DESC:FIELD
The present disclosure relates to a field of construction, paints and coatings.
DEFINITIONS
As used in the present disclosure, the following terms are generally intended to have the meaning as set forth below, except to the extent that the context in which they are used, indicate otherwise.
Hydrophobic binder composition: The term “hydrophobic binder composition” refers to a composition that has water contact angle of more than 90 degrees.
Water contact angle: The term “water contact angle” or “contact angle” refers to an angle between a liquid surface and a solid surface where they meet. More specifically, it is the angle between the surface tangent on the liquid–vapor interface and the tangent on the solid–liquid interface at their intersection.
Water reducer: The term “water reducer” refers to a property of a lime based composition that helps reducing water intake after application and helps increasing workability and improving the strength.
Open time: The term “open time” refers to a property of a lime based composition that allows the film so formed after application to remain open for a longer time to enable its workability.
Time of developing hydrophobicity: The term “time of developing hydrophobicity” refers to the time required for the hydrophobic binder composition to show hydrophobic characteristic after application, which is one of the characteristic properties of the hydrophobic binder composition.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
Lime occurs in nature abundantly and has unique properties such as strength, durability and flexibility in usage. Lime is also breathable, allowing moisture to evaporate, and reducing the risk of dampness and mold. Further, lime has been explored in many ways.
Conventionally lime is used as a binding agent in many building materials. The sensitivity of the lime-based building material to moisture is due to the characteristic properties of the lime such as capillary-porous structure of lime i.e. readiness to absorb water (hydrophilicity), and the tendency to physical and chemical reactions with water itself or the substances dissolved in it, and the like.
Lime-based building materials can only fulfill their function in long term if their overall cross-section remains free of moisture. This can be achieved by providing hydrophobic properties to the lime. However, improving the hydrophobicity of lime not only increases its practical value, but also provides a scope to understand its unrevealed properties. Such improvement in the hydrophobicity of lime may result in its application in the fields more precise, other than construction or mining industries. The lack of hydrophobic properties in the lime limits its application abilities in the areas otherwise valuable as raw materials because of its other characteristics. The development of new technologies to modify such materials and to provide them with waterproofing properties is required to extend the scope of their application both in everyday life and in many industries.
Therefore, there is a need to provide hydrophobic binder composition to mitigate the above drawbacks or at least provide a useful alternative.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows:
It is an object of the present disclosure to ameliorate one or more problems of the background or to at least provide a useful alternative.
Another object of the present disclosure is to provide a hydrophobic binder composition.
Still another object of the present disclosure is to provide a hydrophobic binder composition that excellent hydrophobicity and acts as a water reducer.
Yet another object of the present disclosure is to provide a hydrophobic binder composition that has excellent stability and adhesion, high open time and dew drop/lotus leaf effect.
Still another object of the present disclosure is to provide a hydrophobic binder composition that requires less time for developing hydrophobicity.
Another object of the present disclosure is to provide a process for the preparation of hydrophobic binder composition.
Still another object of the present disclosure is to provide a simple and economical process for the preparation of hydrophobic binder composition.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
SUMMARY
In an aspect, the present disclosure provides hydrophobic binder composition.
A hydrophobic binder composition comprises 60 mass% to 85 mass% of lime, 4 mass% to 30 mass% of a hydrophobic agent selected from a silane compound and a fatty acid, 0 mass% to 15 mass% of at least one additive selected from the group consisting of a dispersant, a wetting agent, a defoamer, and a thickener, and 0 mass% to 20 mass% of water.
In an embodiment, the composition comprises 60 mass% to 85 mass% of lime, 0 mass% to 8 mass% of a silane compound, 4 mass% to 15 mass% of a fatty acid, 0.5 mass% to 2 mass% of a dispersant, 0.5 mass% to 3 mass% of a wetting agent, 0.5 mass% to 2 mass% of a defoamer, 2 mass% to 8 mass% of a thickener, and 0 mass% to 20 mass% of water.
In another embodiment, the composition comprises 60 mass% to 80 mass% of lime, 15 mass% to 30 mass% of a silane compound, and 5 mass% to 15 mass% of water.
In yet another embodiment, the composition comprises 60 mass% to 85 mass% of lime, 10 mass% to 20 mass% of a silane compound, and 0.5 mass% to 2 mass% of a dispersant.
In accordance with the present disclosure, the lime is selected from the group consisting of slaked lime, hydrated lime and solid lime.
In accordance with the present disclosure, the dispersant is a polymeric carboxylic acid salt selected from sodium polyacrylate and ammonium polyacrylate.
In accordance with the present disclosure, the wetting agent is an alkylphenol ethoxylate free non-ionic surfactant selected from fatty acid alkoxylate and polyoxyethylene alkyl ether.
In accordance with the present disclosure, the defoamer is selected from alkylphenol ethoxylate free mineral oil based defoamer and silicone based defoamer.
In accordance with the present disclosure, the silane compound is at least one selected from the group consisting of trimethylchlorosilane (TMCS), dichlorodimethylsilane (DCDMS), dichloro(methyl)phenylsilane (DCMPhS), 3-chloropropylmethyldichlorosilane (CPMDCS), (3, 3, 3-trifluoropropyl) dichloromethylsilane (TFDCMS), 3-aminopropyltrimethoxysilane (APTMS), vinyltrimethoxysilane (VTMO), 3-aminopropyltriethoxysilane (APTES), and vinyl tris(2-ethoxymethoxy) silane (VTEMS).
In accordance with the present disclosure, the fatty acid is selected from the group consisting of oleic acid, lauric acid, myristic acid, palmitic acid, palmitoleic acid, stearic acid, linoleic acid, a-linolenic acid, and arachidonic acid.
In accordance with the present disclosure, the thickener is hydroxyl ethyl cellulose solution.
In accordance with the present disclosure, the composition is characterized by at least one of contact angle in the range of 125o to 140o, and time for developing hydrophobicity is in the range of 1 day to 7 days.
In another aspect, the present disclosure provides a process for the preparation of hydrophobic binder composition. The process comprises adding predetermined amounts of lime, a hydrophobic agent selected from a silane compound and a fatty acid, optionally at least one additive selected from a dispersant, a wetting agent, a deformer and a thickener, and optionally water under stirring at a predetermined speed for a predetermined time period to obtain said hydrophobic binder composition.
In accordance with the present disclosure, the predetermined speed is in the range of 500 rpm to 1500 rpm; and the predetermined time period is in the range of 1 hour to 3 hours.
DETAILED DESCRIPTION
The present disclosure relates to hydrophobic binder composition and a process for its preparation.
Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.
The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms "a,” "an," and "the" may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms "comprises”, “comprising," “including,” and “having,” are open-ended transitional phrases and therefore specify the presence of stated features, integers, steps, operations, elements, modules, units, and/or components, but do not forbid the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
As used herein, the term "and/or" includes any combinations of one or more of the associated listed elements.
The terms first, second, third, etc., should not be construed to limit the scope of the present disclosure as the aforementioned terms may be only used to distinguish one element, component, region, layer, or section from another component, region, layer, or section. Terms such as first, second, third, etc., when used herein do not imply a specific sequence or order unless clearly suggested by the present disclosure.
Lime occurs in nature abundantly and has unique properties such as strength, durability, and flexibility. Lime is also breathable, allowing moisture to evaporate, and reducing the risk of dampness and mold. Further, lime has been explored in many ways.
Conventionally lime is used as a binding agent in many building materials. The sensitivity of the lime-based building material to moisture is due to the characteristic properties of the lime such as capillary-porous structure i.e. readiness to absorb water (hydrophilicity), and the tendency to physical and chemical reactions with water itself or the substances dissolved in it, and the like.
Lime-based building materials can only fulfill their function in long term if their overall cross-section remains free of moisture. This can be achieved by providing hydrophobic properties to the lime. However, improving the hydrophobicity of lime not only increases its practical value, but also provides a scope to understand its unrevealed properties i.e. cognitive. Such improvement in the hydrophobicity of lime may result in its application in the fields more precise, and other than construction or mining industries. The lack of hydrophobic properties in the lime limits its application abilities in the areas otherwise valuable as raw materials because of its other characteristics. The development of new technologies to modify such materials and to provide them with waterproofing properties is required to extend the scope of their application both in everyday life and in many industries.
