CYCLOHEXANE OXIDATION PROCESS BYPRODUCT STREAM DERIVATIVES AND METHODS FOR USING THE SAME
Disclosed are ester compositions, solvents, cleaning formulations, curing agents, reactive diluent solvents, controlled acid function release agents, polyol monomers, drilling mud, methods of making each of the above, methods of using each of the above. In one embodiment, the ester composition is obtained from a process applied to a starting material, wherein the starting material is a portion of products from a cyclohexane oxidation process, wherein the starting material includes products having free acid functional groups, wherein the starting material is selected from the group consisting of a water extract (Water Wash), a concentrated water extract (COP Acid), a non-volatile residue (NVR), and a combination thereof.
1 ) A composition comprising esters, wherein the composition is obtained from a process applied to a starting material, wherein the starting material is a portion of products from a cyclohexane oxidation process, wherein the starting material includes products having free acid functional groups, wherein the starting material is selected from the group consisting of:
a water extract (Water Wash),
a concentrated water extract (COP Acid),
a non-volatile residue (NVR), and
a combination thereof;
wherein the process includes the steps of:
i) converting free acid functional groups of the products to monomeric esters and oligomeric esters, and
ii) converting oligomeric esters to monomeric esters.
2 ) The composition of claim 1 , wherein the esters are hydrocarbyl esters.
3 ) The composition of claim 1 , wherein the esters are methyl esters.
4 ) The composition of any of claims 1 to 3 , further comprising the step of:
iii) dehydrating the portion of products from a cyclohexane oxidation process.
5 ) The composition of any of claims 1 to 4 , further comprising the steps of:
iv) neutralizing a catalyst, and
v) isolating the composition by distillation.
6 ) A solvent comprising the composition of at least one of claims 1 to 5 .
7 ) A curing agent comprising the composition of at least one of claims 1 to 5 .
8 ) A drilling mud comprising the composition of at least one of claims 1 to 5 .
9 ) A paint remover comprising the composition of at least one of claims 1 to 5 .
10 ) A photoresist stripper suitable for use in electronics manufacturing comprising the composition of at least one of claims 1 to 5 .
11 ) A graffiti remover comprising the composition of at least one of claims 1 to 5 .
12 ) A cleaner comprising the composition of at least one of claims 1 to 5 .
13 ) The cleaner of claim 12 , formulated for use in at least one end-use selected from the group consisting of: a consumer application, an institutional application, and an industrial cleaning application.
14 ) A method for dissolving a resin comprising contacting the resin with a solvent comprising one or more of the compositions of claims 1 to 5 .
15 ) The method of claim 14 , wherein said resin is a component of at least one selected from the group consisting of: a coating, an ink, an adhesive, a sealant, a composite, and a binder system.
16 ) The method of claim 14 , wherein said resin comprises a phenolic resin.
17 ) The method of claim 16 , wherein said phenolic resin is suitable for use in a refractory binder system or a foundry binder system.
18 ) The method of claim 14 , wherein said resin is selected from the group consisting of: a phenolic resin, a polyester resin, a polyurethane resin, an epoxy resin, a phenoxy resin, a styrenic resin, a copolymer of a styrenic resin with maleic anhydride, an acrylonitrile or a combination of each, an acrylic resin, a methacrylic resin, a polyvinylbutyral resin, a vinylidene halide resin including a vinylidene fluoride, and a vinylic resin including a vinyl chloride, a vinyl acetate, and a combination thereof.
19 ) The method of claim 14 , wherein said resin is selected from the group consisting of: a urethane, a urethane polymer, and a urethane copolymer.
20 ) A method for hardening a friable substrate comprising the steps of:
a) applying an aqueous solution comprising sodium silicate to said friable substrate;
b) curing said sodium silicate in contact with said friable substrate by applying one or more of the compositions of claims 1 to 5 ;
wherein the aqueous solution comprising sodium silicate and the one or more of the compositions of claims 1 to 5 are applied together, separately, or separately in sequence.
21 ) The method of claim 20 , wherein said friable substrate is a component of a binder for foundry castings.
22 ) The method of claim 20 , wherein said friable substrate is selected from the group consisting of: a soil, a grout, a drilling fluid, and a briquette.
23 ) A method comprising the steps of:
a) providing a starting material recovered from a cyclohexane oxidation process, wherein the starting material includes products having free acid functional groups, wherein the starting material is selected from the group consisting of:
a water extract (Water Wash),
a concentrated water extract (COP Acid),
a non-volatile residue (NVR), and
a combination thereof;
b) wherein the method includes the steps of:
i) converting free acid functional groups of the products to monomeric esters and oligomeric esters, and
ii) converting oligomeric esters to monomeric esters; and
c) recovering a composition comprising methyl hydroxycaproate and dimethyl adipate from at least one of steps (b)(i) and (b)(ii), above.
24 ) A polyester prepared from precursors comprising the composition of at least one of claims 1 to 5 .
25 ) A polyester polyol prepared from precursors comprising the composition of at least one of claims 1 to 5 .
26 ) The method of claim 20 wherein said friable substrate comprises waste metal.
27 ) The method of claim 20 wherein said hardening method produces a briquette containing waste metal.
28 ) The solvent of claim 6 , further comprising a co-solvent.
29 ) The solvent of claim 28 , wherein the co-solvent is ethyl 3-ethoxypropionate.
30 ) The method of claim 14 , wherein the solvent includes a co-solvent.
31 ) The method of claim 30 , wherein the co-solvent is ethyl 3-ethoxypropionate.