Process for preparing cation exchange resins having improved stability

0001This invention relates to a process for preparing cation exchange resins having improved stability. More specifically, it relates to a method of improving the stability of cation exchange resins.

0002Cation exchange resins are useful for such applications as water treatment, for example, water softening and water deionization for powerplant boilers (often referred to as "condensate polishing"); chemical purification of food and pharmaceutical products by chromatographic separation, for example, separating fructose from glucose in the production of high fructose corn syrup; and catalysis. Unfortunately, the resins decompose over time and release organic and inorganic impurities into the process stream. Measurable decomposition products may contaminate the process stream and prevent continued use of the resin for a given application.

0003The decomposition of cation exchange resins is caused by oxidation of the crosslinked, copolymer matrix. The copolymer matrix breaks up as the polymer chains fragment to form various decomposition products, which are described in Stahlbush et al., "Prediction and Identification of Leachables from Cation Exchange Resins", <u>Proceedings of the 48th International Water Conference</u> (held Nov. 2-4, 1987). In addition to introducing decomposition products into the process stream, the decomposition of the resin may also adversely affect its chemical and physical properties. For example, the wet-volume capacity and the crush strength of the resin may be reduced.

0004The rate of release of decomposition products from the resin can vary significantly depending on the amount of crosslinking present in the copolymer matrix and the ionic form of the resin. Generally, the rate of release increases as the level of crosslinking decreases. The hydrogen form of the resin is typically more stable than other ionic forms of the resin, such as the calcium, sodium or ammonium forms of the resin. Therefore, resins in ionic forms other than the hydrogen form and with low levels of crosslinking are most susceptible to unacceptably high rates of decomposition. Unfortunately, resins with these characteristics are often required for numerous applications. For example, a cation exchange resin in the calcium form with low levels of crosslinking is the preferred resin for the chromatographic separation of fructose from glucose in the production of high fructose corn syrup. However, even resins with minimal rates of decomposition may be unsuitable for certain applications if trace amounts of decomposition products in the process stream cannot be tolerated.

0005Attempts have been made to improve the oxidation resistance of cation exchange resins. U.S. Patent No. 3,342,755 discloses halogenating the cross linked copolymer matrix before functionalising the resin to increase oxidation resistance. Unfortunately, large amounts of halogenating agents are required for significant improvements.

0006CS-A-235485 discloses a method of protecting the active surfaces of ion exchange resins from degradation during grinding which comprises the treatment of the resin particles with an antioxidant. The specification is not directed to the prevention of the degradation of the copolymer matrix of the ion exchange resins during use.

0007Encyclopaedia of Polymer Science and Engineering, Volume 2, pages 73 to 91, discusses the use of antioxidants in polymers and discloses the use of hindered phenol antioxidants to protect thermoplastic polymers during processing and in use. These antioxidants are taught only for use in polymers without functional groups on the benzene ring, such as acrylonitrile-butadiene-styrene (ABS).

0008In view of the lack of an available method in the prior art to increase the stability of cation exchange resins, a method of improving the stability of a cation exchange resin is needed.

0009Accordingly, the present invention provides the use of a substituted monohydroxy benzene antioxidant in preparing a stabilised cation exchange resin comprising a copolymer matrix of a monovinyl aromatic monomer and a divinyl aromatic monomer which is functionalised with sulfonic acid groups, in order to reduce the amount of copolymer matrix decomposition products released during use, the substituted monohydroxy benzene being incorporated into the cation exchange resin in an amount of at least 0.001 percent by weight based on the weight of the cation exchange resin.

0010The incorporation of the antioxidant into the cation exchange resin improves the stability of the resin relative to a resin which has not been treated with an antioxidant. The improved resins of this invention are useful in those applications where conventional cation exchange resins are used, especially in those applications where resin in an ionic form other than hydrogen and with low levels of cross linking are preferred.

