CA2326585A1 - Carbon dioxide cleaning and separation systems - Google Patents
Carbon dioxide cleaning and separation systems Download PDFInfo
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- CA2326585A1 CA2326585A1 CA002326585A CA2326585A CA2326585A1 CA 2326585 A1 CA2326585 A1 CA 2326585A1 CA 002326585 A CA002326585 A CA 002326585A CA 2326585 A CA2326585 A CA 2326585A CA 2326585 A1 CA2326585 A1 CA 2326585A1
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- phase
- substrate
- separating
- oil
- solubilizing
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B08—CLEANING
- B08B—CLEANING IN GENERAL; PREVENTION OF FOULING IN GENERAL
- B08B7/00—Cleaning by methods not provided for in a single other subclass or a single group in this subclass
- B08B7/0021—Cleaning by methods not provided for in a single other subclass or a single group in this subclass by liquid gases or supercritical fluids
-
- C—CHEMISTRY; METALLURGY
- C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
- C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
- C11D7/00—Compositions of detergents based essentially on non-surface-active compounds
- C11D7/22—Organic compounds
- C11D7/40—Products in which the composition is not well defined
- C11D7/44—Vegetable products
-
- C—CHEMISTRY; METALLURGY
- C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
- C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
- C11D7/00—Compositions of detergents based essentially on non-surface-active compounds
- C11D7/50—Solvents
Abstract
A separation method includes (a) providing a heterogeneous separation system, the heterogeneous cleaning system comprising CO2 in a first phase and an oil in a separate second phase; (b) entraining a material to be separated in the second phase; (c) wholly or partially solubilizing the second phase in the first phase to produce a separation system in which said material to be separated is insoluble; and then (d) separating the material from the system.
The separating step is preferably followed by the step of (e) recovering at least a portion of the oil. The system is useful in a variety of applications, including cleaning (particularly metal cleaning), polymerization, extraction, coating, and particle formation and treatment.
The separating step is preferably followed by the step of (e) recovering at least a portion of the oil. The system is useful in a variety of applications, including cleaning (particularly metal cleaning), polymerization, extraction, coating, and particle formation and treatment.
Description
, _ 1,_ CARBON DIOXIDE CLEANING AND SEPARATION SYSTEMS
to Field o~the Invention This invention relates to cleaning and separation methods useful in cleaning substrates, particularly metal substrates, and useful for polymerization processes, coatings, extractions, and the manufacture and treatment of particles.
Background of the Invention The cleaning of contaminants from workpieces is an important step in many manufacturing processes. Unfortunately, many processes employ environmentally undesirable solvents, or are high temperature processes that are energy intensive. For example, vapor degreasing techniques employ both volatile organic solvents and high 2o temperatures. Efforts to replace such processes with aqueous systems are not entirely satisfactory because of the problem of contacting water to substrates that may be oxidized thereby, and by the problem of cleaning the contaminated water. In addition, the drying of aqueous systems is very energy intensive.
Vegetable oils such as soybean oil and modified soybean oil have been suggested for cleaning, but have not received significant use because of either their high cost or the difficulty in removing or extracting residual components of the oil.
C02-based cleaning methods have been suggested. Some employ supercritical COZ, which (due to the need to handle higher temperatures and/or pressures) increases the cost of the apparatus used to carry out the processes. U.S. Patent No.
5,377,705 to Smith et al. describes a precision cleaning system in which a variety of different co-solvents may be included (see column 8, lines 19-24 therein), with the mixture of the carbon dioxide and the co-solvent being either homogenous or heterogenous (see column 6, lines 4-11 therein). A problem with this system that it still does not provide a means to separate the contaminant from the co-solvent (see column 7, lines 24-32).
SUBSTITUTE SHEET (RULE 26) Accordingly, an object of the present invention is to provide a carbon-dioxide based cleaning system incorporating a separate cleaner, in which the contaminants may be separated from the cleaner to facilitate subsequent re-use or disposal of the cleaner.
A second object of the invention is to provide oil-based separation systems in which the oil, such as a vegetable oil, may be recovered for subsequent reuse.
Summary of the Invention A separation method comprises (a) providing a heterogeneous separation to system, the heterogeneous cleaning system comprising COZ in a first phase and an oil in a separate second phase; (b) entraining a material to be separated in the second phase; (c) solubilizing the second phase, in whole or in part, in the first phase to produce a separation system in which said material to be separated is insoluble; and then (d) separating the material from the system. The separating step is preferably IS followed by the step of (e) recovering the oil (i.e., some or all of the oil), so that it may be re-used in or recycled to step (a) above. Each of the steps may be carried out with or without agitation.
An advantage of the invention is that the separation system is phase-tunable, in that the material of the second phase can alternately be rendered soluble, in whole 2o or in part, or insoluble in the first phase, alternately rendering the material to be separated soluble or insoluble in the system in a controllable manner. Thus the system is a homogeneous system in one embodiment, when the second phase is wholly solubilized in the first phase to render the material to be separated insoluble therein.
25 The system is useful in a variety of applications, including cleaning, polymerization, extraction, coating, and particle formation and treatment. The system is particularly advantageous where the oil employed is of a relatively high cost. Since environmentally acceptable solvents such as organic or vegetable oils (including synthetic oils) can be relatively expensive, this system enables the use of such 3o products in a broader variety of applications, in a cost-effective manner.
As noted above, one particular aspect of the invention is a method of cleaning a contaminant from a substrate. The method comprises contacting a substrate with a heterogeneous cleaning system. The heterogeneous cleaning system comprising COZ
SUBSTITUTE SHEET (RULE 26}
_ 3~
in a first phase and a cleaner (preferably an oil such as an organic, or vegetable, oil) in a separate second phase, so that contaminant carried by said substrate is entrained in the cleaner. The cleaner is then wholly or partially solubilized in the first phase (e.g., by increasing the pressure of the system) to produce a cleaning system in which the contaminant is immiscible (e.g., a homogeneous cleaning system), and that contaminant is separated from the substrate. The substrate is separated from the cleaning system, either before or after the solubilizing step, and the contaminant (which has been rendered immiscible in the cleaning system) is separated from the cleaner. The cleaning system advantageously can be implemented as a non-aqueous 1o system, thereby reducing drying times and problems with oxidation.
The foregoing and other objects and aspects of the present invention are explained in detail below.
Brief Descri tion of the Drawing Figure 1 is a schematic diagram of a process of the invention, in which the phase-tunable system is represented by boxes 2, 3, 4 and 5 at different steps in the process.
Detailed Description of the Invegtion 2o A COZ-based cleaning and separation system is disclosed herein. The system includes a material that may be alternately rendered miscible or immiscible in the carbon dioxide. Hence, the system is referred to as a "phase-tunable" system in that one phase may alternately be rendered soluble or insoluble in the other, carbon dioxide-containing, phase.
Suitable materials that may alternately be rendered soluble or insoluble in the carbon dioxide-containing phase are, in general, oils such as esters of fatty acids (including methyl, ethyl, propyl, and butyl esters, etc.) mineral oils (including paraffinic and/or naphthenic petroleum distillates), aliphatic hydrocarbons, polyethyleneglycols, polypropylene glycols, polyisobutylenes, poly alpha olefins, saturated and unsaturated carboxylic (fatty) acids, lard, tallow, triglycerides, vegetable oils (including soy, corn, sunflower, safflower, olive, canola corn, almond, and walnut oils, and modified derivatives thereof, particularly SOYSOLV~, etc.), and fatty acids, SUBSTITUTE SHEET (RULE 26) _ 4_ fatty alcohols, fatty amines, and modifications thereof including fatty esters, fatty ethers, and fatty amides.
In general, the first phase comprises carbon dioxide, and the second phase comprises a material that may alternately be rendered soluble or insoluble in carbon dioxide as described above. Typically, the first phase is the continuous phase and the second phase is the dispersed phase, and both phases are liquid phases.
Additional phases or materials can be added where desired or permitted. For example, a substrate to be cleaned or a substrate on which material is to be deposited can be added to the system, an aqueous phase could be incorporated itself into the second oil 1o phase (e.g., the oil phase itself could be an emulsion or microemulsion), etc.
