U.S. patent application number 12/423887 was filed with the patent office on 2009-09-24 for methods for binding particulate solids and particulate solid compositions.
This patent application is currently assigned to KELA ENERGY, LLC. Invention is credited to Thomas K. Flanery, Lorence M. Moot, Lawrence W. Umstadter.
Application Number | 20090235577 12/423887 |
Document ID | / |
Family ID | 41087503 |
Filed Date | 2009-09-24 |
United States Patent
Application |
20090235577 |
Kind Code |
A1 |
Flanery; Thomas K. ; et
al. |
September 24, 2009 |
Methods For Binding Particulate Solids And Particulate Solid
Compositions
Abstract
Embodiments of the present disclosure include methods of binding
particulate solids as well as compositions resulting therefrom.
Inventors: |
Flanery; Thomas K.;
(Worthington, KY) ; Moot; Lorence M.; (Cohutta,
GA) ; Umstadter; Lawrence W.; (Orlando, FL) |
Correspondence
Address: |
THOMAS, KAYDEN, HORSTEMEYER & RISLEY, LLP
600 GALLERIA PARKWAY, S.E., STE 1500
ATLANTA
GA
30339-5994
US
|
Assignee: |
KELA ENERGY, LLC
Orlando
FL
|
Family ID: |
41087503 |
Appl. No.: |
12/423887 |
Filed: |
April 15, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11013948 |
Dec 16, 2004 |
|
|
|
12423887 |
|
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|
60530728 |
Dec 17, 2003 |
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Current U.S.
Class: |
44/550 |
Current CPC
Class: |
C22B 7/00 20130101; B29K
2023/12 20130101; C22B 1/24 20130101; B29L 2031/7322 20130101; B29B
17/0042 20130101; Y02P 10/20 20151101; C22B 7/005 20130101; Y02E
50/30 20130101; B09B 3/0033 20130101; Y02P 10/212 20151101; Y02W
30/62 20150501; B29K 2077/00 20130101 |
Class at
Publication: |
44/550 |
International
Class: |
C10L 5/00 20060101
C10L005/00 |
Claims
1. A composition comprising: a particulate solid component, wherein
the particulate solid component comprises about 50% to 85% of the
composition; and an additional component, wherein the additional
component is selected from the group consisting of: a biomass
component, a polymer component, a composite waste product
component, and a combination thereof.
2. The composition of claim 1, wherein the additional component
comprises a biomass component and a polymer component.
3. The composition of claim 2, wherein the biomass component
comprises about 0.01% to 20% of the composition, and the polymer
component comprises about 0.01% to 20% of the composition.
4. The composition of claim 1, wherein the additional component
comprises a biomass component and a composite waste product
component.
5. The composition of claim 4, wherein the biomass component
comprises about 0.01% to 20% of the composition, and the composite
waste product component comprises about 0.01% to 20% of the
composition.
6. The composition of claim 1, wherein the additional component
comprises a polymer component and a composite waste product
component.
7. The composition of claim 6, wherein the polymer component
comprises about 0.01% to 20% of the composition, and the composite
waste product component comprises about 0.01% to 20% of the
composition.
8. The composition of claim 1, wherein the additional component
comprises a biomass component, a polymer component, and a composite
waste product component.
9. The composition of claim 8, wherein the particulate solid
component comprises about 50% to 85% of the composition, wherein
the biomass component comprises about 0.01% to 20% of the
composition, wherein the polymer component comprises about 0.01% to
20% of the composition, and wherein the composite waste product
comprises about 0.01% to 20% of the composition.
10. The composition of claim 8, wherein the particulate solid
component comprises about 70% of the composition, wherein the
biomass component comprises about 5% of the composition, wherein
the polymer component comprises about 15% of the composition, and
wherein the composite waste product component comprises about 10%
of the composition.
11. The composition of claim 10, wherein the composition is an
industrial stoker grade fuel coal pellet.
12. The composition of claim 10, wherein the composition has a BTU
of about 12,500 BTU/lb or greater.
13. The composition of claim 10, wherein the composition has a
sulfur content of less than about 1%.
14. The composition of claim 1, wherein the particulate solid
component comprises about 60% to 85% of the composition.
15. The composition of claim 14, wherein the additional component
comprises a biomass component and a polymer component.
16. The composition of claim 15, wherein the biomass component
comprises about 0.01% to 25% of the composition, and the polymer
component comprises about 0.01% to 15% of the composition.
17. The composition of claim 14, wherein the additional component
comprises a biomass component and a composite waste product
component.
18. The composition of claim 17, wherein the biomass component
comprises about 0.01% to 25% of the composition, and the composite
waste product component comprises about 0.01% to 10% of the
composition.
19. The composition of claim 14, wherein the additional component
comprises a polymer component and a composite waste product
component.
20. The composition of claim 19, wherein the polymer component
comprises about 0.01% to 15% of the composition, and the composite
waste product comprises about 0.01% to 10% of the composition.
21. The composition of claim 14, wherein the additional component
comprises a biomass component, a polymer component, and a composite
waste product component.
22. The composition of claim 21, wherein the particulate solid
component comprises about 60% to 85% of the composition, wherein
the biomass component comprises about 0.01% to 25% of the
composition, wherein the polymer component comprises about 0.01% to
15% of the composition, and wherein the composite waste product
component comprises about 0.01% to 10% of the composition.
23. The composition of claim 21, wherein the particulate solid
component comprises about 80% of the composition, wherein the
biomass component comprises about 5% of the composition, wherein
the polymer component comprises about 10% of the composition, and
wherein the composite waste product component comprises about 5% of
the composition.
24. The composition of claim 23, wherein the composition is a
utility steam coal fuel pellet.
25. The composition of claim 23, wherein the composition has a BTU
of about 12,500 BTU/lb or greater.
26. The composition of claim 23, wherein the composition has a
sulfur content of less than about 1%.
27. The composition of claim 1, wherein the particulate solid
component comprises about 65% to 85% of the composition.
28. The composition of claim 27, wherein the additional component
comprises a biomass component and a polymer component.
29. The composition of claim 28, wherein the biomass component
comprises about 0.01% to 20% of the composition, and the polymer
component comprises about 8% to 20% of the composition.
30. The composition of claim 27, wherein the additional component
comprises a biomass component and a composite waste product
component.
31. The composition of claim 30, wherein the biomass component
comprises about 0.01% to 20% of the composition, and the composite
waste product comprises about 0.01% to 10% of the composition.