0011Processes for preparing cation exchange resins are well known in the art, as exemplified in Helfferich. <u>Ion Exchange</u>, McGraw-Hill Book Co., Inc., pp. 26-47 (1962). Advantageously, the resins are prepared by first copolymerizing a monovinyl aromatic monomer and a divinyl aromatic monomer to prepare a cross linked copolymer matrix, and then functionalising the copolymer matrix with groups which can exchange cations. Preferred monovinyl aromatic monomers include styrene and its derivatives. Preferred divinyl aromatic monomers include divinylbenzene (DVB) (commercially available DVB containing less than about 45 weight percent ethylvinylbenzene). The copolymer matrix is functionalised with sulfonic acid groups.

0012For purposes of describing this invention, the "stability" of the resin refers to the resin's ability to withstand decomposition during use. Since decomposition is primarily caused by oxidation, a stable resin resists oxidation. Improving the stability of the resin enhances the resin's ability to withstand decomposition, and therefore increases its resistance to oxidation.

0013The antioxidants useful in the practice of this invention is a substituted monohydroxy benzene. Suitable substituents include straight or branched C_1-19 alkyl, preferably straight or branched C_1-4 alkyl; methoxy or ethoxy; <chemistry id="chem0001" num="0001"><img file="EP0366258B1_D0001.tif" /></chemistry> wherein R is straight or branched C_1-19 alkyl, preferably C_1-6 alkyl; each R¹ is independently hydrogen or straight or branched C_1-19 alkyl, preferably hydrogen or straight or branched C_1-4 alkyl; and R² is hydrogen or straight or branched C_1-19 alkyl, preferably hydrogen or C_1-6 alkyl.

0014Preferably, the monohydroxy benzene is substituted with one or more t-butyl groups, e.g. 3-t-butyl-4-methoxyphenol. A more preferred monohydroxy benzene is substituted with one or more t-butyl groups on at least one position ortho to the hydroxy group, preferably on each ortho position. Examples include 2,6-di-t-butyl-4-methylphenol (BHT); 2-t-butyl-4-methoxyphenol; 2,6-di-t-butyl-α-dimethylamino-p-cresol; and calcium bis (0-ethyl-(3,5-di-t-butyl-4-hydroxybenzyl)phosphonate). The most preferred antioxidants are BHT and 2,6-di-t-butyl-α-dimethylamino-p-cresol.

0015The resin and the antioxidant must be contacted in a manner which provides for substantial incorporation of the antioxidant into the resin. The antioxidant is "substantially incorporated" into the resin when a substantial amount of antioxidant is embodied by and remains fixed within the resin, so that an increase in the resin's stability is achieved to the extent necessary or desired. Advantageously, at least about 50 percent by weight of the applied antioxidant is incorporated into the resin. Preferably, at least about 80 percent, more preferably 90 percent, and most preferably 95 percent of the applied antioxidant is incorporated into the resin.

0016Typically, the antioxidant is dissolved in an appropriate nonreacting solvent and then the antioxidant solution is contacted with the resin for a sufficient time period to substantially incorporate the antioxidant into the resin. The resin can be hydrated, or alternatively, it can be dried before contact is made.

0017When the antioxidant is a polar compound, it can typically be dissolved in water. If it can act as a nucleophile, it can react with the functional groups of the resin to promote an ionic interaction between the resin and antioxidant. For example, the ionic interaction between a sulfonated resin in the hydrogen form and 2,6-di-t-butyl-α-dimethylamino-p-cresol can be represented as follows: <chemistry id="chem0002" num="0002"><img file="EP0366258B1_D0002.tif" /></chemistry>

0018When the antioxidant is nonpolar, it is desirable to imbibe the resin with an antioxidant solution. The imbibed resin is dried to evaporate the nonreacting diluent, and then hydrated to promote further precipitation of the antioxidant. In this manner, the antioxidant becomes entrapped within the micropores of the resin.

0019An effective amount of antioxidant must be substantially incorporated into the resin to improve the stability of the resin. This amount can be determined empirically and depends on the extent of improvement desired and the effectiveness of the specific antioxidant being used. The preferred concentration of antioxidant substantially incorporated into the resin can range from 0.001 to 10, preferably from 0.01 to 0.5 percent by weight. The most preferred range is from 0.01 to 0.2 percent by weight.

