August 14 1 2010 H&R International

An Introduction to Wax Emulsions

Version 1.1
August 14 2 2010 H&R International
Contents
What is an emulsion?
Emulsifier systems
Manufacture
Emulsion stability
Applications
Wood Panel board
Gypsum plasterboard
Handling and storage instructions
August 14 3 2010 H&R International
What is an emulsion?
An emulsion is a mixture of two or more immiscible substances
Emulsions are made up of a dispersed phase and a continuous phase






For an oil-in-water emulsion the continuous phase is water and the
dispersed phase is oil or wax. The reverse is true for a water-in-oil
emulsion
Strictly speaking, an emulsion refers to a system where the dispersed
phase is a liquid
A dispersion is a solid dispersed phase in a liquid continuous phase
Continuous phase

Dispersed phase
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Emulsifier system
Generally, an emulsifying agent lowers the interfacial tension of the two
phases preventing the wax particles from readily separating from the
water, and agglomeration of the wax particles
Emulsifiers reduce the mechanical work required to form an emulsion
Emulsifiers typically consist of a hydrophilic group and a long
hydrophobic chain

Hydrophilic group Hydrophobic chain


Some emulsifier systems impart a charge to the surface of the wax
particle leading to repulsion of like charges preventing agglomeration
Different emulsifier systems are more resistant or susceptible to certain
conditions
August 14 5 2010 H&R International
Anionic emulsions
Anionic emulsifiers impart a negative charge to the surface of the wax
particles





A common example of an anionic emulsifier system is fatty acid + base
The base reacts with the hydrophilic group of the fatty acid to form a
negative charge
The hydrophilic group of the fatty acid is attracted to the water
The hydrophobic chain of the fatty acid is repelled by water but attracted to
the wax particle so the emulsifier remains between the interface of the wax
particle and the water
Anionic emulsions are typically only stable in alkaline pH conditions, and
are often instable in hard water and acidic pH conditions
August 14 6 2010 H&R International
Cationic emulsions
Cationic emulsifiers impart a positive charge to the surface of the wax
particles




A common example of an cationic emulsifier system is an acid with
amine groups
The amine reacts with the hydrophilic group of the acid to form a
positive charge
The hydrophilic group of the acid is attracted to the water
The hydrophobic chain of the acid is repelled by water but attracted to
the wax particle so the emulsifier remains between the interface of the
wax particle and the water
Cationic emulsions are typically resistant to hard water but only stable in
acidic pH conditions and are incompatible with other emulsion types
August 14 7 2010 H&R International
Nonionic emulsions
Nonionic emulsifiers prevent agglomeration of the wax particles by steric
hindrance






A nonionic emulsifier has a non-polar hydrophobic chain and some polar
groups to provide the necessary water solubility
The hydrophobic chain is repelled by water but attracted to the wax
particle
The polar groups are hydrophilic which lowers the interfacial tension of
the wax and water phases
Nonionic emulsions are typically resistant to hard water, stable in most
pH conditions, and offer good stability to shear
August 14 8 2010 H&R International
Vivashield emulsifier system (Europe)
Vivashield products sold in Europe all use the same combination of
anionic and nonionic emulsifiers
Vivashield products sold in Europe are named based on 3 variables
The first number indicates the oil-in-wax content
8YZZ contains 15% oil-in-wax for higher shear stability
9YZZ contains 7% oil-in-wax
The second number indicates the solids content
X5ZZ is a 50% solids product
X6ZZ is a 60% solids product
The last two numbers indicates the wax type
XY52 is based on 150 slackwax (Vivamelt S52)
XY62 is based on 400 slackwax (Vivamelt S62)
The 8 products currently sold are 8552, 8562, 8652, 8662, 9552, 9562,
9652, 9662
August 14 9 2010 H&R International
Vivashield emulsifier system (Europe)
Vivashield sold in Europe all use the same combination of anionic and
nonionic emulsifiers
This allows the product to be resistant to hard water, stable in most pH
conditions, and have good stability to shear
The anionic system is derived from stearic acid and monoethanolamine
The nonionic system arises from stearyl alcohol which increases shear
stability
Stearic acid