In an aspect, the present disclosure provides hydrophobic binder composition. The hydrophobic binder composition comprises 60 mass% to 85 mass% of lime, 4 mass% to 30 mass% of a hydrophobic agent selected from a silane compound and a fatty acid, 0 mass% to 15 mass% of at least one additive selected from the group consisting of a dispersant, a wetting agent, a defoamer, and a thickener, and 0 mass% to 20 mass% of water.
In accordance with the present disclosure, the lime is selected from the group consisting of slaked lime, hydrated lime and solid lime. In the exemplary embodiments, the lime is 44% solid lime which is matured for 20 days to 40 days. In an embodiment, the lime is slaked lime.
In accordance with the present disclosure, the dispersant is a polymeric carboxylic acid salt selected from sodium polyacrylate and ammonium polyacrylate. In an embodiment, the dispersant is ammonium polyacrylate. In an exemplary embodiment, the dispersant is Indofil 731TM.
In accordance with the present disclosure, the wetting agent is an alkylphenol ethoxylate free non-ionic surfactant selected from fatty acid alkoxylate and polyoxyethylene alkyl ether. In an exemplary embodiment, the wetting agent is Nupol APF 115TM.
In accordance with the present disclosure, the defoamer is selected from alkylphenol ethoxylate free mineral oil based defoamer and silicone based defoamer. In the exemplary embodiments, the defoamer is mineral oil based defoamer.
In accordance with the present disclosure, the silane compound is at least one selected from the group consisting of trimethylchlorosilane (TMCS), dichlorodimethylsilane (DCDMS), dichloro(methyl)phenylsilane (DCMPhS), 3-chloropropylmethyldichlorosilane (CPMDCS), (3, 3, 3-trifluoropropyl) dichloromethylsilane (TFDCMS), 3-aminopropyltrimethoxysilane (APTMS), vinyltrimethoxysilane (VTMO), 3-aminopropyltriethoxysilane (APTES), and vinyl tris(2-ethoxymethoxy) silane (VTEMS). In the exemplary embodiments, the silane compound is vinyltrimethoxysilane (VTMO).
In accordance with the present disclosure, the fatty acid is selected from the group consisting of oleic acid, lauric acid, myristic acid, palmitic acid, palmitoleic acid, stearic acid, linoleic acid, a-linolenic acid, and arachidonic acid. In the exemplary embodiments, the fatty acid is an oleic acid.
In accordance with the present disclosure, the fatty acid is neutralized by a pH stabilizer. In an embodiment, the pH stabilizer is an alkaline compound.
In accordance with the present disclosure, the thickener is hydroxyl ethyl cellulose solution. In the exemplary embodiments, the thickener is 1% aqueous solution of hydroxyl ethyl cellulose.
In an embodiment, the composition comprises 60 mass% to 85 mass% of the lime, 0 mass% to 8 mass% of the silane compound, 4 mass% to 15 mass% of the fatty acid, 0.5 mass% to 2 mass% of the dispersant, 0.5 mass% to 3 mass% of the wetting agent, 0.5 mass% to 2 mass% of the defoamer, 2 mass% to 8 mass% of the thickener, and 0 mass% to 20 mass% of water. In an exemplary embodiment, the composition comprises 65 mass% of the lime, 5 mass% of the silane compound, 6 mass% of the fatty acid, 1 mass% of the dispersant, 2 mass% of the wetting agent, 1 mass% of the defoamer, 5 mass% of the thickener, and 15 mass% of water. In another exemplary embodiment, the composition comprises 80 mass% of the lime, 12 mass% of the fatty acid, 1 mass% of the dispersant, 1 mass% of the wetting agent, 1 mass% of the defoamer, and 5 mass% of the thickener. In yet another exemplary embodiment, the composition comprises 82 mass% of the lime, 10 mass% of the fatty acid, 1 mass% of the dispersant, 1 mass% of the wetting agent, 1 mass% of the defoamer, and 5 mass% of the thickener. In still another exemplary embodiment, the composition comprises 79 mass% of the lime, 12 mass% of the fatty acid, 1 mass% of the dispersant, 2 mass% of the wetting agent, 1 mass% of the defoamer, and 5 mass% of the thickener.
In another embodiment, the composition comprises 60 mass% to 80 mass% of the lime, 15 mass% to 30 mass% of the silane compound, and 5 mass% to 15 mass% of water. In an exemplary embodiment, the composition comprises 65 mass% of lime, 25 mass% of the silane compound, and 10 mass% of water.
In yet another embodiment, the composition comprises 60 mass% to 85 mass% of the lime, 10 mass% to 20 mass% of the silane compound, and 0.5 mass% to 2 mass% of the dispersant. In an exemplary embodiment, the composition comprises 85 mass% of lime, 14 mass% of the silane compound and 1 mass% of the dispersant.
In accordance with the present disclosure, the composition is characterized by at least one of contact angle in the range of 125o to 140o, and time for developing hydrophobicity is in the range of 1 day to 7 days. In an exemplary embodiment, the hydrophobic binder composition has a contact angle of 134o, and the time for developing hydrophobicity is 3 days. In another exemplary embodiment, the hydrophobic binder composition has a contact angle of 140o, and the time for developing hydrophobicity is 1 days. In still another exemplary embodiment, the hydrophobic binder composition has a contact angle of 125o, and the time for developing hydrophobicity is 7 days.
The hydrophobic binder composition of the present disclosure not only provide the desired hydrophobicity, but it is also sustainable and eco-friendly.
The binder composition of the present disclosure requires less time to develop hydrophobicity despite the composition is lime based which is naturally hydrophilic. The binder composition of the present disclosure is natural, sustainable and provides a highly effective replacement for conventional fillers in paints and coatings.
In another aspect, the present disclosure provides a process for the preparation of hydrophobic binder composition.
The process comprises adding predetermined amounts of lime, a hydrophobic agent selected from a silane compound and a fatty acid, optionally at least one additive selected from a dispersant, a wetting agent, a deformer and a thickener, and optionally water under stirring at a predetermined speed for a predetermined time period to obtain the hydrophobic binder composition.
In accordance with the present disclosure, the lime is selected from the group consisting of slaked lime, hydrated lime and solid lime. In an exemplary embodiment, the lime is 44% solid lime which is matured for 20 days to 40 days. In an embodiment, the lime is slaked lime.
In accordance with the present disclosure, the lime is added in an amount in the range of 60 mass% to 85 mass% with respect to the total amount of the composition. In an exemplary embodiment, the lime is added in an amount of 65 mass% with respect to the total amount of the composition. In another exemplary embodiment, the lime is added in an amount of 80 mass% with respect to the total amount of the composition. In still another exemplary embodiment, the lime is added in an amount of 82 mass% with respect to the total amount of the composition. In yet another exemplary embodiment, the lime is added in an amount of 85 mass% with respect to the total amount of the composition.
In accordance with the present disclosure, the hydrophobic agent selected from the silane compound and the fatty acid is added in an amount in the range of 4 mass% to 30 mass% with respect to the total amount of the composition.
In accordance with the present disclosure, the silane compound is at least one selected from the group consisting of trimethylchlorosilane (TMCS), dichlorodimethylsilane (DCDMS), dichloro(methyl)phenylsilane (DCMPhS), 3-chloropropylmethyldichlorosilane (CPMDCS), (3, 3, 3-trifluoropropyl) dichloromethylsilane (TFDCMS), 3-aminopropyltrimethoxysilane (APTMS), vinyltrimethoxysilane (VTMO), 3-aminopropyltriethoxysilane (APTES), and vinyl tris(2-ethoxymethoxy) silane (VTEMS). In the exemplary embodiments, the silane compound is vinyltrimethoxysilane (VTMO).
In an embodiment, the silane compound is added in an amount in the range of 0 mass% to 8 mass% with respect to the total amount of the composition. In another embodiment, the silane compound is added in an amount in the range of 15 mass% to 30 mass% with respect to the total amount of the composition. In still another embodiment, the silane compound is added in an amount in the range of 10 mass% to 20 mass% with respect to the total amount of the composition. In an exemplary embodiment, the silane compound is added in an amount of 5 mass% with respect to the total amount of the composition. In another exemplary embodiment, the silane compound is added in an amount of 25 mass% with respect to the total amount of the composition. In still another exemplary embodiment, the silane compound is added in an amount of 14 mass% with respect to the total amount of the composition.
In accordance with the present disclosure, the fatty acid is selected from the group consisting of oleic acid, lauric acid, myristic acid, palmitic acid, palmitoleic acid, stearic acid, linoleic acid, a-linolenic acid, and arachidonic acid. In an exemplary embodiment, the fatty acid is an oleic acid.
In an embodiment, the fatty acid is added in an amount in the range of 4 mass% to 15 mass% with respect to the total amount of the composition. In an exemplary embodiment, the fatty acid is added in an amount of 6 mass% with respect to the total amount of the composition. In another exemplary embodiment, the fatty acid is added in an amount of 12 mass% with respect to the total amount of the composition. In still another exemplary embodiment, the fatty acid is added in an amount of 10 mass% with respect to the total amount of the composition.
