U.S. patent application number 10/713748 was filed with the patent office on 2004-05-27 for perlite products with controlled particle size distribution.
Invention is credited to Hayward, Christopher, Palm, Scott K., Roulston, John S., Wang, Bo.
Application Number | 20040099184 10/713748 |
Document ID | / |
Family ID | 24546921 |
Filed Date | 2004-05-27 |
United States Patent
Application |
20040099184 |
Kind Code |
A1 |
Palm, Scott K. ; et
al. |
May 27, 2004 |
Perlite products with controlled particle size distribution
Abstract
Expanded perlite products having controlled particle size
distribution, methods of producing the expanded perlite products,
and methods of use thereof are provided. The expanded perlite
product has, for example, a low ratio of standard deviation of
particle size distribution to median particle size (for example,
less than 0.63) and low median particle size (for example, less
than 50 microns). The expanded perlite product may be used in a
variety of applications including filter applications.
Inventors: |
Palm, Scott K.; (Santa
Maria, CA) ; Wang, Bo; (Lompoc, CA) ; Hayward,
Christopher; (Santa Ana, CA) ; Roulston, John S.;
(Lompoc, CA) |
Correspondence
Address: |
MORRISON & FOERSTER LLP
755 PAGE MILL RD
PALO ALTO
CA
94304-1018
US
|
Family ID: |
24546921 |
Appl. No.: |
10/713748 |
Filed: |
November 13, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10713748 |
Nov 13, 2003 |
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10268573 |
Oct 9, 2002 |
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6712898 |
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10268573 |
Oct 9, 2002 |
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09635214 |
Aug 8, 2000 |
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6464770 |
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Current U.S.
Class: |
106/409 |
Current CPC
Class: |
C04B 2111/00793
20130101; B01D 39/06 20130101; B01J 20/106 20130101; Y10S 106/02
20130101; C04B 14/185 20130101; C04B 14/185 20130101; C04B 20/008
20130101 |
Class at
Publication: |
106/409 |
International
Class: |
C08K 007/22; C04B
016/08 |
Claims
What is claimed is:
1. An expanded perlite product having a controlled particle size
distribution; wherein the ratio of the standard deviation of
particle size distribution to the median particle size is less than
0.63; and wherein the median particle size is less than 50
microns.
2. The expanded perlite product of claim 1, wherein the ratio of
the standard deviation of particle size distribution to the median
particle size is less than 0.60.
3. The expanded perlite product of 2, wherein the ratio of the
standard deviation of particle size distribution to the median
particle size is less than 0.58.
4. The expanded perlite product of claim 3, wherein the ratio of
the standard deviation of particle size distribution to the median
particle size is less than 0.55.
5. The expanded perlite product of claim 1, wherein the product has
a wet density less than 50 pounds per cubic foot.
6. The expanded perlite product of claim 5, wherein the product has
a wet density less than 40 pounds per cubic foot.
7. The expanded perlite product of claim 6, wherein the product has
a wet density less than 35 pounds per cubic foot.
8. The expanded perlite product of claim 7, wherein said product
further has a wet density less than 30 pounds per cubic foot.
9. The expanded perlite product of claim 8, wherein the product has
a wet density less than 25 pounds per cubic foot.
10. The expanded perlite product of claim 9, wherein the product
has a wet density less than 20 pounds per cubic foot.
11. The expanded perlite product of claim 1, wherein the product
has a floater content of less than 10 percent by volume.
12. The expanded perlite product of claim 11, wherein the product
has a floater content of less than 5 percent by volume.
13. The expanded perlite product of claim 12, wherein the product
has a floater content of less than 2.5 percent by volume.
14. The expanded perlite product of claim 13, wherein the product
has a floater content of less than 2 percent by volume.
15. The expanded perlite product of claim 1, wherein the product
has a blue light brightness greater than 80.
16. The expanded perlite product of claim 15, wherein the product
has a blue light brightness greater than 82.
17. The expanded perlite product of claim 16, wherein the product
has a blue light brightness greater than 83.
18. The expanded perlite product of claim 17, wherein the product
has a blue light brightness greater than 85.
19. The expanded perlite product of claim 1, wherein the product
has a Hegman fineness greater than 1.0.
20. The expanded perlite product of claim 19, wherein the product
has a Hegman fineness greater than 2.0.
21. The expanded perlite product of claim 20, wherein the product
has a Hegman fineness greater than 3.0.
22. The expanded perlite product of claim 21, wherein the product
has a Hegman fineness greater than 4.0.
23. The expanded perlite product of claim 22, wherein the product
has a Hegman fineness greater than 5.0.
24. The expanded perlite product of claim 23, wherein the product
has a Hegman fineness greater than 6.0.
25. A process for the preparation of an expanded perlite product of
claim 1, the method comprising using air classification equipment
to effect both milling and air classification, thereby to obtain
the expanded perlite product.
26. A process for the preparation of an expanded perlite product of
claim 1, the method comprising obtaining the product by centrifugal
sieving.
27. A filter, insulating material, filler, horticultural media,
hydroponic media, or chemical carrier comprising the expanded
perlite product of claim 1.
28. A method of separating components from a solution, comprising
filtering a solution comprising the components through a filter
comprising the expanded perlite product of claim 1.
Description
TECHNICAL FIELD
[0001] This invention relates to a siliceous perlite product having
controlled particle size distribution, which is useful in filter
and filler applications.
BACKGROUND ART
[0002] Throughout this application, various publications, patents,
and published patent applications are referred to by an identifying
citation; full citations for these documents may be found at the
end of the specification. The disclosure of the publications,
patents, and published patent specifications referred in this
application are hereby incorporated by reference into the present
disclosure.
[0003] Many methods for the separation of particles from fluids
employ cellular or porous siliceous media, such as diatomite or
perlite, as filter aids (Bear, 1988; Cain, 1984; Carman, 1937;
Heertjes, 1949, 1966; Ruth, 1946; Sperry, 1916; Tiller, 1953, 1962,
1964).
[0004] Perlite products have been prepared by milling, screening,
and thermal expansion. Depending on the quality of the perlite ore
and the method of processing, expanded perlite products have been
used as filter aids, lightweight insulating materials, filler
materials, horticultural and hydroponic media, and chemical
carriers; expanded perlite has been used in filtration applications
since about the late 1940's (Breese and Barker, 1994). Expanded
perlite is also used as an absorbent for treating oil spills (e.g.,
Stowe, 1991).
[0005] Conventional processing of perlite consists of comminution
of the ore (crushing and grinding), screening, thermal expansion,
milling, and air size separation of the expanded material to meet
the specification of the finished product. For example, perlite ore
is crushed, ground, and separated to a predetermined particle size
range (e.g., passing 30 mesh), then the separated material is
heated in air at a temperature of 870-1100.degree. C. in an
expansion furnace (c.function.. Neuschotz, 1947; Zoradi, 1952),
where the simultaneous softening of the glass and vaporization of
contained water leads to rapid expansion of glass particles to form
a frothy glass material with a bulk volume up to 20 times that of
the unexpanded ore. The expanded perlite is then air separated to
meet the size specification of the final product. The expanded
perlite product may further be milled and separated for use as
filter aid or filler material (Breese and Barker, 1994). Some
degree of separation after expansion is common, for example, using
cyclones, which are simple conical devices that separate particles
according to their aerodynamic mass by suspending them in a stream
of air. Stein (1955) states that two or more cyclones in series are
sometimes used, the first cyclone having lower efficiency than the
following ones, so as to air-separate the product into several size
fractions.
