AU609012B2 - High solids liquid alkaline cleaners - Google Patents

Description

rj 1 .J U-A-13496/°"o PCT WORLD INTELLECTUAL PROPERTY ORGANIZATION PC L Ia onaurea INTERNATIONAL APPLICATION BNt THI P T COOPEPATION TREATY (PCT) (51) International Patent Classification 4 (11) Internat'cal Publication Number: WO 88/ 05814 CllD 7/06, 7/14 Al (43) International Publication Date: 11 August 1988 (11.08.88) (21) International Application Number: PCT/US88/00327 (81) Designated States: AT (European patent), AU, BE (European patent), BR, CH (European patent), DE, DE (22) International Filing Date: 4 February 1988 (04.02.88) (European patent), DK, FI, FR (European patent), GB, GB (European patent), IT (European patent), JP, KR, LU (European patent), NL, NL (European pa- (31) Priority Application Number: 012,697 tent), NO, SE (European patent).

(32) Priority Date: 9 February 1987 (09.02.87) Published (33) Priority Country: US Wiih international search report, Before the expiration of the time limit for amending the claims and to be republished in the elvent of the receipt (71) Applicant: PENNWALT CORPORATION [US/US]; of amendments.

Pennwalt Building, Three Parkway, Philadelphia, PA 19102 (US).

(72) Inventor: JOHNSON, Mark, David 27 West Main Street, Cortland, NY 13045 (US).

(74) Agent: HUNT, Leigh; Pennwalt Corporation, Penn- A.O. J.P. 2 9 SEP 1988 Walt Building, Three Parkway, Philadelphia, PA 19102

AUSTRALIAN

a 2 4 AUG 1988 r PATENT OFFICE (54) Title: HIGH SOLIDS LIQUID ALKALINE CLEANERS (57) Abstract An ultra-high solids, stable, liquid, highly alkaline caustic cleaner containing 40 to 80 weight percent total solids having 5 to 30 weight percent of an inorganic particulate material dispersed therein, such as an alkaline silicate, that is nonreactive and insoluble in the caustic of the composition.

Note: No legalizaoo or other witneu required Assistant Secretar.y FOR AND ON BEHALF OF PENNWALT CORPORATION To: The Commissioner of Patents i P 8/7/81 PHILLIPS ORMONDE FITZPATRICK Patent and Trade Mark Attorneys 367 Collins Street Melbourne, Australia High Solids Liquid Alkaline Cleaners This is a continuation of co-pending application Ser.

No. 012,697 filed on Feb. 9, 1987 now abandoned.

Background of the Invention 0 f

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'pcu This invention relates to liquid, highly alkaline cleaners having a high solids content that are useful in such applications as in the production of finished steel.

For years, many industri-i have used liquid alkaline cleaners, normally based on sodium or potassium hydroxide, tor various applications such as laundry, textile, maintenance and metal working processes. A specific example of such an application is the alkaline cleaning of steel strip in the steel industry. Operations such as continuous ;i^ -1ti Y i -ln I i. .ih II l ,l1L ll,^.iii i l,,l..ii iu^m l WO 88/05814 PCT/US88/00327 aand batch annealing, galvanizing and electrolytic plating require the complete removal of cold rolling lubricant residuals as the first step in their processes. In general, liquid cleaners have been preferred to powdered formulations for their ease of handling and inherent safety. Previous to this invention, the active content of these cleaners has been limited to approximately 50% by weight, with the balance composed of water. More highly concentrated versions of this class of cleaners are desirable as it reduces the volume of concentrate required to obtain a given cleaner bath concentration. This in turn reduces the end cost of the cleaner by minimizing the manufacturing, shipping and handling cost components. This invention permits the manufacture of liquid alkaline cleaners that contain as high as 80% active ingredients; furthermore, due to the basic chemical and physical properties upon which they are based, virtually unlimited combinations of normally employed alkaline cleaner additives can be used depending upon the intended application and performance specifications.

In addition to percent solids limitations, one of the major problems previous to this invention was the relatively low concentrations of inorganic alkaline silicates that could be incorporated into a high alkalinity liquid formula without destabilizing or gelling the cleaner, For example, using the conventional preparation procedure for a concentrated alkaline liquid which involves dissolving the caustic SSUBSTITUTE

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Ir WO 8hib5814 PCT/US88/00327 3 insoluble ingredients into a water based premix, adding the premix to the caustic base of the cleaner (normally NaOH), mixing the combination for a specified time and set of conditions, and then sometimes homogenizing the final product by various mechanical means, the maximum amount of silicate that may be included has been approximately 5% on a Si02 basis.