A schematic overview of the method of the invention is shown in Figure 1, which shows a separation method, comprising providing a heterogeneous separation system 2, the heterogeneous cleaning system comprising COZ in a first phase 12 and a separate second phase I3. In the next step 15, a material to be separated 14 is entrained in the second phase. In the next step 16, the second phase is solubilized in the COZ to produce a homogeneous separation system 19 in which said material 14 to be separated is insoluble or immiscible (note that some material may remain soluble or slightly soluble in the separation system, as long as a sufficient portion of the material to be separated is rendered insoluble, to achieve the desired separation). In 2o step 17, the insoluble material is then separated from the system, and in step 18 the system is recycled to re-form the heterogeneous system (e.g., by decreasing pressure) to thereby recover the oil. The method is typically carried out in a closed vessel to permit maintenance and control of the pressure in a suitable manner. While step 16 of Figure 1 illustrates a homogeneous system, note that not all of the second phase must be solubilized into the first phase, so. long as a sufficient amount is solubilized into the first phase to render an effective portion of material to be separated insoluble in, and separable from, the system.
In a cleaning process, the material to be separated is carried into the system on a substrate, and that material is then entrained or solubilized into the second phase.
3o In a polymerization process, the material to be separated is a polymer. The entraining step is earned out by adding a monomer to the system; and then polymerizing the monomer in the second phase. The polymer may be either soluble or insoluble in the second phase.
SUBSTITUTE SHEET (RULE 26) - S
In an extraction process, the process is simply carried out by extracting the material to be separated into the second phase as the separation step.
In a coating or treatment process, the separating step is carried out by depositing the material on a substrate and then separating the substrate from the system. The depositing step can be carried out in a manner that forms a coating on the surface of the substrate (e.g., with a solid substrate such as a metal or glass), or can be carned out in a manner so that the material impregnates the substrate (e.g., polymer particles or beads).
In a particle manufacture process, the separating step is carried out by forming to particles comprising said material during said solubilizing step, and then collecting the particles from the system. This process may advantageously be combined with the polymerization process discussed above.
The recovering step is carried out by any suitable means. For example, the recovering step may be carried out by separating the oil from the carbon dioxide to provide a heterogeneous separation system; and then recycling the heterogeneous separation system to the initial "providing" step as illustrated by line 18 in Figure 1.
Alternatively, the recovering step may be carried out by physically separating the oil from the carbon dioxide (e.g., by venting the carbon dioxide from the vessel in which the system is contained, and then optionally draining the oil, or a concentrated oil and 2o carbon dioxide mixture, from the vessel).
Where the instant invention is carned out to apply or incorporate a material or other additive to a substrate from the second phase (see coating and treatment methods below), after the recovery step a portion of the additive is regained.
Make-up and maintenance of a desired charge of ingredient can occur by several routes:
l .) Metering of the make-up fluid into a low pressure area of the system. The low pressure area is the Cleaning/Treatment Chamber (where materials and substrates must be put in and out of the system. This can be affected by many means: (a) A
blocked off segment of pipe that is isolated from the chamber and substrate but will be flushed by the incoming process fluid (process fluid could also be circulated during 3o the cycle, then the additional ingredient could be brought into the system at any time during the cycle --- this is important if one desires to incorporate any kind of pre-treatment at a lower concentration} (b) Placed directly into the chamber before, during of after the addition of a substrate. (c) Metering pump pulling from a low SUBSTITUTE SHEET (RULE 26) pressure reservoir to the high pressure point in the system. The high presssure point can be anywhere.
to Field o~the Invention This invention relates to cleaning and separation methods useful in cleaning substrates, particularly metal substrates, and useful for polymerization processes, coatings, extractions, and the manufacture and treatment of particles.
Background of the Invention The cleaning of contaminants from workpieces is an important step in many manufacturing processes. Unfortunately, many processes employ environmentally undesirable solvents, or are high temperature processes that are energy intensive. For example, vapor degreasing techniques employ both volatile organic solvents and high 2o temperatures. Efforts to replace such processes with aqueous systems are not entirely satisfactory because of the problem of contacting water to substrates that may be oxidized thereby, and by the problem of cleaning the contaminated water. In addition, the drying of aqueous systems is very energy intensive.
Vegetable oils such as soybean oil and modified soybean oil have been suggested for cleaning, but have not received significant use because of either their high cost or the difficulty in removing or extracting residual components of the oil.
C02-based cleaning methods have been suggested. Some employ supercritical COZ, which (due to the need to handle higher temperatures and/or pressures) increases the cost of the apparatus used to carry out the processes. U.S. Patent No.
5,377,705 to Smith et al. describes a precision cleaning system in which a variety of different co-solvents may be included (see column 8, lines 19-24 therein), with the mixture of the carbon dioxide and the co-solvent being either homogenous or heterogenous (see column 6, lines 4-11 therein). A problem with this system that it still does not provide a means to separate the contaminant from the co-solvent (see column 7, lines 24-32).
SUBSTITUTE SHEET (RULE 26) Accordingly, an object of the present invention is to provide a carbon-dioxide based cleaning system incorporating a separate cleaner, in which the contaminants may be separated from the cleaner to facilitate subsequent re-use or disposal of the cleaner.
A second object of the invention is to provide oil-based separation systems in which the oil, such as a vegetable oil, may be recovered for subsequent reuse.
Summary of the Invention A separation method comprises (a) providing a heterogeneous separation to system, the heterogeneous cleaning system comprising COZ in a first phase and an oil in a separate second phase; (b) entraining a material to be separated in the second phase; (c) solubilizing the second phase, in whole or in part, in the first phase to produce a separation system in which said material to be separated is insoluble; and then (d) separating the material from the system. The separating step is preferably IS followed by the step of (e) recovering the oil (i.e., some or all of the oil), so that it may be re-used in or recycled to step (a) above. Each of the steps may be carried out with or without agitation.
An advantage of the invention is that the separation system is phase-tunable, in that the material of the second phase can alternately be rendered soluble, in whole 2o or in part, or insoluble in the first phase, alternately rendering the material to be separated soluble or insoluble in the system in a controllable manner. Thus the system is a homogeneous system in one embodiment, when the second phase is wholly solubilized in the first phase to render the material to be separated insoluble therein.
25 The system is useful in a variety of applications, including cleaning, polymerization, extraction, coating, and particle formation and treatment. The system is particularly advantageous where the oil employed is of a relatively high cost. Since environmentally acceptable solvents such as organic or vegetable oils (including synthetic oils) can be relatively expensive, this system enables the use of such 3o products in a broader variety of applications, in a cost-effective manner.
As noted above, one particular aspect of the invention is a method of cleaning a contaminant from a substrate. The method comprises contacting a substrate with a heterogeneous cleaning system. The heterogeneous cleaning system comprising COZ
SUBSTITUTE SHEET (RULE 26}
_ 3~
in a first phase and a cleaner (preferably an oil such as an organic, or vegetable, oil) in a separate second phase, so that contaminant carried by said substrate is entrained in the cleaner. The cleaner is then wholly or partially solubilized in the first phase (e.g., by increasing the pressure of the system) to produce a cleaning system in which the contaminant is immiscible (e.g., a homogeneous cleaning system), and that contaminant is separated from the substrate. The substrate is separated from the cleaning system, either before or after the solubilizing step, and the contaminant (which has been rendered immiscible in the cleaning system) is separated from the cleaner. The cleaning system advantageously can be implemented as a non-aqueous 1o system, thereby reducing drying times and problems with oxidation.
The foregoing and other objects and aspects of the present invention are explained in detail below.
Brief Descri tion of the Drawing Figure 1 is a schematic diagram of a process of the invention, in which the phase-tunable system is represented by boxes 2, 3, 4 and 5 at different steps in the process.
Detailed Description of the Invegtion 2o A COZ-based cleaning and separation system is disclosed herein. The system includes a material that may be alternately rendered miscible or immiscible in the carbon dioxide. Hence, the system is referred to as a "phase-tunable" system in that one phase may alternately be rendered soluble or insoluble in the other, carbon dioxide-containing, phase.
Suitable materials that may alternately be rendered soluble or insoluble in the carbon dioxide-containing phase are, in general, oils such as esters of fatty acids (including methyl, ethyl, propyl, and butyl esters, etc.) mineral oils (including paraffinic and/or naphthenic petroleum distillates), aliphatic hydrocarbons, polyethyleneglycols, polypropylene glycols, polyisobutylenes, poly alpha olefins, saturated and unsaturated carboxylic (fatty) acids, lard, tallow, triglycerides, vegetable oils (including soy, corn, sunflower, safflower, olive, canola corn, almond, and walnut oils, and modified derivatives thereof, particularly SOYSOLV~, etc.), and fatty acids, SUBSTITUTE SHEET (RULE 26) _ 4_ fatty alcohols, fatty amines, and modifications thereof including fatty esters, fatty ethers, and fatty amides.