[0006] Expanded perlite products have found widespread utility in
filtration applications. The principles of filtration using porous
media have been developed over many years (Carman, 1937; Heertjes,
1949, 1966; Ruth, 1946; Sperry, 1916; Tiller, 1953, 1962, 1964),
and have been recently reviewed in detail from both practical
perspectives (Cain, 1984; Kiefer,1991) as well as from their
underlying theoretical principles (Bear, 1988; Norden, 1994).
[0007] Perlite products are applied to a septum to improve clarity
and increase flow rate in filtration processes, in a step sometimes
referred to as "precoating." Perlite products are also added
directly to a fluid as it is being filtered to reduce the loading
of undesirable particulate at the septum while maintaining a
designed liquid flow rate, in a step often referred to as "body
feeding". Depending on particular separation involved, perlite
products may be used in precoating, body feeding, or both. Perlite
products, especially those which are surface treated, can enhance
clarification or purification of a fluid (Ostreicher, 1986).
Expanded perlite products are often used as insulating fillers,
resin fillers, and in the manufacture of textured coatings (Breese
and Barker, 1994).
[0008] Particle size has strong effect on both filter aid and
filler applications. The selection of the proper grade of filter
aid depends on the size of the suspended particles that are to be
removed. It is axiomatic in the use of filter aids that as the
filter aid particle size and the liquid flow rate increase, the
ability of the filter aid to remove small particles of suspended
matter decreases (Kadey, 1983). Conversely, as filter aid particle
size and liquid flow rate decrease, the ability of the filter aid
to remove small particles of suspended matter increases. The
performance of fillers is also closely related to the particle
size. Particle size effects result from the average size, the top
size, and the size distribution. For example, in a paint system,
the average size of a filler may affect viscosity and binder
demand, the size distribution may affect packing and resultant
density and film integrity, and the top size may affect paint
gloss/sheen and smoothness, or cause fracture failures or cracking
(Trivedi and Hagemeyer, 1994).
[0009] The as-expanded perlite normally contains a significant
amount of light-weight material called floaters, which are expanded
perlite particles that often contain entrapped air. As the name
suggests, floaters quickly float to the surface of liquid rather
than remain buoyantly suspended in it. The floater content has a
negative effect on filter aid and filler applications because they
often float away from their intended functional location, for
instance, either away from the filter septum or away from a desired
location within a filler system. Therefore, floaters should be
minimized during the processing of perlite for many
applications.
[0010] Color is also important for a filler in any application,
especially where color of the end product is important. Whiter
filler products with high blue light brightness normally have
greater utility, as they can be used in all colored and white
products and, relative to non-white fillers, reduce the demand for
expensive white pigments, such as titanium dioxide. For these
reasons, perlite products with controlled particle size
distribution, low floater content, and high blue light brightness
are often desirable.
[0011] The particle size distribution, floater content and blue
light brightness of commercially available expanded perlite
products, measured using the standard methods described below, are
shown in Table I. The lowest median particle size (d.sub.50) for
the product having a ratio of the standard deviation of particle
size distribution to the median particle size (sd/d.sub.50) less
than 0.63 is 53 microns (sometimes abbreviated ".mu."; i.e., .mu.m,
or micrometer). The lowest floater content for the product having a
ratio of the standard deviation of particle size distribution to
the median particle size (sd/d.sub.50) less than 0.63 is 10 percent
by volume.
1TABLE 1 Wet d.sub.50 sd Floater Blue light Density Product
Manufacturer (.mu.m) (.mu.m) sd/d.sub.50 (%) Brightness
(lb/ft.sup.3) Harborlite .RTM. 2000 Harborlite Corp. 58.84 35.52
0.60 22 83 * Harborlite .RTM. 1950S Harborlite Corp. 62.40 39.13
0.63 12 73 * Harborlite .RTM. 1900S Harborlite Corp. 54.94 34.22
0.62 12 71 * Harborlite .RTM. 1500S Harborlite Corp. 52.64 33.64
0.64 12 69 * Harborlite .RTM. 1500 Harborlite Corp. 50.45 32.24
0.64 14 81 * Harborlite .RTM. 900S Harborlite Corp. 54.00 35.97
0.67 10 70 * Harborlite .RTM. 900 Harborlite Corp. 44.37 29.52 0.67
10 82 * Harborlite .RTM. 800 Harborlite Corp. 39.69 26.97 0.68 10
81 * Harborlite .RTM. 700 Harborlite Corp. 38.66 26.62 0.69 10 81 *
Harborlite .RTM. 635 Harborlite Corp. 25.30 18.46 0.73 <2 79
12.9 Harborlite .RTM. 500 Harborlite Corp. 44.15 31.66 0.72 8 76
14.5 Harborlite .RTM. 475 Harborlite Corp. 28.50 21.22 0.74 <2
77 13.6 Harborlite .RTM. 400 Harborlite Corp. 36.55 28.26 0.76
<2 76 13.9 Harborlite .RTM. 300C Harborlite Corp. 18.75 15.95
0.85 <2 80 17.1 Harborlite .RTM. 200Z Harborlite Corp. 19.18
16.18 0.84 <2 75 15.4 Harborlite .RTM. 200 Harborlite Corp.
21.85 18.12 0.83 <2 75 19.2 Europerlita .TM. 1500 Europerlita
52.69 36.03 0.68 18 74 * Espanola, S.A. Europerlita .TM. 900
Europerlita 49.59 32.52 0.66 18 72 * Espanola, S.A. Europerlita
.TM. 700 Europerlita 46.45 33.03 0.71 18 71 * Espanola, S.A.
Europerlita .TM. 475 Europerlita 37.93 27.45 0.72 10 71 * Espanola,
S.A. Europerlita .TM. 400 Europerlita 22.91 20.64 0.90 <2 76
14.3 Espanola, S.A. Europerlita .TM. 350 Europerlita 18.13 16.22
0.89 <2 74 17.8 Espanola, S.A. Europerlita .TM. 75 Europerlita
15.98 16.39 1.02 <2 70 17.6 Espanola, S.A. Dicalite .TM. 416
Grefco, Inc. 12.02 15.84 1.32 6 77 19.5 Dicalite .TM. 426 Grefco,
Inc. 23.91 25.24 1.06 10 82 * Dicalite .TM. 476 Grefco, Inc. 49.93
33.91 0.68 34 80 * Dicalite .TM. 419 Grefco, Inc. 46.89 31.43 0.67
28 81 * Clarcel Flo .TM. 2A Ceca S.A. 53.05 33.85 0.64 10 71 *
Randalite .TM. W9 Winkelmann 33.90 25.68 0.76 6 73 16.6 Materaria
S.r.L. Randalite .TM. W12 Winkelmann 42.35 31.02 0.73 10 78 *
Materaria S.r.L. Randalite .TM. W19 Winkelmann 43.04 31.79 0.74 14
73 * Materaria S.r.L. Randalite .TM. W24 Winkelmann 45.21 30.49
0.67 10 80 * Materaria S.r.L. Randalite .TM. W28 Winkelmann 53.81
36.21 0.67 34 77 * Materaria S.r.L. Randalite .TM. W32 Winkelmann
63.44 40.29 0.64 20 76 * Materaria S.r.L. Topco .TM. #54 Showa
Chemical 5.47 5.769 1.05 <2 76 20.8 Industry Co., Ltd Topco .TM.