Inorganic alkaline silicates as a general class are important ingredients for alkaline cleaning for at least two major reasons. First, in all alkaline cleaning applications, silicates are relatively inexpensive additives, yet exhibit good detergency, soil-suspension and surface-active properties. Where permitted, the inclusion of silicates in a formulation can significantly improve the cost-performance of an alkaline cleaner. Secondly, in metal cleaning, particularly for electrolytic cleaning, highly silicated alkaline cleaners deposit a thin layer of silicate onto the metal surface. This film is important in the cleaning of strip steel prior to batch annealing, where the silicate layer helps prevent the welding of adjacent coil laps during batch anneal a defeat appropriately called "Stickers" in the industry vernacular.

Prior to this invention any cleaning operation requiring or desiring the use of a high silicate content, highly alkaline cleaner was forced to use a powdered form of cleaner. This invention provides a stable, highly silicated, SUBSTITUTE SHEET

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WO 88/05814 PCT/US88/00327 4 high solids liquid alkaline cleaner composition and a method for manufacturing the composition. Using the method of this invention, a liquid alkaline cleaner can be produced with a Si02 content of 0-30%. By substituting phosphates, borates, carbonates or other cleaning additives that are insoluble and inert in concentrated liquid caustic solutions, almost any desired alkaline cleaning formulation can be produced in a highly concentrated liquid form.

The conventional manufacturing methods for the production of concentrated liquid alkaline cleaners involve the dissolution of the caustic insoluble ingredients, such as the organic additives (surfactants, chelating agents, foam controls, etc.) and the inorganic additives (silicates, phosphates, borates, etc.), into water as a premix. This conventional method cannot be used with high levels of the inorganic additives as these additives precipitate and the entire product then thickens beyond an acceptable point, sometimes resulting in complete solidification, when the premix is added to the caustic base a\id blended.

Furthermore, using the quantity of water required to completely dissolve the additives in the premix severely limits the maximum attainable solids content of the formulation. As an alternative conventional method of preparation, the addition of commercially available additives to the caustic base prior to premix addition or to a final blended product has also been largely unsuccessful, with the SSUBSTITUTE SHEET

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WO 88/05814 PCT/US88/00327 5 resulting blends having been found to be too unstable or thick to be practical.

Summary of the Invention The composition of the invention is defined as a free-flowing, liquid, highly alkaline, stable cleaner composition having a high total solids content within the range of about 40 weight percent to about 80 weight percent, said total solids include from about 20 to about 50 weight percent caustic based on total composition and a cleaning effective amount of an inorganic particulate material dispersed and suspended in the caustic, said inorganic material being both nonreactive and insoluble in said caustic of the composition.

The inorganic material is preferably present in an amount wi th the range of 5 to 30 weight percent of the composition and most preferably is sodium metasilicate.

The caustic preferably includes both NaOH and KOH with each present up to an amount sufficient to saturate the composition with NaOH and KOH.

The inorganic material is preferably suspended in the caustic and is made stable by making the particulate material of a small enough size preferably colloidal and/or by coating the small particles with a surface active agent to enable the particles to act as colloidal particles and remain in suspension, thereby creating a stable solution.

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4 WO 88/05814 PCT/US88/00327 6 The caustic is preferably formed by mixing solid NaOH with an aqueous solution of KOH or vice versa. Such a procedure allows high caustic levels without lowering of the freezing point to unacceptable levels.

The method of manufacture of the invention is defined as the method for preparing a free-flowing, liquid, highly alkaline, stable cleaner composition which includes forming a solution of caustic of a concentration sufficient to provide from about 20 to about 50 weight percent caustic in the final composition and dispersing and suspending in the composition a cleaning effective amount of an inorganic particulate material, said inorganic material being both nonreactive and insoluble in said caustic of the composition.

