Process for the Production of Crystalline Sodium Sheet Silicate With Kanemite Structure

The present invention relates to a process for the production of crystalline sodium sheet silicate with kanemite structure with the chemical formula NaH Si.sub.2 O.sub.5 .multidot.X H.sub.2 O in which X represents a value between 1 and 3.

Modern light-duty detergents and dishwashing agents should have a low pH of 8 to 10 and represent mixtures of many substances containing, inter alia, builders, cobuilders, a bleaching system and a stabilizer. Moreover, sodium tripolyphosphate or zeolite A, for example, are used as builders, polycarboxylates are used as cobuilders, percarbonate or a mixture of perborates and tetraacetylethylenediamine (TAED) is used as bleaching systems, and phosphonates are used as stabilizers.

EP-C 164 514 discloses a detergent and cleaner which, besides surfactants, contains crystalline sodium silicates in sheet form with the composition NaMSi.sub.x O.sub.2x+1 .multidot.yH.sub.2 O (with M equal to sodium or hydrogen, x from 1.9 to 4 and y from 0 to 20) as builders. Moreover, crystalline sodium silicates show a higher calcium binding capacity than amorphous types, which is attributable to their structure in sheet form with increased degree of polymerization.

Known crystalline sodium silicates occur in nature, but they are also produced artificially, for example

Of particular interest for use in light-duty detergents and dishwashing agents are the sodium silicates derived from the structure of kanemite, because these display in the wash liquor a lower pH than the sodium silicate which is mentioned in EP-C 164 514 and is essentially composed of .delta.-Na.sub.2 Si.sub.2 O.sub.5. Kanemite can be produced by treating either .beta.-Na.sub.2 Si.sub.2 O.sub.5 or .alpha.-Na.sub.2 Si.sub.2 O.sub.5 with a water/methanol mixture at 100.degree. C. with subsequent heating at 700.degree. C. for 5 to 24 hours and final extraction of the heated material with water.

The disadvantage in this case is that this production is elaborate because of the need for controlled addition of the individual substances and requires considerable safety precautions because of the flammability of methanol.

Kanemite can be obtained by a variant described in EP-C 164 514 when .delta.-Na.sub.2 Si.sub.2 O.sub.5 is hydrolyzed with water, and the solid is filtered off and dried at 40.degree.-105.degree. C.

The disadvantages of this variant are that the hydrolysis results in a solid which is difficult to filter, and one equivalent of NaOH is removed with the filtrate.

The object of the present invention is to indicate a process for the production of crystalline sodium sheet silicate with kanemite structure of the chemical formula NaHSi.sub.2 O.sub.5 .multidot.XH.sub.2 O in which X represents a value between 1 and 3, with a high Ca binding capacity of 60 to 100 mg Ca/g (based on NaHSi.sub.2 O.sub.5) and a pH of 10 to 11 for a suspension of 1 g/1000 ml of water, which operates without filtration and where the sodium ions introduced into the process remain in the crystalline sodium sheet silicate with kanemite structure.

The object is surprisingly achieved by sodium disilicate, silica and water being mixed in the molar ratio of 1:2:(6-8) and maintained at a temperature of 20.degree. to 100.degree. C. for a period of 0.2 to 10 h.

Furthermore, optional embodiments of the process according to the invention can entail

a) employing as sodium disilicate .delta.-Na.sub.2 Si.sub.2 O.sub.5 or a mixture of .delta.-Na.sub.2 Si.sub.2 O.sub.5 and up to 80% by weight of amorphous Na.sub.2 Si.sub.2 O.sub.5 .multidot.n H.sub.2 O;

b) employing as silica precipitated silica, pyrogenic silica, silica sol or silica gel;

c) employing the sodium disilicate with a particle fineness of less than 1000 .mu.m;

d) employing the silica with a particle fineness of less than 200 .mu.m;

e) maintaining the reaction product where appropriate at 50.degree. to 100.degree. C. for a further 0.5 to 5 h;

f) comminuting the crystalline sodium sheet silicate with kanemite structure by milling to a particle fineness of less than 100 .mu.m.

The crystalline sodium sheet silicate with kanemite structure produced according to the invention can be used as detergent and cleaner builder to eliminate the hardness of water which contains calcium and/or magnesium ions.

FIG. 1 is an X-ray diffraction diagram of the product of the present invention.

FIG. 2 is an X-ray diffraction diagram of a product made by a comparative example.

The crystalline sodium sheet silicate with kanemite structure produced according to the invention can be composed of

NaHSi.sub.2 O.sub.5 .multidot.1H.sub.2 O or

NaHSi.sub.2 O.sub.5 .multidot.3H.sub.2 O.