Carboxylate formed with
reaction of Stearic acid
and MEA

Stearyl alcohol

August 14 10 2010 H&R International
Aqualite emulsifier system
Aqualite is based on an anionic emulsifier system
Aqualite 70 is a 40% solids product
Aqualite 72 is a 50% solids product
The emulsifier system arises from the carboxylic acid and ester groups of
the montan wax reacting with the potassium hydroxide



Carboxylic acid R2 = H, Ester R2 = alkyl chain

Polyvinyl alcohol is used in Aqualite primarily as a waterproofing additive,
and partly as an emulsifier
Lignosulfonate can be used in Aqualite primarily to help reduce viscosity
when emulsion is added to the gypsum slurry, and partly as an emulsifier
C
O
O R
2
R
1
K
d+ d-
OH +
C
-
O
O R
2
R
1
K
+ -
OH +
August 14 11 2010 H&R International
Manufacturing emulsions An overview
It is possible to prepare the raw materials in a single kettle when
producing Aqualite or Vivashield
In Aqualite, PVOH must be dissolved in hot water before the addition of
wax
After this step all remaining raw materials can be added to the vessel
All raw materials are heated to above the melting point of the wax
phase, so a minimum of 70C for Vivashield, >85C for Aqualite
All of the raw materials are mixed prior to the homogeniser to form a
pre-emulsion
The hot blend is passed through the homogeniser, which provides a
constant flow of material through a highly pressurised chamber,
reducing the wax particle size to approximately 1 micron
The blend is then shock-cooled to below 35C in seconds, which cools
the wax particle below its melting point ensuring a stable emulsion is
formed

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Manufacturing emulsions An overview
Plant setup in Nuth melts Montan
wax in separate vessel prior to
addition to paraffin wax in order
to reduce melt time
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Emulsion Stability Shelf life
The stability of an emulsion is critical to the customers process,
storage and handling
The emulsion stability (shelf life) is the rate of separation of the
dispersed phase from the continuous phase
The mechanisms of destabilisation are
i) Creaming ii) Sedimentation iii) Flocculation iv) Coalescence



The rate of each mechanism will be different for different emulsions
Due to the lighter density, waxes will tend to cream
Additives that are readily soluble in water will tend to sediment
In some emulsions, flocculation can be reversible if the emulsion is
sufficiently mixed
However, coalescence is generally irreversible in wax emulsions
Frequent agitation of the emulsion can help reduce the amount of
material that has creamed or sedimented, and can help reverse
flocculation, but increases the shear the emulsion is exposed to
August 14 14 2010 H&R International
Emulsion Stability Shear stability
Shear stability is another important property of the emulsion
Emulsions can be exposed to shear by any form of agitation or
movement, e.g. mixing, pumping, transferring
During shear, the wax particles can begin to coalesce due to the
emulsifiers being removed from the surface of the wax particle
Shear stability can be measured using:
Silverson method: An individual times how long it takes a high shear
mixer to break the emulsion.
Rheometer method: A constant high shear rate shears the emulsion
between a cone and plate and measures the point in time at which
the emulsion breaks.
The emulsifying system employed is to ensure the wax emulsion remains
stable until it reaches the injection point in the customers process
Shear stability is achieved through selection of emulsifiers, e.g. stearyl
alcohol, and/or a higher oil-in-wax content
August 14 15 2010 H&R International
Panel board applications
Wax emulsions are used in wood panel boards for either waterproofing
or to act as a binder and lubricant during the manufacture of the board
There are 3 main types of wood panel boards MDF, OSB, chipboard