The method of use of the composition of the invention is defined as a method of cleaning a metal surface which includes treating the surface for a sufficient period of time with a free-flowing, liquid, highly alkaline, stable cleaner composition having a high total solids content within the range of about 40 weight percent to about 80 weight percent, said total solids include from about 20 to about 50 weight percent caustic based on totl composition and a cleaning effective amount of an inorganic particulate material dispersed and suspended in the caustic, said inorganic material being both nonreacti e and insoluble in said caustic of the composition.

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WO 88/05814 PCT/US88/00327 7 Detailed Description of the Invention This invention eliminates the previous instability, thickening and maximum solids limitations of conventional liquid compositions. Because powdered solid inorganic cleaner additives are only very slightly soluble or reactive, if at all, at lower temperatures with highly concentrated caustic solutions (above these inorganic additives can be suspended and dispersed in caustic solutions containing sodium and/or potassium hydroxide using the teachings of this invention, without reacting to any appreciable extent, which reaction would cause the mixture to significantly thicken or solidify over time, Also, the smaller the size of insoluble particles in a liquid medium, the easier they are to disperse and suspend to form a stable colloidal-type suspension.

Thus, if the particle size of the solid additives is reduced below a certain point, they can be dispersed and suspended in a highly caustic liquid medium with the aid of surfactants, protective colloids and other methods. The certain point for the particle size depends on many variables, including the density of the solid additives chosen, but can be determined through empirical formulation evaluation using standard sieves of known mesh to quantify the particle size range distribution of the additives prior to blending. Once a stable formula has been achieved, the data collected using the sieves can be used as a guideline for precise production specifications for a given formulation system, SUBSTITUTE SHEET WO 88/05814 PCT/US88/00327 8 To prepare high solids liquid alkaline cleaners of this invention, the procedure described below is utilized.

The caustic liquid, either potassium or sodium hydroxide is charged into the main blending vessel. Usually 50% sodium hydroxide or 45% potassium hydroxide is used as a base because they are readily available commercially and have acceptable freezing points. 70% sodium hydroxide or higher than 50% concentrations could be used as well, but the freezing point of liquid sodium hydroxide increases rapidly from 50-70%, which would require heated storage of the end product. Heated storage for such high solids formulae would be very difficult due to the accelerated evaporation of water.

To either liquid caustic base, the solid form of the other caustic base can be added directly into the main mixing vessel and dissolved. This can be done to the saturation point for either solid form. For example, using 50% NaOH as the base liquid, a 70% 50% NaOH/30% solid KOH mixture can be prepared that is stable and acts similarly to 50% NaOH with respect to freezing point. A similar blend can be prepared using 45% KOH as the base fluid and adding solid NaOH. This method of combining the two types of caustic aids to maximize the total solids content and alkalinity of the cleaner. The amount added depends on th* physical properties desired in the end product such as viscosity, alkalinity, specific gravity and pour point.

I, s SUBSTITUTE SHEET L -L WO 88/05814 PCT/US88/00327 "4 Next, the other caustic soluble additives are added and dissolved. The powdered, caustic insoluble, inorganic additives are added next with stirring in their desired quantities to form a slurry. Depending upon the additives used, the maximum amount added represents approximately by weight. The smaller the particle size of the additives, the better the slurry stability and homogeneity. A ball or stone mill, or other means of mechanically grinding these solid additives can be used to improve the blend, but is not required. The invention requires that enough solid additives are charged to reach minimum viscosity that will support the final product as a stable suspension. Using a Brookfield Viscometer, this viscosity range is on the order of 200-500 cps with a No. 4 spindle at 100 rpm and 100 0

F.

Generally, any solid additive can be used a long as it will not react appreciably with the caustic fluid base over the storage time of the product. Examples of formula variations are included to demonstrate some of the ranges of this invention.

After preparing the slurry, a premix is then prepared in a second vessel which contains the organic and inorganic additives required to stabilize the slurry suspension. The composition and amount of premit required to stabilize the final product is highly variable, depending upon such factors as the particle size range and density of the solid slurry Aty additives, the viscosity of the slurry and the desired SUBSTITUTE SHEET WO 88/05814 PCT/US88/00327 viscosity of final product, and the water content of the product and its specific gravity. The functi(li of the premix is to first coat the individual solid particles of the slurry. Then, since the premix ingredients are insoluble iu the liquid caustic base, the organic and inorganic additives begin to precipitate or congeal at different rates around the solid particles to act as a protective colloid. The protective colloid is believed to function by reducing the density of the individual solid particles by coating them with the less dense congealed premix ingredients such as inorganic surfactants or inorganic phosphates or carbonates; and/or causing a thickening of the product by the formation of aggregate colonies of solid particles covered with the premix contents which reduces settling to insignificant levels while maintaining a free-flowing liquid product.

