Processes and systems for making particulate masterbatches, and compositions obtained therefrom

Abstract

Improved processes and systems are disclosed for making masterbatches of particulates to be incorporated into polymers. In some variations, a process for making a particulate masterbatch comprises the sequential steps of: providing particulates; conveying an aqueous polymer latex and the particulates to a mixing unit, thereby generating a particulate-latex mixture comprising water; conveying the particulate-latex mixture to a homogenizer; conveying the homogenized particulate-latex mixture to a centrifuge to remove a first portion of water; and then conveying the dewatered and homogenized particulate-latex mixture to a screw mixer configured to remove a second portion of water, thereby generating a particulate masterbatch. Other variations employ polymer solids rather than a polymer latex. The processes and systems enable higher energy efficiency, more robust operability that minimizes process fouling, and exceptional particulate dispersion within the masterbatch. Also, these processes do not require the use of a latex coagulant.