Tips for using viscosity reducing dispersants: unlocking efficient industrial production
In the complex chess game of industrial production, viscosity reducing dispersants are like a key chess piece,
which can cleverly resolve the problems of material viscosity and uneven dispersion, and help promote efficient
production. However, to give full play to its role, correct use is crucial. Here is a "treasure book" of recommendations
for the use of viscosity reducing dispersants.
Accurate selection, the right medicine for the right disease
There are many types of viscosity reducing dispersants on the market, and different viscosity reducing dispersants
differ in chemical structure, performance characteristics and application range. Therefore, before use, it is necessary to
accurately select according to the specific material system and application requirements.
Taking the coating industry as an example, if water-based coatings are produced, it is necessary to select viscosity reducing
dispersants suitable for water-based systems. This type of viscosity reducing dispersant usually has good water solubility and
dispersibility, which can effectively reduce the interaction between pigment and filler particles in water-based coatings, prevent
particle agglomeration, and improve the fluidity and stability of the coating. For oil-based coatings, it is necessary to select
a matching oil-based viscosity reducing dispersant to ensure that it can play a good viscosity reducing and dispersing effect
in organic solvents.
In the field of oil extraction, targeted viscosity-reducing dispersants are also needed for crude oils of different properties,
such as high-wax crude oil and high-asphalt crude oil. High-wax crude oil is prone to increase viscosity due to wax crystal
precipitation at low temperatures. At this time, a viscosity-reducing dispersant that can effectively inhibit the growth and
aggregation of wax crystals should be selected; high-asphalt crude oil requires products that can disperse asphaltene
particles and reduce crude oil viscosity.
Strictly control the dosage, just right
The dosage of viscosity-reducing dispersant is not the more the better, but needs to be strictly controlled. Insufficient
dosage may not achieve the ideal viscosity reduction and dispersion effect, and the material still has problems such as
high viscosity and uneven dispersion; excessive dosage will not only increase production costs, but may also have a negative
impact on the performance of the material, and even cause product quality problems.
In actual operation, the optimal dosage range can be determined through small tests and pilot tests. In the small test, the
viscosity-reducing dispersant is added to a small amount of material according to different dosage gradients to observe the
viscosity changes, dispersion of the material, and the performance indicators of the final product. According to the results of the
small test, several dosages with better effects are selected for pilot tests to further verify its applicability in large-scale production.
For example, in the production of ceramic slurry, after determining the optimal dosage of viscosity-reducing dispersant through
small and medium tests, it can not only ensure that the slurry has good fluidity and dispersibility, but also avoid the reduction of
the solid content of the slurry due to excessive dosage, which affects the quality of ceramic products.
Optimize the addition method to ensure uniformity
The addition method of the viscosity-reducing dispersant will directly affect its dispersion effect and function in the material.
Generally speaking, common addition methods include direct addition method, pre-dispersion method and solvent dilution method.
The direct addition method is suitable for some easily dispersed viscosity-reducing dispersants and material systems. Add the
viscosity-reducing dispersant directly to the material, and then mix it evenly by stirring. However, this method may not be suitable for
some insoluble or easily agglomerated viscosity-reducing dispersants, which may easily lead to excessive local concentration and affect
the viscosity reduction and dispersion effect.
The pre-dispersion method is to first mix the viscosity-reducing dispersant with a small amount of solvent or carrier to make a uniform
pre-dispersion liquid, and then add the pre-dispersion liquid to the material. This method can improve the uniformity of the dispersion
of the viscosity-reducing dispersant in the material, and is particularly suitable for some high-viscosity and difficult-to-stir material
systems. For example, when producing high-viscosity rubber compounds, the viscosity-reducing dispersant is made into a pre-dispersed
liquid by the pre-dispersion method and then added, which can make the viscosity-reducing dispersant interact with the rubber
molecules better and effectively reduce the viscosity of the rubber compound.
The solvent dilution method is to dissolve the viscosity-reducing dispersant in an appropriate solvent and then add it to the material as
needed. This method can accurately control the amount and concentration of the viscosity-reducing dispersant added, and is suitable for
occasions with high requirements for product quality.
Pay attention to the conditions of use and take advantage of the situation
The performance of the viscosity-reducing dispersant will be affected by the conditions of use, such as temperature, pH value, stirring
speed, etc. Therefore, during use, it is necessary to reasonably control these conditions of use according to the characteristics of the
viscosity-reducing dispersant.
Temperature has a significant effect on the effect of the viscosity-reducing dispersant. Generally speaking, appropriately increasing the
temperature can increase the thermal motion of the molecules, which is conducive to the diffusion and adsorption of the
viscosity-reducing dispersant in the material, thereby improving the viscosity reduction and dispersion effect. However, too high a
temperature may cause the viscosity-reducing dispersant to decompose or fail, or change the properties of the material. For example,
in the treatment of some heat-sensitive materials, the temperature needs to be strictly controlled to avoid damage to the material due
to excessive temperature.
pH value is also an important factor affecting the performance of viscosity-reducing dispersants. Different viscosity-reducing dispersants
have different adaptability ranges to pH values. Before use, it is necessary to understand their suitable pH range and adjust the pH value
of the material by adding acid or alkali. For example, some water-based viscosity-reducing dispersants have good viscosity reduction and
dispersion effects under neutral or weakly alkaline conditions. If the pH value of the material is too low or too high, it may affect the
adsorption of the viscosity-reducing dispersant on the particle surface and reduce its use effect.
Stirring speed and time will also affect the dispersion effect of the viscosity-reducing dispersant in the material. Appropriate stirring
speed and time can fully mix the viscosity-reducing dispersant with the material and promote its function. However, too fast stirring
speed or too long time may produce too many bubbles, affecting the quality of the product.
Regularly evaluate the effect and continuously improve
During the production process, the use effect of the viscosity-reducing dispersant should be evaluated regularly. The viscosity,
dispersibility, and performance indicators of the product can be tested to determine whether the viscosity-reducing dispersant is still
effective. If the viscosity reduction and dispersion effects are not ideal, or the quality of the product fluctuates, it is necessary to analyze
the reasons in time. It may be that the quality of the viscosity reduction dispersant has changed, the use conditions are not suitable,
or the material system has changed.
According to the evaluation results, timely adjust the type, dosage, addition method or use conditions of the viscosity reduction
dispersant, continuously improve the production process, ensure that the viscosity reduction dispersant can always play the best role,
and provide strong guarantee for the efficient and stable operation of industrial production.
The use of viscosity reduction dispersants is a science, which requires us to work hard in selection, dosage, addition method, use
conditions, etc., and regularly evaluate the effects for continuous improvement. Only in this way can we give full play to the
advantages of viscosity reduction dispersants and bring greater benefits to industrial production.