The composition of the premix is highly variable.

Products have been successfully prepared using exclusively inorganic or organic additives. Normally, however, a combination of these two general classes is used to provide the best cleaning performance characteristics for the product, Once the premix has been added to the main vessel with stirring, it is northally allowed to mix and react for a minimum of 20 minutes. As with the preparation of the premix and the slurry, no heating is required for the process.

RAlthough a certain amount of heat is generated by exotherms SSUBSTITUTE SHEET 1 i, WO088/05814 PCT/US88/00327 and mixing during the procedure, the maximum temperature experienced for the final blend has been 1301F and no problems have been noticed at or below this temperature, Lower temperature is actually desirable to reduce the potential for reaction between the liquid caustic base and the other ingredients and to reduce the build up of scale in the mixing tank from dehydration, Also, a higher temperature can slow the complete precipitation and congealing of the premix, which potentially can result in the complete gelling of the final product in the shipping container when it finally cools, The final blend can then be homogenized mechanically using, standard colloid mills or other units which shear and grind the liquid to increase its stability, However, depending on the formulation of the product and the particle size range of the solid additives, this step is not necessary for the manufacture of a stable product, Homogenization) particularly Where the unit employed hias the capability to grind the solid particles to further reduce their size, as well as shear the liquid, can significantly eeduce the amount of premix required to obtain a stable liquid cleaner. It fact, using a very efficient grinder, a stable product can be produced if the particle size range Of the solid additives is reduced to a point where they act as colloidal particles (see Example The required particle size of IIthe solid matter to yield a stable liquid, depends o-4i the 4WBSTITUTE SHEET

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C i I I WO 88/05814 PCT/US88/00327 12 viscosity, specific gravity and solids content of the liquid caustic base, but the maximum size is on the order of five microns or less. Therefore, under the proper conditions, this invention includes preparation of high solids liquid alkaline cleaners without the use of a premix.

Once homogenized, if desired, the product is complete.

The closer the final product is to ambient temperature when packaged, for reasons discussed earlier, the better and more consistent its shelf life. This type of product is a stable, viscous, free-flowing liquid with a high active ingredient content. It can be employed in any application that requires a highly alkaline cleaner. Therefore, it would find utility in industries as diverse as metalworking, laundry, textiles or maintenance, The stability and other characteristics of these formulations can vary considerably, as expected, depend, upon their chemical composition and physical attributes.

The minimum stability required to allow a product to be commercial is dependent upon the storage conditions and time period to which the product would be subjected. In certain applications where alkaline cleaner consumption is high, the material is appropriately purchased in bulk quantities and stored in large tanks equipped with agilators. Under these circumstances, a liquid cleaner formulation that exhibits less than 10% top layer separation without the formation of heavy bottom sedimentation after seven days of static storage SUBSITiTUTE SHEET _i-ir and insoluble in said caustic of the composition.

'O 88/05814 PCT/US88/00327 13 is considered to meet the minimum stability requirements for a commercially viable product. Of course, during this period the product must not undergo any significant changes in te chemical or physical characteristics. With the exception of the Example 4 non-premix, non-homogenized processed product, all of the products of the other examples met or exceeded this definition of stability.

In the Examples that follow, unless otherwise stated, the procedureq specified above were utilized in blending and preparing the product of each Example.

Examples Example I This Example uses only sodium hydroxide as the liquid caustic base, anhydrous sodium metasilicate fines as the solid slurry additive, and sodiumi hexametaphosphate and sodium carbonate (inorganics) in the premix. The small amount of 50% NaOH is added to the premix to neutralize the phosphate before adding the (carbonate, Ingredients: by Weight 50% NaOH 53.68 Anhydrous Sodium etasilicate Fines (Na 2 SiO 3 40 2 Premix: Water 3.35 Sodium Hexametaphospate 1 67 NaOH 0.1 Sodium Carbonate STOTAL 1000 J* SUBSTITUTE SHEET ml-\ r

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WO 88/05814 PCT/US88/00327

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14 Properties: Appearance Viscous Blueish-White Stable Colloidal Supension Pounds/Gallons (70 0

F)

Solids Pour Point approx.