In general, the first phase comprises carbon dioxide, and the second phase comprises a material that may alternately be rendered soluble or insoluble in carbon dioxide as described above. Typically, the first phase is the continuous phase and the second phase is the dispersed phase, and both phases are liquid phases.
Additional phases or materials can be added where desired or permitted. For example, a substrate to be cleaned or a substrate on which material is to be deposited can be added to the system, an aqueous phase could be incorporated itself into the second oil 1o phase (e.g., the oil phase itself could be an emulsion or microemulsion), etc.
A schematic overview of the method of the invention is shown in Figure 1, which shows a separation method, comprising providing a heterogeneous separation system 2, the heterogeneous cleaning system comprising COZ in a first phase 12 and a separate second phase I3. In the next step 15, a material to be separated 14 is entrained in the second phase. In the next step 16, the second phase is solubilized in the COZ to produce a homogeneous separation system 19 in which said material 14 to be separated is insoluble or immiscible (note that some material may remain soluble or slightly soluble in the separation system, as long as a sufficient portion of the material to be separated is rendered insoluble, to achieve the desired separation). In 2o step 17, the insoluble material is then separated from the system, and in step 18 the system is recycled to re-form the heterogeneous system (e.g., by decreasing pressure) to thereby recover the oil. The method is typically carried out in a closed vessel to permit maintenance and control of the pressure in a suitable manner. While step 16 of Figure 1 illustrates a homogeneous system, note that not all of the second phase must be solubilized into the first phase, so. long as a sufficient amount is solubilized into the first phase to render an effective portion of material to be separated insoluble in, and separable from, the system.
In a cleaning process, the material to be separated is carried into the system on a substrate, and that material is then entrained or solubilized into the second phase.
3o In a polymerization process, the material to be separated is a polymer. The entraining step is earned out by adding a monomer to the system; and then polymerizing the monomer in the second phase. The polymer may be either soluble or insoluble in the second phase.
SUBSTITUTE SHEET (RULE 26) - S
In an extraction process, the process is simply carried out by extracting the material to be separated into the second phase as the separation step.
In a coating or treatment process, the separating step is carried out by depositing the material on a substrate and then separating the substrate from the system. The depositing step can be carried out in a manner that forms a coating on the surface of the substrate (e.g., with a solid substrate such as a metal or glass), or can be carned out in a manner so that the material impregnates the substrate (e.g., polymer particles or beads).
In a particle manufacture process, the separating step is carried out by forming to particles comprising said material during said solubilizing step, and then collecting the particles from the system. This process may advantageously be combined with the polymerization process discussed above.
The recovering step is carried out by any suitable means. For example, the recovering step may be carried out by separating the oil from the carbon dioxide to provide a heterogeneous separation system; and then recycling the heterogeneous separation system to the initial "providing" step as illustrated by line 18 in Figure 1.
Alternatively, the recovering step may be carried out by physically separating the oil from the carbon dioxide (e.g., by venting the carbon dioxide from the vessel in which the system is contained, and then optionally draining the oil, or a concentrated oil and 2o carbon dioxide mixture, from the vessel).
Where the instant invention is carned out to apply or incorporate a material or other additive to a substrate from the second phase (see coating and treatment methods below), after the recovery step a portion of the additive is regained.
Make-up and maintenance of a desired charge of ingredient can occur by several routes:
l .) Metering of the make-up fluid into a low pressure area of the system. The low pressure area is the Cleaning/Treatment Chamber (where materials and substrates must be put in and out of the system. This can be affected by many means: (a) A
blocked off segment of pipe that is isolated from the chamber and substrate but will be flushed by the incoming process fluid (process fluid could also be circulated during 3o the cycle, then the additional ingredient could be brought into the system at any time during the cycle --- this is important if one desires to incorporate any kind of pre-treatment at a lower concentration} (b) Placed directly into the chamber before, during of after the addition of a substrate. (c) Metering pump pulling from a low SUBSTITUTE SHEET (RULE 26) pressure reservoir to the high pressure point in the system. The high presssure point can be anywhere.
2.) By fractionation of the contaminant/extract. For example in a metal cleaning application, little or no oil need to be added over. Loses would be recovered by using the fraction of the contaminant with the same solubility characteristics as the original active ingredient. Note that the composition of the oil could change over time without adversely affecting the operation of the system.
Specific embodiments of the invention are discussed in greater detail below.
1. Cleaning methods.
to Contaminants to be cleaned are miscible in the cleaner when the cleaner is immiscible in carbon dioxide but immiscible in the cleaner when the cleaner is miscible in carbon dioxide. The solvating characteristics of the cleaner makes possible both the cleaning of the contaminant from the substrate and the separation of the contaminant from the cleaner. The cleaner may then be re-used, either in combination with the COz in the original cleaning system or by separating the cleaner from the CO2. Alternatively, the cleaner may be disposed of without the problem of substantial amounts of contaminants entrained therein.
COZ used to carry out the present invention is preferably liquid C02, particularly during the step of contacting the cleaning system to the substrate.
2o Cleaners that may be used in the present invention are, in general, cleaners that are immiscible in COZ, at the temperature, pressure and concentrations, in which the cleaning step is carried out. The cleaner is, however, selected so that it may be rendered soluble in COz by manipulating the temperature, pressure, and/or concentration thereof (i.e., by raising one, or both, of temperature and pressure; by increasing COZ volume, etc.). The cleaner is typically an oil as described above.
Cleaning systems of the present invention (that is, systems used during the cleaning step) are mixtures of CO2, typically liquid CO2, and the second phase (the C02-immiscible cleaner). The mixture may be in any suitable form, including suspensions, dispersions, and emulsions (including microemulsions). Preferably the 3o COz is the continuous phase and the immiscible cleaner is the disperse phase in the system, but in an alternate embodiment the COZ may be the disperse phase and the immiscible cleaner may be the continuous phase. In either case, the two phases are rendered miscible during the separation step, as discussed in greater detail below.
SUBSTITUTE SHEET (RULE 26) _ '7' _ The cleaning systems are preferably non-aqueous. The second phase comprises from about 1, 2 or 3 percent to about 40, 50, or 60 percent by volume of the cleaning system.
The C02-containing phase may optionally include a co-solvent. Any co-solvent may be employed that is miscible in COz under the conditions of the process.
Examples of suitable co-solvents include, but are not limited to, methanol, ethanol, methyl ethyl ketone, acetone, and alcohols. Where a co-solvent is included, it may be included in any suitable amount, typically from about 1, 2 or 3 to about 20, 30, or 40 percent by volume of the first phase.
1o Contaminants that may be cleaned by the present invention include hydrocarbons, particularly hydrocarbons that are insoluble in liquid CO2.
Examples of such contaminants are quench oils such as FERROCOTETM, honey oils, cutting oils, heat transfer oils, etc. Such hyrocarbons may or may not be halogenated, and include numerous paraffins. Other contaminants include fingerprints, dust, residuals, grit, grime, adhesives, coatings such as paint, varnish, films, rust, scale and corrosion, etc.
Substrates that may be cleaned by the method of the present invention include metals such as steel, copper, and aluminum. The substrate may be in any form, including small parts such as screws, nuts, aircraft components, radiator channels and elbows, etc.
Additional substrates to be cleaned include plastics, ceramics, wood, glass and fiberglass and combinations thereof, such as textiles (e.g., gloves and rags for decontamination). The substrate may be an item to be restored or recycled such as an item having a painted surface, etc.
In general, the instant method initially involves contacting a substrate with a heterogeneous cleaning system. The contacting step is typically carried out in an enclosed pressure vessel (a cleaning vessel), and is carried out at a pressure and temperature and concentrations of C02 and cleaner such that the heterogeneous cleaning system comprises COZ in a first phase and the cleaner in a separate second 3o phase. The contacting step is carried out for a time sufficient for contaminant carned by said substrate to be entrained, in whole or in part, in the cleaner.
Liquid conditions are preferred because of the ease of separating the contacting fluid from the substrate. This is a function of temperature and pressure as SUBSTITUTE SHEET (RULE 26) _ g' described in the literature (e.g., A New Equation of State for Carbon Dioxide Covering the Fluid Region from the Triple-Point Temperature to 1100 Kelvin at Pressures up to 800 Mpa, R. Span, W Wagner; J. Phys. Chem. Ref. Data Vol 25, No.