0020If an antioxidant solution is contacted with the resin, the preferred volume ratio for contact between the antioxidant solution and the resin can range from 1:3 to 5:1, preferably from 1:2 to 2:1. A volume ratio less than 1:3 is usually insufficient to promote intimate contact with the total surface area of the resin and a volume ratio greater than 5:1 requires excessive nonreactive diluent which must be removed and in many instances recovered. The concentration of antioxidant in solution can vary over a wide range and depends in part on the volume ratio of antioxidant to resin and the weight percent of antioxidant incorporated into the resin.

0021The antioxidant and resin can be contacted at any temperature below which degradation of either component can occur. Temperatures greater than room temperature increase the rate of diffusion of the antioxidant into the resin. The preferred contact temperature can range from 20°C to 80°C. The time required for contact can be readily determined empirically.

0022The following examples illustrate this invention.

<b>Example 1</b>

0023For each of three runs, a cation exchange resin was prepared by heating 100 grams (g) of a crosslinked copolymer (styrene/DVB gel copolymer containing 0.75 percent DVB) in 2,000 g 99 percent sulfuric acid and 40 g methylene chloride at 100°C for 60 minutes. The reaction mixture was cooled and the resin was washed with water. The resin prepared for the first run contained 90.3 percent water by weight and had a dry weight capacity of 5.18 moles per kilogram.

0024For each of the three runs, an antioxidant (2,6-di-t-butyl-α-dimethylamino-p-cresol, sold commercially by the Ethyl Corporation as Ethanox® 703) was incorporated into the cation exchange resin.

0025For the first run, 100 ml of a 0.1 percent aqueous antioxidant solution was stirred with 100 ml (80.0 g) of resin for 30 minutes. The resin was separated from the solution and washed with water. 99 Percent of the antioxidant was incorporated into the resin based on the level of total organic carbon (TOC) in the aqueous solution before and after the 30 minute contact time. The resin contained 0.125 percent of the antioxidant by weight.

0026For the second run, 100 ml of a 0.03 percent aqueous antioxidant solution was stirred with 100 ml of resin. Similarly, for the third run, 100 ml of a 0.01 percent aqueous antioxidant solution was stirred with 100 ml of resin. The resin for the second and third runs contained 0.036 percent and 0.012 percent of the antioxidant, respectively.