In an embodiment, the additive is added in an amount in the range of 0 mass% to 15 mass% with respect to the total amount of the composition. The additive is selected from the group consisting of a dispersant, a wetting agent, a defoamer, and a thickener.
In accordance with the present disclosure, the dispersant is a polymeric carboxylic acid salt selected from sodium polyacrylate and ammonium polyacrylate. In an embodiment, the dispersant is ammonium polyacrylate. In an exemplary embodiment, the dispersant is Indofil 731TM.
In accordance with the present disclosure, the dispersant is added in an amount in the range of 0.5 mass% to 2 mass% with respect to the total amount of the composition. In the exemplary embodiment, the dispersant is added in an amount of 1 mass% with respect to the total amount of the composition.
In accordance with the present disclosure, the wetting agent is an alkylphenol ethoxylate free non-ionic surfactant selected from fatty acid alkoxylates and polyoxyethylene alkyl ethers. In an exemplary embodiment, the wetting agent is Nupol APF 115TM.
In an embodiment, the wetting agent is added in an amount in the range of 0.5 mass% to 3 mass% with respect to the total amount of the composition. In an exemplary embodiment, the wetting agent is added in an amount of 2 mass% with respect to the total amount of the composition. In another exemplary embodiment, the wetting agent is added in an amount of 1 mass% with respect to the total amount of the composition.
In accordance with the present disclosure, the defoamer is selected from alkylphenol ethoxylate free mineral oil based defoamer and silicone based defoamer. In an exemplary embodiment, the defoamer is mineral oil based defoamer.
In an embodiment, the defoamer is added in an amount in the range of 0.5 mass% to 2 mass% with respect to the total amount of the composition. In the exemplary embodiments, the defoamer is added in an amount of 1 mass% with respect to the total amount of the composition.
In accordance with the present disclosure, the thickener is hydroxyl ethyl cellulose solution. In an exemplary embodiment, the thickener is 1% aqueous solution of hydroxyl ethyl cellulose.
In an embodiment, the thickener is added in an amount in the range of 2 mass% to 8 mass% with respect to the total amount of the composition. In an exemplary embodiment, the thickener is added in an amount of 5 mass% with respect to the total amount of the composition.
In accordance with the present disclosure, water is added in an amount in the range of 0 mass% to 20 mass% with respect to the total amount of the composition. In an embodiment, water is added in an amount in the range of 5 to 15 mass% with respect to the total amount of the composition. In an exemplary embodiment, water is added in an amount of 15 mass% with respect to the total amount of the composition. In another exemplary embodiment, water is added in an amount of 10 mass% with respect to the total amount of the composition.
In accordance with the present disclosure, the speed of stirring is in the range of 500 rpm to 1500 rpm. In an exemplary embodiment, the speed of stirring is 1100 rpm for mixing lime. In the exemplary embodiment, the speed of stirring is 500 rpm during adding the dispersant, the wetting agent, and the deformer in lime. In the exemplary embodiment, the speed of stirring is 700 rpm which is gradually increased to 1300 rpm while adding the silane compound due to increase in viscosity. In the exemplary embodiment, the speed of stirring is 1100 rpm while adding the fatty acid. In the exemplary embodiment, the speed of stirring is 700 rpm while adding the thickener and water.
In accordance with the present disclosure, the predetermined time period is in the range of 1 hour to 3 hours. In an exemplary embodiment, the predetermined time period is 1 hour and 40 minutes. In another exemplary embodiment, the predetermined time period is 1 hour and 20 minutes. In still another exemplary embodiment, the predetermined time period is 1 hour. In still another exemplary embodiment, the predetermined time period is 1 hour and 10 minutes.
In an exemplary embodiment, lime is charged in a vessel followed by mixing under stirring at 1100 rpm for 18 minutes to obtain a homogenous lime. A dispersant, a wetting agent, and a defoamer are sequentially added in the homogeneous lime under stirring at 500 rpm for 20 minutes to obtain a free-flowing first mixture. A predetermined amount of silane is added in portions to the free-flowing mixture under stirring at 700 rpm followed by increasing the stirring speed to 1100 rpm and 1300 rpm, and allowed to stir for 22 minutes to obtain a second mixture. A predetermined amount of fatty acid is added to the second mixture under stirring at 1100 rpm for 18 minutes to obtain a third mixture. A thickener is added to the third mixture under stirring 700 rpm for 10 minutes to obtain a fourth mixture; and a predetermined amount of water is added to the fourth mixture under stirring at 700 rpm for 10 minutes to obtain hydrophobic binder composition.
In an embodiment, the sequential addition of the ingredients is required to keep the final composition in dispersed or suspended form.
In accordance with the present disclosure, the addition of silane compound during the process liberates heat and requires external cooling.
In accordance with the present disclosure, the route used for preparing the hydrophobic binder composition is selected from of a natural route, a synthetic route and a combination of natural route and synthetic route.
The natural route involves the use of fatty acid. The hydrophobicity of the composition is affected by the fatty acid. Further, the synthetic route involves the use of silanes. The silanes are used to treat slaked lime to improve hydrophobicity of the composition.
In accordance with the present disclosure, the hydrophobicity of the lime based binder composition depends on the structure of the alkyl chain in fatty acid. A longer alkyl chain in fatty acid increases the hydrophobicity. Additionally, the hydrophobicity is increased as the number of unsaturated parts increases. Fatty acids with branched structures is less hydrophobic than that with straight-chained structures. Fatty acids can be long-chain hydrocarbons with a carboxylic acid functional group. They are relatively long non-polar hydrocarbon chains and can be made hydrophobic.
In accordance with the present disclosure, the silane compounds react with inorganic surfaces to form metallo-siloxane covalent bonds for strong adhesion between silanes and inorganic substrates, while they react with polymers to form chemical bonds and interpenetrating polymer network (IPNs) for good silane/polymer adhesion.
For imparting hydrophobicity in the binder composition, the mechanism can entail the long-chain alkyl silanes replacing the H in the Si-OH groups through bonding with oxygen. Although silane and silicone-derived coatings can be very hydrophobic and can maintain a high degree of permeability to water vapor. This can allow coatings to breathe and reduce deterioration at the coating interface associated with entrapped water.
Conventionally, the lime is converted from the rock form to a paste form by using a process called slaking. To manufacture calcium hydroxide, the limestone calcium carbonate is converted to calcium oxide and the calcium oxide then converted to calcium hydroxide.
The following is a brief chemical formula of the slaking process:
(Limestone) CaCO3 + HEAT ? (Calcium Oxide) CaO + CO2
However, CaO is unstable in the presence of moisture and CO2. A more stable form of lime can be calcium hydroxide Ca(OH)2.
(Calcium Oxide) CaO + (Water) H2O ? Calcium Hydroxide Ca(OH)2 + HEAT.
This hydration process can be done with just the right amount of water and is called “Dry Hydration.” In this case, the hydrated material can be a dry powder. If excess water is used for hydration, the process is called “slaking”, and the resultant hydrate can be in a slurry form. Lime manufacturers can generally use the dry hydration process for producing powdered hydrated lime.
The slaking process can normally be done with considerably excess water ranging from 21/2 parts water to 1-part lime to 6 parts water to 1-part lime. The process of slaking can be continued and the Ca(OH)2 can be matured for 20 days to 40 days.
The foregoing description of the embodiments has been provided for purposes of illustration and is not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment but are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
The present disclosure is further illustrated herein below with the help of the following non-limiting examples. The experiments disclosed under these examples herein are intended merely to facilitate an understanding of how the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the experiments should not be construed as limiting the scope of embodiments herein. These laboratory-scale experiments can be scaled up to an industrial/ commercial scale and the results obtained can be extrapolated to industrial/ commercial scale.
EXPERIMENTAL DETAILS
The following ingredients were used during the process for the preparation of hydrophobic binder compositions.
Table 1: Ingredients used in the preparation of the hydrophobic binder composition
Ingredient A Lime 44% Solids (Matured for 21 Days)
Ingredient B Polymeric carboxylic acid salt for dispersion (Indofil 731TM)
Ingredient C APEO-free non-ionic surfactant for wetting (Nupol APF 115TM)
Ingredient D APEO free mineral oil based defoamer
Ingredient E Polymeric reactive organo silane
Ingredient F Fatty acid based on coconut oil
Ingredient G Hydroxy ethyl cellulose solution for thickening
Ingredient H Fatty acid based on oleic acid (Potassium oleate)
Ingredient I Silane compound
Ingredient J Fatty acid based on oleic acid neutralized by pH stabilizer
Ingredient K Polycarboxylate for dispersion

