U.S. patent application number 12/251954 was filed with the patent office on 2010-04-15 for composition for dust control and limiting moisture re-absorption.
Invention is credited to Merle L. Branning.
Application Number | 20100090160 12/251954 |
Document ID | / |
Family ID | 41429689 |
Filed Date | 2010-04-15 |
United States Patent
Application |
20100090160 |
Kind Code |
A1 |
Branning; Merle L. |
April 15, 2010 |
COMPOSITION FOR DUST CONTROL AND LIMITING MOISTURE
RE-ABSORPTION
Abstract
The current invention relates to a composition that allows for
the reduction of dust in an environment through application to a
hard surface in that environment or dispersal of dust into the
environment is minimized. The composition allows for instant
reduction of dust and for the elimination of the absorption of
moisture on surfaces that are prone to this over time. The
invention is usable with mined minerals or synthesized materials
that are prone to produce dust and absorb moisture during storage
and transport so the composition can allow for a safer environment
and longer storage of products.
Inventors: |
Branning; Merle L.; (Plano,
IL) |
Correspondence
Address: |
Michael B. Martin;Patent and Licensing Department
Nalco Company, 1601 West Diehl Road
Naperville
IL
60563-1198
US
|
Family ID: |
41429689 |
Appl. No.: |
12/251954 |
Filed: |
October 15, 2008 |
Current U.S.
Class: |
252/88.1 |
Current CPC
Class: |
C09K 3/22 20130101; E21F
5/06 20130101 |
Class at
Publication: |
252/88.1 |
International
Class: |
C09K 3/22 20060101
C09K003/22 |
Claims
1. A dust control composition comprised of an effective amount of a
transport component, a dispersant and a surface modifying
agent.
2. The dust control composition of claim 1 including a coupling
agent.
3. The dust control composition of claim 1 where the transport
component is a mixture of synthetic oils.
4. The dust control composition of claim 1 where the transport
component is a mixture of natural oils.
5. The dust control composition of claim 2 including a curing
control agent.
6. The dust control composition of claim 1 wherein the transport
component is one or more of biodiesel, mineral oils, LOPS, Escaid
and paraffinic oils.
7. The dust control composition of claim 2 wherein the coupling
agent is one or more surfactants.
8. The dust control composition of claim 7 wherein the surfactant
is one or more phospholipids.
9. The dust control composition of claim 1 wherein the dispersant
is one or more of the following: orange oil, pine oil, essential
oil, terpenes, cationic ethoxylates, nonionic ethoxylates,
propoxylates and anionic ethoxylates.
10. The dust control composition of claim 1 wherein the surface
modifying agent is derived from a natural source.
11. The dust control composition of claim 1 wherein the surface
modifying agent is derived from a synthetic source.
12. The dust control composition of claim 10 wherein the surface
modifying agent is natural rubber latex.
13. The dust control composition of claim 11 wherein the surface
modifying agent is a polyisoprene suspension.
14. The dust control composition of claim 2 wherein there is 50 to
98 percent transport component, 0.05 to 10 percent dispersant, 0.05
to 20 percent surface modifying agent and 0.1 to 50 percent
coupling agent.
15. The dust control composition of claim 2 wherein there is 80 to
90 percent transport component, 0.5 to 2 percent dispersant, 0.5 to
5 percent surface modifying agent and 5 to 20 percent coupling
agent.
16. A method of dust control wherein the composition of claim 1 is
applied to a surface in an effective amount to allow for the
immediate elimination of dust particles and remain effective for an
extended period of time.
17. The method of claim 16 wherein the composition is applied with
a properly engineered spray bar or application device.
18. The method of claim 16 wherein the composition is applied in an
effective amount to control residual dust for the storage or
transportation of the surface.
19. The method of claim 18 wherein the composition is applied in an
effective amount to prevent moisture re-absorption during storage
and transport.
20. The method of claim 19 where in the surface is a mined
mineral.
21. The method of claim 19 where in the surface is a synthesized
dry material.
22. The method of claim 20 where in the mined mineral is coal,
potash or phosphate.
23. The method of claim 16 wherein the surface is a road and the
dust particles are road dust.
Description
COPYRIGHT NOTICE
[0001] A portion of the disclosure of this patent document contains
or may contain copyright protected material. The copyright owner
has no objection to the photocopy reproduction by anyone of the
patent document or the patent disclosure in exactly the form it
appears in the Patent and Trademark Office patent file or records,
but otherwise reserves all copyright rights whatsoever.