32. The composition of claim 27, wherein the additional component
comprises a polymer component and a composite waste product
component.
33. The composition of claim 32, wherein the polymer component
comprises about 8% to 20% of the composition, and the composite
waste product component comprises about 0.01% to 10% of the
composition.
34. The composition of claim 27, wherein the additional component
comprises a biomass component, a polymer component, and a composite
waste product component.
35. The composition of claim 34, wherein the particulate solid
component comprises about 65% to 85% of the composition, wherein
the biomass component comprises about 0.01% to 20% of the
composition, wherein the polymer component comprises about 8% to
20% of the composition, and wherein the composite waste product
component comprises about 0.01% to 10% of the composition.
36. The composition of claim 34, wherein the particulate solid
component comprises about 80% of the composition, wherein the
polymer component comprises about 15% of the composition, and
wherein the composite waste product component comprises about 5% of
the composition.
37. The composition of claim 36, wherein the composition is a
metallurgical MET coal pellet.
38. The composition of claim 32, wherein an additive component is
selected from the group consisting of: coke breeze, carbon black,
PET coke, and a combination thereof.
39. The composition of claim 38, wherein the composition is capable
of oversees transport and outdoor storage without degradation and
moisture absorption.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation-in-part of co-pending
U.S. utility application entitled "Methods for Binding Particulate
Solids," having Ser. No. 11/013,948, filed Dec. 16, 2004, which
claims priority to U.S. provisional application entitled "Method
for Binding Particulate Solids," having Ser. No. 60/530,728, filed
Dec. 17, 2003, both of which are entirely incorporated herein by
reference.
BACKGROUND
[0002] In the past, particulate materials, such as coal fines, coke
breeze, saw dust, and other biomass wastes, have presented storage,
handling, and processing challenges. Additionally, metal oxides
from blast furnaces, basic oxygen furnaces and electric arc
furnaces have routinely been discarded, in large quantities,
creating a source of pollution and presenting an environmental
hazard, which continues for decades. Further, composite waste
products, including post-consumer and post-industrial carpet waste,
are routinely discarded into waste storage facilities, such as
landfills. In addition to presenting challenges related to handling
the composite waste products, the slow rate of decomposition
results in an unfavorable environmental impact that continues for
decades.
[0003] Prior attempts at disposing of or re-use of coke breeze,
coal fines, and other particulate solids by producing solid forms,
such as briquettes or pellets, have been largely unsuccessful
because the particulate solids do not adequately bind, and the
resulting product can be mechanically unstable, disintegrating or
degrading back into small, fine particles during storage and
handling. Other attempts at producing solid forms from the
particulate solids may use costly and/or poor performing binder
materials, such as petroleum pitch or water-based latexes, and may
use costly and complex processing techniques. Water-based materials
will reduce the heating value of fuel based solids and produce a
formed material which is unstable during outside storage and
transport and may disintegrate causing fugitive dust emissions or
ground water contamination. Further, previous attempts have
utilized binders, including petroleum-based materials, which become
tacky and difficult to transport at ambient and elevated
temperatures, and may cause contamination and run-off problems when
stored outside.
[0004] Fine coal particulates collected during coal processing and
washing operations have been found to be high in moisture and thus
lower in heating value and/or less usable for fuel or non-fuel
applications. The coal fines were either discarded into permanent
impounds or were all or in part blended into steam coal products
for sale. The addition of the high moisture fines reduced the
quality and BTU value of the coal products, driving down the value,
and making them less desirable as a fuel or for metallurgical grade
coal use in the production of iron or steel.
[0005] Most coal consumers limit the total of fine coal in their
fuel. This is particularly true of wet coal fines. Thermal driers
have been used to dry the wet coal fines, but they are costly and
have environmental impacts of their own. Dry coal fines are not
immune to rain and moisture when exposed to normal outdoor storage
and shipping methods. Those weaknesses make thermal drying a
temporary solution. This forces coal processing plants to limit the
efficiency of the washing and separation process, and to also limit
the collection of fines to avoid the need to dry wet fines or blend
them into other products. Previous methods for the pelletization of
coal fines to improve their quality and handling have been either
not economical or ineffective.
[0006] Thus, a heretofore-unaddressed need exists in the industry
to address the aforementioned deficiencies and inadequacies.
SUMMARY
[0007] Embodiments of the present disclosure include methods of
binding particulate solids as well as compositions resulting
therefrom.
[0008] Briefly described, embodiments of the present disclosure
include compositions comprising: a particulate solid component,
where the particulate solid component comprises about 50% to 85% of
the composition; and an additional component, where the additional
component is selected from the group consisting of: a biomass
component, a polymer component, and a composite waste product
component.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Many aspects of the disclosure can be better understood with
reference to the following drawings. The components in the drawings
are not necessarily to scale, emphasis instead being placed upon
clearly illustrating the principles of the present disclosure.
Moreover, in the drawings, like reference numerals designate
corresponding parts throughout the several views.
[0010] FIG. 1 is a block diagram illustrating an embodiment of the
methods disclosed herein.
[0011] FIG. 2 is a block diagram illustrating an exemplary process
under the methods disclosed herein.
[0012] FIG. 3 is a block diagram illustrating an exemplary process
under the methods disclosed herein.
[0013] FIG. 4 is a block diagram illustrating a non-limiting
example of elements in a composite waste product.
[0014] FIG. 5 is a block diagram illustrating an exemplary process
under the methods disclosed herein.
[0015] FIG. 6 is a block diagram illustrating an exemplary process
under the methods disclosed herein.
[0016] FIG. 7 is a block diagram illustrating components of an
exemplary production plant for practicing the methods disclosed
herein.
[0017] FIG. 8 illustrates the sulfur emissions reduction in pounds
per year for an embodiment of the present disclosure versus stoker
coal.
[0018] FIG. 9 illustrates the yield increase shown to be about 134%
based on an example of sample pellets formed from embodiments of
the present disclosure. The yield increase is calculated comparing
the amount of product produced (coal fine plus binder, 2,689 lbs.)
compared to the amount of coal fines fed into the process (2,000
lbs.).
[0019] FIG. 10 is a graph that illustrates the water pick-up and
drying characteristics of five pellets. The comparison is between
pellet weight in grams and time. Total time is two hours. At time
represented by 1-2 (30 mins), the pellets are being soaked in
water. From times 2-5 the pellets are being air dried. After two
hours the pellets are essentially back to their starting
weights.
