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ALL YOU EVER WANTED TO KNOW ABOUT WAXES;
Wax
usually refers to a substance that is a solid at ambient temperature and
that, on being subjected to slightly higher temperatures, becomes a low
viscosity liquid. The chemical composition of waxes is complex; all of the
products have relatively wide molecular weight profiles, with the
functionality ranging from products, which contain mainly normal alkanes to
those, which are mixtures of hydrocarbons and reactive functional species. Insect and Animal Waxes
Beeswax. Vegetable Waxes
Carnauba.
Mineral Waxes
Montan Wax.
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Table 3. Typical Properties of Petroleum Waxes |
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Wax
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Property
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Paraffin
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Microcrystalline
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Flash point, closed cup, C
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204’
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260’
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Viscosity at 98.90C, mm-9/s
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4.2-7.4
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10.2-25
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Melting range, ~C
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46-68
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60-93
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Refractive index at 98.9~C
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1.430-1.433
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1.435-1.445
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Number average molecular weight
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350-420
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600-800
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Carbon atoms per molecule
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20-36
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30-75
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Ductility crystallinity of solid wax
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Friable to crystalline
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Ductile-plastic to tough-brittle
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Value is minimum.
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Paraffin
wax is macro crystalline, brittle, and is composed of 40-90 wt % normal
alkanes, with the remainder C18-C36 isoalkanes and cycloalkanes. Paraffin
wax has little affinity for oil content: fully refined paraffin has less
than 1 wt %; crude scale, 1-2 wt %, and slack [64742-61-61, above 2 wt %.
Within these classes, the melting point of the wax determines the actual
grade, with a range of about 46-71”C. Typical properties of petroleum waxes
are listed in Table‘3.
The separation of paraffin wax from crude oil occurs during distillation, as
shown in Figure 1. The distillate is processed to remove oil to the degree
desired through solvent extraction. It is then decolorized, usually by
hydrogenation, but percolation through bauxite is also used.
Microcrystalline wax is produced either from the residual fraction of crude
oil distillation or from crude oil tank bottoms 10). After deasphalting of
the residual fraction, heavy lubricating oil is removed by solvent
extraction. The degree of solvent extraction is dictated by the economics of
the lubrication oil market. The filtrate is crude petrolatum, a
dark-colored, unctuous material containing oil and microcrystalline wax.
Percentages of each may vary, but are usually about 40 wt % wax and 60 wt %
oil. This material is then solvent-extracted for the wax. Because
microcrystalline wax has great affinity for oil, the oil content of the wax
is 1-4 wt %, depending on the grade of the wax. Unlike paraffin wax, oil is
held tightly in the crystal lattice of the microcrystalline wax, and does
not migrate to the surface. The microcrystalline waxes obtained from
petrolatums are generally known as plastic grades, with penetrations greater
than 11 dmm at 25’C.
Crude oil contains high molecular weight fractions, which are soluble at the
high temperatures found in underground formations, but not very soluble at
ambient conditions once the crude oil is produced. These high molecular
weight fractions precipitate onto the walls and floors of storage tanks, and
are known as crude oil tank bottoms. Crude oil tank bottoms are essentially
crude Oil with very high wax contents and are processed as indicated in
Figure 1. The microcrystalline waxes obtained from crude oil tank bottoms
are generally known as hard grades, with penetrations less than 11 dmm at
250C.
The Bundesges undheitsamt
(BGA) of Germany also has specifications for refined petroleum waxes used in
food applications. Many other countries reference either the FDA or BGA
specifications for their food regulations. Petroleum wax is widely used in
chewing gum to modify the properties of the chewing gum base. The wide range
of properties available help chewing gum base manufacturers formulate a
broad variety of chewing gum, ranging from the traditional hard stick gum to
the softer bubble gum. Petroleum wax can also be used as protective coatings
for fruits, vegetables, and cheeses. Petroleum wax is outstanding as a
cost-effective moisture and gas barrier, and food-packaging applications are
a major market for refined food-grade petroleum wax. Blends of paraffin and
microcrystalline wax are used by themselves or in combination with other
additives such as high molecular weight polyethylene and ethylene vinyl
acetate copolymers to improve the performance of paper packaging such as
paperboard boxes, paper containers, and flexible packaging.
Petroleum waxes are also widely used in other industrial applications.
