium sulfate and dihyro-sulfate;   combining the acid and the solubilized sulfate within a reaction vessel to form a mixture (I);
 wherein the mixture generates an exothermic reaction, generating temperatures in the range of 150° F. to 950° F. to form a mixture (II); and 
   cooling mixture (II) within the reaction vessel using either an air coolant, a liquid coolant, a gas coolant, or a combination thereof to form the dry-strength enhancing composition; and
 wherein the dry-strength enhancing composition has a pH value of less than 6.5. 
   
     
     
         16 . The method of  claim 15  wherein the reaction vessel is an inline blending apparatus to which no pressure is added as the acid and the solubilized sulfate (mixture (I)) passes through the reaction vessel. 
     
     
         17 . The method of  claim 15  wherein the inline blending apparatus is a static inline mixer which continuously blends the acid and the solubilized sulfate (mixture (I)) as it passes through the reaction vessel. 
     
     
         18 . The method of  claim 15  wherein the acid is a food grade acid. 
     
     
         19 . The dry-strength enhancing composition of  claim 15  wherein the acid is of at least 90%, 91%, 92%, 93%, 94%, 95%, 96%, 97%, 98% or 99% purity. 
     
     
         20 . The method of  claim 15  further comprising the step of:
 applying the dry-strength enhancing composition to pulp during a paper-making process to enhance the dry strength of the paper.