[0020] FIG. 11 is a graph that illustrates % WPU (percent water
pick up) of an embodiment of the present disclosure. The pellets
were soaked from time zero to time 0.5 hours and air dried after
0.5 hours.
[0021] FIG. 12 is a graph that illustrates water soak data in grams
vs. time.
[0022] FIG. 13 is a graph that illustrates carbon reduction in ash
based on the first stoker test burn. The lower amount of carbon in
the ash (material left in the bottom of the boiler after burning)
indicates a more complete burn (carbon is the material burned).
DETAILED DESCRIPTION
[0023] Before the present disclosure is described in greater
detail, it is to be understood that this disclosure is not limited
to particular embodiments described, as such may, of course, vary.
It is also to be understood that the terminology used herein is for
the purpose of describing particular embodiments only, and is not
intended to be limiting, since the scope of the present disclosure
will be limited only by the appended claims.
Discussion:
[0024] Reference is made to FIG. 1, which is a block diagram
illustrating an embodiment of the methods disclosed herein. The
method 100 includes reducing a composite waste product 110 through,
for example, a shredding, densifying, or pelletizing process. An
exemplary composite waste product in an embodiment herein includes
waste carpet. Waste carpet can be, for example, consumer recycled
carpet or industrial waste carpet. The methods disclosed herein
thus allow for an advantageous reduction of both post consumer and
post industrial nylon or other types of carpet and waste stream
polyolefin or other suitable polymeric material that would have
otherwise gone into municipal land fills. One of ordinary skill in
the art knows or will know that the reducing function can be
performed as a separate step prior to the other steps of the
methods described herein or, alternatively, as an integrated
step.
[0025] As stated above, an exemplary composite waste product
includes carpet. Carpet can include, but is not limited to,
industrial carpet processing waste and cuttings, post industrial
waste carpet, consumer installation waste, post consumer carpet,
separated carpet fibers, densified whole carpet, and densified
carpet fibers. In addition, composite waste products can include,
but are not limited to, industrial, post industrial, or post
consumer nylon (polyamide) waste fiber or other materials;
industrial, post industrial, or post consumer nylon (polyamide)
waste fiber or other materials with mixed or added components of
plastic, inorganic fillers, minerals, and/or biomass; industrial,
post industrial, or post consumer fiberous materials, including but
not limited to, fiberglass, other mineral fibers, polymeric fibers,
organic fibers, and natural fibers; and industrial, post
industrial, or post consumer polymers or other materials that will
melt during processing. These composite waste products may be used
alone or in a mixture with carpet. One of ordinary skill in the art
will appreciate that the methods disclosed herein can also be run
using virgin (e.g., non-waste), first quality materials of the same
description.
[0026] After the composite waste product is reduced, particulate
solids are added to the composite waste product 120. The
particulate solids may be fuel solids including, but not limited
to, coke breeze, coke fines, coal fines, and wood wastes.
Alternatively, the particulate solids may be non-fuel particulate
waste including, but not limited to, particulate radiation
contaminates, metal wastes, toxic waste particulates, and metal
oxides. The adding step 120 may be performed in a batch operation,
where all of the particulate solids for a process batch are added
at one time. Alternatively, the adding step 120 may be performed in
a continuous process where the particulate solids are added in a
continuous stream.
[0027] The particulate solids are blended with the composite waste
product to create a mixture of the composite waste product and the
particulate solids 130. In the case of recycled carpet, the
composite waste product generally includes, for example, a
polypropylene or other polymeric binder element and a nylon fiber
element. The temperature of the mixture is increased to fluidize
all or parts of the binder element 140 through, for example, a
combination of heat generated by the mixing process and heat
provided to the process by external devices 140. The fluid
polypropylene binder element captures the fine particulate solids.
Further, the nylon carpet fibers become tacky at the temperature at
which the binder fluidizes, which causes the nylon carpet fiber to
sinter to both the particulate solids and the fluid binder. In an
embodiment, the process temperatures for fluidizing the
polypropylene binder without fluidizing the nylon fibers are about
125.degree. C. to 250.degree. C. or about 135.degree. C. to
235.degree. C. The combination of the fluid polypropylene binder
and the nylon fiber results in a mechanical capture of the
particulate material in a combined polypropylene and nylon fiber
polymer matrix.
[0028] The mixture is then formed into solid formed products, such
as, for example, briquettes or pellets, using heat and/or pressure
150. In an embodiment, the pellet is extruded into various shapes
(e.g., a cylindrical pellet) that can be cut randomly into any
size. After the forming process, the resulting solid formed product
is structurally stable and does not retrogress into fine particles
during storage and handling.
[0029] When particulate solids are fuel based, the solid formed
product is bound reliably together and constitutes a high BTU
(e.g., an increase of about 10% to 16%) fuel for industrial,
utility, and residential use, which does not materially pollute the
air to a degree different from conventional fuels. High BTU
includes BTU values of about 12,500 BTU/lb or greater. In the case
of non-fuel particulate solids, such as industrial waste, the solid
formed product is bound reliably together and constitutes a durable
way of recycling in a subsequent industrial process or long term
stable storage which does not materially pollute the air, soil, or
ground water.
[0030] Embodiments of the present disclosure include compositions
where sulfur in the particulate solid is reduced by about 25% to
40% by dilution, depending on the blend and initial quality of the
particulate solid (e.g., a composition comprised of 70% coal/coal
fines with 1% sulfur; 10% carpet; 15% plastic; and 5% biomass will
produce a composition with 0.7% sulfur, which is a 30% decrease in
sulfur based on blending). Embodiments of the present disclosure
include compositions including all types of coal (e.g., peat,
lignite, sub-bituminous, bituminous, anthracite, and graphite).
Embodiments of the present disclosure include a method that
significantly reduces sulfur through both dilution and self
scrubbing during combustion.
[0031] Reference is now made to FIG. 2, which illustrates a block
diagram of an exemplary process under the methods disclosed herein.
The process 200 combines recycled carpet 210 and particulate solids
220 into a mixture by heating and blending or mixing as indicated
in block 230. Additionally, other polymers 250 may be optionally
added to achieve specific characteristics relating to mechanical
properties, chemical composition, or a combination thereof. Other
polymers can include, but are not limited to, polyolefins,
polyolefin blends with other thermoplastics, polyolefin blends with
fillers and other inorganic materials, polyolefin blends with
biomass and other natural materials, polyamides, polyamides mixed
with other thermoplastic polymers, polyamides with inert fillers,
thermoplastics, and thermoplastics in mixtures with thermoset
plastics. After the heating and blending or mixing is completed,
solid formed products are formed in block 240 using, for example,
conventional briquette or pellet forming technology. Additionally,
one of ordinary skill in the art knows or will know that the
mixture may be formed into solid products including extrusions,
sheets or other homogeneous or non-homogeneous shapes, as
needed.