6, 1996 and references therein) Also useful in carrying out the invention are "denisfied phases" of COZ. These are: (1) any state of 'compressed liquid', typically at a pressure above the saturation pressure and all temperatures below the critical point, Pmax = 500 bar, (2) supercritical, or near-critical state which are temperatures above the critical point, Tmax = 150°C and pressures such that the density of the fluid is greater than the l0 critical density, rmin = 0.4 g/cc, Pmax = 500 bar.
In general, all densities above 0.4g/cc and pressures less than 500 bar in the fluid regions (fluid = supercritical, near-critical and liquid), are useful in carrying out the present invention.
The step of solubilizing the cleaner in the COZ to produce a homogeneous cleaning system in which the contaminant is immiscibIe may be carried out in the same vessel or a different vessel from the contacting step, depending on the particular form of the apparatus used to carry out the method. Solubilizing of the cleaner in the COz may be carried out by any suitable means, including manipulating temperature, pressure, concentration of C02, and combinations thereof. For example, the pressure of the system could be increased, the temperature could be increased, or the concentration of COZ could be decreased (e.g., by partial venting of the COz).
As with the contacting step, the system is preferably a liquid system during the solubilizing step. Whether carried out in the same vessel as the contacting step or a separate vessel, the contaminant is separated from the substrate (e.g., by proper positioning of the substrates within a basket in the contacting vessel so that the contaminant rises or settles to a different location therein).
After the contacting step, the substrate is preferably rinsed with COZ before it is removed from the vessel. Rinsing may be accomplished by any means. The vessel may be drained of the cleaning system and a separate COZ rinse solution (which may or may not contain co-solvents) passed into the vessel. Alternatively, the rinsing may be carried out with the cleaning solution itself after it has been rendered homogeneous. In the latter case, the cleaning solution may again be rendered SUBSTITUTE SHEET (RULE 26) _ 9 '_ homogeneous in either the same or a different pressure vessel in which the contacting step is carried out, depending on the particular form of the apparatus employed.
As will be apparent from the foregoing, the substrate can be separated from the cleaning system either before or after the solubilizing step. For example, if the cleaning system is drained from the cleaning vessel and the two phases then rendered miscible in a separate vessel, the substrate is thereby separated from the cleaning system before the solubilizing step. If the two phases are rendered miscible within the reaction vessel (and the system then used as a rinse solution), the substrate will be separated from the cleaning system after the solubilizing step (e.g., by subsequent 1 o draining of the system or venting of the carbon dioxide).
Separation of the contaminant from the cleaner may be carried out in a variety of ways. The cleaning system may be transferred from the cleaning vessel to a separate vessel, the two phases rendered miscible, and the immiscible contaminant separated therein by any suitable means, such as filtering, sedimentation, distillation, etc.
Materials and methods employed in carrying out cleaning methods as described herein may be applied in like manner to the methods described below.
2. Polymerization methods.
In a polymerization process, the material to be separated is a polymer and the entraining step is carried out by adding a monomer to the system; and then polymerizing the monomer in the second phase. Any suitable polymerization process may be employed, and monomers and initiators may be located in any suitable compartment of the system. The reaction may be carried out with other polymers dissolved or dispersed in any suitable compartment of the system.
Temperatures, pressures, and other processing steps employed in carrying out these techniques may be essentially the same as described in conjunction with cleaning methods above, as modified by the requirements of the specific process.
~. Extraction methods.
In an extraction process, a single component or multiple components to be 3o retained or removed are separated from a liquid or solid mixture. In the present invention, the extraction process is simply carned out by extracting the material to be separated into the second phase as the separation step. The invention is particularly advantageous in extracting material from a mixture comprising biological materials or SUBSTITUTE SHEET (RULE 26) biomass {e.g., a microbiological fermentation broth, vascular plant material such as leaves, needles, stems, roots, and bark, etc.), or in separating a constituent from the product mixture of an organic reaction or biochemical reaction.
Temperatures, pressures, and other processing steps employed in carrying out these techniques may be essentially the same as described in conjunction with cleaning methods above, as modified by the requirements of the specific process.
4. Coating_and treatment methods As noted above, in a coating or treatment process, the separating step is carried out by depositing the material on a substrate and then separating the substrate to from the system. The depositing step can be carried out in a manner that forms a coating on the surface of the substrate (e.g., with a solid substrate such as a metal or glass part, or a drug particle), or can be carried out in a manner so that the material impregnates the substrate (e.g., polymer, metal, or clay or zeolite particles or beads).
Fibers, including natural fibers (e.g., cotton, wool) and synthetic or polymer fibers (e.g., poly(ethylene terephthalate)), can be treated or impregnated with materials by this method.
Particles and fibers may be coated with materials such as biopolymers (e.g., polypeptides, oligonucleotides), fluoropolymers, organic compounds, fire retardants, biocides, plasticizing agents, colorants or dyes, etc. to impart drugs, pharmaceutical agents, modify toxicity, add dyes and colorants, modify surfaces (including modification of hydrophobicity/hydrophilicity, roughness or surface texture, uniformity, spherocity, packing density, adhesive properties, etc.
Drug particles used to carry out the present invention are typically solid particulate drugs (optionally in combination with a pharmaceutically acceptable carrier such as lactose). Drug particles for inhalation use are, in general, respirable particles, typically from about 0.1 or 0.5 to 5 or 10 microns in size. The present invention is particularly useful for coating such drug particles with polymers or other materials that inhibit aggregation in a propellant so that the particles may subsequently be used in a metered dose inhaler. Examples of drugs from which 3o respirable particles may be formed include, but are not limited to, peptides, oligonucleotides (including natural and synthetic), and organic compounds such as epinephrine hydrochloride or bitartrate, ergotamine tartrate, albuterol, metaproterenol sulfate, beclomethasone dipropionate, flunisolide hemihydrate, cromolyn sodium, SUBSTITUTE SHEET (RULE 26) nedocromil sodium, iptropium bromide, salmeterol xinafoate, triamcinolone acetonide, pirbuterol acetate, bitolterol mesylate, dexamethasone sodium phosphate, terbutaline sulfate, nitroglycerin, budesonide, etc.
Temperatures, pressures, and other processing steps employed in carrying out these techniques may be essentially the same as described in conjunction with cleaning methods above, as modified by the requirements of the specific process.
5. Particle manufacture methods.
In a particle manufacture process, the separating step is carried out by forming particles comprising said material during said solubilizing step, and then collecting to the particles from the system. This process may advantageously be combined with the polymerization process discussed above. Thus, particles may be formed from a polymer (latex, dispersion, emulsion products, drug delivery particles, particles for use in aerosol formulations or photocopy toner). In general, as the process progresses, particle formation occurs as the carbon dioxide solubilizes the oil phase.
Control of the size of the dispersed oil phase advantageously enables control of the size of the particles formed.
Temperatures, pressures, and other processing steps employed in carrying out these techniques may be essentially the same as described in conjunction with cleaning methods above, as modified by the requirements of the specific process.
2o The present invention is explained in greater detail in the following non-limiting examples.
Cleaning of a Screw Machine Part Carbon steel machined nuts (200 g) coated with a heat quench oil (13 g) are added to a 1.6-L pressure-rated vessel at room temperature. SOYSOLV~ (80 mL), an immiscible soybean oil obtained from Steyer Farms, Inc. (6154 N. Co. Rd. 33, Tiffin, Ohio, 44883 USA), is added and the vessel is filled with COz to liquid half full (~700mL at 850-875 psia). The parts are rotated at 5-10 RPM inside a mesh cage 3o while the wash fluid is circulating and emulsified by a pump for 5 minutes.
The wash fluid is then drained and the vessel is refilled with COZ to 1000-1500 psia.
The rinse liquid is circulated for 5 minutes and then drained. After the residual pressure is SUBSTITUTE SHEET (RULE 26) vented, the parts are removed from the vessel. No quench oil remains on the parts by visual inspection, and wiping the parts on a white sheet of paper leaves no residue.
In a separate chamber, the wash fluid is subjected to 1600 psig, solubilizing the SOYSOLV~ oil in the COZ phase and allowing separation of a substantial portion of the heat quench oil contaminant from the system.