TECHNICAL FIELD
[0002] This invention relates to production of a dust control
product that over time exhibits residual dust control capabilities.
The invention discloses a composition and a method for application
of the product onto a surface to provide dust control and further
allows for residual dust control after the curing process. The
invention not only demonstrates initial and residual dust control
it additionally limits moisture re-absorption during storage and
transport.
BACKGROUND
[0003] The invention describes a composition for use in dust
control on surfaces and it is particularly effective in mineral
mining, processing and storage environments. The product is
effective for use in the mining sector because it also reduces
moisture re-absorption during storage and transport of the
minerals. Further the invention relates to the method of use of the
composition in relation to dust reduction and long term dust
control.
[0004] The invention may be used to include dust control where the
solids are selected from the group consisting of coal, clean coal,
bauxite, iron ore, copper ore, sand, gravel, clay, dirt, phosphate
rock, lead/zinc, taconite, beryllium, Trona, kaolin, titania,
uranium, precious metals and the like. More than one type of solids
may be present to the total surface for dust control.
[0005] Dust suppression is the reduction of the extent to which
finely divided solid particulate material becomes suspended in the
air. A variety of materials such as coal, sulfur, phosphate, clay,
potash and other finely divided ores and minerals, generate dust in
transfer and handling operations during mining, transportation,
storage, and use.
[0006] Dust is a particularly severe safety and health hazard in
coal mining, handling, and storage operations. Coal often chips
into small fragments by the action of wind and rain, frictional
movement due to motion in transit, and abrasion in handling.
Respirable coal dust has a particle size of less than about 10
microns and its inhalation can lead to pneumoconiosis, i.e., "black
lung disease". Also, dust explosions due to spontaneous combustion
may occur when the dust is confined to a small air space such as in
coal mining operations.
[0007] It is known to suppress dust in mines by spraying with
various aqueous systems containing chemical additives to improve
working conditions and reduce the toxicological risks and explosion
hazards. For example, U.S. Pat. No. 4,425,252 describes a method to
abate coal dust using an anionic surfactant, preferably sodium
dodecylbenzene sulphonate and a nonionic surfactant, preferably a
polyethoxylated nonylphenol, in an aqueous formulation. The method
comprises spraying the coal dust area with a formulation comprising
water containing up to 0.1% by weight of the mixture of the anionic
surfactant, i.e., a water soluble salt of an alkyl aryl sulfonic
acid and nonionic surfactant having an HLB of from 10 to 16.
Optimally, the mixture contains one or more cosolvents generally of
the class of alkylene glycol monoalkyl ethers, C.sub.2 to C.sub.5
alkanols and mixtures thereof.
[0008] Furthermore, several techniques have been developed
utilizing foamable compositions for suppressing coal dust. For
example, U.S. Pat. No. 4,551,261 describes a foam comprising water,
a foaming agent, and an elastomeric water insoluble polymer. A
variety of anionic and nonionic surfactants and detergent wetting
agents are described as useful foaming agents, and a variety of
elastomeric and water insoluble synthetic organic polymer binders
are described as useful elastomeric water insoluble polymers.
[0009] U.S. Pat. No. 4,971,720 relates to a method for suppressing
dust process emissions. The method utilizes a foaming agent which
may be a low salt tolerant surfactant selected from salts of fatty
acids, alkyl sulphates, and alkyl aryl sulphonates.
[0010] U.S. Pat. No. 4,561,905 describes a coal dust suppression
mixture of oil, water and a surfactant in the form of an emulsion
that is diluted and foamed. The foam is then sprayed into a falling
mass of coal. The oils suitable for use are described as heavy
process oils and include asphalt dissolved in a moderately heavy
oil, residual flush oils or relatively high viscosity fuel oil. The
preferred oils have a viscosity in the range of from approximately
600 to 7,000 SUS at 38.degree. C., a pour point in the range of
approximately -18.degree. to 21.degree. C., a molecular weight of
at least 300 and a boiling point of at least 204.degree. C.
[0011] U.S. Pat. No. 4,944,892 teaches an aqueous composition which
comprises a linear primary alcohol ethoxylate surfactant, a
suitable scenting oil such as pine oil or lemon oil and water among
other adjuvants.
[0012] U.S. Pat. No. 4,929,278 discloses an aqueous bath
preparation which comprises essential oils such as orange peel oil,
orange oil, lemon oil or the like. Further, the bath preparation
comprises a soap or surfactant which may include straight chain
alkyl benzenesulfonates, alkyl sulfuric acid ester, alkyl ether
sulfuric acid ester and the like.