0027The stability of the resins prepared for each run was determined using an accelerated aging test. Each resin was stirred and heated in 500 ml of DI water at 80°C while oxygen was continuously purged at 50-60 cc/minute through the water. The TOC of the water was measured at different times to determine the amount of decomposition products released from the resin. The stability of the resins was compared with the stability of an untreated resin. The results appear in Table 1. <tables id="tabl0001" num="0001"><table frame="all"><title>TABLE I</title><tgroup cols="7" colsep="1" rowsep="1"><colspec colnum="1" colname="col1" colwidth="22.50mm" colsep="1" /><colspec colnum="2" colname="col2" colwidth="22.50mm" /><colspec colnum="3" colname="col3" colwidth="22.50mm" /><colspec colnum="4" colname="col4" colwidth="22.50mm" /><colspec colnum="5" colname="col5" colwidth="22.50mm" /><colspec colnum="6" colname="col6" colwidth="22.50mm" /><colspec colnum="7" colname="col7" colwidth="22.50mm" /><thead valign="top"><row><entry namest="col1" nameend="col7" align="center">Stability of Cation Exchange Resin In Hydrogen Form Incorporating Antioxidant</entry></row><row><entry namest="col1" nameend="col1" rowsep="0" align="center">Concentration of Antioxidant¹ in Resin, Weight Percent</entry><entry namest="col2" nameend="col7" align="center">Resin Decomposition Products Solution TOC² (ppm)</entry></row><row rowsep="1"><entry namest="col1" nameend="col1" /><entry namest="col2" nameend="col2" align="center">1 day</entry><entry namest="col3" nameend="col3" align="center">2 days</entry><entry namest="col4" nameend="col4" align="center">3 days</entry><entry namest="col5" nameend="col5" align="center">4 days</entry><entry namest="col6" nameend="col6" align="center">5 days</entry><entry namest="col7" nameend="col7" align="center">7 days</entry></row></thead><tbody valign="top"><row><entry namest="col1" nameend="col1" align="left">none³</entry><entry namest="col2" nameend="col2" align="right">20</entry><entry namest="col3" nameend="col3" align="right">200</entry><entry namest="col4" nameend="col4" align="right">970</entry><entry namest="col5" nameend="col5" align="right">2300</entry><entry namest="col6" nameend="col6" align="right">no data</entry><entry namest="col7" nameend="col7" align="center">no data</entry></row><row><entry namest="col1" nameend="col1" align="char" char=".">0.125</entry><entry namest="col2" nameend="col2" align="right">12</entry><entry namest="col3" nameend="col3" align="right">15</entry><entry namest="col4" nameend="col4" align="right">17</entry><entry namest="col5" nameend="col5" align="right">21</entry><entry namest="col6" nameend="col6" align="right">29</entry><entry namest="col7" nameend="col7" align="center">no data</entry></row><row><entry namest="col1" nameend="col1" align="char" char=".">0.036</entry><entry namest="col2" nameend="col2" align="right">12</entry><entry namest="col3" nameend="col3" align="right">14</entry><entry namest="col4" nameend="col4" align="right">22</entry><entry namest="col5" nameend="col5" align="right">28</entry><entry namest="col6" nameend="col6" align="right">36</entry><entry namest="col7" nameend="col7" align="center">48</entry></row><row rowsep="1"><entry namest="col1" nameend="col1" align="char" char=".">0.012</entry><entry namest="col2" nameend="col2" align="right">36</entry><entry namest="col3" nameend="col3" align="right">52</entry><entry namest="col4" nameend="col4" align="right">72</entry><entry namest="col5" nameend="col5" align="right">100</entry><entry namest="col6" nameend="col6" align="right">122</entry><entry namest="col7" nameend="col7" align="center">260</entry></row></tbody></tgroup><tgroup cols="7" colsep="0" rowsep="0"><colspec colnum="1" colname="col1" colwidth="22.50mm" /><colspec colnum="2" colname="col2" colwidth="22.50mm" /><colspec colnum="3" colname="col3" colwidth="22.50mm" /><colspec colnum="4" colname="col4" colwidth="22.50mm" /><colspec colnum="5" colname="col5" colwidth="22.50mm" /><colspec colnum="6" colname="col6" colwidth="22.50mm" /><colspec colnum="7" colname="col7" colwidth="22.50mm" /><tbody valign="top"><row><entry namest="col1" nameend="col7" align="justify">¹Ethanox® 703</entry></row><row><entry namest="col1" nameend="col7" align="justify">²Determined using a Model 700 TOC analyzer sold by O.I. Corporation</entry></row><row><entry namest="col1" nameend="col7" align="justify">³Not an example of this invention</entry></row></tbody></tgroup></table></tables>

0028The results indicate that the resins treated with the antioxidant release lower amounts of decomposition products relative to an untreated resin. Therefore, the stability of the resins improves when an antioxidant is incorporated into the resin.

<b>Example 2</b>

0029For each of three runs, varying amounts of an antioxidant (2,6-di-t-butyl-α-dimethylamino-p-cresol) were incorporated into a styrene/DVB gel cation exchange resin sold commercially by The Dow Chemical Company under the trademark DOWEX MONOSPHERE® 99.

0030For the first run, 100 ml of a 0.1 percent aqueous antioxidant solution was placed in a bottle with 100 ml (82.0 g) of the hydrogen form of the resin. The mixture was shaken in an Eberbach shaker for 30 minutes and the solution was filtered from the resin to remove any excess antioxidant not incorporated into the resin. 99 Percent of the antioxidant was incorporated into the resin based on the TOC of the solution before and after the 30 minute contact time. The resin was rinsed with water and converted to the calcium form by passing an aqueous solution of 1,000 ml 4 percent calcium chloride through the resin over 40 minutes. The resin in the calcium form was then rinsed with water. TOC analysis of the calcium chloride solution which passed through the resin indicated that 7 percent of the antioxidant was displaced from the resin during the ionic conversion from the hydrogen to the calcium form. Therefore, the resin contained 0.111 percent antioxidant by weight.