Paraffin waxes are added to rubber during compounding, and exude to the
surface during curing, which helps protect the rubber from degradation
resulting from ozone.
Paraffin and other waxes can be added to
plastics, especially poly (vinyl chloride) (PVC) as lubricants.
Both paraffin and microcrystalline waxes are widely used to help control the
properties of hot-melt adhesives. Dispersions of microcrystalline are added
to ink to improve slip and rub properties. Petroleum waxes are used in many
consumer applications such is cosmetics, polishes, and candles. Unrefined
petroleum waxes are often used n fireplace logs.
Polyethylene Waxes.
Low molecular weight
(less than ca 10,000 Mn) polyethylenes [9002-88-41 having wax like
properties are made either by high-pressure polymerization or low-pressure
(Zeigler-type catalysts) polymerization. All the products have the same
basic structure, but the processes yield products h distinctly different
properties. Some polyethylenes have fairly low density owing to branching
that occurs during the polymerization. Molecular weight distributions,
expressed as the weight average molecular weight divided by the number
average molecular weight, or polydispersity, also varies widely among the
different processes, as does the range of molecular weights available.
Differences among the processes have a major impact on the use of the
products. Products from a particular process or manufacturer may dominate
one market, while products from a different process may be preferred in a
different application. Major uses include hot-melt adhesives for
applications requiring high temperature performance, additives to improve
the processing of plastics, slip and rub additives for inks and paints, and
cosmetic applications.
Products used in food applications require regulatory approvals. This
regulation includes a maximum amount of hexane-soluble material with other
requirements. The amount of material extracted by hexane is a function of
molecular weight and branching. The FDA under the synthetic petroleum wax
regulation, 21 CFR 172.888, regulates polyethylenes in the
500-1200-molecular weight range. In addition to molecular weight
requirements, this regulation includes an absorbance test to verify the
suitability of the product for food applications.
Some by-product polyethylene waxes have been recently introduced. The
feedstock for these materials is mixtures of low molecular weight
polyethylene fractions and solvent, generally hexane, produced in making
polyethylene plastic resin. The solvent is stripped from the mixture, and
the residual material offered as polyethylene wax. The products generally
have a wider molecular weight distribution than the polyethylene waxes
synthesized directly, and are offered to markets able to tolerate that
characteristic. Some of the by-product polyethylene waxes are distilled
under vacuum to obtain a narrower molecular weight distribution.
Several of the polymerization processes allow different functionality to be
added to the backbone of the polymer, including copolymers of ethene,
propene, hexene, vinyl acetate, and acrylic acid, with warlike properties.
Copolymers of ethene with other olefins provide a method of extending the
range of properties available. The addition of other olefins creates a
branched polymer, which decreases the melting point and hardness, while
increasing viscosity as compared to a linear polyethylene of the same
molecular weight distribution. Longer branches created through the addition
of hexene show a larger effect than those from propene. Copolymers with
vinyl acetate and acrylic acid provide a method of introducing oxygen
functionality. These products may be further reacted with metal salts to
form ionomers.
In addition to co polymerization, polyethylene's terminated as ketones.
Alcohols, and carboxylic acids with molecular weights as high as 700 Daltons
are now available. The products offer the same chemical functionality as
common fatty alcohols and acids, but are higher melting and harder. Similar
to the fatty alcohols and acids, derivatives such as ethoxylates, esters,
and amides also are available as higher melting versions of the fatty
derivatives.
Functional polyethylene waxes provide both the physical properties obtained
by the high molecular weight polyethylene wax and the chemical properties of
an oxidized product, and one derived from a fatty alcohol or acid. The
functional groups improve adhesion to polar substrates, compatibility with
polar materials, and dispersibility into water. Uses include additives for
inks and coatings, pigment dispersions, plastics, cosmetics, toners, and
adhesives.
Fischer-Tropsch
Waxes.
Polyethylene wax [8OO2-74-2] production is based on the Fischer-Tropsch
synthesis, which is basically the polymerization of carbon monoxide under
high pressure and over special catalysts to produce hydrocarbons (see FUELS,
SYNTHETIC-LIQUID FUELS). Distillation is then used to separate the
hydrocarbons into different products, including liquid fuels and waxes with
melting points ranging from about 45-1060C. Currently the waxes are produced
in large volumes in South Africa and Malaysia, with an estimated
12,000-14,000 t consumed in the United States in 1994. Uses are similar to
those for polyethylene waxes, including hot-melt adhesives and additives for
inks and coatings.
