Melt processing recovery of high purity polymeric antioxidants

Claim 2

The process for recovering a diolefin-phenolic copolymer antioxidant from a crude condensation reaction product containing the copolymer, reaction solvent, catalyst and monomers and polymeric contaminants having a molecular weight below about 500 Daltons which comprises: A. removing catalyst from the reaction product and adjusting the reaction solvent content into the range of up to 50%w to yield an adjusted reaction product, B. fusing the adjusted reaction product and maintaining the fused product at a surface area of not less than 4 cm 2 per gram, a temperature of from 200° C. to 425° C. and an absolute pressure of from 0.1 to 10 mm Hg for from 0.5 to 7.5 minutes thereby forming an overhead fraction comprising solvent, monomers and low molecular weight polymeric contaminants and a bottoms fraction consisting essentially of the copolymer antioxidant and, C. recovering the copolymer antioxidant-containing bottoms fraction.

Claim 3

The process of claim 1 wherein the reaction solvent content of the crude condensates reaction product is over 50%w and, wherein in Step A the reaction solvent content is adjusted by stripping into the range of 10-50%w.

Claim 4

The process of claim 2 wherein in Step B the temperature in the range of from 250° to 400° C., the pressure is from 0.1 to 5 mm Hg.

Claim 5

The process for recovering a diolefin-phenolic copolymer antioxidant contaminated with not more than 0.3% of materials having a molecular weight less than 500 Daltons from a condensation polymerization reaction product comprising the copolymer antioxidant, greater than 50%w basis reaction product of reaction solvent, greater than 4000 ppm basis antioxidant of unreacted phenolic and diolefinic monomers, greater than 3% (basis antioxidant) of condensation products having a molecular weight less than 500 and a polymerization catalyst; which process comprises the steps of: A. removing the polymerization catalyst by extraction with aqueous mineral acid and stripping reaction solvent from the reaction product to adjust the solvent level to from 10% to 50%w basis reaction product to form a catalyst-free reaction product. B. maintaining the catalyst-free reaction product as a melt at a temperature of from 250° C. to 400° C. at an absolute pressure of from 0.1 mm Hg to 5 mm Hg at a surface area of the melt of from 6 cm 2 /gram to 30 cm 2 /gram for from 1 to 5 minutes to form an overhead fraction composed of solvents, monomers and low molecular weight contaminants and a bottoms fraction consisting essentially of the diolefin-phenolic copolymer antioxidant and not more than 50 ppm of solvents and not more than 0.3% by weight having a molecular weight less than 500 Daltons and C. separating and recovering the bottoms fraction.

Claim 6

The process for recovering a diolefin-phenolic copolymer antioxidant contaminated with not more than 0.3% of materials having a molecular weight less than 500 Daltons from a condensation polymerization reaction product comprising the copolymer antioxidant, greater than 50%w basis reaction product of reaction solvent, greater than 4000 ppm basis antioxidant of unreacted phenolic and diolefinic monomers, greater than 3% (basis antioxidant) of condensation products having a molecular weight less than 500 and a polymerization catalyst; which process comprises the steps of: A. removing the polymerization catalyst by extraction with aqueous mineral acid and stripping reaction solvent from the reaction product to adjust the solvent level to from 10% to 50%w basis reaction product to form a catalyst-free reaction product. B. maintaining the catalyst-free reaction product as a melt at a temperature of from 250° C. to 400° C. at an absolute pressure of from 0.1 mm Hg to 5 mm Hg at a surface area of the melt of from 6 cm 2 /gram to 30 cm 2 /gram for from 1 to 5 minutes to form an overhead fraction composed of solvents, monomers and low molecular weight contaminants and a bottoms fraction consisting essentially of the diolefin-phenolic copolymer antioxidant and not more than 50 ppm of solvents and not more than 0.3% by weight having a molecular weight less than 500 Daltons and C. separating and recovering the bottoms fraction.

Claim 7

The process of claim 4 wherein step B is effected in a wiped film evaporator.

Claim 8

The process of claim 5 wherein the diolefin-phenolic copolymer antioxidant comprises the following constituents:divinylbenzene, tertiarybutylhydroquinone and paracresol.

Claim 9

The process of claim 6 wherein the antioxidant additionally comprises hydroxyanisole, tertiarybutylphenol and bisphenol A.

Claim 10

A diolefin-phenolic copolymeric antioxidant characterized as containing not more than 0.3% by weight of materials having a molecular weight below 500 Daltons and from 3 to 10% by weight of materials having a molecular weight between 500 and 1000 Daltons, said antioxidant being the product of the process which comprises: A. condensing a diolefin and one or more phenolic oxyhydrocarbons in the presence of a catalyst to yield a crude condensation reaction product comprising the copolymer antioxidant, reaction solvent, catalyst and monomers and polymeric contaminants having a molecular weight below 500 Daltons, B. removing catalyst from the reaction product and adjusting the reaction solvent content into the range of up to 50%w to yield an adjusted reaction product, C. fusing the adjusted reaction product and maintaining the fused product at a surface area of not less than 4 cm 2 per gram, a temperature of from 200° C. to 425° C. and an absolute pressure of from 0.1 to 10 mm Hg for from 0.5 to 7.5 minutes thereby forming an overhead fraction comprising solvent, monomers and low molecular weight polymeric contaminants and a bottoms fraction consisting essentially of the copolymer antioxidant and, D. recovering the copolymer antioxidant-containing bottoms fraction.

Claim 11

A diolefin-phenolic copolymeric antioxidant characterized as containing not more than 0.3% by weight of materials having a molecular weight below 500 Daltons and from 3 to 10% by weight of materials having a molecular weight between 500 and 1000 Daltons, said antioxidant being the product of the process which comprises: A. condensing a diolefin and one or more phenolic oxyhydrocarbons in the presence of a catalyst to yield a crude condensation reaction product comprising the copolymer antioxidant, reaction solvent, catalyst and monomers and polymeric contaminants having a molecular weight below 500 Daltons, B. removing catalyst from the reaction product and adjusting the reaction solvent content into the range of up to 50%w to yield an adjusted reaction product, C. fusing the adjusted reaction product and maintaining the fused product at a surface area of not less than 4 cm 2 per gram, a temperature of from 200° C. to 425° C. and an absolute pressure of from 0.1 to 10 mm Hg for from 0.5 to 7.5 minutes thereby forming an overhead fraction comprising solvent, monomers and low molecular weight polymeric contaminants and a bottoms fraction consisting essentially of the copolymer antioxidant and, D. recovering the copolymer antioxidant-containing bottoms fraction.