Silicon containing polymer flocculants

Abstract

Disclosed herein are silicon containing polymers and compositions containing the same able to flocculate suspended solids in the Bayer or Sinter process stream.

1 . A silicon-containing polymer comprising a silicon-containing reaction product of at least a hydroxamate polymer and a hydroxamate reactive compound, wherein the hydroxamate reactive compound comprises an —Si(OR) 3  group where each R is independently selected from the group consisting of hydrogen, C 1-20  alkyl, C 1-20  alkenyl, C 6-12  aryl, C 7-20  aralkyl, a group I metal ion, a group II metal ion, and NR′ 4   + ; wherein R′ is independently selected from the group consisting of hydrogen, C 1-20  alkyl, C 1-20  alkenyl, C 6-12  aryl, and C 7-20  aralkyl; and wherein R′ is independently unsubstituted, hydroxy-substituted, or beta hydroxy substituted or a mixture, in any proportion, of any of these groups and a hydroxamate-reactive group and wherein the hydroxamate polymer comprises; about 7.5% or less by mole, based on total mers in the polymer, of an H mer according to formula (VIII); 
       
         
           
           
               
               
           
         
         wherein R 4  and R 5  are each independently H or optionally substituted C 1-6  alkyl. 
       
     
     
         2 . The polymer of  claim 1 , wherein the hydroxamate polymer comprises about 2.0% or less by mole, based on total mers in the polymer, of the H mer of formula (VIII). 
       
         
           
           
               
               
           
         
       
     
     
         3 . The polymer of  claim 2 , wherein the hydroxamate polymer further comprises an I-1 mer according to formula (IX-A) or an I-2 mer according to formula (IX-B); 
       
         
           
           
               
               
           
         
         wherein R 8  and R 9  are each independently H or C 1-6  alkyl and M is independently a group I metal ion, group II metal ion, or N(R 3 ) 4   +  where each R 3  is independently H, C 1-6  alkyl. 
       
     
     
         4 . The polymer according to  claim 1 , wherein the silicon-containing reaction product comprises an A mer according to formula (I); 
       
         
           
           
               
               
           
         
         wherein: 
         R 1  and R 2  are each independently H or C 1-6  alkyl; and T is a direct bond or an organic connecting group comprising from about 1 to about 20 carbons; and each R is independently selected from the group consisting of hydrogen, C 1-20  alkyl, C 1-20  alkenyl, C 6-12  aryl, C 7-20  aralkyl, a group I metal ion, a group II metal ion, and NR′ 4   + ; wherein R′ is independently selected from the group consisting of hydrogen, C 1-20  alkyl, C 1-20  alkenyl, C 6-12  aryl, and C 7-20  aralkyl; and wherein R′ is independently unsubstituted, hydroxy-substituted, or beta hydroxy substituted or a mixture, in any proportion, of any of these groups; and each R 3  is independently H or C 1-6  alkyl; wherein the amount of A mer according to formula (I) is at least about 1% by mole, based on total mers in the silicon-containing polymeric reaction product. 
       
     
     
         5 . The polymer according to  claim 4 , wherein the hydroxamate reactive compound is a halogen functional silane, an epoxy functional silane, or an isocyanate functional silane. 
     
     
         6 . The polymer according to  claim 5 , wherein the hydroxamate reactive compound is glycidoxypropyl trimethoxysilane. 
     
     
         7 . The polymer according to  claim 1 , wherein the hydroxamate polymer is poly(acrylamide-co-acrylate-co-hydroxamate). 
     
     
         8 . The polymer according to  claim 1 , wherein the silicon-containing reaction product has a Standard Viscosity (SV) of about 9 mPa·s or greater. 
     
     
         9 . The polymer of  claim 8 , wherein the silicon-containing reaction product has a Standard Viscosity (SV) of about 10 mPa·s or greater. 
     
     
         10 . A composition comprising a polymer according to  claim 1  and at least one additional polymer. 
     
     
         11 . The composition according to  claim 10 , wherein the additional flocculant is chosen from polyacrylic acid, and salts thereof; including sodium and ammonium salts; hydroxamic acid polymers and salts thereof, including sodium and ammonium salts; acrylic acid:acrylamide copolymers and salts thereof, including sodium and ammonium salts; starch; and dextran. 
     
     
         12 . A composition comprising a silicon-containing polymer having a silicon-containing pendant group wherein the silicon-containing polymer has a standard viscosity (SV) of greater than 9 mPa·s. 
     