#51 Showa Chemical 34.27 26.65 0.78 8 78 13.9 Industry Co., Ltd
Topco .TM. #31 Showa Chemical 37.96 30.99 0.82 12 75 * Industry
Co., Ltd Topco .TM. #34 Showa Chemical 39.74 31.42 0.79 16 78 *
Industry Co., Ltd Topco .TM. #36 Showa Chemical 44.33 33.71 0.76 16
76 * Industry Co., Ltd Topco .TM. #38 Showa Chemical 45.56 32.48
0.71 20 77 * Industry Co., Ltd Roka Help .TM. #419 Mitsui Mining
& 19.29 18.29 0.95 <2 77 13.0 Smelting Co., Ltd Roka Help
.TM. #479 Mitsui Mining & 39.43 29.95 0.76 14 73 * Smelting
Co., Ltd Roka Help .TM. #4159 Mitsui Mining & 47.52 32.43 0.68
24 77 * Smelting Co., Ltd SM 101 Samson Co., Ltd. 11.60 12.00 1.03
<2 75 17.1 SM 201 Samson Co., Ltd 17.87 14.35 0.80 <2 81 11.3
SM 441 Samson Co., Ltd 37.03 28.62 0.77 16 79 * SM 501 Samson Co.,
Ltd 52.21 34.86 0.67 26 77 * SM 601 Samson Co., Ltd 56.65 38.35
0.68 32 74 * SM 771 Samson Co., Ltd 60.02 36.82 0.61 38 75 * SM 881
Samson Co., Ltd 62.17 39.97 0.64 40 75 * SM 901 Samson Co., Ltd
62.98 62.98 1.00 42 75 * * not determined because of high floater
content.
[0012] Fine expanded perlite products typically have a median
particle size of 40 .mu.m or less. The production of fine, expanded
perlite products of a controlled particle size distribution having
low wet density has been difficult due to the characteristics of
expanded perlite and the limitations of existing commercial mineral
milling equipment. For example, when unexpanded perlite ore is
crushed and screened to a size finer than approximately 54
micrometers, and is then expanded, it forms virtually 100%
microspheres (sometimes referred to as microbubbles), a form of
floaters, which are hereinafter referred to as expanded perlite
microspheres. As a result, fine, low wet density perlite products
containing a low percentage of floaters are not generally produced
by expanding finely milled ore. Conventional perlite products that
are fine and relatively lower in floater content are produced by
one of two methods: (i) expanding perlite to a coarser size than
desired and milling the expanded product to the desired size; or
(ii) recovering a small percentage of the by-product fines produced
during the milling of coarser products in a fines recovery
circuit.
[0013] When a coarse expanded perlite product is milled by
conventional means, the wet density of the product increases
substantially. In addition, existing commercial milling and
classifying equipment is designed for much denser materials and
does not provide good control of the particle size of milled light
density materials, such as expanded perlite. Fine expanded perlite
with typically somewhat lighter wet density can be produced by
recovering by-product fines from a conventional perlite milling
operation, but the quality control of these products is difficult,
yields are low, and perlite products with controlled particle size
distribution are not generally produced.
[0014] There is a need for improved perlite products with
controlled particle size distribution.
SUMMARY OF THE INVENTION
[0015] An expanded perlite product having a controlled particle
size distribution is provided, wherein the ratio of the standard
deviation of particle size distribution to the median particle size
is less than 0.63; and wherein the median particle size is less
than 50 microns.
[0016] In the expanded perlite product, for example, the ratio of
the standard deviation of particle size distribution to the median
particle size is less than 0.60; less than 0.58; or less than 0.55.
The expanded perlite product has, for example, a wet density less
than 50 pounds per cubic foot; less than 40 pounds per cubic foot;
less than 35 pounds per cubic foot; less than 30 pounds per cubic
foot; less than 25 pounds per cubic foot; or less than 20 pounds
per cubic foot.
[0017] The expanded perlite product has, for example, a floater
content of less than 10 percent by volume; a floater content of
less than 5 percent by volume; a floater content of less than 2.5
percent by volume; or a floater content of less than 2 percent by
volume. The expanded perlite product has, for example, a blue light
brightness greater than 80; greater than 82; greater than 83; or
greater than 85.
[0018] The expanded perlite product has, for example, a Hegman
fineness greater than 1.0; greater than 2.0; greater than 3.0;
greater than 4.0; greater than 5.0; or greater than 6.0.
[0019] Processes for the preparation of an expanded perlite also
are provided, for example, comprising using air classification
equipment to effect both milling and air classification, thereby to
obtain the expanded perlite product. The expanded perlite product
also can be obtained, for example, by centrifugal sieving.
[0020] Further provided are filters, insulating materials, fillers,
horticultural media, hydroponic media, and chemical carriers
comprising the expanded perlite product. Also provided are methods
of separating components from a solution, comprising filtering a
solution comprising the components through a filter comprising the
expanded perlite products.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a scanning electron micrograph of the expanded
perlite product of Example 10, showing the intricate cellular
structure of this perlite product.
MODES FOR CARRYING OUT THE INVENTION
[0022] Provided is a perlite product having controlled particle
size distribution. In one embodiment, there is provided an expanded
perlite product having a low ratio of standard deviation of
particle size distribution to median particle size (for example,
less than 0.63) and low median particle size (for example, less
than 50 microns).
[0023] In a further embodiment, the perlite product is
characterized by low floater content (for example, less than 10
percent by volume), high blue light brightness (for example,
greater than 80), and/or high Hegman fineness (for example, greater
than 1.0). The perlite product advantageously can retain the
intricate and cellular characteristics of the feed material, while
also having controlled particle size distribution, low floater
content, high blue light brightness, thereby permitting much
greater utility in both filtration and filler applications.
[0024] Perlite
[0025] Improved perlite products with controlled particle size
distribution are provided, as well as methods of making, and
methods of use thereof. The improved perlite product with
controlled particle size distribution is derived from the expanded
natural glass, perlite. The perlite product is useful in a variety
of filtration and functional filler applications. The intricate
porous and cellular structure of the siliceous perlite product
promotes its usefulness for the physical entrapment of particles in
filtration processes, and also for modifying properties of various
materials when added as a functional filler.
[0026] The perlite product disclosed herein is derived from perlite
ore, which belongs to the class of natural glasses. The term
"natural glass" is used herein the conventional sense and refers to
natural glasses, commonly referred to as volcanic glasses, which
are formed by the rapid cooling of siliceous magma or lava. Most
natural glasses are chemically equivalent to rhyolite. Natural
glasses which are chemically equivalent to trachyte, dacite,
andesite, latite, and basalt are known but are less common. The
term "obsidian" is generally applied to dark, most often black,
massive natural glasses that are rich in silica (i.e., SiO.sub.2).
Obsidian glasses may be classified into subcategories according to
their silica content, with rhyolitic obsidians (containing
typically about 73% SiO.sub.2 by weight) as the most common (Berry
et al., 1983).
[0027] Perlite ore is a hydrated natural glass containing typically
about 72-75% SiO.sub.2, 12-14% Al.sub.2O.sub.3, 0.5-2%
Fe.sub.2O.sub.3, 3-5 % Na.sub.2O, 4-5% K.sub.2O, 0.4-1.5% CaO (by
weight), and small concentrations of other metallic elements.
Perlite ore is distinguished from other natural glasses by a higher
content (2-10% by weight) of chemically bonded water, the presence
of a vitreous, pearly luster, and characteristic concentric or
arcuate onion skin-like (i.e., perlitic) fractures.
[0028] Perlite products may be prepared by methods disclosed herein
which may include milling, screening, and thermal expansion. The
perlite products can possess commercially valuable physical
properties such as high porosity, low bulk density, and chemical
inertness. Depending on the quality of the perlite ore and the
method of processing, expanded perlite products can be used as
filter aids, lightweight insulating materials, filler materials,
horticultural and hydroponic media, and chemical carriers.
[0029] The processing of perlite can include comminution of the ore
(crushing and grinding), screening, thermal expansion, milling, and
air size separation of the expanded material to meet the
specification of the finished product and other methods known in
the art. For example, perlite ore is crushed, ground, and separated
to a predetermined particle size range (e.g., passing 30 mesh),
then the separated material is heated in air at a temperature of
870-1 100.degree. C. in an expansion furnace (c.function..