Free Alkalinity, Phenolphthalein, Na20 Total Alkalinity, Methyl Orange, Na20

P

2 0 5 Si02 Brookfield Viscosities Spindle at 100 rpm, 14.9 39.6 41.5 1.1 18.7 cps) Without homogenization (97 0 F) 516 Using 4" Colloid Mill* 0.001" Gap (110 0 F) 3,400 Using 4" Colloid Mill 0.002" Gap (98F) 2,767 Using Supermill* 85% Load ZrSO 4 (113 0 F) 3,040 at 2,000 fpm, 8.0 psig.

*The Colloid Mill and Supermill are manufactured by Premier Mill Corporation. The Colloid Mill was equipped 'wth KCD Fine Grit tooling and operated in all cases at 5,500 rpm.

Example II This Example uses a combination of potassium and sodium hydroxide as the liquid caustic base, anhydrous sodium metasilicate fines as the solid slurry additive, and a combination of inorganic/organic additives in the premix.

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i i. I PCT/US83/00327 WO 88/05814 15 Ingredients by Weight KOH 41.53 Beaded, Solid NaOH 15.38 Anhydrous Sodium Metasilicate Fines (Na 2 SiOa) 33.31 Premix: Water 5.34 Sodium Hexametaphosphate 1.14 NaOH 0.62 Anionic Phosphate Surfactant 0.62 Anionic Organic Surfactant 1.06 Sodium Carbonate 0.62 Foam Control 2201 0.38 TOTAL 100.0 1 Product made by Pennwalt Corporation, Philadelphia, PA Properties: Appearance Viscous Blueish-White Stable Colloidal Suspension Pounds/Gallon (70 0

F)

Solids Pour Point Less than Free Alkalinity, Phenolphthalein, Na20 Total Alkalinity, Methyl Orange, Na20

P

2 0 5 Si0 2 14.83 72 37.7 39.6 0.8 15.5 SUBSTITUTE SHEET ZL conventional preparation procedure for a concentrated alkaline liquid which involves dissolving the caustic 1,A- SRL SUBSTITUTE SHEET To WO 88/05814 PCT/US88/00327 16 Brookfield Viscosities Spindle at 100 rpm, cps) Without homogenization (100°F) 480 Using 4" Colloid Mill, 0.001" Gap (110°F) 500 Using 4" Colloid Mill, 0.002" Gap (106°F) 540 Using 4" Colloid Mill, 0.005" Gap (101 0 F) 480 Supermill, 85% Load, 1.6-2.0 mm ZrSO 4 (87 0 F) 1,620 at 2,000 fpm, 5.0 psig.

Example III This Example uses a combination of sodium and potassium hydroxide for the liquid caustic base, a lesser amount of anhydrous sodium metasilicate and the addition of sodium carbonate as a filler for the solid slurry additives, wi'h a combination inorganic/organic premix as specified below.

Ingredients: by Weight KOH 44.53 Beaded Solid Caustic (NaOH) 16.95 Anhydrous Sodium Metasilicate Fines (Na 2 SiOs) 10.54 Light Density Sodium Carbonate 18.13 Premix: Water 5.38 Sodium Hexametaphosphate 1.15 NaOH 0.62 Anionic Phosphate Surfactant 0.62 Anionic Surfactant 1.08 Sodium Carbonate 0.62 SUBSTITUTE

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alkaline cleaner was forced to use a powdered form of RAZ cleaner. This invention provides a stable, highly silicated, 1 SUBSTITUTE SHEET WO 88/0584 PCT/US88/00327 -17 Foam Control 220 0.38 TOTAL 100.0 Properties: Appearance Viscous White Stable Colloidal Suspension Pounds/Gallon Solids Pour Point Less than Free Alkalinity, Phenolphthalein, Na20 34.2 Total Alkalinity, Methyl Orange, Na20 40.5

P

2 0O 0.8 Si0 2 4.9 Brookfield Viscosities Spindle at 100 rpm, cps) Without homogenization (960F) 240 Using 4" Colloid Mill 0.001" Gap (110 0 F) 460 Using 4" Colloid Mill 0.005" Gap (96 0 F) 420 Using Supermill, 85% Load, 1.6-2.0 mm ZrSO 4 (78 0

F)

at 2,000 fpm at 4.0 psig; 800 at 3.5 psig 880 Example

IV

This Example contains only 50% sodium hydroxide for the liquid caustic base and anhydrous sodium metasilicate as the solid slurry additive. No premix was used to determine if physical means alone, using a homogenizer, could form a stable product.

