Dow Corning Corporation

Case Western Reserve University

Ollie W Marko

Robert D Steinmeyer

Chi-long Lee

Gary N Bokerman

Stefan F Rentsch

Ronald H Baney

Malcolm Edward Kenney

John Patrick Cannady

Charles Edmund Skinner

Larry Herbert Wood

Thomas A Bush

John Eric Herman

Jay R Schulz

Allan M Alanko

Panela Sue Borah

Li-Tain Yeh

Stuart Michael Bolland

Denise Lynne McClure

A process for preparing a flowable slurry comprising mixing 25-70 wt. % water; an alkaline material selected from the group consisting of chlorosilicon manufacturing byproducts, direct process residue gels, cement kiln dust, and mixtures thereof; and a process aid selected from the group consisting of sucrose, raffinose, lignin, methylglucopyranoside, lactose, fructose, sodium polyphosphate, trehalose and mixtures thereof to form a flowable slurry. This slurry is especially useful in the manufacture of cement.

Process aid for preparing a flowable slurry

A method of forming a granular siloxane gel having reduced chloride content. The method comprises contacting a chlorosilicon mixture with an aqueous medium at a temperature within a range of about 50.degree. C. to 180.degree. C. to form a granular siloxane gel, and washing the granular siloxane gel with an aqueous solution comprising a surfactant having a HLB number within a range of about 1 to 28.

Method of forming a granular siloxane gel having reduced chloride content

A method for grinding silicon metalloid comprising grinding silicon metalloid in the presence of an effective amount of a grinding aid selected from the group consisting of carboxylic acids comprising at least 8 carbon atoms, alkali metal salts of carboxylic acids comprising at least 8 carbon atoms, and polydiorganosiloxanes.

Method for grinding silicon metalloid

A process for treating a plurality of by-product streams containing chlorosilicon compounds. The process comprises the steps of determining the average SiCl functionality of a plurality of by-product streams comprising chlorosilicon compounds, blending at least two of the by-product streams to form a blended by-product stream having an average SiCl functionality greater than or equal to 2.8, adding to the blended by-product stream a surfactant having a HLB number within range of about 3 to 28, and contacting the blended by-product stream with an aqueous medium at a temperature within a range of about 50.degree. C. to 120.degree. C. to form a granular siloxane gel.

Method for hydrolyzing organochlorosilanes

A process for reducing the chlorocarbon content of a mixture comprising an organochlorosilane, a chlorocarbon, and a hydrosilane. The process comprises contacting a mixture comprising as a major portion an organochlorosilane and as a minor portion a chlorocarbon and a hydrosilane with an alumina-zirconia cogel to effect formation of a mixture having reduced chlorocarbon content. When the mixture is contacted with the alumina-zirconia cogel the chlorocarbon reacts with the hydrosilane to form a hydrocarbon that is easily separated from the organochlorosilane. The process improves chlorocarbon removal efficiency while maintaining high throughput rates.

Removal of chlorocarbons from organochlorosilanes

A redistribution process for enriching a low-boiling methylsilane mixture in a methylchlorosilane selected from a group consisting of dimethylhydrochlorosilane and trimethylchlorosilane. The process comprises contacting a low-boiling methylsilane mixture, resulting from the contact of methyl chloride with silicon, with alumina under non-equilibrium conditions at a temperature greater than about 150.degree. C. The present inventors have discovered that the concentrations of dimethylhydrochlorosilane and trimethylchlorosilane reach maximum levels under non-equilibrium conditions occurring at a temperature greater than about 150.degree. C. The process is also useful for facilitating the removal of olefin and chlorocarbon organic contaminants from the low-boiling methylsilane mixture.

Method for redistribution and purification of methylsilanes

The present invention is a method for reducing the ionic chloride content of hydroxyl-terminated siloxanes. The method involves contacting the hydroxyl-terminated siloxanes with a molecular sieve effective in removing residual water from the siloxanes. Since ionic chloride strongly partitions into the water phase, ionic chloride is removed along with the water phase. In a preferred embodiment of the present method as aprotic solvent is employed to facilitate water removal from the hydroxyl-terminated siloxanes.