     
         13 . The composition according to  claim 12 , wherein the SV of the silicon-containing polymer is greater than 10 mPa·s. 
     
     
         14 . The composition according to  claim 13 , wherein the silicon-containing polymer is an acrylamide copolymer. 
     
     
         15 . The composition according to  claim 12 , wherein the silicon-containing polymer comprises an A mer of the formula (I): 
       
         
           
           
               
               
           
         
         wherein: 
         R 1  and R 2  are each independently H or C 1-6  alkyl; 
         T is a direct bond or an organic connecting group comprising from about 1 to about 20 carbons; 
         each R is independently selected from the group consisting of hydrogen, C 1-20  alkyl, C 1-20  alkenyl, C 6-12  aryl, C 7-20  aralkyl, a group I metal ion, a group II metal ion, and NR′ 4   + ; wherein R′ is independently selected from the group consisting of hydrogen, C 1-20  alkyl, C 1-20  alkenyl, C 6-12  aryl, and C 7-20  aralkyl; and wherein R′ is independently unsubstituted, hydroxy-substituted, or beta hydroxy substituted or a mixture, in any proportion, of any of these groups; and 
         wherein the amount of A mer according to formula (I) is at least about 1% by mole, based on total mers in the silicon-containing polymer. 
       
     
     
         16 . The composition according to  claim 15 , wherein the silicon-containing polymer comprises about 7.5% or less by mole, based on total mers in the silicon containing polymer, of a B mer according to formula (II); 
       
         
           
           
               
               
           
         
         wherein R 1  is hydrogen or C 1-6  alkyl and each R a  is independently selected from the group consisting of hydrogen, C 1-20  alkyl, C 1-20  alkenyl, C 6-12  aryl, C 7-20  aralkyl, a group I metal ion, a group II metal ion, and NR′ 4   + ; wherein R′ is independently selected from the group consisting of hydrogen, C 1-20  alkyl, C 1-20  alkenyl, C 6-12  aryl, C 7-20  aralkyl; 
         and wherein R′ is independently unsubstituted, hydroxy-substituted, or beta hydroxy substituted or a mixture, in any proportion, of any of these groups, and H mer according to formula VIII; 
       
       
         
           
           
               
               
           
         
         wherein R 4  and R 5  are each independently H or optionally substituted C 1-6  alkyl group combined. 
       
     
     
         17 . The composition according to  claim 16 , further comprising a E mer according to formula (V); 
       
         
           
           
               
               
           
         
         wherein R 1  is H or C 1-6  alkyl and R 6  is H, group I metal ion, group II metal ion, or N(R 3 ) 4   +  where each R 3  is independently H, C 1-6  alkyl, and further comprising a F mer according to formula (VI); 
       
       
         
           
           
               
               
           
         
         wherein R 1  is H or C 1-6  alkyl and R 7  is H, group I metal ion, group II metal ion, or N(R 3 ) 4   +  where each R 3  is independently H, C 1-6  alkyl, and further comprising a G mer according to formula (VII) 
       
       
         
           
           
               
               
           
         
         wherein R 1  is H or C 1-6  alkyl. 
       
     
     
         18 . A method of flocculating a solid suspended in a Bayer or Sinter process stream comprising intermixing a polymer according to  claim 1  with a Bayer or Sinter process stream in an amount effective to flocculate at least a portion of a solid suspended in the process stream, thereby forming an at least partially clarified process stream, wherein the suspended solid is chosen from red mud, sinter mud, desilication product, and mixtures thereof. 
     
     
         19 . A method of flocculating a solid suspended in a Bayer or Sinter process stream comprising intermixing a composition according to  claim 12  with a Bayer or Sinter process stream in an amount effective to flocculate at least a portion of a solid suspended in the process stream, thereby forming an at least partially clarified process stream, wherein the suspended solid is chosen from red mud, sinter mud, desilication product, and mixtures thereof. 
     
     
         20 . The method according to  claim 18 , further comprising settling the flocculated solid from the at least partially clarified process stream. 
     
     
         21 . The method according to  claim 18 , comprising filtering at least a portion of the flocculated solid from the at least partially clarified process stream. 
     
     
         22 . The method according to  claim 18 , wherein the amount of polymer or composition intermixed with the process stream is from about 0.1 g/t to about 50 g/t.