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to the caustic base prior to premix addition or to a final blended product has also been largely unsuccessful, with the SUBSTITUTE SHEET I

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WO 88/05814 PCT/US88/00327 18 Ingredients: NaOH Anhydrous Sodium Metasilicate Fines (Na 2 SiO 3

TOTAL

by Weight 57.12 42.88 100.0 Properties: Appearance Blueish-White Visc Pounds/Gallon Solids Pour Point (oF) approx.

0 Free Alkalinity, Phenolphthalein, Na20 Total Alkalinity, Methyl Orange, Na 2

O

P

2 0 5 SiO 2 Brookfield Viscosities Spindle at 100 rpm, ous Liquid 71.5 41.9 43.5 0 cps) Without homogenization (75 0 F) 460 Using the 4" Colloid Mill, 0.001" Gap (76 0 F) 420 Using the 4" Colloid Mill, 0.002" Gap 321 Using Supermill, 85% Load, 1.6-2,0 mm ZrSO 4 (108 0

F)

at 2,000 fpm at 7.0 psig; 3,560 at 8.0 psig (113 0 F) 2,761 This Example is the only Example that was not stable enough without homogenization to be considered a viable commercial product. Without homogenization, this product experienced gross separation within a matter of hours, Furthermore, even when homogenized using the Colloid Mill at SUBSTITUTE

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particles to act as colloidal particles and remain in suspension, thereby creating a stable solution.

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I. II i i> I p, -18aeither the 0.001" or 0.002" gap settings, the product still experienced greater than separation within 24 hours. However, when this product was homogenized using the Supermill, a much more severe grinding mill, the resulting product experienced less than 5% separation within 24 hours. However, when this product was homogenized using the Supermill, a much more severe grinding mill, the resulting product experienced less than separation over a period of one week. Although not completely stable, this product could be commercially viable if the storage container was equipped with a mixing device.

of the composition.

SUBSTITUTE SHEET 77 WO 88/05814 PCT/US88/00327 19 1r~ 1 1,i tk n nM 11 r* n n)1 n3> cefnot4nc SS S. L~ eLr)-CI1LCIV~C L J..L 4 experienced greater than 20% separation w-thin 24 hours.

However, when this product was homogenized using the Supermill, a much more severe inding mill, the resulting product experienced les han 5% separation over a period of one week. Althoug -not completely stable, this product could be commerci y viable if the storage container was equipped 1 Example V This is an example of a phosphated-silicated formula using three types of phosphates.

Ingredients by We: KOH 42.09 Beaded Solid NaOH 16.04 1' Crystalline Trisodium Phosphate (Na 3 P0 4 10H20) 8.15 Anhydrous Sodium Tripolyphosphate 5.21 Anhydrous Sodium Metasilicate Fines 20.71 Premix: Water 4.25 Sodium Hexametaphosphate 0.92 50% NaOH 0.49 Anionic Phosphate Surfactant 0.49 Anionic Surfactant 0.86 Sodium Carbonate 0.49 Foam Control 220 0.30 ight 4't O1k Ki 0 100.0 TOTAL SUBSTITUTE SHEET I I WO 88/05814 PCT/US88/00327 WO S8/05814 PCT/US88/00327 20 Properties: Appearance White Viscous Colloidal Suspension Pounds/Gallon 0/0 Solids Pour Point (IF) Free Alkalinity, Phenolphthalein, Na 2

O

Total Alkalinity, Methyl Orange, Na 2

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P20S Si0 2 Viscosity 14.8 67.8 Not Established 33.2 35.5 5.1 9.6 Not Established SUBSTITUTE

SHEET

Claims (26)

1. A free-flowing, liquid, highly alkaline, stable cleaner composition having a high total solids content within the range of about weight percent to about 80 weight percent, said total solids include from about 20 to about weight percent caustic based on total composition and a cleaning effective amount of at least weight percent of an inorganic particulate material dispersed and suspended in the caustic, said inorganic material being both nonreactive and insoluble in said caustic of the composition.