Neuschotz, 1947; Zoradi, 1952), where the simultaneous softening of
the glass and vaporization of contained water leads to rapid
expansion of glass particles to form a. frothy glass material with
a bulk volume up to 20 times that of the unexpanded ore. The
expanded perlite is then separated to meet the size specification
of the final product.
[0030] Expanded perlite includes one or more cells, or parts of
cells, in which a cell is essentially a void space partially or
entirely surrounded by walls of glass, usually formed from
expansion of gases when the glass is in a softened state. The
presence of gas-filled or vacuous cells in a given volume of glass
results in lower centrifuged wet density than for the same volume
of solid glass. If cells are closed and air is entrapped, the
particles of perlite may float on liquid. Fracturing of perlite,
for example, by milling, can create an intricate cellular structure
that retains the characteristic of low wet density and also
provides useful features for filtration and functional filler
applications. However, excessive milling can degrade intricate
cellular structures, leading to increased centrifuged wet density
while diminishing the desired function obtained from structural
features.
[0031] The expanded perlite products can be used in a variety of
filtration applications. The term "filtration" is used herein in
the conventional sense and refers to the removal of particulate
matter from a fluid in which the particulate matter is suspended.
An exemplary filtration process is one which comprises the step of
passing the fluid through a filter aid material supported on a
septum (e.g., mesh screen, membrane, or pad).
[0032] The intricate cellular structure of expanded perlite is
particularly effective for the physical entrapment of particles in
filtration processes. The perlite products can be applied to a
septum to improve clarity and increase flow rate in filtration
processes, in a step sometimes referred to as "precoating." Perlite
products are also can be added directly to a fluid as it is being
filtered to reduce the loading of undesirable particulate at the
septum while maintaining a designed liquid flow rate, in a step
often referred to as "body feeding". Depending on particular
separation involved, the perlite products may be used in
precoating, body feeding, or both. The perlite products, especially
those which are surface treated, also may provide preselected
properties during filtration that can further enhance clarification
or purification of a fluid.
[0033] The expanded perlite products can thus be used to separate
components, especially particulate matter from solutions, fluids,
and fluid suspensions. For example, solid particulate matter from
fermentation process solutions may include cells, cell debris,
protein aggregates, and other components that can be separated from
the remaining solutions, thus clarifying these solutions.
[0034] The intricate and cellular structure of perlite products
also provides them with commercially valuable filler properties.
For example, the expanded perlite products disclosed herein may be
used as insulating fillers, resin fillers, and in the manufacture
of textured coatings.
[0035] The particle size can be preselected for filter aid and
filler applications. Particle size effects result from the average
size, the top size, and the size distribution. For a filter aid of
moderate permeability, the preferred average size of the improved
perlite product is around 20-40 microns, the size distribution is
preferably between 3-150 microns, and the top size is preferably
around 80-150 microns. For use in a typical flat latex paint, the
preferred average size of the improved perlite product is around
20-30 microns, the size distribution is preferably between 3-150
microns, and the top size is preferably around 80-150 microns. For
use in a typical low gloss or semi-gloss latex paint, the preferred
average size of the improved perlite product is around 14-18
microns, the size distribution is preferably between 2-80 microns,
and the top size is preferably around 60-80 microns.
[0036] The improved perlite product with controlled particle size
distribution of the present invention retains the intricate
cellular structure unique to perlite, as shown in FIG. 1, which is
a a scanning electron micrograph of the expanded perlite product of
Example 10, but has controlled particle size distribution, low
floater content and high blue light brightness, thereby permitting
much greater utility, particularly as filter aid or filler
products.
[0037] Using methods disclosed herein, commercially available
equipment designed to classify but not to mill minerals of normal
densities may be used for both milling and classifying expanded
perlite to thereby produce the improved perlite products with
controlled particle size distribution of the present invention. The
products so made are superior in many applications to existing
products, and the production process is economically attractive
because a high yield of the desired product is obtained.
[0038] In one embodiment, an improved perlite product is provided
with controlled particle size distribution, as defined by a ratio
of the standard deviation of particle size distribution to the
median particle size, less than 0.63, and a median particle size
less than 50 microns. In another embodiment, the ratio of the
standard deviation of particle size distribution to the median
particle size is less than 0.60, for example, less than 0.58, or
less than 0.55.
[0039] In another embodiment, the improved perlite product with
controlled particle size distribution has a wet density not greater
than 50 lb/ft.sup.3; not greater than 40 lb/ft.sup.3;
[0040] not greater than 35 lb/ft.sup.3; not greater than 30
lb/ft.sup.3; not greater than 25 lb/ft.sup.3; or in one preferred
embodiment, not greater than 20 lb/ft.sup.3.
[0041] In another embodiment, the improved perlite product with
controlled particle size distribution is further characterized by
having a blue light brightness greater than 80; greater than 82;
greater than 83; or in one preferred embodiment, greater than
85.
[0042] In another preferred embodiment, the improved perlite
product with controlled particle size distribution has a floater
content less than 10 percent by volume; less than 5 percent by
volume; less than 2.5 percent by volume; or in one preferred
embodiment, less than 2 percent by volume.
[0043] In another embodiment, the improved perlite product with
controlled particle size distribution has a ratio of the standard
deviation of particle size distribution to the median particle size
of less than 0.63 and with a Hegman fineness greater than 1.0; a
Hegman fineness greater than 2.0; a Hegman fineness greater than
3.0; a Hegman fineness greater than 4.0; a Hegman fineness greater
than 5.0; or, in one preferred embodiment, a Hegman fineness
greater than 6.0.
[0044] Another aspect of the present invention comprises a method
of preparing the improved perlite product with controlled particle
size distribution using air classification equipment to effect both
milling and air classification.
[0045] Still another aspect of the present invention comprises a
method of preparing the improved perlite product with controlled
particle size distribution by centrifugal sieving.
A. METHODS FOR PREPARING THE IMPROVED PERLITE GLASS PRODUCT WITH
CONTROLLED PARTICLE SIZE DISTRIBUTION
[0046] As described above, the perlite product with controlled
particle size distribution has a defined particle size distribution
and retains the intricate and cellular characteristics of the feed
material. The improved perlite product with controlled particle
size distribution can be prepared by several methods.
[0047] One preferred method of preparing the improved perlite
product of the present invention is by air classification on a
classifier equipped with high speed classifier wheel. Surprisingly,
this method not only removes the coarse particles from the feed
materials but also mills the feed material in a controlled manner,
resulting in the improved perlite product with controlled particle
size distribution.
[0048] Commercially available materials may be used as feed
material. For example, milled expanded perlite, such as
Harborlite.RTM. 2000, and expanded microspheres made from
unexpanded perlite ores, such as Harborlite.RTM. PA4000 (from
Harborlite Corporation, Vicksburg, Mich.), are useful feed
materials.
[0049] The feed material may be classified on commercially
available air classifiers equipped with high speed classifier
wheel. For example, a lab scale Alpine.TM. 50 ATP classifier
(Hosokawa Micron Powder Systems, Summit, N.J.) or a large scale
Alpine.TM. 200 ATP classifier equipped with a top feeding system
(Hosokawa Alpine Aktiengesellchaft, Augsburg, Germany) may be used
for the classification of milled expanded perlite, such as
Harborlite.RTM. 2000. These classifiers mainly consist of a
horizontally mounted high speed classifying wheel and a classifying
air outlet. The classifying air injected into the machine base
flows inwards through the classifying wheel and discharges the fine
material, whereas the coarse particles rejected by the classifying
wheel leave the classifier through the coarse material outlet.