Chemically Modified Waxes.
Hydrocarbon waxes of the microcrystalline, polyethylene, and polyethylene
classes are chemically modified to meet specific market needs. In the vast
majority of cases, the first step is air oxidation of the wax with or
without catalysts (11). The product has an acid number usually no higher
than 30 and a saponification number usually no lower than 25. An alternative
step is the reaction of the wax with a polycarboxylic acid, e.g., maleic, at
high temperature (12). Through its carboxyl groups, the oxidized wax can be
further modified in such reactions as saponification or esterification.
Oxidized wax is easily emulsified in water through the use of surfactants or
simple soaps, and is widely used in many coating and polish applications.
Substituted Amide Waxes.
The product of fatty acid amidation has unique wax like properties (13).
Probably the most widely produced material is N,N’distearylethylenediamine
[110-30-5], which has a melting point of ca 140’C, an acid number of ca 7,
and a low melt viscosity. Because of its unusually high melting point and
unique functionality, it is used in additive quantities to raise the
apparent melting point of thermoplastic resins and asphalts, as an
internal-external lubricant in the compounding of a variety of thermoplastic
resins, and as a processing aid for elastomers.
Polymerized a-Olefins. Some polymers of higher a-olefins, e.g., C>20, have
wax like properties and are sold as synthetic waxes. The polymerization
process yields highly branched materials, with broad molecular weight
distributions. Properties of the individual products are highly dependent on
the a-olefin monomers and polymerization conditions. Melting points for the
products range from 540C to 740C, with number average molecular weights ca
2600-2800, and penetrations at 250C of 5-12 dmm. The unique structure makes
these products very effective when used in additive amounts to modify the
properties of paraffin wax, primarily for use in candles. The products can
increase the hardness and opacity of the paraffin, without increasing the
cloud point or viscosity. Other uses include mold release for polyurethane
foams, additives for casting wax, and additives for leather treating.
Most
waxes are complex mixtures of molecules with different carbon lengths,
structures, and functionality. Attempts to measure the exact chemical
composition are extremely difficult, even for the vegetable waxes, which are
based on a relatively few number of basic molecules. Products such as
oxidized microcrystalline wax not only have a mixture of hydrocarbon lengths
and types as starting materials, but also add complexity through the
introduction of various types of carboxylic functionality onto those
hydrocarbons during the oxidation process.
Because of the difficulty in analysis of chemical composition, most of the
routine test procedures on waxes are for the measurement of the physical
proper-ties of the waxes and are used to compare the properties of waxes
within a class. Some properties, such as acid number or saponification
number, give insight into the chemical functionality of the product, and are
widely used for products, which contain carboxyl groups such as vegetable,
Montan, and oxidized waxes. Increasingly, instrumental methods such as gas
chromatography (GC), gel permeation (also known as size exclusion)
chromatography (GPC), refractive index (RI), differential scanning
calorimetry (DSC), infrared spectroscopy (IR), and nuclear magnetic
resonance (NMR) are being used to further characterize the products.
Properties such as molecular weight distribution, degree of branching,
degree of crystallinity, and functionality can be readily measured with
these techniques.
Melting and Congealing Points.
Selection of the proper melting point method depends upon the
characteristics of the wax. Drop melting point (ASTM D127) is suitable for
amorphous waxes, e.g., microcrystallines, but is not reliable for higher
viscosity synthetic waxes, for which ring-and-ball softening point (ASTM
D36) should be used. ASTM D87 may evaluate waxes whose time-temperature
cooling curves exhibit plateaus, e.g., paraffin wax. Open or closed
capillary tubes are used to measure the melting point of many of the natural
waxes. The congealing point (ASTM D938) is the temperature at which a melted
wax ceases to flow, and is more consistent than melting points for some
waxes.
Hardness
(Penetration). The standard test for the hardness of waxes in industry is
the penetration test (ASTM D1321). This test measures the depth in tenths of
a millimeter that a needle of a certain configuration under a given weight
penetrates the surface of a wax at a given temperature. A series of
penetrations measured at different temperatures, rather than at a single
temperature, is preferred.
Color.