[0032] Reference is now made to FIG. 3, which illustrates a block
diagram of an exemplary process under the methods disclosed herein.
The process 300 utilizes recycled carpet 310, which is reduced in
step 315. The reducing function includes, but is not limited to,
shredding, grinding, pelletizing, and other techniques known by one
of ordinary skill in the art. Additionally, as indicated in block
325, particulate solids 320 are processed to achieve a maximum
particle size by grinding or crushing. A mixture of the reduced
recycled carpet and the ground particulate solids is produced by
heating and blending or mixing, as indicated in block 330.
Additionally and optionally, recycled plastics may be added to the
mixture for supplemental fuel content and/or environmentally
beneficial disposal. After the heating and blending or mixing is
completed, solid products are formed, as indicated in block 340,
using conventional forming technology including, but not limited
to, the methods and forms discussed above.
[0033] Reference is now made to FIG. 4, which is a block diagram
illustrating a non-limiting example of elements in a composite
waste product. An embodiment of the composite waste product 400
includes, but is not limited to, a polypropylene backing material
410, nylon carpet fibers 420 and calcium carbonate 430. The
polypropylene backing material 410 becomes fluid at a processing
temperature allowing it to capture the particulate solids. The
nylon carpet fibers 420 become tacky, but not fluid at the
processing temperature and, in the process of blending, serve to
form a fiber matrix in the mixture. The calcium carbonate element,
when used in a sulfur containing fuel application and under present
combustion methods, may result in a reduction of sulfur dioxide
emissions. An additional about 10% reduction in sulfur (SOx)
emissions may be found during combustion when sulfur in the
particulate solid combines with calcium carbonate found in the
binder materials to form calcium sulfate instead of sulfur dioxide.
As a result, the calcium sulfate is captured as an inert in the ash
and can be safely land-filled as opposed to aerial gaseous
emissions of SOx. This reduction is advantageous because it
diminishes or eliminates the utility of powdered limestone
injection associated with conventional sulfur dioxide emission
reduction methods. Additionally, remaining binding ingredients
include other polymers (not shown) as normal components of carpet
backing material. As used in this disclosure "SOx" includes any
possible combinations of sulfur and oxygen (e.g., SO, SO.sub.2,
SO.sub.3).
[0034] Reference is now made to FIG. 5, which is a block diagram
illustrating an exemplary process under the methods disclosed
herein. An embodiment of the process 500 applies recycled baled
carpet 510 to a bale breaker 512 for subsequent processing by a
shredder/grinder 514. The shredder/grinder 514 is one of a number
of reducing techniques known by one of ordinary skill in the art.
The reduced carpet is then received by an accumulator 550. An
accumulator 550 receives raw or intermediately processed materials
from multiple sources. For example, in this case, the accumulator
550 receives reduced carpet and other materials, as discussed
below, for subsequent processing.
[0035] As discussed above, recycled plastic 530 is optionally
included in the mixture to facilitate improved fuel content,
mechanical properties, or a combination thereof, and to facilitate
an environmentally beneficial method of disposal. To aid in
processing, the recycled plastic 530 is processed through a
shredder/grinder 532 and transferred to a mixer 540. In the case
where specific chemical or mechanical properties are desirable,
additional virgin polymers 536 may be optionally added. Since the
virgin polymers 536 are typically purchased in a form ready for
processing, such as pellets, the virgin polymers 536 are deposited
directly into the mixer 540.
[0036] In addition to the recycled plastic 530 and the virgin
polymers 536, cellulose material 534, including but not limited to,
wood wastes, may be optionally added to the mixture 540. The
blending of cellulose material 534 provides a partial fuel content
from a renewable resource, thus extending the life of available
fossil fuels, such as the coal, PET coke, or coke fines, with a
clean burning alternative synthetic fuel. The synthetic solid fuels
can be formed into various shapes and sizes for use in devices
including, but not limited to, stoker boilers, pulverized utility
boilers, circulating fluidized bed (CFB) boilers, pressurized
fluidized bed combustion (PFBC) boilers, coal gasification (IGCC)
units, and wood and coal burning furnaces. The addition of biomass
allows for a reduction in sulfur, ash, and other hazardous air
pollutants (HAP's) as well as allows for a renewable energy in the
product and extending the fossil resource.
[0037] Coal or coke fines 520 are processed through a crusher or
grinder 522 to reduce the particulate solid fuels to a maximum
particle size. The crushed coal or coke fines are then transferred
to the mixer 540. The contents of the mixer 540 including the
processed coal or coke fines 520, recycled plastic 530, cellulose
534 and virgin polymers 536 is mixed and transferred to the
accumulator 550. The accumulator 550, which includes the combined
contents of the mixer 540 and the recycled carpet from the
shredder/grinder 514, conveys its contents to a pellet mill 560
using a feeder 552.
[0038] The pellet mill 560 blends the combined contents and uses,
for example, a combination of heat, pressure, and forming
technology to form solid products, including but not limited to
pellets, briquettes, extrusions or sheets, of the mixture, which
are then transferred to a cooler 562. After cooling, the solid
products are structurally stable and do not retrogress into fine
particles during storage and handling. The solid products are then
transferred to storage 564 where they remain intact because the
solid particulate materials are encapsulated to prevent
degradation, leaching or contamination into the environment. The
solid products also exhibit resistance to moisture because the
moisture is driven out by the process heat and then sealed out by
the encapsulating function of the binder element. In an embodiment,
the moisture level of the product is about 1% to 2%. In another
embodiment, the product locks out moisture even when immersed in
water for several hours.
[0039] Reference is now made to FIG. 6, which illustrates a block
diagram of an exemplary process under the methods disclosed herein.
The process 600 includes reducing waste carpet 610 including, but
not limited to, shredding, grinding, or pelletizing the waste
carpet. Particulate solids, which may have a fuel content are added
620 and the particulate solids are mixed with the waste carpet 630.
The mixture is heated using, for example, a combination of heat
generated by the process plus any supplemental heat necessary to
fluidize the binder element of the waste carpet 640. One of
ordinary skill in the art knows or will know that supplemental heat
may be provided by any number of methods including, but not limited
to, electric resistive and inductive devices, combustion causing
devices, electromagnetic wave devices, and recaptured heat from
other processes. After the mixing is completed, the mixture is
formed into solid products by pressure, heat, or extrusion 650, for
example.