~leanin og f Scrgw Machine Part Carbon steel machined nuts (2.89 g) coated with a heat quench oil (0.01-0.05 1o g) are added to a 10-mL pressure-rated vessel at room temperature. An immiscible hydrocarbon solvent, 1.0 mL Isopar V, available from the Exxon Company, is added and the vessel is filled with COz to liquid half full (~5.0 mL at 850-875 psia). The wash fluid is stirred via a magnetically coupled stir bar for 5 minutes. The wash fluid is then drained and the vessel is refilled with COz to 1000-1500 psia. The rinse liquid is circulated for 5 minutes and then drained. After the residual pressure is vented, the parts are removed from the vessel. A major portion of the contaminant is removed from the parts as determined by visual inspection, and wiping the parts on a white sheet of paper leaves a slight residue.
In a separate chamber, the wash fluid is subjected to 1600 psig, solubilizing 2o the SOYSOLV~ in the COZ phase and allowing separation of a substantial portion of the heat quench oil contaminant from the system.
Demonstration of "Oil" Solubilization Sten A 50:50 volume mixture of a heat quench oil and SOYSOLV~ oil (8.5g) is added to a 160-mL pressure rated vessel at room temperature. Liquid COz (80 mL) at 850-875 psia is introduced into the vessel. The vessel contents separate into two liquid layers, and the bottom layer is drained from the vessel. This 4.70g fraction is predominantly heat quench oil. The vessel is then depressurized by distillation of 3o COz. The remaining 3.63 g of oil is predominantly SOYSOLV~ oil.
SUBSTITUTE SHEET (RULE 26) Polymerization of Acrylamide and Isolation of Polymer A mixture of C02 (80 vol %) and SOYSOLV ~ oil (20 vol%} is maintained at 50°C under pressure conditions where two phases (one primarily soy and the other primarily COz) are present. The soy phase is dispersed in the COZ continuous phase through agitation. A mixture of acrylamide monomer and 2,2-bisazobutyronitiile (AIBN) dissolved in acetone is metered into the reactor. Acrylamide is largely insoluble in CO2, and partitions into the soy phase. Once polymerization is complete, the pressure is increased until the soy phase becomes soluble in COz. The soy / COZ
1o solvent system is then displaced with COz at sufficient pressure to dissolve the soy product. The pressure is released and solid polyacrylamide recovered from the reactor.
IS Polymerization of Styrene and Isolation of Pol,~er A 25°C mixture of SOYSOLV~ oil (20 %) and COz (80%) is prepared in a well circulated polymerization reactor at 850 psig. The heterogeneous mixture consists of small droplets of soysolv dispersed in a continuous phase of COZ.
Diisopropyl peroxy dicarbonate, a room temperature free radical polymerization 2o initiator and styrene monomer are simultaneously metered into the reactor.
As polystyrene, which is insoluble in COZ and soluble in SOYSOLV~ oil, is formed, it is entrained in the dispersed droplets of the oil. Once the polymerization reaction is complete, pressure is increased to 2500 psig (by adding additional COz), solubilizing the soy and allowing isolation of polystyrene. The homogeneous mixture of soy and 25 C02 is removed from the reactor, the pressure is vented, and polystyrene is isolated.
Natural Product Extraction A natural product is extracted from organic matter using a heterogeneous 3o mixture of SOYSOLV~ OIL and COz. The natural product is soluble in Soysolv~
oil and relatively insoluble in CO2. The heterogeneous extraction fluid is then pumped into a higher pressure zone where the SOYSOLV~ oil is soluble in COz and SUBSTITUTE SHEET (RULE 26) the desired natural product is precipitated into the solution of SOYSOLV~ OIL
and CO2. The fine suspension of natural product is then isolated in a cyclone separator.
Coatin, of a Metal Park Metal screw machine parts are placed in a high-pressure chamber containing polystyrene dissolved in SOYSOLV~ oil. The parts are rotated at a low speed through the liquid as COz is added to the vessel. The liquid heterogeneous mixture so formed in the vessel consists of a predominantely COz continuous phase and a to dispersed phase of SOYSOLV~ oil and polystyrene. As more COZ is added, the SOYSOLV~ oil is extracted into the continuous phase, leaving the polystyrene coated on the parts. The COz/SOYSOLV~ oiI homogeneous liquid is then drained from the vessel, and the parts are rinsed with fresh CO2. After the vessel is vented, the metal parts, coated with polystyrene, are removed.
Coating/Imn_r~gnation of PrefnrmPrl Particles Preformed particles of respirable drug particles are placed into a chamber.
The chamber is pressurized to the vapor pressure of COZ and a heterogeneous mixture of SOYSOLV~ oil and C02, the soy oil phase containing lecithin, is pumped into the chamber with mixing. The pressure is raised to ca. 2500 psi, solubilizing the soy product in the COZ and depositing the lecithin on the drug particles. The soy oil/COZ
solvent mixture is then removed by flushing with pure CO2. The remaining COZ
is vented, the chamber opened, and lecithin coated drug particles recovered for use.
Fiber Coating Polyethylene teraphthalate) (or "PET") fiber is processed in a high pressure chamber containing a heterogeneous liquid mixture of acrylic copolymer dissolved in 3o SOYSOLV~ soy oil dispersed phase, suspended in a COz continuous phase. As the pressure is raised by adding more COz, the soy oil dissolves into the COZ
phase, precipitating the acrylic copolymer onto the PET fiber. The solution of COZ
and soy SUBSTITUTE SHEET (RULE 26) oil is then replaced with pure COZ which is removed and the acrylic coated PET
fiber is recovered.
Production of PEEK Particles Poly(ether ether ketone) (or "PEEK") and liquid Biphenyl sulphone as the oil are added to a vessel containing CO2. Under the conditions employed the mixture forms a heterogeneous mixture of two liquids: a solution of PEEK dissolved in Biphenyl sulphone, dispersed in a COz continuous phase. The COZ pressure and temperature are raised to a point where Biphenyl sulfone is soluble in COz precipitating PEEK as particles.
Production of Polvstvrene Particles Polystyrene is dissolved into the oil phase of a pre-made oil-in-COZ
suspension. The pressure of the COZ is increased, solubilizing the oil, precipitating polystyrene as particles. The polystyrene particles are isolated in a cyclone separator and the solution of oil and COZ recycled to a lower pressure where it again forms two phases and can be used to dissolve more polystyrene.
The foregoing is illustrative of the present invention, and is not to be construed 2o as limiting thereof. The invention is defined by the following claims, with equivalents of the claims to be included therein.
SUBSTITUTE SHEET (RULE 26)
Specific embodiments of the invention are discussed in greater detail below.
1. Cleaning methods.
to Contaminants to be cleaned are miscible in the cleaner when the cleaner is immiscible in carbon dioxide but immiscible in the cleaner when the cleaner is miscible in carbon dioxide. The solvating characteristics of the cleaner makes possible both the cleaning of the contaminant from the substrate and the separation of the contaminant from the cleaner. The cleaner may then be re-used, either in combination with the COz in the original cleaning system or by separating the cleaner from the CO2. Alternatively, the cleaner may be disposed of without the problem of substantial amounts of contaminants entrained therein.
COZ used to carry out the present invention is preferably liquid C02, particularly during the step of contacting the cleaning system to the substrate.
2o Cleaners that may be used in the present invention are, in general, cleaners that are immiscible in COZ, at the temperature, pressure and concentrations, in which the cleaning step is carried out. The cleaner is, however, selected so that it may be rendered soluble in COz by manipulating the temperature, pressure, and/or concentration thereof (i.e., by raising one, or both, of temperature and pressure; by increasing COZ volume, etc.). The cleaner is typically an oil as described above.
Cleaning systems of the present invention (that is, systems used during the cleaning step) are mixtures of CO2, typically liquid CO2, and the second phase (the C02-immiscible cleaner). The mixture may be in any suitable form, including suspensions, dispersions, and emulsions (including microemulsions). Preferably the 3o COz is the continuous phase and the immiscible cleaner is the disperse phase in the system, but in an alternate embodiment the COZ may be the disperse phase and the immiscible cleaner may be the continuous phase. In either case, the two phases are rendered miscible during the separation step, as discussed in greater detail below.
SUBSTITUTE SHEET (RULE 26) _ '7' _ The cleaning systems are preferably non-aqueous. The second phase comprises from about 1, 2 or 3 percent to about 40, 50, or 60 percent by volume of the cleaning system.
The C02-containing phase may optionally include a co-solvent. Any co-solvent may be employed that is miscible in COz under the conditions of the process.
Examples of suitable co-solvents include, but are not limited to, methanol, ethanol, methyl ethyl ketone, acetone, and alcohols. Where a co-solvent is included, it may be included in any suitable amount, typically from about 1, 2 or 3 to about 20, 30, or 40 percent by volume of the first phase.