The following examples were experimentally tried to obtain the hydrophobic binder composition of the present disclosure.
Example 1: Process for the preparation of the hydrophobic binder composition in accordance with the present disclosure
The following steps were followed to obtain a hydrophobic binder composition in accordance with the present disclosure, which combines natural route and synthetic route for improving hydrophobicity in lime.
Ingredient A (lime) was charged into a vessel and mixed well at 1100 rpm for 18 minutes to achieve a uniform, homogeneous and free flowing consistency of lime. Ingredient B (polymeric carboxylic acid), Ingredient C (APEO-free non-ionic surfactant) and Ingredient D (APEO-free mineral oil based defoamer) were added sequentially one after another to the homogeneous lime under stirring at 500 rpm and mixed for 20 minutes to obtain a free flowing first mixture. Ingredient I (silane compound i.e. vinyl trimethoxy silane) was slowly added under medium speed of 700 rpm to the first mixture, as the addition progressed the viscosity was increased, and the speed was gradually increased to 1100 rpm. Due to exothermic reaction the temperature of material increases, and water circulation was necessary to control the temperature. Mixing was allowed for 22 minutes under high speed stirring (1300 rpm) to obtain a second mixture. Ingredient J (fatty acid based on oleic acid neutralized by pH stabilizer) was added to a second mixture under controlled stirring (1100 rpm) and further mixed for 18 minutes to obtain a third mixture. Ingredient G (1% hydroxy ethyl cellulose solution) was added to the third mixture under medium speed (700 rpm) and further mixed for 10 minutes to complete the process and to obtain a fourth mixture. Water was added to the fourth mixture under medium speed (700 rpm) and mixed for 10 minutes to obtain the hydrophobic binder composition in accordance with the present disclosure. The so obtained hydrophobic binder composition was sent to the QC lab.
Table 2 illustrates the amounts of the ingredients used to obtain the hydrophobic binder composition of the present disclosure.
Table 2: The amounts of the ingredients used in example 1
Ingredients Dosage (in %)
Ingredient A (Lime) 65
Ingredient B (dispersant - polymeric carboxylic acid ) 1
Ingredient C (wetting agent - non-ionic surfactant) 2
Ingredient D (mineral oil based defoamer) 1
Ingredient I (vinyl trimethoxy silane) 5
Ingredient J (fatty acid based on oleic acid neutralized by pH stabilizer) 6
Ingredient G (1% hydroxy ethyl cellulose solution) 5
Water 15