On solidification of a wax and depending on factors such as the rate of
cooling, the amount of occluded air, and surface finish, the color of
solidified samples of the same wax may be different. For this reason, the
color of most waxes is judged only while molten, although some commercial
standards for certain waxes, e.g., carnauba, are based on the color of the
solid wax. The accurate measurement of color in light-colored, i.e., amber
to off-white to white, waxes is difficult but very important because of the
additional processing costs required to achieve the light color. The two
most widely used color standards providing numerical measurement are ASTM
D1500, which is used to measure dark-brown to off-white color, and ASTM
D156, which is used to measure off-white to pure white.
Oil content.
The production of petroleum waxes involves the removal of oil; therefore,
the oil content (actually the percentage of oil and low molecular weight
fractions) is one indication of the quality of the wax. Oil content is
determined (ASTM D721) as that percentage of the wax soluble in methyl ethyl
ketone at -31.7 degrees C.
Viscosity.
Although traditionally of little importance in the evaluation of vegetable
and insect waxes, viscosity is an important test for mineral and synthetic
waxes. One of the most frequently used tests, ASTM D88, is used to measure
the time in seconds required for a specified quantity of wax at a specified
temperature to flow by gravity through an orifice of specified dimensions.
This viscosity is expressed in Saybolt Universal Seconds (SUS) at the
temperature of the test. The SI unit for kinematic viscosity is mm2/s (=cSt).
Acid Number.
The acid number (ASTM D1386) is the milligrams of potassium hydroxide
necessary to neutralize one gram of wax, and indicates the amount of free
carboxylic acid present. The test is widely used for vegetable and insect
waxes, and synthetic waxes containing carboxylic acid groups.
Saponification Number.
The saponification number (ASTM D1387) is the milligrams of potassium
hydroxide, which react with one gram of wax under elevated temperatures, and
indicates the amount of free carboxylic acid plus any ester materials, which
may be saponified. Both the acid number and saponification numbers are
generally provided to give an indication of the free carboxylic acid and
ester content of vegetable and insect waxes, and synthetic waxes containing
carboxylic acids and or esters.
Differential Scanning Calorimetry (DSC).
The dsc has become widely used to characterize waxes. Under controlled
heating and cooling rates, the amount of energy consumed or released is
measured. Curves of heat flow v/s temperature provide insight into the
thermal characteristics of a wax, including crystalline transitions such as
solid-to-solid, solid-to-liquid, and liquid-to-solid. Common values obtained
from the curves include the initial and ending temperatures for heat flow,
and heat of fusion, expressed as joules per gram.
Gas Chromatography (GC).
Gas chromatography has been used for many years, especially on the
relatively simple structures of vegetable and insect waxes. Use of the GC
for petroleum and synthetic waxes was limited by the maximum carbon number
which could be eluted, and the number of isomers for each carbon number.
Improvements in technology have allowed wider use of this technique, with
columns and equipment available, which can resolve carbon numbers up to
C100. Good resolution can be obtained on products with generally only one
type of structure, e.g., paraffins with a high preponderance of primary
alkanes. Products such as microcrystalline wax, which contain several
different branched isomers for each carbon number, plus some cyclic
compounds, cannot be completely resolved, although useful information can
still be obtained.
Gel Permeation Chromatography (GPC).
The gpc (also known as size exclusion chromatography) is widely used to
measure the molecular weight distribution for synthetic polyethylene waxes.
Whereas gpc cannot match the resolution available in GC techniques, useful
information regarding the molecular weight, and molecular weight
distribution can be obtained for products with molecular weights too high
for gas chromatography. The molecular weight is normally reported using the
number average, Mn, or the weight average, Mw The ratio of the weight
average to the number average is known as the polydispersity.Pd.
Infrared Spectroscopy (Ir).
Infrared curves are used to identify the chemical functionality of waxes.
Petroleum waxes with only hydrocarbon functionality show slight differences
based on crystallinity, while vegetable and insect waxes contain
hydrocarbons, carboxylic acids, alcohols, and esters. The ir curves are
typically used in combination with other analytical methods such as DSC or
gc/gpc to characterize waxes.
Nuclear Magnetic Resonance (NMR).
The NMR analysis has been used in the polymer industry to measure
properties such as amount and type of branching, polymerized ethylene oxide
content, and hydroxyl content. The same techniques are applicable to waxes,
and are used for both characterization and quality control.
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