1o Contaminants that may be cleaned by the present invention include hydrocarbons, particularly hydrocarbons that are insoluble in liquid CO2.
Examples of such contaminants are quench oils such as FERROCOTETM, honey oils, cutting oils, heat transfer oils, etc. Such hyrocarbons may or may not be halogenated, and include numerous paraffins. Other contaminants include fingerprints, dust, residuals, grit, grime, adhesives, coatings such as paint, varnish, films, rust, scale and corrosion, etc.
Substrates that may be cleaned by the method of the present invention include metals such as steel, copper, and aluminum. The substrate may be in any form, including small parts such as screws, nuts, aircraft components, radiator channels and elbows, etc.
Additional substrates to be cleaned include plastics, ceramics, wood, glass and fiberglass and combinations thereof, such as textiles (e.g., gloves and rags for decontamination). The substrate may be an item to be restored or recycled such as an item having a painted surface, etc.
In general, the instant method initially involves contacting a substrate with a heterogeneous cleaning system. The contacting step is typically carried out in an enclosed pressure vessel (a cleaning vessel), and is carried out at a pressure and temperature and concentrations of C02 and cleaner such that the heterogeneous cleaning system comprises COZ in a first phase and the cleaner in a separate second 3o phase. The contacting step is carried out for a time sufficient for contaminant carned by said substrate to be entrained, in whole or in part, in the cleaner.
Liquid conditions are preferred because of the ease of separating the contacting fluid from the substrate. This is a function of temperature and pressure as SUBSTITUTE SHEET (RULE 26) _ g' described in the literature (e.g., A New Equation of State for Carbon Dioxide Covering the Fluid Region from the Triple-Point Temperature to 1100 Kelvin at Pressures up to 800 Mpa, R. Span, W Wagner; J. Phys. Chem. Ref. Data Vol 25, No.
6, 1996 and references therein) Also useful in carrying out the invention are "denisfied phases" of COZ. These are: (1) any state of 'compressed liquid', typically at a pressure above the saturation pressure and all temperatures below the critical point, Pmax = 500 bar, (2) supercritical, or near-critical state which are temperatures above the critical point, Tmax = 150°C and pressures such that the density of the fluid is greater than the l0 critical density, rmin = 0.4 g/cc, Pmax = 500 bar.
In general, all densities above 0.4g/cc and pressures less than 500 bar in the fluid regions (fluid = supercritical, near-critical and liquid), are useful in carrying out the present invention.
The step of solubilizing the cleaner in the COZ to produce a homogeneous cleaning system in which the contaminant is immiscibIe may be carried out in the same vessel or a different vessel from the contacting step, depending on the particular form of the apparatus used to carry out the method. Solubilizing of the cleaner in the COz may be carried out by any suitable means, including manipulating temperature, pressure, concentration of C02, and combinations thereof. For example, the pressure of the system could be increased, the temperature could be increased, or the concentration of COZ could be decreased (e.g., by partial venting of the COz).
As with the contacting step, the system is preferably a liquid system during the solubilizing step. Whether carried out in the same vessel as the contacting step or a separate vessel, the contaminant is separated from the substrate (e.g., by proper positioning of the substrates within a basket in the contacting vessel so that the contaminant rises or settles to a different location therein).
After the contacting step, the substrate is preferably rinsed with COZ before it is removed from the vessel. Rinsing may be accomplished by any means. The vessel may be drained of the cleaning system and a separate COZ rinse solution (which may or may not contain co-solvents) passed into the vessel. Alternatively, the rinsing may be carried out with the cleaning solution itself after it has been rendered homogeneous. In the latter case, the cleaning solution may again be rendered SUBSTITUTE SHEET (RULE 26) _ 9 '_ homogeneous in either the same or a different pressure vessel in which the contacting step is carried out, depending on the particular form of the apparatus employed.
As will be apparent from the foregoing, the substrate can be separated from the cleaning system either before or after the solubilizing step. For example, if the cleaning system is drained from the cleaning vessel and the two phases then rendered miscible in a separate vessel, the substrate is thereby separated from the cleaning system before the solubilizing step. If the two phases are rendered miscible within the reaction vessel (and the system then used as a rinse solution), the substrate will be separated from the cleaning system after the solubilizing step (e.g., by subsequent 1 o draining of the system or venting of the carbon dioxide).
Separation of the contaminant from the cleaner may be carried out in a variety of ways. The cleaning system may be transferred from the cleaning vessel to a separate vessel, the two phases rendered miscible, and the immiscible contaminant separated therein by any suitable means, such as filtering, sedimentation, distillation, etc.
Materials and methods employed in carrying out cleaning methods as described herein may be applied in like manner to the methods described below.
2. Polymerization methods.
In a polymerization process, the material to be separated is a polymer and the entraining step is carried out by adding a monomer to the system; and then polymerizing the monomer in the second phase. Any suitable polymerization process may be employed, and monomers and initiators may be located in any suitable compartment of the system. The reaction may be carried out with other polymers dissolved or dispersed in any suitable compartment of the system.
Temperatures, pressures, and other processing steps employed in carrying out these techniques may be essentially the same as described in conjunction with cleaning methods above, as modified by the requirements of the specific process.
~. Extraction methods.
In an extraction process, a single component or multiple components to be 3o retained or removed are separated from a liquid or solid mixture. In the present invention, the extraction process is simply carned out by extracting the material to be separated into the second phase as the separation step. The invention is particularly advantageous in extracting material from a mixture comprising biological materials or SUBSTITUTE SHEET (RULE 26) biomass {e.g., a microbiological fermentation broth, vascular plant material such as leaves, needles, stems, roots, and bark, etc.), or in separating a constituent from the product mixture of an organic reaction or biochemical reaction.
Temperatures, pressures, and other processing steps employed in carrying out these techniques may be essentially the same as described in conjunction with cleaning methods above, as modified by the requirements of the specific process.
4. Coating_and treatment methods As noted above, in a coating or treatment process, the separating step is carried out by depositing the material on a substrate and then separating the substrate to from the system. The depositing step can be carried out in a manner that forms a coating on the surface of the substrate (e.g., with a solid substrate such as a metal or glass part, or a drug particle), or can be carried out in a manner so that the material impregnates the substrate (e.g., polymer, metal, or clay or zeolite particles or beads).
Fibers, including natural fibers (e.g., cotton, wool) and synthetic or polymer fibers (e.g., poly(ethylene terephthalate)), can be treated or impregnated with materials by this method.
Particles and fibers may be coated with materials such as biopolymers (e.g., polypeptides, oligonucleotides), fluoropolymers, organic compounds, fire retardants, biocides, plasticizing agents, colorants or dyes, etc. to impart drugs, pharmaceutical agents, modify toxicity, add dyes and colorants, modify surfaces (including modification of hydrophobicity/hydrophilicity, roughness or surface texture, uniformity, spherocity, packing density, adhesive properties, etc.
Drug particles used to carry out the present invention are typically solid particulate drugs (optionally in combination with a pharmaceutically acceptable carrier such as lactose). Drug particles for inhalation use are, in general, respirable particles, typically from about 0.1 or 0.5 to 5 or 10 microns in size. The present invention is particularly useful for coating such drug particles with polymers or other materials that inhibit aggregation in a propellant so that the particles may subsequently be used in a metered dose inhaler. Examples of drugs from which 3o respirable particles may be formed include, but are not limited to, peptides, oligonucleotides (including natural and synthetic), and organic compounds such as epinephrine hydrochloride or bitartrate, ergotamine tartrate, albuterol, metaproterenol sulfate, beclomethasone dipropionate, flunisolide hemihydrate, cromolyn sodium, SUBSTITUTE SHEET (RULE 26) nedocromil sodium, iptropium bromide, salmeterol xinafoate, triamcinolone acetonide, pirbuterol acetate, bitolterol mesylate, dexamethasone sodium phosphate, terbutaline sulfate, nitroglycerin, budesonide, etc.
Temperatures, pressures, and other processing steps employed in carrying out these techniques may be essentially the same as described in conjunction with cleaning methods above, as modified by the requirements of the specific process.
5. Particle manufacture methods.
In a particle manufacture process, the separating step is carried out by forming particles comprising said material during said solubilizing step, and then collecting to the particles from the system. This process may advantageously be combined with the polymerization process discussed above. Thus, particles may be formed from a polymer (latex, dispersion, emulsion products, drug delivery particles, particles for use in aerosol formulations or photocopy toner). In general, as the process progresses, particle formation occurs as the carbon dioxide solubilizes the oil phase.