Parameters such as classifier wheel speed and air flow pressure may
be optimized to achieve desired products. Examples of typical
parameters for the 50 ATP classifier include: classifier wheel
speed from 6000 rpm to 22000 rpm and air flow pressure from 8.0 to
15.0 mBar. Examples of typical parameters for the 200 ATP
classifier include: classifier wheel speed from 3500 rpm to 6000
rpm and total air flow from 900 to 950 m.sup.3/h. The fine fraction
collected in the cyclone is the product and coarse fraction
collected in the separator is a by-product or waste.
[0050] Another preferred method of preparing the product of the
present invention is by careful sieving of the feed materials. For
example, a KEK model K1350 centrifugal sifter (Kemutec Inc,
Bristol, Pa.) is used for removing particles larger than 250 mesh
(53 .mu.m) from Harborlite.RTM. 800 feed (Harborlite Corporation,
Vicksburg, Mich.).
[0051] Other possible methods of preparing the product of the
present invention also include milling through a fixed gap mill,
such as a roller mill, and wet classification techniques such as
sedimentation, which separates suspended solid particles from a
liquid by gravity settling, and hydrocycloning, which uses
centrifugal action to classify particles in a liquid media.
[0052] The perlite product with controlled particle size
distribution may be further modified to enhance its performance in
specific applications. For example, its surfaces may be treated
with acids or complexing agents to reduce the concentration of
soluble substances. The perlite product with controlled particle
size distribution may be leached, for example, by methods
appropriate for natural glasses (Palm, 1999). Such methods include,
but are not limited to, leaching at ambient or elevated
temperatures in the presence of such substances as sulfuric acid
(i.e., H.sub.2SO.sub.4), hydrochloric acid (i.e., HCl), nitric acid
(i.e., HNO.sub.3), phosphoric acid (i.e., H.sub.3PO.sub.4), acetic
acid (i.e., CH.sub.3COOH), citric acid (i.e.,
C.sub.6H.sub.3O.sub.7.H.sub.2O), or ethylenedinitrilotetraacetic
acid (i.e., "EDTA").
[0053] The perlite product with controlled particle size
distribution may also be modified by silanization to render the
surfaces either more hydrophobic or hydrophilic using the methods
appropriate for silicate minerals (Moreland, 1975; Sample, 1981).
For example, the perlite product with controlled particle size
distribution can be placed in a plastic vessel, and a small
quantity of dimethyldichlorosilane (i.e.,
SiCl.sub.2(CH.sub.3).sub.2) or hexadimethylsilazane (i.e.,
(CH.sub.3).sub.3Si--NH--Si(CH.sub.3).sub.3) added to the vessel.
Reaction is allowed to take place at the surface in the vapor phase
over a 24 hr period, resulting in more hydrophobic products. Such
products have applications in compositions used in chromatography,
for example, and also when used in conjunction with other
hydrophobic materials for improved mechanical performance, for
example, in applications involving hydrocarbons and oils, and also
to provide reinforcement in plastics and other polymers.
[0054] Similarly, the perlite product with controlled particle size
distribution can be reacted, for example, by suspending it in a
solution containing 10% (w/v) aminopropyltriethoxysilane (i.e.,
C.sub.9H.sub.23NO.sub.3Si) in water, refluxing at 70.degree. C. for
3 hr, filtering the mixture, and drying the remaining solids to
obtain more hydrophilic products. Such products have applications
in compositions used in chromatography, for example, especially
when used in conjunction with aqueous systems for improved
mechanical performance, and to permit further derivatization of the
product, having converted terminal hydroxyl (i.e., --OH) functional
groups at the surface of the perlite product with controlled
particle size distribution to aminopropyl groups (i.e.,
--(CH.sub.2).sub.3NH.sub.2). The hydrophilic (e.g., silanized)
modified perlite product with controlled particle size distribution
can be further reacted to bind an organic compound, for example, a
protein; the improved perlite product with controlled particle size
distribution thereby serves as a support for the immobilization of
the organic compound. So modified, the product has utility in
applications such as affinity chromatography and biochemical
purification.
[0055] The surfaces of the improved perlite product with controlled
particle size distribution may also be etched with etchants
appropriate for glasses, including, but not limited to,
hydrofluoric acid (i.e., HF), ammonium bifluoride (i.e.,
NH.sub.4F.HF), or sodium hydroxide (i.e., NaOH). Surface etching
may enhance subsequent treatment processes; for example, etching
may increase the number of terminal hydroxyl groups, which in turn
may subsequently react with various silanes.
[0056] A number of other reactions pertaining to the surfaces of
glasses have been previously described (Hermanson, 1992). However,
derivatizations of the improved perlite product with controlled
particle size distribution which offer specific properties yield
products with improved efficacy.
[0057] Modifications and variations of the invention as
hereinbefore set forth can be made without departing from the
spirit and scope thereof.
B. METHODS FOR CHARACTERIZING THE IMPROVED PERLITE PRODUCT WITH
CONTROLLED PARTICLE SIZE DISTRIBUTION
[0058] 1. Particle Size Distribution
[0059] The particle size distribution of samples is determined in
accordance with the phenomenon of scattered light from a laser beam
projected through a stream of particles. The amount and direction
of light scattered by the particles is measured by an optical
detector array and then analyzed by a microcomputer which
calculates the size distribution of the particles in the sample
stream. Data reported may be collected on a Leeds and Northrup
Microtrac X100 laser particle size analyzer (Leeds and Northrup,
North Wales, Pa.). This instrument can determine particle size
distribution over a particle size range from 0.12 to 704 microns.
Median particle size (d.sub.50) is defined as that size for which
50 percent of the volume that is smaller than the indicated size.
Rather than providing an indication of the statistical error about
the mean of multiple measurements, the standard deviation (sd) as
used herein describes a specified width of the measured particle
size distribution. In particular, it subtracts the size of
particles comprising the finest 16% of the volume from the size
that comprises 84% of the volume, and divides that number by 2.
Both values may be calculated from the instrument's algorithms, and
are discussed in detail in the instrument's documentation (Leeds
and Northrup, Operator's Manual, 1993). The ratio of standard
deviation to median particle size shows the relative tightness of
the particle size distribution.
[0060] The improved perlite product with controlled particle size
distribution in one embodiment has a ratio of the standard
deviation of particle size to the median particle size less than
0.63 (for example in the range of from 0.50 to 0.63) and a median
particle size less than 50 microns (usually in the range of from 30
to 50 microns). In another embodiment, the ratio of the standard
deviation of particle size to the median particle size is less than
0.60 (for example, in the range of 0.50 to 0.60); the ratio of the
standard deviation of particle size to the median particle size is
less than 0.58 (for example, in the range of 0.50 to 0.58); or the
ratio of the standard deviation of particle size to the median
particle size is less than 0.55 (for example, in the range of 0.50
to 0.55). The median particle size of the conventional perlite
products with the ratio of the standard deviation of particle size
to the median particle size less than 0.63 is greater than 50
microns. Compared to conventional products, the present invention
consists of particles of reduced median particle size with a narrow
particle size distribution.
[0061] 2. Floater Content
[0062] The floater content of samples in one embodiment is
determined on a volume basis. The loose product is introduced into
a calibrated 100 mL container until it overflows. The excess is
carefully removed with a steel straight edge. The sample is then
introduced a 250 ml graduated glass cylinder using a plastic
funnel. The graduated glass cylinder is filled with water up to the
200 mL level and is shaken thoroughly. Additional water is filled
to 250 mL level. After resting for 5 minutes, the volume of the
floater particles can be read in units of mL and the floater
content in volume percentage can thus be calculated:
Floater content (percent by volume)=(Reading of floater volume in
mL/100 mL container volume ).times.100.