Table 3 illustrates the properties of the hydrophobic binder composition so obtained.
Table 3: Properties of the hydrophobic binder composition of the present disclosure
Parameter Result
Appearance White thick Paste
Solids 35 +/- 2 %
Contact Angle 134o
Hydrophobicity Developed after 3 days

The hydrophobic binder composition of the present disclosure demonstrated excellent hydrophobicity, and provided hydrophobicity faster than the compositions obtained by natural route. The hydrophobic binder composition was sustainable than synthetic route. The combination of natural and synthetic chemistry was used to produce the desired end result with respect to hydrophobicity, making the binder composition more sustainable than the compositions obtained by using purely synthetic route.
The hydrophobic binder composition of the present disclosure provided excellent stability, adhesion and high open time. The hydrophobic binder composition of the present disclosure was water reducer.
Example 2: Process for the preparation of a binder composition by natural route
The following steps were followed to obtain a binder composition by natural route:
• Ingredient A (lime) was charged into a vessel and mixed well for 18 minutes at 1100 rpm to achieve uniform and free flowing consistency of the ingredient A (lime).
• Ingredient B (polymeric carboxylic acid), Ingredient C (non-ionic surfactant) and Ingredient D (mineral oil based defoamer) were added sequentially one after another to Ingredient A (lime) under stirring at 500 rpm and mixed for 20 minutes to obtain a mixture having free-flowing consistency.
• Ingredient F (fatty acid based on coconut oil) was slowly added to the mixture under medium speed stirring and mixed for 35 minutes to obtain a resultant mixture.
• Ingredient G (hydroxy ethyl cellulose solution) was added under medium speed stirring of 900 rpm, and mixed it for 10 minutes to complete the process to obtain a binder composition A.
• The material so obtained binder composition A was sent to quality control (QC) lab.
Table 4 illustrates the amounts of the ingredients used to obtain the binder composition A by natural route.
Table 4: The amounts of the ingredients used to prepare binder composition A
Ingredients Dosage (in %)
Ingredient A (lime) 80
Ingredient B (dispersant - polymeric carboxylic acid) 1
Ingredient C (wetting agent - non-ionic surfactant) 1
Ingredient D (mineral oil based defoamer) 1
Ingredient F (fatty acid based on coconut oil) 12
Ingredient G (thickener - 1% hydroxy ethyl cellulose solution) 5