0031In a similar manner for the second and third runs, 100 ml samples of resin in the hydrogen form were stirred with 100 ml of 0.03 percent aqueous antioxidant solution for the second run and 0.01 percent aqueous antioxidant solution for the third run. The resins were then converted to the calcium form. The resins contained 0.037 percent and 0.011 percent of the antioxidant by weight, respectively.

0032Each of the three resins was analyzed for stability using the procedure outlined in Example 1 and compared with an untreated resin. The results appear in Table II. <tables id="tabl0002" num="0002"><table frame="all"><title>TABLE II</title><tgroup cols="6" colsep="1" rowsep="1"><colspec colnum="1" colname="col1" colwidth="26.25mm" colsep="1" /><colspec colnum="2" colname="col2" colwidth="26.25mm" /><colspec colnum="3" colname="col3" colwidth="26.25mm" /><colspec colnum="4" colname="col4" colwidth="26.25mm" /><colspec colnum="5" colname="col5" colwidth="26.25mm" /><colspec colnum="6" colname="col6" colwidth="26.25mm" /><thead valign="top"><row><entry namest="col1" nameend="col6" align="center">Stability of Cation Exchange Resin In Calcium Form Incorporating Antioxidant</entry></row><row><entry namest="col1" nameend="col1" rowsep="0" align="center">Concentration of Antioxidant¹ in Resin, Weight Percent</entry><entry namest="col2" nameend="col6" align="center">Resin Decomposition Products, Solution TOC² (ppm)</entry></row><row rowsep="1"><entry namest="col1" nameend="col1" /><entry namest="col2" nameend="col2" align="center">1 day</entry><entry namest="col3" nameend="col3" align="center">2 days</entry><entry namest="col4" nameend="col4" align="center">3 days</entry><entry namest="col5" nameend="col5" align="center">4 days</entry><entry namest="col6" nameend="col6" align="center">5 days</entry></row></thead><tbody valign="top"><row><entry namest="col1" nameend="col1" align="left">none³</entry><entry namest="col2" nameend="col2" align="char" char=".">410</entry><entry namest="col3" nameend="col3" align="right">1540</entry><entry namest="col4" nameend="col4" align="right">2080</entry><entry namest="col5" nameend="col5" align="right">2470</entry><entry namest="col6" nameend="col6" align="right">no data</entry></row><row><entry namest="col1" nameend="col1" align="char" char=".">0.112</entry><entry namest="col2" nameend="col2" align="char" char=".">7.5</entry><entry namest="col3" nameend="col3" align="right">22</entry><entry namest="col4" nameend="col4" align="right">31</entry><entry namest="col5" nameend="col5" align="right">no data</entry><entry namest="col6" nameend="col6" align="right">60</entry></row><row><entry namest="col1" nameend="col1" align="char" char=".">0.037</entry><entry namest="col2" nameend="col2" align="char" char=".">17</entry><entry namest="col3" nameend="col3" align="right">25</entry><entry namest="col4" nameend="col4" align="right">45</entry><entry namest="col5" nameend="col5" align="right">110</entry><entry namest="col6" nameend="col6" align="right">940</entry></row><row rowsep="1"><entry namest="col1" nameend="col1" align="char" char=".">0.011</entry><entry namest="col2" nameend="col2" align="char" char=".">23</entry><entry namest="col3" nameend="col3" align="right">325</entry><entry namest="col4" nameend="col4" align="right">1000</entry><entry namest="col5" nameend="col5" align="right">1260</entry><entry namest="col6" nameend="col6" align="right">1780</entry></row></tbody></tgroup><tgroup cols="6" colsep="0" rowsep="0"><colspec colnum="1" colname="col1" colwidth="26.25mm" /><colspec colnum="2" colname="col2" colwidth="26.25mm" /><colspec colnum="3" colname="col3" colwidth="26.25mm" /><colspec colnum="4" colname="col4" colwidth="26.25mm" /><colspec colnum="5" colname="col5" colwidth="26.25mm" /><colspec colnum="6" colname="col6" colwidth="26.25mm" /><tbody valign="top"><row><entry namest="col1" nameend="col6" align="justify">¹Ethanox® 703</entry></row><row><entry namest="col1" nameend="col6" align="justify">²Determined using a Model 700 TOC analyzer sold by O.I. Corporation</entry></row><row><entry namest="col1" nameend="col6" align="justify">³Not an example of this invention</entry></row></tbody></tgroup></table></tables>

0033The results indicate that the treated resins release lower amounts of decomposition products relative to the untreated resin despite conversion of the resins from the hydrogen form to the calcium form. Therefore, conversion of the resin from one ionic form to another does not adversely affect the ability of the antioxidant to improve the stability of the resin.

