Dow Corning Corporation

Roland L Halm

Kirk M Chadwick

Regie H Zapp

Oliver K Wilding, Jr

Richard G Johnson

Ajay K Dhaul

Brian R Keyes

Charles S Kuivila

Oliver K Wilding

Michael A Diaz

Steven K Freeburne

Brian M Naasz

Michael A McIntyre

Dennis Gene Van Koevering

Christopher Darren Gatti

David S Niswonger

Vishu D Dosaj

Ora L Flaningam

Stefan F Rentsch

Robert D Steinmeyer

Charles Alan Hall

Charles E Neal, Jr

Timothy Rex Bunce

Joseph Peter Kohane

Sidney A Hansen

Dennis G VanKoevering

Andrew Bruce Gammie

Rick D Streu

Christopher James Kozenski

James R Hasler, Jr

James S Smith

Richard D Daugherty

Todd F Bischoff

Andrew B Pierce

Keith Quentin Hayes, Ii

Jodi A Bourgoin

Ronald E Lund

Jonathan D Wineland

Catherine L Bothe Almquist

Chlorosilanes such as dimethyldichlorosilane are hydrolyzed in a first super-azeotropic hydrochloric acid distillation column A to produce cyclosiloxanes, chlorosiloxanes, and hydrogen chloride gas. The cyclosiloxanes and the chlorosiloxanes are washed and separated according to their volatility in a second sub-azeotropic hydrochloric acid distillation column B, to produce a substantially chloride free volatile cyclosiloxane stream and a substantially chloride free non-volatile siloxane stream. The process is substantially chloride efficient.

Reactive distillation of chlorosilanes

A method for removing a particulate from a liquid silicon containing compound. The method comprises contacting a suspension comprising a non-conducting liquid silicon containing compound and a particulate having a different dielectric constant than the non-conducting liquid silicon containing compound with a non-conducting packing substrate in an electric field. The present method is especially useful for removing suspended particulate ranging in size from about 0.01 to 100 microns from silicon fluids.

Method for removing particulate from a liquid silicon containing compound

An improved structured packing for use in a liquid-vapor contact column. More specifically in a structured packing for liquid-vapor contact where the structured packing comprises laterally orientated channels having peripheral openings, the improvement comprises substantially occluding the peripheral openings with a barrier film. The present invention also includes an improved liquid-vapor contact column comprising a column shell having positioned within a structured packing comprising an outer surface in non-occlusive proximation to the column shell and laterally orientated channels having peripheral openings through the outer surface, the improvement comprising substantially occluding the peripheral openings with a barrier film.

Structured packing containing liquid-vapor contact column

A process for separating an emulsion into separate and easily recoverable phases. The process comprises exposing an emulsion comprising a discontinuous phase and a non-conducting continuous phase to an electric field thereby effecting coalescence of the discontinuous phase into droplets of a size for effective gravitation from the continuous phase, where the discontinuous phase and the continuous phase have different dielectric constants and densities and at least one of the phases comprise a silicon containing compound or a silicon containing polymer. The present process is especially useful for separating emulsions where the discontinuous phase is an aqueous acid solution and the continuous phase is diorganopolysiloxane.

Electric field enhanced coalescence of emulsions comprising a silicon

A method for controlling the direct process to vary the concentrations of trialkylhalosilanes and alkyltrihalosilanes in the product. The method comprises contacting an alkyl chloride with silicon metalloid in the presence of a catalytic amount of a catalyst comprising 0.5 to 10 weight percent copper, 5 to 200 ppm tin, 25 to 2,500 ppm phosphorous, and greater than zero to less than 50 ppm zinc, where the concentration of each of the catalyst components is based on the weight of the silicon, at a temperature within a range of about 250.degree. C. to 400.degree. C. The present inventors have found that by controlling the zinc concentration the concentrations of trialkylhalosilanes and alkyltrihalosilanes in the product can be varied.

Method for controlling the direct process product distribution

A process for separating dimethyldichlorosilane from methyltrichlorosilane in a mixture. The process comprises contacting a mixture comprising methyltrichlorosilane and dimethyldichlorosilane with silica gel, where the dimethyldichlorosilane is selectively retained by the silica gel. The process provides for the recovery of a methyltrichlorosilane fraction reduced in dimethyldichlorosilane concentration. The present process is especially useful for removing low levels of dimethyldichlorosilane present as a contaminate in methyltrichlorosilane.

Process for separation of dimethyldichlorosilane from

A process for separating methyltrichlorosilane from dimethyldichlorosilane in a mixture. The process comprises contacting a mixture comprising methyltrichlorosilane and dimethyldichlorosilane with activated carbon, where the methyltrichlorosilane is selectively adsorbed by the activated carbon. The process allows for the recovery of a dimethyldichlorosilane fraction reduced in methyltrichlorosilane concentration. The methyltrichlorosilane can be recovered by desorption from the activated carbon. The present process is especially useful for removing low levels of methyltrichlorosilane present as a contaminate in dimethyldichlorosilane.