2. The composition as defined in Claim 1 wherein the inorganic material is present in an effective amount within the range of about 5 to 42 weight percent of total composition.

3. The composition as defined in Claim 1 wherein said caustic includes KOH and NaOH.

4. The composition as defined in Claim 3 wherein the KOH and NaOH are each present up to an amount -1 mIL-.L-L.uiu u L u i.Lnu1te. AS wi.n tne preparacion of the premix and the slurry, no heating is required for the process. Although a certain amount of heat is generated by exotherms SUBSTITUTE SHEET Tj, i 22 sufficient to saturate the composition with NaOH and KOH. The composition as defined in Claim 1 wherein said inorganic material is of a sufficiently small particle size to enable the material to remain suspended within the caustic.

6. The composition as defined in Claim 5 wherein the particles are colloidal in size.

7. The composition as defined in Claim 1 wherein the inorganic particulate material is coated with a surface active agent to enable the material to remain dispersed within the caustic.

8. The composition as defined in Claim i wherein the inorganic particulate material is an alkaline silicate.

9. The composition as defined in Claim 8 wherein the silicate is sodium metasilicate. reduced to a point where they act as colloidal particles themselves (see Example The required particle size of 7LS the solid matter to yield a stable liquid depends on the L S SUBSTITUTE SHEET 23 The composition as defined in Claim 1 wherein the inorganic particulate material is selected from the group consisting eeoeantiall of phosphates or metasilicates,

11. The composition as defined in Claim I wherein the inorganic particulate material is selected from the group consisting dsential- y of sodium metasilicate, sodium tripolyphosphate, and sodium hexametaphosphate.

12. The composition as defitoed in claim 1 wherein said caustic is present within the range of 25 to 40 weight percent.

13. The composition as defined in Claim 12 wherein said caustic includes NaOH and KOH and the particulate material includes sodium metasilicate.

14. The composition as defined in Claim 13 wherein said particulate material is coated with an anionic surface active agent. I1 F!l^ 24 The composition as defined in Cla. 13 wherein the particulate material is aufficiently small in size to enable the material to remain suspended within the composition.

16. The method for preparing a free-flowing, liquid, highly alkaline, stable cleaner composition having a high total solids content within the range of about 60 weight percent to about 80 weight percent which solids include from about 20 to about 50 weight percent caustic based on total composition, which method includes forming a solution of caustic of a concentration sufficient to provide from about 20 to about weight percent caustic in the final composition and dispersing and suspending in the composition a cleaning effective amount of at least 15 weight percent of an inorganic particulate material, said inorganic material being both nonreactive and insoluble in said caustic of the composition.

17. The method as defined in Claim 16 wherein the inorganic material is present in an effective I lp1/Pb TOTAL 100.0? SUBSTITUTE SHEET amount within the range of about 5 to 42 weight percent of total com~position.

18. The method as defined in Claim 16 wherein said caustic includes KOH and NatOH in an amiount of 25 to 40 weight percent of the composition.

19. The method as defined in Claim 16 wherein the KOH and NaOH are each present up to an amount sufficient to saturate the composition with NaOH and KOH.

20. The method as defined in Claim 16 wherein the caustic is prepared by mixing solid KOH and an aqueous NaCH solution.

21. The method as defined in Claim 16 wherein the caustic is prepared by mixing solid NaOH and j an 6iqueous KOH solution.

22. The method as defited in Claim 16 Wherein said inorganiic material is of a sufficiently small particle size to enable the material to remain suspended Within the composition. SUBSTITUTE SHEET 26

23. The method as defined in claim 16 wherein the inorganic particulate material is coated with an anionic surface active agent by adding the agent to the caustic containing the inorganic material.

24. The method as defined in Claim 23 wherein the caustic and inorganic material are then milled to further reduce to particle size of the inorganic material. The method as defined in Claim 16 wherein ths inorganic particulate material is coated with a premix that includes a surface active agent to enable the material to remain dispersed within the composition.

26. The method as defined in Claim 16 wherein the inorganic particulate material is an alkaline silicate.

27. The method as doefin d in claim 16 wherein said caustic is present in an amount within tho range of 25 to SUBSTITUTE SHEET I- 27 weight percent of the composition.