Control of the size of the dispersed oil phase advantageously enables control of the size of the particles formed.
Temperatures, pressures, and other processing steps employed in carrying out these techniques may be essentially the same as described in conjunction with cleaning methods above, as modified by the requirements of the specific process.
2o The present invention is explained in greater detail in the following non-limiting examples.
Cleaning of a Screw Machine Part Carbon steel machined nuts (200 g) coated with a heat quench oil (13 g) are added to a 1.6-L pressure-rated vessel at room temperature. SOYSOLV~ (80 mL), an immiscible soybean oil obtained from Steyer Farms, Inc. (6154 N. Co. Rd. 33, Tiffin, Ohio, 44883 USA), is added and the vessel is filled with COz to liquid half full (~700mL at 850-875 psia). The parts are rotated at 5-10 RPM inside a mesh cage 3o while the wash fluid is circulating and emulsified by a pump for 5 minutes.
The wash fluid is then drained and the vessel is refilled with COZ to 1000-1500 psia.
The rinse liquid is circulated for 5 minutes and then drained. After the residual pressure is SUBSTITUTE SHEET (RULE 26) vented, the parts are removed from the vessel. No quench oil remains on the parts by visual inspection, and wiping the parts on a white sheet of paper leaves no residue.
In a separate chamber, the wash fluid is subjected to 1600 psig, solubilizing the SOYSOLV~ oil in the COZ phase and allowing separation of a substantial portion of the heat quench oil contaminant from the system.
~leanin og f Scrgw Machine Part Carbon steel machined nuts (2.89 g) coated with a heat quench oil (0.01-0.05 1o g) are added to a 10-mL pressure-rated vessel at room temperature. An immiscible hydrocarbon solvent, 1.0 mL Isopar V, available from the Exxon Company, is added and the vessel is filled with COz to liquid half full (~5.0 mL at 850-875 psia). The wash fluid is stirred via a magnetically coupled stir bar for 5 minutes. The wash fluid is then drained and the vessel is refilled with COz to 1000-1500 psia. The rinse liquid is circulated for 5 minutes and then drained. After the residual pressure is vented, the parts are removed from the vessel. A major portion of the contaminant is removed from the parts as determined by visual inspection, and wiping the parts on a white sheet of paper leaves a slight residue.
In a separate chamber, the wash fluid is subjected to 1600 psig, solubilizing 2o the SOYSOLV~ in the COZ phase and allowing separation of a substantial portion of the heat quench oil contaminant from the system.
Demonstration of "Oil" Solubilization Sten A 50:50 volume mixture of a heat quench oil and SOYSOLV~ oil (8.5g) is added to a 160-mL pressure rated vessel at room temperature. Liquid COz (80 mL) at 850-875 psia is introduced into the vessel. The vessel contents separate into two liquid layers, and the bottom layer is drained from the vessel. This 4.70g fraction is predominantly heat quench oil. The vessel is then depressurized by distillation of 3o COz. The remaining 3.63 g of oil is predominantly SOYSOLV~ oil.
SUBSTITUTE SHEET (RULE 26) Polymerization of Acrylamide and Isolation of Polymer A mixture of C02 (80 vol %) and SOYSOLV ~ oil (20 vol%} is maintained at 50°C under pressure conditions where two phases (one primarily soy and the other primarily COz) are present. The soy phase is dispersed in the COZ continuous phase through agitation. A mixture of acrylamide monomer and 2,2-bisazobutyronitiile (AIBN) dissolved in acetone is metered into the reactor. Acrylamide is largely insoluble in CO2, and partitions into the soy phase. Once polymerization is complete, the pressure is increased until the soy phase becomes soluble in COz. The soy / COZ
1o solvent system is then displaced with COz at sufficient pressure to dissolve the soy product. The pressure is released and solid polyacrylamide recovered from the reactor.
IS Polymerization of Styrene and Isolation of Pol,~er A 25°C mixture of SOYSOLV~ oil (20 %) and COz (80%) is prepared in a well circulated polymerization reactor at 850 psig. The heterogeneous mixture consists of small droplets of soysolv dispersed in a continuous phase of COZ.
Diisopropyl peroxy dicarbonate, a room temperature free radical polymerization 2o initiator and styrene monomer are simultaneously metered into the reactor.
As polystyrene, which is insoluble in COZ and soluble in SOYSOLV~ oil, is formed, it is entrained in the dispersed droplets of the oil. Once the polymerization reaction is complete, pressure is increased to 2500 psig (by adding additional COz), solubilizing the soy and allowing isolation of polystyrene. The homogeneous mixture of soy and 25 C02 is removed from the reactor, the pressure is vented, and polystyrene is isolated.
Natural Product Extraction A natural product is extracted from organic matter using a heterogeneous 3o mixture of SOYSOLV~ OIL and COz. The natural product is soluble in Soysolv~
oil and relatively insoluble in CO2. The heterogeneous extraction fluid is then pumped into a higher pressure zone where the SOYSOLV~ oil is soluble in COz and SUBSTITUTE SHEET (RULE 26) the desired natural product is precipitated into the solution of SOYSOLV~ OIL
and CO2. The fine suspension of natural product is then isolated in a cyclone separator.
Coatin, of a Metal Park Metal screw machine parts are placed in a high-pressure chamber containing polystyrene dissolved in SOYSOLV~ oil. The parts are rotated at a low speed through the liquid as COz is added to the vessel. The liquid heterogeneous mixture so formed in the vessel consists of a predominantely COz continuous phase and a to dispersed phase of SOYSOLV~ oil and polystyrene. As more COZ is added, the SOYSOLV~ oil is extracted into the continuous phase, leaving the polystyrene coated on the parts. The COz/SOYSOLV~ oiI homogeneous liquid is then drained from the vessel, and the parts are rinsed with fresh CO2. After the vessel is vented, the metal parts, coated with polystyrene, are removed.
Coating/Imn_r~gnation of PrefnrmPrl Particles Preformed particles of respirable drug particles are placed into a chamber.
The chamber is pressurized to the vapor pressure of COZ and a heterogeneous mixture of SOYSOLV~ oil and C02, the soy oil phase containing lecithin, is pumped into the chamber with mixing. The pressure is raised to ca. 2500 psi, solubilizing the soy product in the COZ and depositing the lecithin on the drug particles. The soy oil/COZ
solvent mixture is then removed by flushing with pure CO2. The remaining COZ
is vented, the chamber opened, and lecithin coated drug particles recovered for use.
Fiber Coating Polyethylene teraphthalate) (or "PET") fiber is processed in a high pressure chamber containing a heterogeneous liquid mixture of acrylic copolymer dissolved in 3o SOYSOLV~ soy oil dispersed phase, suspended in a COz continuous phase. As the pressure is raised by adding more COz, the soy oil dissolves into the COZ
phase, precipitating the acrylic copolymer onto the PET fiber. The solution of COZ
and soy SUBSTITUTE SHEET (RULE 26) oil is then replaced with pure COZ which is removed and the acrylic coated PET
fiber is recovered.
Production of PEEK Particles Poly(ether ether ketone) (or "PEEK") and liquid Biphenyl sulphone as the oil are added to a vessel containing CO2. Under the conditions employed the mixture forms a heterogeneous mixture of two liquids: a solution of PEEK dissolved in Biphenyl sulphone, dispersed in a COz continuous phase. The COZ pressure and temperature are raised to a point where Biphenyl sulfone is soluble in COz precipitating PEEK as particles.
Production of Polvstvrene Particles Polystyrene is dissolved into the oil phase of a pre-made oil-in-COZ
suspension. The pressure of the COZ is increased, solubilizing the oil, precipitating polystyrene as particles. The polystyrene particles are isolated in a cyclone separator and the solution of oil and COZ recycled to a lower pressure where it again forms two phases and can be used to dissolve more polystyrene.
The foregoing is illustrative of the present invention, and is not to be construed 2o as limiting thereof. The invention is defined by the following claims, with equivalents of the claims to be included therein.