Process for separation of methyltrichlorosilane from

A process for purifying halosilanes consisting of contacting a mixture comprising a halosilane and a hydrocarbon with an adsorbent selective for the hydrocarbon, thereby reducing the hydrocarbon content of the mixture. The present process is particularly useful for removing hydrocarbon contaminates from chlorosilanes, where the hydrocarbon contaminates have a boiling point similar to that of the chlorosilanes.

Process for purifying halosilanes

The present invention is a method for analyzing silicon for nonmetallic contaminants. The method comprises: (A) forming an alloy comprising silicon and a metal which promotes separation of nonmetallic contaminants present in the alloy, (B) separating the nonmetallic contaminants from the alloy, and (C) analyzing the separated nonmetallic contaminants for chemical content. The present invention is particularly useful for analyzing metallurgical grade silicon intended for use in the direct process for the production of organohalosilanes for the presence of oxides and carbides of calcium, aluminum, and silicon.

Analytical method for nonmetallic contaminates in silicon

The present invention is an improved process for preparing a portland cement composition where the process comprises heat calcining a mixture comprising a source of calcium and a source of silicon to form clinker. The improvement comprises providing to the process a silicon containing product resulting from the hydrolysis of chlorosilicon by-product as at least a portion of the source of silicon.

Hydrolyzed chlorosilicon by-product addition to cement

A process for the hydrogenation of chlorosilanes. The process comprises contacting a chlorosilane with aluminum and a hydrogen source selected from a group consisting of hydrogen gas and gaseous hydrogen chloride in the presence of a catalyst. The catalyst is selected from a group consisting of copper and copper compounds, tin and tin compounds, zinc and zinc compounds, and mixtures thereof.

Process for hydrogenation of chlorosilane

The present invention is a process for converting a high-boiling component resulting from the reaction of an organochloride with silicon into commercially more desirable monosilanes. The process comprises contacting the high-boiling component with hydrogen gas at a temperature within a range having a lower limit greater than 250.degree. C. and an upper limit of 1000.degree. C. Yield of the present process may be improved by use of a catalyst selected from a group consisting of activated carbon, platinum metal, platinum supported on alumina, palladium supported on carbon, SbCl.sub.5, H.sub.2 PtCl.sub.6, BCl.sub.3, AlCl.sub.3, and AlCl.sub.3 supported on a support material selected from a group consisting of carbon, alumina, and silica. In a preferred embodiment of the present process the process is run at a pressure within a range of about 250-1000 psig. The present process is preferential for the production of diorganodichlorosilane in relation to organotrichlorosilane in the monosilane product.

Conversion of direct process high-boiling component to silane monomers

The present invention is a process for converting a high-boiling component resulting from the reaction of an organochloride with silicon into commercially more desirable monosilanes. The process comprises contacting the high-boiling component with chlorine at a temperature within a range of about 250.degree. C. to 1000.degree. C. Improved yield of monosilanes can be obtained in the process by the use of a catalyst selected from a group consisting of alumina, silica. activated carbon, AlCl.sub.3, and AlCl.sub.3 supported on a support selected from a group consisting of alumina, silica, and carbon.

Conversion of direct process high-boiling component to chlorosilane

The present invention is an improved process for the reaction of an alkyl halide with particulate silicon in a fluidized-bed process. The improvement comprises controlling the particle size of the silicon within a range of one micron to 85 microns. Preferred is when the particle size of the silicon has a mass distribution characterized by a 10th percentile of 2.1 to 6 microns, a 50th percentile of 10 to 25 microns, and a 90th percentile of 30 to 60 microns. Most preferred is when the particle size mass distribution of the silicon is characterized by a 10th percentile of 2.5 to 4.5 microns, a 50th percentile of 12 to 25 microns, and a 90th percentile of 35 to 45 microns. The process is run in the presence of a catalyst composition comprising copper and other catalysts.

Particle size distribution for fluidized-bed process for making

The present invention is a process for converting a high-boiling component resulting from the reaction of an organochloride with silicon into commercially more desirable monosilanes. The process comprises contacting the high-boiling component with hydrogen chloride and hydrogen gas at a temperature within a range of about 250.degree. C. to 1000.degree. C. in the presence of a catalyst selected from a group consisting of activated carbon, alumina, silica, zeolite, AlCl.sub.3, AlCl.sub.3 supported on a support selected from a group consisting of carbon, silica, and alumina; platinum supported on a support selected from a group consisting of carbon, silica, and alumina; and palladium supported on a support selected from a group consisting of carbon, silica, and alumina.

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Madison, IN, United States of America

Roland L Halm