[0063] For example, the reading of floater particles for Example 12
in Table II, below, was 8 mL. The floater content for this product
is thus calculated to be 8 percent by volume.
[0064] The improved perlite product with controlled particle size
distribution preferably has a floater content less than 10 percent
by volume (usually in the range of from 5 to 10 percent by volume),
more preferably has a floater content less than 5 percent by volume
(usually in the range of from 2.5 to 5 percent by volume), still
more preferably has a floater content of less than 2.5 percent by
volume (usually in the range of 2 to 2.5 percent by volume), still
more preferably has a floater content of less than 2 percent by
volume (usually in the range of 0 to 2 percent by volume). Compared
with the floater content of conventional perlite products which are
typically greater than 20 percent by volume, the improved perlite
product with controlled particle size distribution has a
significantly lower floater content.
[0065] 3. Blue Light Brightness
[0066] The preferred method for determining the blue light
brightness of the samples in the present invention uses calculation
from Hunter scale color data collected on a Spectro/plus
Spectrophotometer (Color and Appearance Technology, Inc.,
Princeton, N.J.). A krypton-filled incandescent lamp is used as the
light source. The instrument is calibrated according to the
manufacturer's instructions using a highly polished black glass
standard and a factory calibrated white opal glass standard. A
plastic plate having a depressing machined into it is filled with
sample, which is then compressed with a smooth-faced plate using a
circular pressing motion. The smooth-faced plate is carefully
removed to insure an even, unmarred surface. The sample is then
placed under the instrument's sample aperture for the
measurements.
[0067] The improved perlite product with controlled particle size
distribution for example has a blue light brightness greater than
80 (e.g., in the range from 80 to 82); has a blue light brightness
greater than 82 (e.g., in the range from 82 to 83); has a blue
light brightness greater than 83 (e.g., in the range from 83 to
85), or has a blue light brightness greater than 85 (e.g., in the
range from 85 to 88).
[0068] 4. Wet Density
[0069] The preferred method for determining the packed density of
the samples in the present invention is specifically by measurement
of the centrifuged wet density, also referred to herein as wet
density. A sample of known weight between 1.00 and 2.00 g is placed
in a calibrated 15 ml centrifuge tube to which deionized water is
added to make up a volume of approximately 10 ml. The mixture is
shaken thoroughly until all of the sample is wetted and there is no
dry powder remaining. Additional deionized water is added around
the top of the centrifuge tube to rinse down any mixture adhering
to the side of the tube from shaking. The tube is centrifuged for 5
min at 2500 rpm on an IEC Centra.RTM. MP-4R centrifuge, equipped
with a Model 221 swinging bucket rotor (International Equipment
Company, Needham Heights, Mass.). Following centrifugation, the
tube is carefully removed so as not to disturb the solids and the
level (i.e., volume) of the settled matter is measured in cm.sup.3.
The centrifuged wet density of powder is readily calculated by
dividing the sample weight by the measured volume. Typically,
centrifuged wet density is reported in units of lb/ft.sup.3 or in
units of g/cm.sup.3; the conversion factor for these units is 1
lb/ft.sup.3.about.0.01602 g/cm.sup.3.
[0070] An expanded perlite product having an excessive floater
content can interfere with an accurate determination of centrifuged
wet density. Especially when the floater content of an expanded
perlite product is 10% or greater, a significant quantity of the
material refuses to pack in the bottom of the calibrated centrifuge
tube, thus not allowing a reasonably accurate measurement to be
taken.
[0071] The improved perlite product with controlled particle size
distribution has a wet density for example less than 50 lb/ft.sup.3
(e.g., in the range from 11 to 50 lb/ft.sup.3); less than 40
lb/ft.sup.3 (e.g., in the range from 11 to 40 lb/ft.sup.3); less
than 30 lb/ft.sup.3 (e.g., in the range from 11 to 30 lb/ft.sup.3);
less than 25 lb/ft.sup.3 (e.g., in the range from 11 to 25
lb/ft.sup.3); or, for example, less than 20 lb/ft.sup.3 (e.g., in
the range from 11 to 20 lb/ft.sup.3). The improved perlite product
with controlled particle size distribution may be prepared with
still lower centrifuged wet density.
[0072] 5. Hegman Fineness Measurements
[0073] The fineness of grind or the degree of the dispersion of the
fillers in a pigment-vehicle system such as paint is measured by
Hegman fineness. The test is based on a standard method of the
American Society of Testing and Materials (ASTM D-1210). In a
preferred method, 80 g of lettering white oil based high gloss
enamel paint (C.P.E.--A Division of Courtaulds Coatings Inc., Gary,
Ind.) are mixed with 20 ml mineral sprits in a 1/2-pint paint can
using a shaft stirrer. After adding 8.5 g sample, the mixture is
kept stirring for 5 minutes for dispersion. An alternative sample
preparation is to mix motor oil and sample at about a 10:1 ratio by
weight in a watch glass with the spatula and read the Hegman value
as hereinafter described.
[0074] A small amount of dispersed sample is placed in the deep end
of the path of the Hegman fineness gage (Precision Gage & Tool
Co., Dayton, Ohio). By using a steel draw-down blade/scraper, the
material is then drawn down the length of the path toward the
shallow end of the gage with a uniform, brisk motion. The fineness
reading, in Hegman units (0-8) is obtained by observing the point
where the material first shows a definite speckled pattern. Typical
fineness patterns described in the ASTM D 1210 procedure can be
used for comparison.
[0075] In one embodiment, the improved expanded perlite product
with controlled particle size distribution has a ratio of the
standard deviation of particle size distribution to the median
particle size of less than 0.65 and with a Hegman fineness greater
than 1.0, with a Hegman fineness greater than 2.0, with a Hegman
fineness greater than 3.0, with a Hegman fineness greater than 4.0,
with a Hegman fineness greater than 5.0, or with a Hegman fineness
greater than 6.0.
[0076] 6. Flatting Efficiency (85.degree. Sheen) Measurements
[0077] The flatting efficiency of the paint fillers is determined
by measuring their ability to reduce the sheen, sometimes referred
to as specular gloss, of high gloss paint. The test is based on a
standard method of the American Society for Testing and Materials
(ASTM D 523), and is usually performed concurrently with the Hegman
test. The sample is mixed in paint using the same procedure used
for determining Hegman fineness. Occasionally, a super white high
gloss Latex enamel paint (The Sherwin-Williams Company, Cleveland,
Ohio) can be used to replace the oil based paint. In this case, no
solvent is used for mixing. The mixed paint sample is poured on a
Leneta chart (The Leneta Company, Mahwah, N.J.) at the top of the
white area to form a 2" diameter spot. A Bird applicator gage
(Precision Gage & Tool Co., Dayton, Ohio) with a 0.003" gap is
placed on the chart above the paint spot with the gap down and the
side of the blade with the longer taper facing the paint spot. A
film of the paint is formed on the Leneta chart by drawing down the
Bird applicator with a smooth, rapid, downward motion. The paint is
allowed to air dry at room temperature, and the sheen reading is
then taken on the dried paint chart using a calibrated
Glossgard.RTM. II 85.degree. glossmeter (Pacific Scientific, Silver
Springs, Md.).
C. METHODS OF USING THE IMPROVED PERLITE PRODUCTS WITH CONTROLLED
PARTICLE SIZE DISTRIBUTION
[0078] The improved expanded perlite product with controlled
particle size distribution can be used in a manner analogous to the
currently available natural glass products, including, for example,
in filtration (e. g., as a filter aid), and as a filler.