[0040] In an embodiment of the present disclosure, the methods use
a single machine to mix and heat the mixture to flux temperatures
(e.g., about 125.degree. C. to 250.degree. C.) using process heat,
shear heat, and friction to heat the materials. In another
embodiment, the same machine blends in filler materials (e.g.,
biomass or other particulates) and forms pellets using a die
mechanism. The pellets are then cut at the die using a cutter
(e.g., a rotary cutter) and cooled. The pellets may be cooled by,
including but not limited to, using water bath, water spray, or
blending the hot pellets with wet fine particulates. Thus, the
processing takes about 1 to 3 minutes and generally does not need
any form of curing time.
[0041] The methods described herein do not require water, acids or
any other chemical or elemental component from the particulate
solids to form the bond. As a result, virtually any particulate or
blended materials can be reliably pelletized using methods
described herein. Although waste carpet is presented in an
embodiment described herein, one of ordinary skill in the art
knows, or will know that any composite waste product having binder
and fiber elements may be used. For example, polymer impregnated
cloth used in some industrial processes may also be a suitable
composite waste product.
[0042] In an embodiment of the methods disclosed herein, the
components are added at ambient temperature and rapidly heated
using process heaters, friction, and shear heat to activate or flux
the binder. In another embodiment, the application of vacuum to the
processing unit can be used to efficiently remove water vapor and
other volatiles.
[0043] The methods described herein allow for a reduction of coal
fines wasted into long term impounds as refuse as well as an
environmentally preferable pelletized product that is cleaner than
coal while retaining similar properties as a fuel or as a carbon
source for other applications. The methods described herein further
allow for the reclamation of older coal fines impounds that results
in an improved product that has useful applications where coal is
specified.
[0044] The methods described herein allow for a means to introduce
biomass in various amounts into coal fired boilers and other coal
applications without the need for boiler modification or separate
fuel handling systems.
[0045] The methods described herein further allow for improving the
yield and efficiency of the coal processing and washing operation,
which both improves overall average coal quality and quantity, and
reduces waste in the mineral recovery process.
[0046] Reference is now made to FIG. 7, which is a block diagram
illustrating components of an exemplary production plant for
practicing the methods disclosed herein. The plant 700 includes a
composite waste reducer 710, which, for example, shreds, grinds, or
pelletizes waste carpet. A solid particulate delivery device 720
provides solid particulates to the reduced composite waste at, for
example, a combining device 730. The combining device 730 combines
the reduced composite waste product with particulate solids to
create a mixture. Additionally and possibly in combination with the
combining device 730, heat generation/regulation equipment 740
provides sufficient supplemental heat to the mixture to fluidize
one element of the composite waste product. The heated mixture is
then provided to a solid product forming device 750, configured to
produce solid formed products. The solid formed products include
but are not limited to pellets, briquettes, extrusions and sheets,
among others. As discussed above, the solid formed products may be
produced for subsequent consumption wherein the solid particulates
have a useful fuel content or other desirable recycle value.
Alternatively, the solid formed product may provide a safe and
effective method of storing and handling useful or potentially
harmful solid particulate materials. The plant 700 also includes
sufficient process control equipment 760 such that the production
steps are integrated into a continuous process. In the alternative,
the process control equipment 760 is configured, for example, to
perform production steps in independent stages.
[0047] Application of the method disclosed herein produces a
composition (e.g., product) that may be used, depending upon the
blend, for stoker coal fuel for industrial steam and heating
purposes, utility grade steam coal fuel for power generation and
other purposes, or metallurgical grade coal (MET) for iron and
steel production as well as specialty applications. Some product
pellets include biomass of various sources to both further reduce
sulfur, ash, and other HAP's as well as extend the fossil material
resource by the inclusion of a renewable component. The inclusion
of both the binder materials comprised of recycled nylon carpet and
other polymer reclaim material and the optional biomass component
result in an increased yield of total fuel production when compared
to the wet coal fines alone. The yield increase is dependant upon
the starting moisture content and the specific blend used, but is
usually in a range from about 20% to 35%. In an embodiment of the
present disclosure, final moisture content of the composition may
be reduced to about 2% due to the heat and pressure generated by
the binding process. This has added benefits in that the biomass
material (when included) is broken down into a form that is better
suited for boiler fuel.
[0048] Embodiments of the present disclosure can include
compositions with the following characteristics: lower product
moisture content compared to washed coal fines; higher heating
value in coal fuel pellets; lower sulfur and HAP's content when
compared to coal fines used to make the compositions; improved and
more complete combustion properties (e.g., about 2% unburned
carbon); lower SOx emissions (e.g., SOx emissions reduced by about
35%); lower NOx emissions (based on the type of boiler) (e.g.,
nitrogen dioxide reduction of about 18.8%); higher hydrogen content
(e.g., about 33%); and increased total yield of coal pellet product
(e.g., about 12% to 30% increase). As used in this disclosure,
"NOx" includes any possible combinations of nitrogen and oxygen
(e.g., NO, NO.sub.2). In an embodiment of the method disclosed
herein, the total yield is increased because waste coal fines are
used in the composition (e.g., pellet), thus increasing the overall
yield because yield at the mine compares the amount of salable coal
based on the amount of mined coal, and for every ton of material
not sent to waste, the yield increases.
[0049] Embodiments of the present disclosure include compositions
that may be blended to meet MET coal specifications using coal
fines of suitable grade. These compositions can be consumed in MET
coal applications for production of iron, steel, and coke, alone or
as a blend with other coals. The addition of other desirable
particulates such as iron ore, iron oxides, and fluxing agents
(e.g., calcium carbonate, limestone, or dolomite) offers the option
of self fluxing iron pellets. Embodiments of this type are
advantageous because they provide for self fluxing for production
of iron without coke or with less coke.
[0050] Embodiments of the present disclosure include a composition
comprising: a particulate solid component, where the particulate
solid component comprises about 50% to 85% of the composition, and
an additional component, where the additional component is selected
from the group consisting of: a biomass component, a polymer
component, a composite waste product component, and a combination
thereof.
[0051] The particulate solid component can include, but is not
limited to, coke breeze, coke fines, coal fines, and wood
wastes.