Table 5 illustrates the properties of the binder composition A.
Table 5: Properties of the binder composition A prepared by natural route
Parameter Result
Appearance White flowable liquid
Solids 34 +/- 2 %
Contact Angle 128o
Hydrophobicity developed after 7 days

Example 3: Process for the preparation of a binder composition by natural route
The following steps were performed to obtain a binder composition by natural route:
• Ingredient A (lime) was charged into the vessel and mixed well for 18 minutes at 1100 rpm to achieve uniform and free flowing consistency of Ingredient A (lime).
• Ingredient B (polymeric carboxylic acid), Ingredient C (non-ionic surfactant) and Ingredient D (mineral oil based defoamer) were added sequentially one after another to Ingredient A (lime) under stirring at 500 rpm and mixed for 20 minutes to obtain a mixture having free-flowing consistency.
• Ingredient H (potassium oleate) was slowly added to the mixture under medium-speed stirring and mixed for 35 minutes to obtain a resultant mixture.
• Ingredient G (1% hydroxy ethyl cellulose solution) was added to the resultant mixture under medium-speed stirring and mixed it for 10 minutes to complete the process, and to obtain a binder composition B.
• The so obtained binder composition B was sent to the QC lab.
Table 6 illustrates the amounts of the ingredients used to obtain the binder composition B.
Table 6: The amounts of the ingredients used in the binder composition B
Ingredient Dosage (in %)
Ingredient A (lime) 82
Ingredient B (dispersant - polymeric carboxylic acid) 1
Ingredient C (wetting agent - non-ionic surfactant) 1
Ingredient D (mineral oil based defoamer) 1
Ingredient H (potassium oleate) 10
Ingredient G (hydroxy ethyl cellulose solution) 5