[0079] The intricate cellular structure unique to these glass
materials is particularly effective for the physical entrapment of
particles in filtration processes. The improved perlite product
with controlled particle size distribution of the present invention
can be applied to a septum (i.e., used in "precoating") to improve
clarity and increase flow rate in filtration processes. They can
also be added directly to a fluid as it is being filtered to reduce
the loading of undesirable particulate at the septum while
maintaining a designed liquid flow rate (i.e., used in "body
feeding").
[0080] Examples of fluid and/or fluid suspensions which may be
filtered using the improved perlite product with controlled
particle size distribution of the present invention include: water,
beverages (for example, beer, fruit juice), botanical extracts (for
example, sugar solutions, vegetable oils, flavors, antibiotics),
animal extracts (for example, fats, oils), fermentation broths (for
example, cell suspensions and cell cultures, including, for
example, yeast extracts, bacterial broths, mammalian cell
cultures), blood or blood products, vaccines, or chemicals (for
example, organic and inorganic chemicals including, for example,
solvents such as methanol, and solutions such as aqueous sodium
chloride).
[0081] The expanded perlite product with controlled particle size
distribution may be used in conjunction with a wide variety of
filtration and separation devices that are designed to use
particulate media, including those devices which use principles of
gravity, pressure, vacuum, or other applied forces to encourage
passage of liquid through the media.
[0082] Further, mixtures of the perlite product with controlled
particle size distribution with other kinds of filter media or
filtration-related materials, such as cellulose or diatomite, are
possible. Such mixtures are sometimes used to modify filtration
performance to achieve a desired result in terms of clarity or
throughput. Also, adsorbents such as silica gel, tannin, or
activated carbon may be added in some filtrations to achieve
auxiliary performance, usually to obtain specific chemical
properties in the filtrate.
[0083] Such mixtures may also be used in loose form, or in some
cases may be consolidated into forms such as filter sheets, pads,
or cartridges, in which a resin is usually added as a binder to
hold the mixture firmly together. These find utility in compact or
specially constrained filtration applications.
[0084] The improved expanded perlite product with controlled
particle size distribution is also useful as a component in
composite media, such as thermally sintered media comprised of a
functional filtration component and a matrix component
(c.function.. Palm, 1999).
[0085] Certain applications may gain additional benefit from using
the improved perlite product with controlled particle size
distribution that has been modified or derivatized, for example, by
leaching with acid or complexing agents, by etching, by
silanization, or by coupling organic molecules to a silanized
functionality.
[0086] Following filtration, the improved expanded perlite product
with controlled particle size distribution is inevitably
contaminated with turbidity that has been removed from the liquid
being filtered. The improved perlite product with controlled
particle size distribution can be chemically regenerated by
applying an appropriate solvent that is chemically compatible. Such
a solvent will usually dissolve the turbidity while leaving the
improved perlite product with controlled particle size distribution
intact. Often, the turbidity entrained from the filtration of many
foods and beverages is organic in nature, and can be dissolved in
dilute solutions of sodium hydroxide (i.e., caustic soda lye,
NaOH). Turbidity obtained from filtration of petroleums,
petrochemicals, coal tars, or from similar substances can often be
dissolved in aliphatic or aromatic hydrocarbons, which do not
attack the improved perlite product with controlled particle size
distribution. Once the turbidity has been removed, the improved
perlite product with controlled particle size distribution can
again be used for filtration, offering greater economy of use.
[0087] Alternatively, many kinds of turbidity can also be
eliminated by heating to a temperature hot enough to combust the
turbidity to gases, but moderating the heat so as to avoid
distortion of the intricate structure of the improved perlite
product with controlled particle size distribution, thus allowing
thermal regeneration of the improved perlite product with
controlled particle size distribution. The usefulness of this
technique depends in part on the composition of both the turbidity
and the improved perlite product with controlled particle size
distribution. The turbidity should be relatively low in ash
content, and the improved perlite product with controlled particle
size distribution should undergo little reaction with either the
turbidity or its ash. For an improved perlite product with
controlled particle size distribution, a temperature of
approximately 750.degree. C. (1380.degree. F.) is a typical maximum
limit. Still other methods of regeneration are also possible.
[0088] The improved expanded perlite product with controlled
particle size distribution may also be sterilized using a
sterilizing agent such as steam, chlorine, iodine, chlorinated
compounds or iodinated compounds useful for disinfection, ozone, or
ionizing radiation. These may be applied prior to filtration in
order to effect sterile filtration, or following filtration to
disinfect entrained turbidity that may be pathogenic or
biohazardous.
[0089] The improved perlite product with controlled particle size
distribution of the present invention can also be used as a
functional filler. Functional fillers are typically added, that is,
"compounded," to other substances to make a material mixture that
may commonly be referred to as "filled." The means of compounding
usually allows one or more specific functional properties to be
imparted to the filled material. These functional properties are
often physical in nature, and may involve various mechanical or
optical effects. Occasionally, chemical functionality is imparted,
and this may also alter electrical properties. The improved perlite
product with controlled particle size distribution is effective
when compounded in filled materials so as to impart the
functionality of the improved perlite product to the filled
material.
[0090] Examples of such applications include use of the improved
expanded perlite product with controlled particle size distribution
as a flatting agent or as an aid to improve scrubbability in paints
and coatings; as an antiblock agent in polymers, such as
polyethylene or polypropylene film; as a functional filler in
paper, including as a drainage aid and in stickies pacification in
paper manufacture; as a reinforcing agent in plastics, including
nylon, polypropylene, phenolics and brake pad manufacture; and as a
filler for adhesive, sealant, and joint compounds.
[0091] The improved perlite product with controlled particle size
distribution is also useful in abrasive, polishing, buffing, or
cleansing formulations, wherein it may impart an abrasive property.
Further, the improved perlite product with controlled particle size
distribution is useful in ceramics and ceramic mixtures, including
tile, asphalt, concrete, mortar, plaster, stucco, grout, and
aggregate, especially to decrease the density of these materials.
The improved perlite product with controlled particle size
distribution may be applied to other architectural products,
including roofing shingles or sheets, architectural siding,
flooring, or acoustical tile with similar efficacy.
[0092] The most common method of adding the improved perlite
product with controlled particle size distribution to prepare a
filled material is to blend it into a mixture at a concentration
needed to impart the desired level of a property. For example, to
reinforce nylon, the improved perlite product with controlled
particle size distribution may be added to a controlled-temperature
twin-screw extruder to which unfilled nylon is being fed and made
molten. The improved perlite product with controlled particle size
distribution is fed into the extruder through a hopper and
uniformly blends in to the nylon. The mixture emerges from the
extruder and is cooled. Then, for example, the mixture can be
further compression molded or injection molded into useful shapes,
and the molded pieces of filled nylon will be suitably reinforced
compared with the unfilled nylon.
[0093] Because of the intricate porosity of the improved perlite
product with controlled particle size distribution, is it useful as
an absorbent in many applications. Its absorbent properties also
make it useful as a carrier of other substances.
[0094] The aforementioned applications describe the utility of the
improved perlite product with controlled particle size
distribution, but many other applications may be envisioned for the
improved perlite product with controlled particle size
distribution.
EXAMPLES
[0095] The improved perlite products with controlled particle size
distribution of the present invention and methods for their
preparation are described in the following examples, which are
offered by way of illustration and not by way of limitation.
[0096] Particle size data were collected on a Leeds and Northrup
Microtrac X100 laser particle size analyzer (Leeds and Northrup,
North Wales, Pa.).
[0097] Examples 1 to 13 were prepared using a lab scale Alpine.TM.