[0052] The polymer component can include, but is not limited to
plastics (e.g., recycled plastics), polyolefins, polyolefin blends
with other thermoplastics, polyolefin blends with fillers and other
inorganic materials, polyolefin blends with biomass and other
natural materials, polyamides, polyamides mixed with other
thermoplastic polymers, polyamides with inert fillers,
thermoplastics, and thermoplastics in mixtures with thermoset
plastics.
[0053] The composite waste product component can include, but is
not limited to, carpet. Carpet can include, but is not limited to,
industrial carpet processing waste and cuttings, post industrial
waste carpet, consumer installation waste, post consumer carpet,
separated carpet fibers, densified whole carpet, and densified
carpet fibers. In addition, composite waste products can include,
but are not limited to, industrial, post industrial, or post
consumer nylon (polyamide) waste fiber or other materials;
industrial, post industrial, or post consumer nylon (polyamide)
waste fiber or other materials with mixed or added components of
plastic, inorganic fillers, minerals, and/or biomass; industrial,
post industrial, or post consumer fiberous materials, including but
not limited to, fiberglass, other mineral fibers, polymeric fibers,
organic fibers, and natural fibers; and industrial, post
industrial, or post consumer polymers or other materials that will
melt during processing. These composite waste products may be used
alone or in a mixture with carpet.
[0054] Embodiments of the present disclosure include compositions
where the additional component comprises a biomass component and a
polymer component. In an embodiment, the biomass component
comprises about 0.01% to 20% of the composition, and the polymer
component comprises about 0.01% to 20% of the composition.
[0055] Embodiments of the present disclosure include compositions
where the additional component comprises a biomass component and a
composite waste product component. In an embodiment, the biomass
component comprises about 0.01% to 20% of the composition, and the
composite waste product component comprises about 0.01% to 20% of
the composition.
[0056] Embodiments of the present disclosure include compositions
where the additional component comprises a polymer component and a
composite waste product component. In an embodiment, the polymer
component comprises about 0.01% to 20% of the composition, and the
composite waste product component comprises about 0.01% to 20% of
the composition.
[0057] Embodiments of the present disclosure include compositions
where the additional component comprises a biomass component, a
polymer component, and a composite waste product component. In an
embodiment, the particulate solid component comprises about 50% to
85% of the composition, the biomass component comprises about 0.01%
to 20% of the composition, the polymer component comprises about
0.01% to 20% of the composition, and the composite waste product
comprises about 0.01% to 20% of the composition. In another
embodiment, the particulate solid component comprises about 70% of
the composition, the biomass component comprises about 5% of the
composition, the polymer component comprises about 15% of the
composition, and the composite waste product component comprises
about 10% of the composition.
[0058] Embodiments of the present disclosure include compositions
used as industrial stoker grade fuel coal pellets. Stoker grade
pellets are those pellets engineered and manufactured for use in
boilers requiring stoker fuel. Stoker boilers and combustion units
burn chunk coal on a stationary or moving grate. Boilers of this
type are typically used in industrial manufacturing locations and
institutional facilities to manufacture steam and other forms of
high temperature fluids. The fuel is delivered to the boiler in
"chunks" and pieces nominally about 3/8''.times.3/8'' to
3/4''.times.3/4''. This fuel will typically have low sulfur content
(less than about 1%), low ash (non-combustibles, less than about
10%), and low concentrations of HAP's.
[0059] Embodiments of the present disclosure include compositions
that have a very high BTU (e.g., BTU values of about 12,500 BTU/lb
or greater) and are very low in sulfur content (e.g., less than
about 1%).
[0060] Embodiments of the present disclosure include compositions
comprising a cleaner burning product (e.g., emissions compared to
coal are lower, less carbon in ash, less smoke at start-up), that
is lower in moisture and fines, and enables coal fired boilers and
furnaces to operate with less emissions of SOx, NOx, and HAP's.
Embodiments of the present disclosure include compositions
comprising products that enable better Environmental Protection
Agency (EPA) emissions compliance without additional flue gas
treatment.
[0061] Embodiments of the present disclosure include compositions
that ignite rapidly (e.g., ignite faster in a stoker boiler
environment compared to coal). In an embodiment, the compositions
include a rough surface (e.g., more surface area) that ignites
faster.
[0062] Embodiments of the present disclosure include a composition
comprising: a particulate solid component, where the particulate
solid component comprises about 60% to 85% of the composition, and
an additional component, where the additional component is selected
from the group consisting of: a biomass component, a polymer
component, and a composite waste product component.
[0063] Embodiments of the present disclosure include compositions
where the additional component comprises a biomass component and a
polymer component. In an embodiment, the biomass component
comprises about 0.01% to 25% of the composition, and the polymer
component comprises about 0.01% to 15% of the composition.
[0064] Embodiments of the present disclosure include compositions
where the additional component comprises a biomass component and a
composite waste product component. In an embodiment, the biomass
component comprises about 0.01% to 25% of the composition, and the
composite waste product component comprises about 0.01% to 10% of
the composition.
[0065] Embodiments of the present disclosure include compositions
where the additional component comprises a polymer component and a
composite waste product component. In an embodiment, the polymer
component comprises about 0.01% to 15% of the composition, and the
composite waste product comprises about 0.01% to 10% of the
composition.
[0066] Embodiments of the present disclosure include compositions
where the additional component comprises a biomass component, a
polymer component, and a composite waste product component. In an
embodiment, the particulate solid component comprises about 60% to
85% of the composition, the biomass component comprises about 0.01%
to 25% of the composition, the polymer component comprises about
0.01% to 15% of the composition, and the composite waste product
component comprises about 0.01% to 10% of the composition. In
another embodiment, the particulate solid component comprises about
80% of the composition, the biomass component comprises about 5% of
the composition, the polymer component comprises about 10% of the
composition, and the composite waste product component comprises
about 5% of the composition.
[0067] Embodiments of the present disclosure include compositions
used as a utility steam coal fuel pellet (e.g., fuel to be used in
a utility boiler to generate steam/electricity).
[0068] Embodiments of the present disclosure include a composition
comprising: a particulate solid component, where the particulate
solid component comprises about 65% to 85% of the composition; and
an additional component, where the additional component is selected
from the group consisting of: a biomass component, a polymer
component, and a composite waste product component.
[0069] Embodiments of the present disclosure include compositions
where the additional component comprises a biomass component and a
polymer component. In an embodiment, the biomass component
comprises about 0.01% to 20% of the composition, and the polymer
component comprises about 8% to 20% of the composition.
[0070] Embodiments of the present disclosure include compositions
where the additional component comprises a biomass component and a
composite waste product component. In an embodiment, the biomass
component comprises about 0.01% to 20% of the composition, and the
composite waste product comprises about 0.01% to 10% of the
composition.