Panelboard processes

MDF OSB Chipboard
Types of boards Flooring

Function of wax Waterproofing Binder
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The Role of Wax
In wood panelboard, the binding performance and the waterproofing
performance are dependant on the wax
In panelboard, literature suggests that n-paraffins are better at
waterproofing
n-paraffins are not branched so better coverage on the wood fibres or
chips is achieved compared to iso-paraffins
In chipboard the most waterproofing molecules are found to be C26 31
In MDF, the most waterproofing molecules are found to be higher
For binding performance a higher oil-in-wax content is desirable

August 14 17 2010 H&R International
Moisture Resistant Gypsum Plasterboard
For high humidity applications there are moisture resistant gypsum
wallboard
The two major commercial methods to make gypsum wallboard moisture
resistant are by incorporation of hydrocarbon wax or siloxane in to the
gypsum slurry during board manufacture
The desired effect of the water resistance treatment is to lower the two
hour water uptake of the gypsum board from over 40% to the ASTM
specifications of less that 10% for Gypsum sheathing and less than 5%
for Water Resistant Gypsum Backing Board
The manufacture of wallboard is a continuous process
Gypsum is dried and then a flowable slurry of gypsum, water, wax
emulsion and other additives is rapidly prepared
The slurry is pumped on to a paper line and then a second paper lining
sandwiches the gypsum slurry
The gypsum sets within a few minutes whilst travelling horizontally
down a continuous line
Boards are cut from the solid gypsum and then passed through ovens
with controlled temperature profiles to remove water
Dried boards are then cut to size more accurately and stacked on pallets
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Plasterboard Plant
August 14 19 2010 H&R International
Gypsum Cycle
Calcium Sulfate
Dihydrate
CaSO
4
.2H
2
O
Calcium Sulfate
Hemihydrate
CaSO
4
.H
2
O
Water, Additives, wax/
siloxane, accelerators,
retarders, etc.
Flowable slurry
Add Heat
Loses Water
Gypsum is calcium sulphate dihydrate with an
average of two molecules of water per molecule
of calcium sulphate (CaSO4.2H2O)
Gypsum originates from 2 major sources:
Natural: Limestone (calcium carbonate)
mines where over time, pressure and
sulfur addition the carbonate is
oxidised to calcium sulphate
Synthetic: Limestone is injected into
power plant stack discharge gases
to form calcium
sulphite, which is later oxidised and recrystallised to form calcium
sulphate
For wallboard, gypsum is heated to remove some of the water to generate
calcium sulphate hemihydrate (CaSO4.H2O)
On the addition of water, a flowable slurry is formed which quickly sets as the
dihydrate form crystallises
Once cut, the board is passed through the ovens to remove water to produce
the hemihydrate form
August 14 20 2010 H&R International
Moisture Resistant Gypsum plasterboard applications
For the wax emulsion to have the greatest beneficial effect, the emulsion
must maintain integrity until the stucco is set
As water is removed during drying the wax emulsion is broken and
allows the wax particle to become available
As the drying temperature is above the melting point of the wax
fractions, the wax melts and flows to increase coverage
Waxes give moisture resistance due to the their hydrophobocity and
distribution in the wallboard matrix
It is believed that the water resistance mechanism of the wax is blocking
of the pores in the gypsum matrix that protect the dried board from
liquid water intrusion



Wax

August 14 21 2010 H&R International
The Role of Wax, and Gypsum Slurry Additives
For maximum waterproofing performance the following paraffin wax
properties are desirable:
Low oil-in-wax content (<1%)
High n-paraffin content
C27 - 29
Montan wax and PVOH also provide waterproofing

Other additives that are added to the gypsum slurry during production
of the board:
Water reducing agents: Lignosulfonates, naphthenaline sulfonates, PCEs. All to reduce
the amount of water that is needed to maintain a gypsum slurry with the correct flow
characteristics, saving energy in the drying stages
Retarders: To increase the set time of the gypsum slurry
Accelerators: To decrease the set time of the gypsum slurry
Variances between and in gypsum sources cause the efficiency of these
additives, including waterproofing additives, to vary significantly