Since the partial pressure of water vapor from NaHSi.sub.2 O.sub.5 .multidot.3H.sub.2 O is high even at temperatures of 40.degree.-70.degree. C., it is possible to convert part of the NaHSi.sub.2 O.sub.5 .multidot.3H.sub.2 O into NaHSi.sub.2 O.sub.5 .multidot.1H.sub.2 O. The value for X thus represents a value which indicates what proportion of the NaHSi.sub.2 O.sub.5 .multidot.3H.sub.2 O is already in the form of NaHSi.sub.2 O.sub.5 .multidot.1H.sub.2 O.

If it is particularly important that the crystalline sodium sheet silicate with kanemite structure according to the invention acts to eliminate the hardness of water, a good crystallinity is desirable. The crystallinity of the sodium sheet silicate with kanemite structure can be increased further by a subsequent thermal treatment.

It may be regarded as surprising that, under the production conditions according to the invention, crystalline sodium sheet silicate with kanemite structure is formed even if up to 80% by weight of the crystalline .delta.-sodium disilicate are replaced by amorphous sodium disilicate in the reaction mixture. Reaction of quartz powder and .delta.-Na.sub.2 Si.sub.2 O.sub.5 astonishingly does not lead to the formation of crystalline sodium sheet silicate with kanemite structure.

1. .delta.-Na.sub.2 Si.sub.2 O.sub.5 : Was produced by the procedure of DE-A 41 42 711 and can be purchased as SKS-6 from Hoechst AG, Frankfurt.

2. Na.sub.2 Si.sub.2 O.sub.5 (18% H.sub.2 O): Amorphous sodium disilicate was purchased from Societe Francaise Hoechst, Paris.

3. Precipitated silica: Type FK 320 was purchased from Degussa AG, Hanau.

4. Silica: Type HDKP 170 was purchased from Wacker-Chemie GmbH, Munich.

5. Silica sol: Type Klebosol 1346 was purchased from Societe Francaise Hoechst, Paris.

6. Quartz powder: Type Microsil 20 was purchased from F. Lieben, Maastricht.

The following were mixed in a Type KM 70 D mixer from Lodige, Paderborn,

3643 g of .delta.-Na.sub.2 Si.sub.2 O.sub.5 (SKS-6)

2451 g of precipitated silica, loss on drying at 105.degree. C. 6% by weight; loss on ignition at 1000.degree. C. 5% by weight; particle size 0.2% by weight>45 .mu.m; SiO.sub.2 content: 98% by weight

and

2522 g of water.

The solid mixture was then maintained at a temperature of 60.degree. C. in a closed container for 8 h. After cooling, the product was broken up and milled.

Screen analysis of the final product was as follows:

10%<6.7 .mu.m

50%<28.3 .mu.m

90%<66.5 .mu.m

Lines of .delta.-Na.sub.2 Si.sub.2 O.sub.5 are no longer identifiable in the X-ray diffraction diagram of this product. Only kanemite lines are observed (FIG. 1). The pH of the substance is 10.9 (1 g/l; 7 min), the calcium binding capacity is 75 mg Ca/g (based on NaHSi.sub.2 O.sub.5).

The following were vigorously mixed in a laboratory mortar

129 g of silica, SiO.sub.2 content: 98% by weight loss on drying: 6% by weight,

182 g of .delta.-Na.sub.2 Si.sub.2 O.sub.5

with

130 g of water

and then maintained at 60.degree. C. in a closed glass bottle for 2 h. After cooling, the product was milled.

The X-ray diffraction diagram showed only kanemite lines.

The following were mixed together in a laboratory mortar

400 g of silica sol, SiO.sub.2 content: 30% by weight,

100 g of .delta.-Na.sub.2 Si.sub.2 O.sub.5

and

100 g of amorphous sodium disilicate.

172 g of water were evaporated out of this mixture at 60.degree. C. The remaining mixture was maintained at 60.degree. C. in a closed bottle for 2 h and, after cooling, ground in a mortar.

The X-ray diffraction diagram showed only kanemite lines.

The following were vigorously mixed in a laboratory mortar

120 g of quartz powder, SiO.sub.2 content: 99.3% by wt. d.sub.50 4.4 .mu.m,

180 g of .delta.-Na.sub.2 Si.sub.2 O.sub.5

and

130 g of water

and subsequently maintained at 60.degree. C., in a closed bottle for 8 h. A sticky mass formed, and its X-ray diffraction diagram showed only the diffraction lines of quartz (FIG. 2 ).