[0071] Embodiments of the present disclosure include compositions
where the additional component comprises a polymer component and a
composite waste product component. In an embodiment, the polymer
component comprises about 8% to 20% of the composition, and the
composite waste product component comprises about 0.01% to 10% of
the composition.
[0072] Embodiments of the present disclosure include compositions
where the additional component comprises a biomass component, a
polymer component, and a composite waste product component. In an
embodiment, the particulate solid component comprises about 65% to
85% of the composition, the biomass component comprises about 0.01%
to 20% of the composition, the polymer component comprises about 8%
to 20% of the composition, and the composite waste product
component comprises about 0.01% to 10% of the composition. In
another embodiment, the particulate solid component comprises about
80% of the composition, wherein the polymer component comprises
about 15% of the composition, and wherein the composite waste
product component comprises about 5% of the composition.
[0073] Embodiments of the present disclosure include compositions
used as a metallurgical MET coal pellet. In an embodiment, the
particulate solid component is coal fines that are of a low
volatility, higher in fixed carbon, and posses the type of
petrography properties needed in the metals industry for either
coke production or direct injection applications. MET coal is not
burned, but is used during the steel and metal making process to
add carbon to the material. In direct injection, the MET material
is added directly to the steel making vats.
[0074] Embodiments of the present disclosure include compositions
with an additive component where the additive component is selected
from the group consisting of: coke breeze, carbon black, PET coke,
and a combination thereof. The particular additive components are
selected for their high concentrations of carbon and/or low
concentrations of volatiles. In an embodiment, the composition is
capable of oversees transport and outdoor storage without
degradation and moisture absorption.
EXAMPLES
Example 1
[0075] As illustrated in Table 1 below, Example 1 is based on
combustion testing emission data and data on the make-up of an
embodiment of the present disclosure burned during a trial. The top
portion of Table 1 shows the basic properties of a standard coal
that is burned in a boiler. The lower portion of Table 1 depicts
the reduction in sulfur emissions based on blending of materials in
a composition of the present disclosure, Btu increase (sulfur
emissions are reduced by the higher Btu value of an embodiment of
the present disclosure because less fuel needs to be burned to
provide the same amount of energy, thus generating less emissions),
and the effect of SO.sub.2 scrubbing by the calcium carbonate
contained in the recycled carpet.
TABLE-US-00001 TABLE 1 Basis - 6,675 tons per year of Stoker Coal
with the following properties: 1% Sulfur 12,500 Btu/lb 253,650
Pounds per year (PPY) SO2 emissions Reductions using Sulfur
Reduction an embodiment of Lower Sulfur by 30% 73,051 PPY the
present due to blending disclosure Increase Btu by 500 10,146 PPY
Btu/lb SO2 scrubbing during 5,848 PPY combustion Total Reduction
89,045 PPY Total Sulfur Reduction - 35%
Example 2
[0076] Example 2 illustrates sulfur reduction in an embodiment of
the present disclosure including a pellet based on coal fines
blending with the binder materials. This data is pre-combustion and
is illustrated in Table 2 below.
TABLE-US-00002 TABLE 2 EXAMPLE #2 Sulfur % Sulfur % % Dec Coal 015
4.48 Composition 015-A 3.93 12.3% Composition 015-B 2.89 35.5% Coal
016 0.76 Composition 016-A 0.57 25.0% Composition 016-B 0.62 18.4%
Coal 019 1.5 Composition 019-A 1.09 27.3% Composition 019-B 1.12
25.3% NOTES: "A" blends contain biomass, "B" blends do not contain
biomass. Coal 015 Nothern Appalachan Coal Coal 016 East KY
Bituminous Coal Coal 019 KY Blue Gem Coal Based on Short Prox lab
testing.
Example 3
[0077] Example 3 illustrates moisture reduction in produced pellets
compared to the starting coal in an embodiment of the present
disclosure including a pellet based on coal fines blending with the
binder materials. As an example, coal fine at 19.2% moisture are
processed into pellets which have a total moisture content of
0.93%. This data is illustrated in Table 3 below.
TABLE-US-00003 TABLE 3 Moisture % Coal 015 18.2 Composition 015-A
0.93 Composition 015-B 0.96 Coal 016 10.91 Composition 016-A 1.4
Composition 016-B 1.1 Coal 019 16.28 Composition 019-A 1.74
Composition 019-B 1.62 NOTES: "A" blends contain biomass, "B"
blends do not contain biomass. Coal 015 Nothern Appalachan Coal
Coal 016 East KY Bituminous Coal Coal 019 KY Blue Gem Coal Based on
Short Prox lab testing.
Example 4
[0078] Example 4 illustrates heating value increase in an
embodiment of the present disclosure including a pellet based on
coal fines blending with the binder materials. As an example,
pelletizing coal with a heating value of 8,897 Btu/lb produces a
pellet with a heating value of 12,160 Btu/lb (an increase of
36.7%). This data is illustrated in Table 4 below.
TABLE-US-00004 TABLE 4 Heating Value Btu/lb % Increase Coal 015
8,897 Composition 015-A 12,160 36.7% Composition 015-B 12,102 36.0%
Coal 016 11,231 Composition 016-A 13,115 16.8% Composition 016-B
13,561 20.7% Coal 019 11,924 Composition 019-A 14,412 20.9%
Composition 019-B 14,436 21.1% NOTES: "A" blends contain biomass,
"B" blends do not contain biomass. Coal 015 Nothern Appalachan Coal
Coal 016 East KY Bituminous Coal Coal 019 KY Blue Gem Coal Based on
Short Prox lab testing.
Example 5
[0079] The data contained in Tables 5 and 6 illustrates that
embodiments of the present disclosure pick up very low amounts of
water when soaked (e.g., less than about 2%) and pellets formed
from compositions of the present disclosure dry very rapidly. Thus,
the pellets are not adversely affected by water, nor do they fall
apart when soaked in water. In the Tables, all weight is in grams;
"initial" includes the weight of a pellet prior to water soak;
"removal" is the weight after water soak of thirty (30) minutes
with immediate dry; and % WPU is percent wet pick up.
[0080] Table 6 includes % WPU of water during soak and the loss of
water over time.