[0013] U.S. Pat. No. 3,367,878 shows a composition which comprises
20.2% by weight water, 1.0% by weight pine oil, 1.8% by weight
sodium xylene sulphonate surfactant.
[0014] U.S. Pat. No. 4,175,062 teaches an aqueous composition which
comprises 7.5% by weight of sodium dodecylbenzene sulfonate, 0.8%
by weight of pine oil and other adjuvants.
[0015] Japanese Patent 44,495 discloses an aqueous composition
which comprises 20% by weight of sodium lauryl benzene sulfonate
and 1% by weight of D-limonene along with other adjuvants.
[0016] Thus, various techniques have been developed to suppress and
control dust especially in the mining of minerals, and many of the
techniques are effective for reducing dust. However, there is still
a need for improvement in dust suppression. In relation to finely
divided ores and mineral mining many of the prior techniques were
developed without a need to address problems associated with modern
mining practices.
Definitions:
[0017] Transport Component (carrier oil, acts to transport other
reagents)
[0018] These carrier oils of hydrocarbons are extracted from
petroleum crude oil (ex: low odor paraffin solvent, Escaid 110
solvent Exxon, Mineral Oils). These oils also come from crop
sources, such as, Biodiesel, that is derived from corn or soybeans
to name a few. Other crop sources also exist and should not limit
this invention.
[0019] Dispersant (aids in effective surface coverage)
[0020] These materials could be derived from natural or synthetic
sources (ex: orange oil, pine oil, essential oils, terpenes,
cationic, nonionic, cationic and anionic ethoxylated surfactant
materials and blends, thereof).
[0021] Surface Modifying Agent (elastomer)
[0022] This material is any substance that increases the
formulations tackiness such as materials derived from rubber
sources either natural (natural rubber latex, Union Carbide,
NC-358) or synthetic (polyisoprene suspension, Kraton IR401).
[0023] Coupling Agent (aids in homogeneous blending)
[0024] These materials are derived from natural sources, such as,
soybeans and other crops. These are phospholipids. (ex: ALC,
Alcotee S, American Lecithin Company).
SUMMARY
[0025] The current invention describes the following key aspects:
[0026] 1. It is an advantage of the invention to provide increased
dust control. [0027] 2. It is an advantage of the invention to
limit moisture re-absorption. [0028] 3. It is an advantage of the
invention to provide residual dust control. [0029] 4. Provides a
method of dust control during storage or transport.
DETAILED DESCRIPTION
[0030] The current invention relates to a dust control composition
comprised of an effective amount of a transport component, a
dispersant and a surface modifying agent. This composition is for
use on a wide variety of surfaces to assist in the dust reduction
in an open or closed environment.
[0031] The dust control composition can also include a coupling
agent that can assist in the overall appearance of the composition
by making it more homogenous. The coupling agent may be a
surfactant preferable one or more phospholipids.
[0032] The composition contains a transport component that can be a
mixture of synthetic oils or natural oils. The preferred transport
components are one or more of the following: biodiesel, mineral
oils, low odor paraffin solvent, Escaid 110 solvent Exxon and
paraffinic oils. Also the composition may include a curing control
agent which can be used to control the curing time so it can be
varied depending on the surface and the environment.
[0033] The dispersant component of the composition is preferably
one or more of the following: orange oil, pine oil, essential oil,
terpenes, cationic ethoxylates, nonionic ethoxylates, propoxylates
and anionic ethoxylates.
[0034] The surface modifying agent of the composition can be
derived from a natural source, such as natural rubber latex, or a
synthetic source, such as a polyisoprene suspension.
[0035] The dust control composition contains the components in the
following ranges; 50 to 98 percent transport component, 0.05 to 10
percent dispersant, 0.05 to 20 percent surface modifying agent and
0.1 to 50 percent coupling agent. The dust control composition has
the components in the preferred range of 80 to 90 percent transport
component, 0.5 to 2 percent dispersant, 0.5 to 5 percent surface
modifying agent and 5 to 20 percent coupling agent.
[0036] The invention further includes a method using the dust
control composition wherein it is applied to a surface in an
effective amount to allow for the immediate elimination of dust
particles and remain effective for an extended period of time. The
composition is applied with a properly engineered spray bar or
application device. The application of the composition is done with
an effective amount to control residual dust for the storage or
transportation of the surface and to prevent moisture re-absorption
during storage and transport. The composition can be used on a wide
variety of surfaces including but not limited to mined minerals,
synthesized dry material, roads, coal, potash and/or phosphate.
