Absorbent granular product

• US 5,888,345 A
• Filed: 09/15/1997
• Issued: 03/30/1999
• Est. Priority Date: 09/09/1993
• Status: Expired due to Term

• Current Assignee: Marcal Paper Mills, LLC
• Original Assignee: Marcal Paper Mills, Inc. (Nittany Paper Mills Incorporated)
• Inventors: Knapick, Edward G., Wolfer, Ernest P., Willemsen, Brent
• Primary Examiner(s): Lamb, Brenda A.
• Application Number:
  US08/929,601
• Time in Patent Office: 561 Days
• Field of Search: 162/4, 162/109, 162/189, 162/190, 428/372, 119/172, 119/173
• US Class Current: 162/109
• CPC Class Codes: A01K 1/0154 comprising inorganic material
• CPC Class Codes: A01K 1/0155 comprising organic material
• CPC Class Codes: B01J 20/12 Naturally occurring clays or bleaching earth
• CPC Class Codes: B01J 20/24 Naturally occurring macromolecular compounds, e.g. humic acids or their derivatives
• CPC Class Codes: B01J 2220/46 Materials comprising a mixture of inorganic and organic materials materials coated or impregnated on a carrier B01J20/32
• CPC Class Codes: B01J 2220/4831 having been subjected to further processing, e.g. paper, cellulose pulp
• CPC Class Codes: B01J 2220/4881 Residues from shells, e.g. eggshells, mollusk shells
• CPC Class Codes: C05D 3/02 from limestone, calcium carbonate, calcium hydrate, slaked lime, calcium oxide, waste calcium products
• CPC Class Codes: C05D 9/00 Other inorganic fertilisers
• CPC Class Codes: C05F 11/00 Other organic fertilisers
• CPC Class Codes: C05F 9/00 Fertilisers from household or town refuse
• CPC Class Codes: C05G 3/80 Soil conditioners
• CPC Class Codes: C05G 5/40 Fertilisers incorporated into a matrix
• CPC Class Codes: D21B 1/026 Separating fibrous materials from waste
• CPC Class Codes: D21B 1/32 of waste paper
• CPC Class Codes: D21B 1/38 Conserving the finely-divided cellulosic material
• CPC Class Codes: D21C 5/02 Working-up waste paper mechanical part D21B1/08, D21B1/32
• CPC Class Codes: D21F 1/66 Pulp catching, de-watering, or recovering; Re-use of pulp-water
• CPC Class Codes: Y02W 30/64 Paper recycling

Abstract

Granular absorbent products with low amounts of paper fiber are described. The absorbent products are made from recycled paper and include less than about 10% of paper fibers having a length sufficient to be retained on a 100 mesh screen. A process for making such granular absorbent products is also provided. The granular absorbents are highly absorbent for water and oil even though they include only low amounts of paper fiber.

Claims

1. A granular absorbent product comprising:

a plurality of irregular, generally spherical granules containing kaolin clay and cellulose fibers, the granules containing less than 10% by weight of the fibers having a size to be retained on a 100 mesh screen, the granules containing 50-60% organic components and 40-50% by weight inorganic components, the granules having a water absorption capacity of at least about 0.85 ml/g, and a bulk density of at least 24 lbs/ft³, at least some of the fibers communicating between the surface of a granule and the interior of the granule.

2. The granular absorbent product of claim 1 wherein the granules have a resistance to attrition of at least 98%.

3. The granular absorbent product of claim 1 wherein the granules retain their integrity when wet.

4. The granular absorbent product of claim 1 wherein the granules have a porous outer surface.

5. The granular absorbent product of claim 1 wherein the granules have a size distribution wherein less than 60% of the granules have a size of 16 mesh or greater.

6. The granular absorbent product of claim 1 wherein the granules have a capacity for the absorption of oil of at least about 0.65 ml/g.

7. The granular absorbent product of claim 1 wherein less than 7% of the paper fibers have a size to be retained on a 100 mesh screen.

8. A granular product for absorbing liquids comprising:

a plurality of irregular, generally spherical granules having a bulk density of at least 24 lbs/ft³ and a solids content of at least 95%;

the majority of the granules having a size that will pass through a 6 mesh screen and be retained on a 30 mesh screen;

the granules containing kaolin clay and cellulose fibers recovered from waste paper, the granules containing less than 10% of the fibers having a length sufficient to be retained on a 100 mesh screen, said granules containing 40-50% by weight of inorganic constituents and 50-60% by weight organic constituents; and

the granules having the ability to absorb water at the rate of at least 0.85 ml/g.

9. The granular product according to claim 8 wherein the granules contain a sufficient amount of the fibers exposed at the surface of the granules to cause water to be absorbed in the granules by a wicking action.

10. The granular product according to claim 8 wherein the granules have a resistance to attrition of at least 90%.

11. The granular product according to claim 8 wherein the granules have substantially integrity when wet.

12. A granular absorbent product comprising:

(a) a plurality of irregular, generally spherical granules having a bulk density of at least 24 lbs/ft³ and a solids content of at least 95%;

(b) the granules containing organic and inorganic solid constituents, including kaolin clay and cellulose fibers recovered from waste paper, 50-60% by weight of the solid constituents being organic and 40-50% by weight of the solid constituents being inorganic;

(c) at least some of the fibers extending from the surface of the granule to the interior of the granule;

(d) the granules having an absorption capacity for water of at least about 0.85 ml/g and for oil of at least 0.65 ml/g, and having a substantial integrity when wet; and

(e) the granules having a resistance to attrition of at least 98% and having a size distribution wherein less than 60% of the granules have a size of 16 mesh or greater.

13. The granular absorbent product according to claim 12 wherein the granules contain less than 10% of the fibers having a length sufficient to be retained on a 100 mesh screen.

14. The granular absorbent product according to claim 12 wherein the granules have a bulk density of at least about 24 lbs/ft³.

15. The granular absorbent product according to claim 14 wherein the granules in the product have a size distribution wherein less than 60% of the granules have a size of 16 mesh or greater.

16. An absorbent material comprising granules containing 50-60% by weight of inorganic constituents including kaolin clay and 40-50% by weight of organic materials including cellulose material in the form of fibers, the granules containing less than 10 percent of the cellulose fibers having a length sufficient to be retained on a 100 mesh screen, the granules having a bulk density of at least about 24 lbs/ft³, the granules having a porous outer surface and having an irregular, generally spherical shape, and the granules having a resistance to attrition of at least 90%.

17. The absorbent material according to claim 16, wherein the granules have a liquid holding capacity toward water of about 95 ml/gr, and the granules retain their integrity when wet.

18. The absorbent material according to claim 16, wherein the granules have a liquid holding capacity toward oil of about 72 ml/gr , and the granules retain their integrity when wet.

19. The absorbent material according to claim 16, wherein the granule have a size distribution in which the majority of the granules have a size that will pass through a 6 mesh screen and be retained on a 30 mesh screen.