TABLE-US-00005 TABLE 5 0 30 60 90 150 Weight of Pellet in Grams #
Initial Removal 30 min 60 min 120 min Pellet 1 14.98 15.18 15.10
15.04 14.99 Pellet 2 12.72 12.95 12.87 12.82 12.75 Pellet 3 13.09
13.24 13.16 13.13 13.10 Pellet 4 14.62 14.81 14.70 14.65 14.61
Pellet 5 14.59 14.77 14.67 14.62 14.59 Min 12.72 12.95 12.87 12.82
12.75 Max 14.98 15.18 15.10 15.04 14.99 Ave 14.00 14.19 14.10 14.05
14.01 Std Dev 1.01973 1.017472 1.0101238 1.00303 1.009019
TABLE-US-00006 TABLE 6 % WPU # Removal 30 min 60 min 120 min Pellet
1 1.34 0.80 0.40 0.07 Pellet 2 1.81 1.18 0.79 0.24 Pellet 3 1.15
0.53 0.31 0.08 Pellet 4 1.30 0.55 0.21 -0.07 Pellet 5 1.23 0.55
0.21 0.00 Min 1.15 0.53 0.21 -0.07 Max 1.81 1.18 0.79 0.24 Ave 1.36
0.72 0.38 0.06 Std Dev 0.258268 0.278884 0.240775 0.113249
Example 6
[0081] Tables 7 and 8 illustrate properties for another embodiment
of the present disclosure. The data contained in Tables 7 and 8
illustrates that embodiments of the present disclosure pick up very
low amounts of water when soaked (e.g., less than about 2%) and
pellets formed from compositions of the present disclosure dry very
rapidly. Thus, the pellets are not adversely affected by water nor
do they fall apart when soaked in water. In the Tables, all weight
is in grams; "initial" includes the weight of a pellet prior to
water soak; "removal" is the weight after water soak of thirty (30)
minutes with immediate dry; and % WPU is percent wet pick up.
TABLE-US-00007 TABLE 7 # Initial Removal 30 min 60 min 120 min 1
10.08 10.36 10.27 10.21 10.13 2 9.2 9.41 9.34 9.27 9.23 3 11.46
11.71 11.63 11.56 11.5 4 11.01 11.23 11.09 11.03 10.99 5 10.54
10.67 10.6 10.58 10.56
TABLE-US-00008 TABLE 8 % WPU # Removal 30 min 60 min 120 min 1
2.777778 1.884921 1.289683 0.496032 2 2.282609 1.521739 0.76087
0.326087 3 2.181501 1.483421 0.8726 0.34904 4 1.998183 0.726612
0.181653 -0.18165 5 1.233397 0.56926 0.379507 0.189753 Min 1.233397
0.56926 0.181653 -0.18165 Max 2.777778 1.884921 1.289683 0.496032
Ave 2.094693 1.23719 0.696862 0.235852 Std Dev 0.561382 0.563022
0.433754 0.257431
Example 7
[0082] Table 9 is a comparison of typical HAP values to data
collected during a test burn of an embodiment of the present
disclosure. In all cases, the values for an embodiment of the
present disclosure are within the established range of values or
below the established range (lower values are advantageous).
TABLE-US-00009 TABLE 9 EMISSION FACTORS FOR TRACE ELEMENTS, POM,
AND HCOH FROM UNCONTROLLED BITUMINOUS AND SUBBITUMINOUS COAL
COMBUSTION Firing Configuration Emission Factor, lb/1.0E12 Btu
(SCC) As Be Cd Cr Pb b Mn Hg Ni POM HCON Pulverized coal,
configuration ND ND ND 1922 ND ND ND ND ND 112 C unknown (no SCC)
Pulverized coal, wet bottom 538 81 44-70 1020-1570 507 808-2980 16
840-1290 ND ND Pulverized coal, dry bottom 684 81 44.4 1250-1570
507 228-2980 16 1030-1290 2.08 ND Pulverized coal, dry bottom ND ND
ND ND ND ND ND ND 2.4 ND tangental Cyclone furnace 115 <81 28
212-1502 507 228-1300 16 174-1296 ND ND Stoker, configuration
unknown ND 73 ND 19-300 ND 2170 16 775-1290 ND ND Spreader stoker
264-542 ND 21-43 942-1570 507 ND ND ND ND 221 d Overfeed stoker,
traveling grate 542-1030 ND 43-82 ND 507 ND ND ND ND 140 a An
embodiment of a composition 87.6 1.2 2.86 204 91.6 73.6 9.74 1120
ND ND of the present disclosure a References 56-61. The emission
factors in this table represent the ranges of factors reported in
the literature. If only one data point is found it is still
reported in this table. To convert from displayed units to pg/J,
multiply by 0.43. SCC = Source Classification Code. ND = no data. b
Lead emission factors were taken directly from an EPA background
document for support of the national Ambient Air Quality Standards.
C Based on two units; 133 E6 Btu/hr and 1550 E5 Btu/hr. d Based on
1 unit; 59E6 Btu/hr.
[0083] It should be noted that ratios, concentrations, amounts, and
other numerical data may be expressed herein in a range format. It
is to be understood that such a range format is used for
convenience and brevity, and thus, should be interpreted in a
flexible manner to include not only the numerical values explicitly
recited as the limits of the range, but also to include all the
individual numerical values or sub-ranges encompassed within that
range as if each numerical value and sub-range is explicitly
recited. To illustrate, a concentration range of "about 0.1% to
about 5%" should be interpreted to include not only the explicitly
recited concentration of about 0.1 wt % to about 5 wt %, but also
include individual concentrations (e.g., 1%, 2%, 3%, and 4%) and
the sub-ranges (e.g., 0.5%, 1.1%, 2.2%, 3.3%, and 4.4%) within the
indicated range. The term "about" can include .+-.1%, .+-.2%,
.+-.3%, .+-.4%, .+-.5%, .+-.6%, .+-.7%, .+-.8%, .+-.9%, or .+-.10%,
or more of the numerical value(s) being modified. In embodiments
where "about" modifies 0 (zero), the term "about" can include
.+-.1%, .+-.2%, .+-.3%, .+-.4%, .+-.5%, .+-.6%, .+-.7%, .+-.8%,
.+-.9%, .+-.10%, or more of 0.00001 to 1. In addition, the phrase
"about `x` to `y`" includes "about `x` to about `y`".
[0084] It should be emphasized that the above-described embodiments
of the present disclosure are merely possible examples of
implementations, and are merely set forth for a clear understanding
of the principles of the disclosure. Many variations and
modifications may be made to the above-described embodiments. All
such modifications and variations are intended to be included
herein within the scope of this disclosure and protected by the
following claims.
* * * * *