SUBSTITUTE SHEET (RULE 26)
Claims (38)
1. A method of cleaning a contaminant from a substrate, comprising:
contacting a substrate with a heterogeneous cleaning system, the heterogeneous cleaning system comprising CO2 in a first phase and a cleaner in a separate second phase, so that contaminant carried by said substrate is entrained in said cleaner; then solubilizing said cleaner in said first phase to produce a cleaning system in which said contaminant is immiscible and said contaminant is separated from said substrate; and separating said substrate from said cleaning system before or after said solubilizing step; and separating said contaminant from said cleaner.
contacting a substrate with a heterogeneous cleaning system, the heterogeneous cleaning system comprising CO2 in a first phase and a cleaner in a separate second phase, so that contaminant carried by said substrate is entrained in said cleaner; then solubilizing said cleaner in said first phase to produce a cleaning system in which said contaminant is immiscible and said contaminant is separated from said substrate; and separating said substrate from said cleaning system before or after said solubilizing step; and separating said contaminant from said cleaner.
2. A method according to claim 1, wherein said step of separating said substrate from said cleaning system is carrier out prior to said solubilizing step.
3. A method according to claim 1, wherein said step of separating said substrate from said cleaning system is carried out after said solubilizing step.
4. A method according to claim 1, further comprising the step of rinsing said substrate with CO2 after said contacting step.
5. A method according to claim 1, further comprising the steps of rinsing said substrate in said homogeneous cleaning system after said solubilizing step; and then separating said substrate from said homogeneous cleaning system.
6. A method according to claim 1, further comprising the step of:
separating said cleaner from said CO2 following said step of separating said homogeneous cleaning system from said contaminant.
separating said cleaner from said CO2 following said step of separating said homogeneous cleaning system from said contaminant.
7. A method according to claim 1, wherein said contaminant is insoluble in said CO2 during said contacting step.
8. A method according to claim 1, wherein said contaminant is a hydrocarbon.
9. A method according to claim 1, wherein said cleaner is an oil.
10. A method according to claim 1, wherein said cleaner is a vegetable oil.
11. A method according to claim 1, wherein said first phase is the continuous phase and said second phase is a disperse phase.
12. A method according to claim 1, wherein said first phase and said second separate phase are both liquid phases.
13. A method according to claim 1, wherein said cleaning system is a non-aqueous cleaning system.
14. A method according to claim 1, wherein said substrate is a metal substrate.
15. A method according to claim 1, wherein said solubilizing step is carried out by solubilizing substantially all of said cleaner in said first phase to produce a substantially homogeneous cleaning system in which said contaminant is insoluble.
16. A separation method, comprising:
providing a heterogeneous separation system, the heterogeneous separation system comprising CO2 in a first phase and an oil in a separate second phase;
then entraining a material to be separated in said second phase; and then solubilizing said second phase in said first phase to produce a separation system in which said material to be separated is insoluble; and then separating said material from said system.
providing a heterogeneous separation system, the heterogeneous separation system comprising CO2 in a first phase and an oil in a separate second phase;
then entraining a material to be separated in said second phase; and then solubilizing said second phase in said first phase to produce a separation system in which said material to be separated is insoluble; and then separating said material from said system.
17. A method according to claim 16, wherein said separating step is followed by the step of:
recovering at least a portion of said oil.
recovering at least a portion of said oil.
18. A method according to claim 16, wherein said material to be separated is a polymer and said entraining step is carried out by:
adding a monomer to said system; and polymerizing said monomer in said second phase.
adding a monomer to said system; and polymerizing said monomer in said second phase.
19. A method according to claim 16, wherein said entraining step is carried out by:
extracting said material to be separated into said second phase.
extracting said material to be separated into said second phase.
20. A method according to claim 16, wherein said separating step is carried out by:
depositing said material on a substrate; and then separating said substrate from said system.
depositing said material on a substrate; and then separating said substrate from said system.
21. A method according to claim 20, wherein said substrate is a particle.
22. A method according to claim 20, wherein said depositing step is carried out on the surface of said substrate to form a coating on said substrate.
23. A method according to claim 16, wherein said separating step is carried out by:
forming particles comprising said material during said solubilizing step; and then collecting said particles from said system.
forming particles comprising said material during said solubilizing step; and then collecting said particles from said system.
24. A method according to claim 16, wherein said oil is a vegetable oil.
25. A method according to claim 16, wherein said first phase is the continuous phase and said second phase is a disperse phase.
26. A method according to claim 16, wherein said first phase and said second separate phase are both liquid phases.
27. A method according to claim 16, wherein said system is a non-aqueous system.
28. A method according to claim 16, wherein said recovering step is carried out by:
separating said oil from said carbon dioxide to provide a heterogeneous separation system; and then recycling said heterogeneous separation system to said providing step.
separating said oil from said carbon dioxide to provide a heterogeneous separation system; and then recycling said heterogeneous separation system to said providing step.
29. A method according to claim 16, wherein said recovering step is carried out by:
physically separating said oil from said carbon dioxide.
physically separating said oil from said carbon dioxide.
30. A method according to claim 16, wherein said solubilizing step is carried out by solubilizing substantially all of said second phase in said first phase to produce a substantially homogeneous separating system in which said material to be separated is insoluble.
31. A method of depositing a material on a substrate, comprising:
providing a heterogeneous separation system, the heterogeneous separation system comprising CO2 in a first phase and an oil in a separate second phase;
then entraining a material to be separated in said second phase; and then solubilizing said second phase in said first phase to produce a separation system in which said material to be separated is insoluble; and then depositing said material on said substrate; and then separating said substrate from said system.
providing a heterogeneous separation system, the heterogeneous separation system comprising CO2 in a first phase and an oil in a separate second phase;
then entraining a material to be separated in said second phase; and then solubilizing said second phase in said first phase to produce a separation system in which said material to be separated is insoluble; and then depositing said material on said substrate; and then separating said substrate from said system.
32. A method according to claim 31, wherein said separating step is followed by the step of:
recovering at least a portion of said oil.
recovering at least a portion of said oil.
33. A method-according to claim 31, wherein said material is a polymer.
34. A method according to claim 31, wherein said substrate is a drug particle.
35. A method according to claim 31, wherein said substrate is a fiber.
36. A method according to claim 31, wherein said depositing step is carried out on the surface of said substrate to form a coating on said substrate.
37. A method according to claim 31, wherein said oil is a vegetable oil.
38. A method according to claim 31, wherein said solubilizing step is carried out by solubilizing substantially all of said second phase in said first phase to produce a substantially homogeneous separating system in which said material to be separated is insoluble.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US09/070,196 | 1998-04-03 | ||
| US09/070,196 US6120613A (en) | 1998-04-30 | 1998-04-30 | Carbon dioxide cleaning and separation systems |
| PCT/US1999/007248 WO1999051364A1 (en) | 1998-04-03 | 1999-04-01 | Carbon dioxide cleaning and separation systems |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2326585A1 true CA2326585A1 (en) | 1999-10-14 |
Family
ID=22093759
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002326585A Abandoned CA2326585A1 (en) | 1998-04-03 | 1999-04-01 | Carbon dioxide cleaning and separation systems |
Country Status (6)
| Country | Link |
|---|---|
| US (3) | US6120613A (en) |
| EP (1) | EP1071523A1 (en) |
| JP (1) | JP2003528705A (en) |
| AU (1) | AU3220499A (en) |
| CA (1) | CA2326585A1 (en) |
| WO (1) | WO1999051364A1 (en) |
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-
1998
- 1998-04-30 US US09/070,196 patent/US6120613A/en not_active Expired - Fee Related
-
1999
- 1999-04-01 CA CA002326585A patent/CA2326585A1/en not_active Abandoned
- 1999-04-01 AU AU32204/99A patent/AU3220499A/en not_active Abandoned
- 1999-04-01 EP EP99914332A patent/EP1071523A1/en not_active Withdrawn
- 1999-04-01 WO PCT/US1999/007248 patent/WO1999051364A1/en not_active Application Discontinuation
- 1999-04-01 JP JP2000542121A patent/JP2003528705A/en active Pending
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2000
- 2000-05-26 US US09/579,676 patent/US6413574B1/en not_active Expired - Fee Related
- 2000-08-07 US US09/632,686 patent/US6200393B1/en not_active Expired - Fee Related
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|---|---|
| JP2003528705A (en) | 2003-09-30 |
| US20020048629A1 (en) | 2002-04-25 |
| AU3220499A (en) | 1999-10-25 |
| EP1071523A1 (en) | 2001-01-31 |
| US6413574B1 (en) | 2002-07-02 |
| WO1999051364A1 (en) | 1999-10-14 |
| US6200393B1 (en) | 2001-03-13 |
| US6120613A (en) | 2000-09-19 |
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