EXAMPLES
[0037] The foregoing may be better understood by reference to the
following examples, which are intended to illustrate methods for
carrying out the invention and are not intended to limit the scope
of the invention.
[0038] It should be understood that various changes and
modifications to the presently preferred embodiments described
herein will be apparent to those skilled in the art. Such changes
and modifications can be made without departing from the spirit and
scope of the invention and without diminishing its intended
advantages. It is therefore intended that such changes and
modifications be covered by the appended claims.
[0039] The testing is conducted using a drop box apparatus where
the dust control effectiveness of the claimed invention is
demonstrated. The majority of the drop box apparatus is a hollow
aluminum piece with a movable steel plate at the top of the
apparatus where the sample is loaded and a detection system at the
bottom consisting of a laser, power supply, detector, and removable
piece necessary for cleaning. The system sits on a base that has an
insert, which fits inside the aluminum part. The following is the
test procedure used to evaluate the samples in the examples.
Sample Prep
[0040] Only dry samples can be tested using this device.
[0041] If required, the materials were ground to dust in a ceramic
container filled with steel spheres. Numerous spheres were placed
into the ceramic container with the material to be tested and
allowed to roll for a predetermined time period. The particles are
then sifted through a #30 mesh screen to separate out larger
particles.
[0042] The material is then heated to the appropriate temperature
in an 180.degree. F. oven for one hour (if required).
[0043] The appropriate amount of dust control agent is applied onto
the dust, while still in the oven (if required), and mixed
thoroughly.
[0044] The dust material dosed with dust control agent is then
allowed to cool to room temperature prior to testing in the drop
box apparatus.
Sampling Procedure
[0045] Turn on the drop box detection system and begin data
acquisition system.
[0046] Secure the steel tray in a horizontal position using a
magnets
[0047] Load a predetermined amount of sample onto the swing down
tray (sample size of 5-15 g).
[0048] Capture the data from data acquisition system.
[0049] Begin trial by connecting to the detection system.
[0050] Officially start recording optical densities.
[0051] The detector will now determine the amount of light
scattering over time.
[0052] A baseline is found first to ensure no contaminants are in
the laser field.
[0053] After a baseline is set, the magnet can be removed causing
the sample to drop down the apparatus resulting in an increase in
optical density.
[0054] After a predetermined amount of time the data collecting is
stopped.
Example 1
Fine Langbeinite Standard
TABLE-US-00001 [0055] Sample Y: 98% Transport component, 1%
dispersant and 1% surface modifying agent. Sum Under Curve %
Reduction Sample (T = 0, 10.sup.x) from blank (T = 0) Blank 4.47
.times. 10.sup.5 NA 0.5 gal/ton/Y 5.34 .times. 10.sup.4 88.84 1.0
gal/ton/Y 3.65 .times. 10.sup.4 92.38 1.5 gal/ton/Y 2.68 .times.
10.sup.4 94.39
Example 2
Coal
TABLE-US-00002 [0056] Sample Z was composed of: 79.4% transport
component 1.6% dispersant 3.2% surface modifying agent 15.8% a
coupling agent % Reduction from Dose and Sample Sum Under Curve (T
= 0, 10.sup.x) blank (T = 0) Blank 4.70 .times. 10.sup.6 NA 10
gm/500 gm/Z 2.90 .times. 10.sup.6 38.33 20 gm/500 gm/Z 1.87 .times.
10.sup.6 60.13 50 gm/500 gm/Z 1.80 .times. 10.sup.3 99.96
Example 3
Fine Langbeinite Standard
TABLE-US-00003 [0057] Sample A was composed of: 79.4% transport
component 1.6% dispersant 3.2% surface modifying agent 15.8% a
coupling agent Sample B was composed of: 88% transport component 1%
dispersant 1% surface modifying agent 10% a coupling agent %
Reduction from Dose and Sample Sum Under Curve (T = 0, 10.sup.x)
blank (T = 0) Blank 4.79 .times. 10.sup.5 NA 0.5 gal/ton/A 4.45
.times. 10.sup.4 90.69 0.5 gal/ton/B 4.20 .times. 10.sup.4 91.23
1.0 gal/ton/A 4.45 .times. 10.sup.4 90.71 1.0 gal/ton/B 4.26
.times. 10.sup.4 91.10 1.5 gal/ton/A 4.60 .times. 10.sup.4 90.38
1.5 gal/ton/B 3.11 .times. 10.sup.4 93.51 2.0 gal/ton/A 2.99
.times. 10.sup.4 93.76 2.0 gal/ton/B 3.89 .times. 10.sup.4
91.88
* * * * *