Table 7 illustrates the properties of the binder composition B.
Table 7: Properties of the binder composition B prepared by natural route
Parameter Result
Appearance White flowable liquid
Solids 34 +/- 2 %
Contact Angle 126o
Hydrophobicity Developed after 7 days

Example 4: Process for the preparation of a binder composition by natural route
The following steps were followed to obtain a binder composition by natural route:
• Ingredient A (lime) was charged into the vessel and mixed well for 18 minutes at speed of 1100 rpm to achieve uniform and free flowing consistency of Ingredient A (lime).
• Ingredient B (polymeric carboxylic acid), Ingredient C (non-ionic surfactant) and Ingredient D (mineral oil based defoamer) were added sequentially one after another under stirring at 500 rpm to Ingredient A (lime), and mixed for 20 minutes to obtain a mixture having free flowing consistency.
• Ingredient J (fatty acid based on oleic acid neutralized by pH stabilizer) was slowly added to the mixture under medium-speed stirring and mixed it for 35 minutes to obtain a resultant mixture.
• Ingredient G (hydroxy ethyl cellulose solution) was added to the resultant mixture under medium-speed stirring and mixed for 10 minutes to complete the process and to obtain a binder composition C.
• The so obtained binder composition C was sent to the QC lab.
Table 8 illustrates the amounts of the ingredients used to obtain binder composition C.
Table 8: The amounts of the ingredients used to obtain binder composition C
Ingredients Dosage (in %)
Ingredient A (lime) 79
Ingredient B (dispersant - polymeric carboxylic acid) 1
Ingredient C (wetting agent - non-ionic surfactant) 2
Ingredient D (mineral oil based defoamer) 1
Ingredient J (fatty acid based on oleic acid neutralized by pH stabilizer) 12
Ingredient G (thickener - hydroxy ethyl cellulose solution) 5

Table 9 illustrates the properties of the binder composition C.
Table 9: Properties of the binder composition C prepared by using natural route
Parameter Result
Appearance White flowable liquid
Solids 34 +/- 2 %
Contact Angle 125o
Hydrophobicity developed after 7 days

The binder compositions A, B and C are the natural, yielding good hydrophobicity and are sustainable, but requires longer time to develop hydrophobicity.
Example 5: Process for the preparation of a binder composition by synthetic route
The following steps were followed to obtain a binder composition D by synthetic route:
• Ingredient A (lime) was charged into the vessel and mixed well at a speed in the range of 1000 to 12000 rpm for 15 to 20 minutes to achieve a uniform and free flowing consistency of Ingredient A (lime).
• Water was added to Ingredient A (lime) and mixed for 10 minutes at slow speed stirring in the range of 800 rpm to 1000 rpm to obtain a mixture.
• Ingredient E (polymeric reactive organo silane) was added to the mixture under slow-speed stirring (400 to 600 RPM) and mixed well for 30 to 40 minutes to obtain a resultant mixture.
• The so obtained binder composition D was sent to the QC lab.
Table 10 illustrates the amounts of the ingredients used to obtain the binder composition D.
Table 10: The amounts of the ingredients used to obtain the binder composition D by synthetic route
Ingredients Dosage (in %)
Ingredient A (lime) 65
Water 10
Ingredient E (polymeric reactive organo silane) 25

Table 11 illustrates the properties of the binder composition D.
Table 11: Properties of the binder composition D prepared by synthetic route
Parameter Result
Appearance White flowable liquid Solids
Solids 34 +/- 2 %
Contact Angle 135o
Hydrophobicity developed after 3 days

The binder composition D showed excellent hydrophobicity, which developed hydrophobicity faster than binder compositions A, B and C. However, the product D was obtained through synthetic route and was less sustainable.
Example 6: Process for the preparation of a binder composition by synthetic route
The following steps were followed to obtain a binder composition by synthetic route:
• Ingredient A (lime) was charged into a vessel and mixed well at 1100 rpm for 18 minutes to achieve a uniform and free flowing consistency of Ingredient A (lime)
• Ingredient K (polycarboxylate) was added to Ingredient A (lime) at slow speed (500 rpm) mixed for 10 minutes to obtain a mixture.
• Ingredient I (silane) was added to the mixture under high speed (900 rpm) and mix well for 35 minutes to obtain a resultant mixture.
• The so obtained binder composition E was sent to the QC lab.
Table 12 illustrates the amounts of the ingredients used to obtain the binder composition E.
Table 12: The amounts of the ingredients used for preparing the binder composition E by synthetic route
Ingredients Dosage (in %)
Ingredient A (lime) 85
Ingredient K (dispersant - polycarboxylate) 1
Ingredient I (silane compound) 14