50 ATP classifier. A commercially available expanded perlite
product, Harborlite.RTM. 2000, was used as the feed material. This
feed material had a particle size distribution (PSD) from 21 .mu.m
(d.sub.10) to 112 .mu.m (d.sub.90). Classification tests were
conducted at a classifier wheel speed from 6000 rpm to 22000 rpm
and air flow pressure from 8.0 to 15.0 mBar. The fine fraction was
then collected as the improved perlite product with controlled
particle size distribution.
[0098] Examples 14 to 17 were prepared on a large scale Alpine.TM.
200 ATP classifier equipped with a top feeding system. A
commercially available expanded perlite product, Harborlite.RTM.
2000, was used as feed material. Classification tests were
conducted at a classifier wheel speed from 3500 rpm to 6000 rpm and
total air flow from 900 to 950 m.sup.3/h. The fine fraction was
then collected as the improved perlite products with controlled
particle size distribution.
[0099] Example 18 was prepared on a KEK model K1350 centrifugal
sifter using a 250 mesh (63 .mu.m) screen. A commercially available
expanded perlite product, Harborlite.RTM. 800, was used as feed
material.
[0100] Examples 19 to 21 were prepared on a lab scale Alpine.TM. 50
ATP classifier. An expanded perlite microsphere product made from
Harborlite.RTM. PA4000 was used as feed material. The expanded
perlite microsphere product made from Harborlite.RTM. PA4000 used
as a feed material had a particle size distribution (PSD) from 21
.mu.m (d.sub.10) to 121 .mu.m (d.sub.90). Classification tests were
conducted at the classifier wheel speed from 14000 rpm to 18200 rpm
and air flow pressure from 8.0 to 15.0 mBar. The fine fraction
product was then collected as the perlite product with controlled
particle size distribution. The light density of the classified
expanded perlite microsphere products indicates that the perlite
product with controlled particle size distribution made from this
feed has intricate and cellular characteristics similar to the
products prepared from Harborlite.RTM. 2000 feed.
[0101] Tests to determine the particle size distribution, floater
content, and blue light brightness were carried out according to
the methods described above. The results for the improved perlite
product with controlled particle size distribution are shown in
Table II. The improved perlite product with controlled particle
size distribution of these examples had a ratio of standard
deviation of particle size distribution to the median particle size
less than 0.63, median particle size less than 50 microns, floater
content less than 10 percent by volume, blue light brightness more
than 80 and wet density less than 50 lb/ft.sup.3.
2TABLE II Classifier Wheel Blue Wet Speed d.sub.50 sd Floater light
Density Examples Feed Classifier (rpm) (.mu.m) (.mu.m) sd/d.sub.50
(volume %) brightness (lb/ft.sup.3) Example 1 Harborlite .RTM. 50
ATP 22000 7.90 4.91 0.62 <2 85 40 2000 Example 2 Harborlite
.RTM. 50 ATP 21000 8.62 5.04 0.58 <2 87 38 2000 Example 3
Harborlite .RTM. 50 ATP 20000 9.51 5.63 0.59 <2 88 37 2000
Example 4 Harborlite .RTM. 50 ATP 19000 10.43 6.12 0.59 <2 88 37
2000 Example 5 Harborlite .RTM. 50 ATP 18000 11.20 6.60 0.59 <2
87 29 2000 Example 6 Harborlite .RTM. 50 ATP 17000 14.17 7.82 0.55
<2 85 23 2000 Example 7 Harborlite .RTM. 50 ATP 16000 15.23 8.43
0.55 <2 85 24 2000 Example 8 Harborlite .RTM. 50 ATP 14000 18.79
10.25 0.55 <2 82 21 2000 Example 9 Harborlite .RTM. 50 ATP 12000
22.00 11.91 0.54 <2 81 20 2000 Example Harborlite .RTM. 50 ATP
10000 26.85 15.25 0.57 <2 82 18 10 2000 Example Harborlite .RTM.
50 ATP 8000 32.21 19.48 0.60 6 81 17 11 2000 Example Harborlite
.RTM. 50 ATP 7000 36.09 21.99 0.61 8 81 17 12 2000 Example
Harborlite .RTM. 50 ATP 6000 39.05 24.73 0.63 8 80 16 13 2000
Example Harborlite .RTM. 200 ATP 6000 13.95 8.13 0.58 <2 82 24
14 2000 Example Harborlite .RTM. 200 ATP 5100 18.21 10.26 0.56
<2 82 19 15 2000 Example Harborlite .RTM. 200 ATP 4700 20.55
11.47 0.56 <2 81 20 16 2000 Example Harborlite .RTM. 200 ATP
3500 32.60 18.65 0.57 4 81 14 17 2000 Example Harborlite .RTM.
K1350 NA 28.01 16.31 0.58 <2 84 14 18 800 CS Example Expanded 50
ATP 18200 10.73 6.80 0.63 <2 88 21 19 Harborlite .RTM. PA 4000
Example Expanded 50 ATP 15000 14.04 8.05 0.57 <2 86 18 20
Harborlite .RTM. PA 4000 Example Expanded 50 ATP 14000 15.49 8.58
0.55 <2 85 18 21 Harborlite .RTM. PA 4000
[0102] For suitability in paint filler applications, Hegman
fineness and flatting efficiency (85.degree. sheen) were determined
for the improved perlite product according to the methods described
above. The results for both the improved perlite product and the
most commonly used products in these applications today are listed
in the Tables III and IV. The Hegman fineness for the commercial
fine perlite products is also listed for comparison. As can be
readily seen, the improved perlite product examples exceed the
flatting efficiency (in both oil-based paint and Latex paint) for
conventional diatomite products in both low Hegman fineness and
high Hegman fineness product classes. Table III also shows that the
Hegman fineness for most commercial fine perlite products is around
0. This indicates that the improved perlite product with controlled
particle size distribution has superior top size control, offering
the advantage of comparatively smooth-surfaced paint and coating
films, and smoothness in related applications.
3 TABLE III Examples Hegman in oil.sup.a Harborlite .RTM. 200 0.5
Harborlite .RTM. 200Z 0.5 Harborlite .RTM. 300C 0.5 Harborlite
.RTM. 400 0.0 Dicalite .TM. 416 0.0 Europerlita .TM. 75 0.0 SM 101
2.0 SM 201 0.0 Topco .TM. #54 0.0 Example 1 6.0 Example 2 6.0
Example 3 6.0 Example 4 5.5 Example 5 5.0 Example 6 4.0 Example 7
4.0 Example 8 3.5 Example 9 2.3 Celite .RTM. 281 2.0 Example 10 1.0
Example 16 2.0 Celite .RTM. 499 4.0 Example 14 4.0 .sup.aIn
Pennzoil SAE 10W-30 motor oil
[0103]
4 TABLE IV Examples Paint Loading (g) 85.degree. Sheen Example 9
Oil based 8.5 2.1 Celite .RTM. 281 Oil based 8.5 3.2 Celite .RTM.
281 Latex 4.25 13.5 Example 10 Latex 2.0 26.2 Example 10 Latex 3.0
9.8 Example 10 Latex 4.0 4.4 Example 16 Latex 2.0 37.5 Example 16
Latex 3.0 19.0 Example 16 Latex 4.0 8.5 Celite .RTM. 499 Latex 4.0
25.0 Example 14 Latex 4.0 26.4
[0104] D. Publications
[0105] The disclosures of the publications, patents, and published
patent specifications referenced below are hereby incorporated by
reference into the present disclosure in their entirety.
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D 1210-79 (Reapproved 1988), Standard Test Method for Fineness of
Dispersion of Pigment-Vehicle Systems.
[0107] American Society for Testing and Materials, ASTM Designation
D 523-89 (Reapproved 1994), Standard Test Method for Specular
Gloss.
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* * * * *