28. The method as defined in Claim 27 wherein said caustic includes NaOH and KOH and the particulate material includes sodium metasilicate.

29. The method as defined in Claim .27 wherein said particulate material is coated with an anionic surface active agent. The method as defined in Claim 27 wherein the caustic containing the inorganic particulate material is then milled to reduce the particle size of the inorganic material. DATED: 5 JANUARY, 1990 PHILLIPS ORMONDE FITZPATRICK Attorneys For: PENNWALT CORPORATION 'b)W v EL stable product. SUBSTITUTE SHEET SO W i 1 INTERNATIONAL SEARCH REPORT International Application No. R,,f'T l O 0 j\ Z in 9 1. CLASSIFICATION OF SUBJECT MATTER (if several classification symbols apply, indicate all) s According to Inltrnational Patent Classificalion (IPC) or to both National Classification and IPC IPC4 C ID 7/06 C lD 7/14 U.S. C1. 252/156 I FIELDS SEARCHED Minimum Documentation Searched 7 Classification System Classification Symbols U.S. CI. 252/ 135, 156, 174. 15, 174. 14 Documentation Searched other than Minimum Documentation to the Extent that such Documents are Included in the Fields Searched a III. DOCUMENTS CONSIDERED TO BE RELEVANT 9 Category Citation of Document, it with indication, where appropriate, of the relevant passages 12 Relevant to Claim No 1 3 X US,A, 4,521,332 (Milora) 04 June 1985 (04.06.85) (col. I line 32 to col. 4, 1-49 .line 57) Y US,A, 3,625,762 (Kappas) 07 December 1971 1 (reference generally shows caustic and silicate used together). (col. 2, lines 8-35) Y US,A, 3583,923 Cantrell, Jr. et al. 3,4,12-15, 08 June 1971 (08.06.71) 18,19,27-29 (teaches a mixture of KOH and NaOH with 31-34,37,38, a silicate col. I, lines 65-70; col. 2, lines 20-65; col. 3, lines 33-46). 40-43,46-49 A US,A, 3,293,148 (Dell et al. 20 December 1966 1-49 (20.12.66) (Composition and use taught generally; col. 2, lines 20-59) E,Y US,A, 4,731,194 (PRcs man et al). 1-49 March 1988 (shows state of liquid cleaner art) Special categories of cited documents: it later document published alter the international filing date document defnitng the general state of the art hich is not or priority date and not in conflict with the application but considered to be of particular relevance cited to understand the principle or theory underlying the invention earlier d ment but published on or alter the international X" document of particular relevance: the claimed Invention cannot be considered novel or cannot be considered to document which may throw doubts on priority claim(s) or involve an inventive step which is cit ed to establish the publication date of another document of particular relevance: the claimed invention citation or other special reason (as specied) cannot be considered to Involve an inventive step when the document referring to an oral disclosure, use, exhibition or document is combined with one or more other such docu other means ments, such combination being obvious to a person skilled document published prior to the international filing date hut in the art. later than the priority date claimed document member of the same patent family IV. CERTIFICATION Date of the Actual Completion of the International Search Date of Mailing of this International Search Report B nA t 1 Las 0 9 JUN 1988 14 Aptil 1988 09J 1 N 1988 Interrational Searching Authority Signature of Authpi zed Officer ISA/US Ron Krasnow C. Form PCTASA4tQ iworid sheell (lv, t .87) Furthermore, even when homogenized using the Colloid Mill at SUBSTITUTE SHEET liflornational Appjlit'on No, P C T U S 8 8 0 03 2 7

111. DOCUMENTS CONSIDERED TO BE RELEVANT (CONTINUED FROM THE SECOND SHEET) Cailugory Cililiori of Oocunwiil, aahf indicaflor, wheo appropriale. of the relevant possaqos Rolevant to Claim No US,A, 4,390,465 Spekman, Jr. 28 June 1983 (28,06 .83) (reference is from prior art useful for some purpose with compos it ion in acqueous form; Col. 5, 'Lines 31-54; table, cols 2-3 I Claims for which ref- ence is Y are 1,2,8,9,34 Claims for whbich ref- erence is A are 2-7, 10-33 fm PCT/ISX2i0 (exira Shol) (ReV.1 1,87)