Table 13 illustrates the properties of the binder composition E.
Table 13: Properties of the binder composition E prepared by using the synthetic route
Parameter Result
Appearance White thick Paste
Solids 48 +/- 2 %
Contact Angle 140o
Hydrophobicity Within 24 hours

The binder composition E so obtained was super hydrophobic, providing dewdrop/lotus leaf effect. The binder composition E provided excellent stability, adhesion and high open time. The binder composition E was water reducer. The binder composition E was less sustainable and employed a synthetic route.
TECHNICAL ADVANCEMENTS
The present disclosure described herein above has several technical advantages including, but not limited to, the realization of:
a hydrophobic binder composition that:
- is sustainable;
- has excellent hydrophobicity; and
- can develop hydrophobicity faster;
and
a process for the preparation of hydrophobic binder composition that:
- is sustainable; and
- is simple and economical.
The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
The foregoing description of the specific embodiments so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.
Throughout this specification the word “comprise”, or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.
The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.
Any discussion of documents, acts, materials, devices, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.
The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations and it is envisaged that the values higher/lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation. ,CLAIMS:WE CLAIM:
1. A hydrophobic binder composition comprises
(i) 60 mass% to 85 mass% of lime;
(ii) 4 mass% to 30 mass% of a hydrophobic agent selected from a silane compound and a fatty acid;
(iii) 0 mass% to 15 mass% of at least one additive selected from the group consisting of a dispersant, a wetting agent, a defoamer, and a thickener; and
(iv) 0 mass% to 20 mass% of water.
2. The composition as claimed in claim 1 comprises
i) 60 mass% to 85 mass% of lime;
ii) 0 mass% to 8 mass% of a silane compound;
iii) 4 mass% to 15 mass% of a fatty acid;
iv) 0.5 mass% to 2 mass% of a dispersant;
v) 0.5 mass% to 3 mass% of a wetting agent;
vi) 0.5 mass% to 2 mass% of a defoamer;
vii) 2 mass% to 8 mass% of a thickener; and
viii) 0 mass% to 20 mass% of water.
3. The composition as claimed in claim 1 comprises
i) 60 mass% to 80 mass% of lime;
ii) 15 mass% to 30 mass% of a silane compound; and
iii) 5 mass% to 15 mass% of water.
4. The composition as claimed in claim 1 comprises
i) 60 mass% to 85 mass% of lime;
ii) 10 mass% to 20 mass% of a silane compound; and
iii) 0.5 mass% to 2 mass% of a dispersant.
5. The composition as claimed in claim 1, wherein said lime is selected from the group consisting of slaked lime, hydrated lime and solid lime.
6. The composition as claimed in claim 1, wherein said dispersant is a polymeric carboxylic acid salt selected from sodium polyacrylate and ammonium polyacrylate.
7. The composition as claimed in claim 1, wherein said wetting agent is an alkylphenol ethoxylate free non-ionic surfactant selected from fatty acid alkoxylate and polyoxyethylene alkyl ether.
8. The composition as claimed in claim 1, wherein said defoamer is selected from alkylphenol ethoxylate free mineral oil based defoamer and silicone based defoamer.
9. The composition as claimed in claim 1, wherein said silane compound is at least one selected from the group consisting of trimethylchlorosilane (TMCS), dichlorodimethylsilane (DCDMS), dichloro(methyl)phenylsilane (DCMPhS), 3-chloropropylmethyldichlorosilane (CPMDCS), (3, 3, 3-trifluoropropyl) dichloromethylsilane (TFDCMS), 3-aminopropyltrimethoxysilane (APTMS), vinyltrimethoxysilane (VTMO), 3-aminopropyltriethoxysilane (APTES), and vinyl tris(2-ethoxymethoxy) silane (VTEMS).
10. The composition as claimed in claim 1, wherein said fatty acid is selected from the group consisting of oleic acid, lauric acid, myristic acid, palmitic acid, palmitoleic acid, stearic acid, linoleic acid, a-linolenic acid, and arachidonic acid.
11. The composition as claimed in claim 1, wherein said thickener is hydroxyl ethyl cellulose solution.
12. The composition as claimed in claim 1, wherein said composition is characterized by at least one of
(a) contact angle in the range of 125o to 140o, and
(b) time for developing hydrophobicity is in the range of 1 day to 7 days.
13. A process for the preparation of hydrophobic binder composition as claimed in claim 1, said process comprises adding predetermined amounts of lime, a hydrophobic agent selected from a silane compound and a fatty acid, optionally at least one additive selected from a dispersant, a wetting agent, a deformer and a thickener, and optionally water under stirring at a predetermined speed for a predetermined time period to obtain said hydrophobic binder composition.
14. The process as claimed in claim 13, wherein said predetermined speed is in the range of 500 rpm to 1500 rpm; and said predetermined time period is in the range of 1 hour to 3 hours.

Dated this 11th Day of December 2024

_______________________________
MOHAN RAJKUMAR DEWAN, IN/PA – 25
OF R. K. DEWAN & CO.
AUTHORIZED AGENT OF APPLICANT

TO,
THE CONTROLLER OF PATENTS
THE PATENT OFFICE, AT MUMBAI