Method for removal for ionic chloride from hydroxyl-terminated siloxanes

The present invention relates to a novel method of preparing alkoxysilanes and oligomeric alkoxysiloxanes. The method comprises reacting a metal silicate with an acid selected from the group consisting of sulfurous acid and acids with a pKa greater than about 2.5 in the presence of an alcohol. The resultant product is then reacted with an alcohol to form the alkoxysilane or oligomeric alkoxysiloxane, depending on the starting silicate. This method is particularly valuable since the reaction conditions are mild and the reactants are readily available.

Alkoxysilanes and oligomeric alkoxysiloxanes by a silicate-acid route

The instant invention is a method for the quenching of a spent bed resulting from the reaction of organic halides with silicon metal to form organohalosilanes. The method employs a strong base and elevated temperature to digest the hydrophobic siloxane-rich coating and dislodge the carbon coating which forms around the spent bed particles. Removal of these coatings allows more rapid and complete quenching of the autoxidants on the surface of the spent bed particles.

Method for quenching silicon spent bed

The described invention is a process for reducing residual organic chlorides in a crude phenylchlorosilane mixture. The process involves contacting the organic chloride with a Lewis acid forming material, in the presence of a phenyl source. The phenyl source can be the phenylchlorosilanes and other sources of phenyl present in the crude phenylchlorosilane mixture. The organic portion of the organic chloride forms a hydrocarbon adduct with the phenyl source. If desired, the hydrocarbon adduct can be easily separated from the phenylchlorosilanes.

Removal of organic chloride from phenylchlorosilanes

Preceramic polymers composed of [R.sub.2 SiC.tbd.CSiR.sub.2 ] and, optionally, [R.sub.2 Si] units are described where R is hydrogen, an alkyl radicals containing 1 to 8 carbon atoms, phenyl radicals, or vinyl radicals. These preceramic polymers may be converted into silicon carbide-containing ceramic materials by pyrolysis at elevated temperatures.

Silicon carbide preceramic polymers

A process for reducing the chlorocarbon content of alkylsilanes is described. The process comprises (A) contacting crude alkylsilanes, containing as a minor portion chlorocarbons, and a hydrogen-containing silane with a catalyst; wherein the catalyst is a sufficient amount of an effective Lewis acid forming material; (B) facilitating the reaction of the chlorocarbons with the hydrogen-containing silane in contact with the catalyst to convert the chlorocarbons to a linear or branched alkanes; (C) separating catalyst from the alkylsilanes and alkanes; and (D) recovering alkylsilanes with lowered chlorocarbon content.

Removal of chlorinated hydrocarbons from alkylsilanes

A process for purifying alkylhalosilanes to reduce the content of olefinic impurities is described. The process comprises (A) contacting crude alkylhalosilanes, containing as a minor portion the olefinic impurities, with a hydrogen-containing halosilane and a soluble compound of a Group VIII metal; (B) facilitating reaction of the olefins with the hydrogen-containing silicon compound in contact with the Group VIII metal compound to form linear or branched silalkanes, said silalkanes having the formula,

Removal of olefins from organohalosilanes

This invention relates to a process for the preparation of polysiloxanes by reacting halosilanes in the presence of metal oxides and sulfolane. Preferred metal oxides include antimony (III) oxide, antimony (V) oxide, cadmium oxide, calcium oxide, copper (II) oxide, indium oxide, iron (II) oxide, iron (III) oxide, magnesium oxide, manganese (II) oxide, mercury (II) oxide, nickel (II) oxide, thallium (III) oxide, tin (II) oxide, and zinc oxide. Improved yields and rates of reaction can be observed with the process of this invention.

Preparation of polysiloxanes from halosilanes

A process is described by which numerous waste or by-product chlorosilane streams can be treated to obtain a granular gel that is easily handleable in further processing steps, shipment, or disposal operations. By hydrolyzing a combined stream with an average SiCl functionality greater than or equal to 2.8 in an aqueous medium at elevated temperature a granular gel is obtained in all cases. The combined stream can be formed by blending several different streams to obtain the desired average SiCl functionality. If the aqueous medium is concentrated hydrogen chloride, the hydrogen chloride generated in the hydrolysis step can be recovered.

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Carrollton, KY, United States of America

Ollie W Marko