<b>Example 3</b>

003475 Milliliters (61.5 g) of DOWEX MONOSPHERE® 99 in the hydrogen form was completely dried in a vacuum oven. 28 Grams of a 0.20 percent solution of antioxidant (BHT) and methanol was added to the dried resin with mixing. The methanol was then evaporated from the resin by heating the resin in a vacuum oven. After removing the methanol, water was added to the resin. The resin was rinsed with water, converted to the calcium form and analyzed for stability as described in Examples 1 and 2. The stability of the resin was compared with an untreated resin. The results appear in Table III. <tables id="tabl0003" num="0003"><table frame="all"><title>TABLE III</title><tgroup cols="6" colsep="1" rowsep="1"><colspec colnum="1" colname="col1" colwidth="26.25mm" colsep="1" /><colspec colnum="2" colname="col2" colwidth="26.25mm" /><colspec colnum="3" colname="col3" colwidth="26.25mm" /><colspec colnum="4" colname="col4" colwidth="26.25mm" /><colspec colnum="5" colname="col5" colwidth="26.25mm" /><colspec colnum="6" colname="col6" colwidth="26.25mm" /><thead valign="top"><row><entry namest="col1" nameend="col6" align="center">Comparison of Stabilities of Resin in Calcium Form With and Without Antioxidant</entry></row><row><entry namest="col1" nameend="col1" rowsep="0" align="center">Antioxidant Used</entry><entry namest="col2" nameend="col6" align="center">Resin Decomposition Products, Solution TOC¹ (ppm)</entry></row><row rowsep="1"><entry namest="col1" nameend="col1" /><entry namest="col2" nameend="col2" align="center">1 day</entry><entry namest="col3" nameend="col3" align="center">2 days</entry><entry namest="col4" nameend="col4" align="center">3 days</entry><entry namest="col5" nameend="col5" align="center">4 days</entry><entry namest="col6" nameend="col6" align="center">6 days</entry></row></thead><tbody valign="top"><row><entry namest="col1" nameend="col1" align="center">none²</entry><entry namest="col2" nameend="col2" align="right">410</entry><entry namest="col3" nameend="col3" align="right">1540</entry><entry namest="col4" nameend="col4" align="right">2080</entry><entry namest="col5" nameend="col5" align="right">2470</entry><entry namest="col6" nameend="col6" align="center">no data</entry></row><row rowsep="1"><entry namest="col1" nameend="col1" align="center">BHT</entry><entry namest="col2" nameend="col2" align="right">9</entry><entry namest="col3" nameend="col3" align="right">10</entry><entry namest="col4" nameend="col4" align="right">12</entry><entry namest="col5" nameend="col5" align="right">13</entry><entry namest="col6" nameend="col6" align="center">15</entry></row></tbody></tgroup><tgroup cols="6" colsep="0" rowsep="0"><colspec colnum="1" colname="col1" colwidth="26.25mm" /><colspec colnum="2" colname="col2" colwidth="26.25mm" /><colspec colnum="3" colname="col3" colwidth="26.25mm" /><colspec colnum="4" colname="col4" colwidth="26.25mm" /><colspec colnum="5" colname="col5" colwidth="26.25mm" /><colspec colnum="6" colname="col6" colwidth="26.25mm" /><tbody valign="top"><row><entry namest="col1" nameend="col6" align="justify">¹Determined using a Model 700 TOC analyzer sold by O.I. Corporation</entry></row><row><entry namest="col1" nameend="col6" align="justify">²Not an example of this invention.</entry></row></tbody></tgroup></table></tables>

0035The results illustrate a dramatic reduction in the release of decomposition products from the resin treated with BHT relative to the untreated resin. Therefore, different antioxidants can be used to improve the stability of the resin.