Dust control formulations

• US 10,385,246 B2
• Filed: 12/14/2016
• Issued: 08/20/2019
• Est. Priority Date: 12/14/2015
• Status: Active Grant

• Current Assignee: Henry Company LLC (Carlisle Cos., Inc.)
• Original Assignee: Henry Company LLC (Carlisle Cos., Inc.)
• Inventors: Ayambem, Amba
• Primary Examiner(s): McAvoy, Ellen M
• Assistant Examiner(s): Graham, Chantel L
• Application Number:
  US15/378,777
• Publication Number:
  US 20170166792A1
• Time in Patent Office: Days
• CPC Class Codes: C04B 20/1033 obtained by reactions only involving carbon-to-carbon unsaturated bonds
• CPC Class Codes: C04B 2103/0075 Anti-dusting agents
• CPC Class Codes: C04B 2103/0079 Rheology influencing agents
• CPC Class Codes: C04B 2103/40 Surface-active agents, dispersants
• CPC Class Codes: C04B 2103/408 Dispersants
• CPC Class Codes: C04B 2103/67 Biocides
• CPC Class Codes: C04B 24/005 Halogen-containing compounds
• CPC Class Codes: C04B 24/08 Fats; Fatty oils; Ester type waxes; Higher fatty acids, i.e. having at least seven carbon atoms in an unbroken chain bound to a carboxyl group; Oxidised oils or fats
• CPC Class Codes: C04B 24/36 Bituminous materials, e.g. tar, pitch C04B24/243 takes precedence
• CPC Class Codes: C04B 24/42 Organo-silicon compounds
• CPC Class Codes: C04B 40/0039 Premixtures of ingredients
• CPC Class Codes: C09K 3/22 for dust-laying or dust-absorbing
• CPC Class Codes: C10L 2230/14 for improving storage or transport of the fuel
• CPC Class Codes: C10L 2250/04 Additive or component is a polymer
• CPC Class Codes: C10L 2290/18 Spraying or sprinkling
• CPC Class Codes: C10L 5/24 Combating dust during shaping or briquetting; Safety devices against explosion
• CPC Class Codes: E21F 5/06 Fluids used for spraying

Abstract

This disclosure describes formulations and methods for dust control, for example, coal topping, a term which refers to the application of liquid products to the top of coal loads, such as those in open topped coal hopper railcars as commonly used today to transport coal. Disclosed herein are wax-based emulsion formulations that accomplish dust control during industrial operations in which dust handling is required.

Claims

1. A method for controlling dust on a surface of a bulk material, comprising:

(I) preparing a dust control formulation (DCF) comprising a dust reduction additive (DRA) emulsion comprising colloidally-protected wax-based (CPWB) microstructures; and

(II) applying said dust control formulation to said surface of said bulk material in an amount effective for dust control,

wherein said CPWB microstructure comprises;

(A) a wax core,

wherein said wax core comprises a paraffin component and a non-paraffin component,

wherein said paraffin component comprises at least one linear alkane wax defined by the general formula CnH2n+2, where n ranges from 13-80,

wherein said non-paraffin component comprises at least one wax selected from the group consisting of animal-based wax, plant-based wax, mineral wax, synthetic wax, a wax containing organic acids and/or esters, anhydrides, an emulsifier containing a mixture of organic acids and/or esters, and combinations thereof; and

(B) a polymeric shell,

wherein said polymeric shell comprises at least one polymer selected from poly-vinyl alcohol, polyvinyl alcohol copolymers, polyvinyl alcohol terpolymers, polyvinyl acetate, polyvinyl acetate copolymers, polyvinyl acetate terpolymers, cellulose ethers, polyethylene oxide, polyethyleneimines, polyvinylpyrrolidone, polyvinylpyrrolidone copolymers, polyethylene glycol, polyacrylamides and poly (N-isopropylamides), pullulan, sodium alginate, gelatin, starches, and combinations thereof.

2. The method as recited in claim 1, wherein said polymeric shell comprises polyvinyl alcohol.

3. The method as recited in claim 1, wherein said DCF further comprises a binder;

a preservative;

a rheology modifier; and

/or a surfactant.

4. The method as recited in claim 1, wherein said binder is selected from polyvinyl acetate, polyvinyl alcohol, ethylene vinyl acetate co-polymer, vinylacrylic copolymer, styrenebutadiene, polyacrylamide, acrylic polymers, latex, natural starch, synthetic starch, casein, and combinations thereof.

5. The method as recited in claim 1, wherein said dust-reduction additive emulsion further comprises a second water;

a base; and

a dispersant.

6. The method as recited in claim 4, wherein said dispersant is selected from a dispersant having sulfur;

a dispersant having a sulfur-containing group in the compound;

sulfonic acid (R—

S(═

O)₂—

OH);

sulfonic acid salts, wherein the R groups is functionalized with hydroxyl, or carboxyl;

lignosulfonate;

lignosulfonic acid;

naphthalene sulfonic acid;

sulfonate salt of lignosulfonic acid;

sulfonate salt of naphthalene sulfonic acid, derivatized lignosulfonic acid, derivatized naphthalene sulfonic acid, functionalized lignosulfonic acid;

functionalized naphthalene sulfonic acid;

magnesium sulfate;

polycarboxylate;

ammonium hepta molybdate;

combination of ammonium hepta molybdate and starch, alkyl quaternary ammonium;

montmorillonite clay;

non-ionic surfactants;

ionic surfactants;

zwitterionic surfactants; and

mixtures thereof.

7. The method as recited in claim 4, wherein said base is selected from monoethanol amine;

diethanol amine;

triethanol amine;

imidazole;

potassium siliconate; and

combinations thereof.

8. The method as recited in claim 1, wherein the weight of said dust reduction additive emulsion is in the range of from about 0.01% to about 20% by weight of said dust control formulation.

9. The method as recited in claim 1, wherein the weight of said dust reduction additive emulsion is in the range of from about 0.1% to about 10% by weight of said dust control formulation.

10. The method as recited in claim 1, wherein said dust control formulation further comprises at least one component from a silicone, a siliconate, a fluorinated compound, a stearate, or a combination thereof.

11. The method as recited in claim 10, wherein the silicones, siliconates, fluorinated compounds, or stearates are selected from the group consisting of metal siliconate salts, potassium siliconate, poly hydrogen methyl siloxane, polydimethyl siloxane, stearate-based salts, and combinations thereof.

12. The method as recited in claim 1, wherein said dust control formulation is applied to the surface of said bulk material at the rate of from about 0.001 to about 5.0 gallon per square yard for controlling dust.

13. The method as recited in claim 1, wherein said bulk material is coal, limestone, fly ash, cement, carbon black, coke, or mineral material.

14. The method as recited in claim 1, wherein said bulk material is coal, and said dust control formulation is applied the top of said coal load in an open-topped, coal-hopper railcar, used for transporting coal.

15. The method as recited in claim 1, wherein said dust control formulation is applied by sprinkling, and/or a spray nozzle.

16. The method as recited in claim 1, wherein said dust control formulation further comprises a first water.