Composition and process for making the composition

• US 8,557,730 B2
• Filed: 03/29/2012
• Issued: 10/15/2013
• Est. Priority Date: 10/31/2007
• Status: Active Grant

• Current Assignee: Secure Natural Resources LLC (MP Materials Corp.)
• Original Assignee: Molycorp Minerals LLC (Oaktree Capital Management LP)
• Inventors: Burba, John
• Primary Examiner(s): JOHNSON, EDWARD M
• Application Number:
  US13/434,214
• Publication Number:
  US 20120238683A1
• Time in Patent Office: 565 Days
• Field of Search: 502/402, 502/400, 502/401, 502/518, 502/526
• US Class Current: 502/402
• CPC Class Codes: B01D 39/00 Filtering material for liquid or gaseous fluids
• CPC Class Codes: B01J 20/0207 Compounds of Sc, Y or Lanthanides
• CPC Class Codes: B01J 20/0277 Carbonates of compounds other than those provided for in B01J20/043
• CPC Class Codes: B01J 20/06 comprising oxides or hydroxides of metals not provided for in group B01J20/04
• CPC Class Codes: B01J 20/2803 Sorbents comprising a binder, e.g. for forming aggregated, agglomerated or granulated products
• CPC Class Codes: B01J 20/3028 Granulating, agglomerating or aggregating
• CPC Class Codes: B01J 20/3042 Use of binding agents; addition of materials ameliorating the mechanical properties of the produced sorbent
• CPC Class Codes: C02F 1/281 using inorganic sorbents
• CPC Class Codes: C02F 2101/103 Arsenic compounds

Abstract

An aggregate composition and process for making the aggregate composition. The aggregate composition includes an insoluble rare earth-containing compound and a polymer binder. The insoluble rare earth-containing compound can include one or more of cerium, lanthanum, or praseodymium. A suitable insoluble cerium-containing compound can be derived from cerium carbonate or a cerium salt. In a specific embodiment, the aggregate composition consists essentially of one or more cerium oxides, the polymer binder and optionally a flow aid. A process for making the composition includes mixing the insoluble rare earth-containing compound with a polymer binder to form a mixture, and subjecting the mixture to mechanical, chemical and/or thermal treatment to adhere the rare earth compound to the polymer binder. The aggregate composition can be used in a variety of fluid treatment applications to remove one or more chemical and biological contaminants in a fluid.

Claims

1. A composition, comprising:

an insoluble rare earth-containing compound adhered to a polymer binder to form an aggregate composition, the insoluble rare earth-containing compound having one or more of chemical and biological contaminates sorbed in and/or on the insoluble rare earth-containing compound, wherein the aggregate composition is in the form of one of a flowable particulate, granule, bead, pellet, powder, or fiber, wherein the polymer binder comprises less than about 15 wt % of the aggregate composition and wherein the insoluble rare earth-containing compound comprises 75 wt % or more of the aggregate composition.

2. The composition of claim 1, wherein the aggregate composition comprises less than about 10 wt % of the polymer binder.

3. The composition of claim 1, wherein the aggregate composition comprises at least about 95 wt % of the rare earth-containing compound.

4. The composition of claim 1, wherein the biological contaminant is one or more of bacteria, fungi, protozoa, viruses, and algae.

5. The composition of claim 1, wherein the chemical contaminant is a chemical warfare agent, industrial chemical, pesticide, insecticide, fertilizer, organosulfur agent, organophosphorous agent, or a mixture thereof.

6. The composition of claim 1, wherein the polymer binder comprises one or more polymers selected from the group consisting of thermosetting polymers, thermoplastic polymers, elastomeric polymers, cellulosic polymers, and glasses.

7. The composition of claim 1, wherein the insoluble rare earth-containing compound comprises particulates adhered to an outer surface of the polymer binder.

8. The composition of claim 1, wherein the insoluble rare earth-containing compound comprises one or more of cerium, lanthanum, or praseodymium.

9. The composition of claim 1, wherein the insoluble rare earth-containing compound comprises cerium oxide.

10. The composition of claim 1, wherein the insoluble rare earth-containing compound comprises particulates having a mean surface area of at least about 5 m²/g, wherein the insoluble rare earth-containing compound comprises particulates having a mean particle size of at least about 250 nm.

11. The composition of claim 1, wherein the insoluble rare earth-containing compound comprises particulates having a mean particle size of at least about 100 nm and wherein the polymer binder is less than about 10% by weight of the composition.

12. The aggregate composition of claim 1, wherein the aggregate composition comprises aggregated particulates having a mean particle size of at least about 0.1 mm.

13. The composition of claim 1, wherein the aggregate composition comprises aggregated particles having a mean particle size of at least about 0.5 mm and wherein the aggregate composition has a mean surface area of at least about 25 m²/g.

14. The composition of claim 1, wherein the insoluble rare earth-containing compound comprises two or more insoluble rare earth-containing compounds.

15. The composition of claim 14, wherein the insoluble rare earth-containing compounds have one or both of differing valence and oxidation states.

16. The composition of claim 1, wherein the aggregate composition comprises more than about 95% by weight of the insoluble rare earth-containing compound and wherein the insoluble rare earth-containing compound comprises cerium oxide.

17. The composition of claim 4, wherein the bacteria comprises one or more of Escherichia coli, Streptococcus faecalis, Shigella spp, Escherichia coli, Streptococcus faecalis, Shigella spp, Leptospira, Legimella pneumophila, Yersinia enterocolitica, Staphylococcus aureus, Pseudornonas aeruginosa, Klebsiella terrigena, Bacillus anthracis, Vibrio cholerae and Salmonella typhi, viruses such as hepatitis A, notoviruses, rotaviruses, and enteroviruses.

18. The composition of claim 4, wherein the virus comprises one or more of hepatitis A, notoviruses, rotaviruses, and enteroviruses.

19. The composition of claim 4, wherein the protozoa comprising one or more of Entamoeba histolytica, Giardia and Cryptosporidium parvum.

20. The composition of claim 5, wherein the organophosphorous agent comprises one or more of o-alkyl phosphonofluoridates, sarin, soman, o-alkyl phosphoramidocyanidates, tabun, alkylated or protonated salts of o-alkyl, s-2-dialkyl aminoethyl alkylphosphonothiolates, alkyl phosphonyldifluoride, alkyl phosphonites, chlorosarin, chlorosoman, methylphosphonyl dichloride, dimethyl methylphosphonate, dialkyl phosphoramidic dihalides, alkyl phosphoramidates, phosphorous oxychloride, phosphorous trichloride, phosphorus pentachloride, alkyl phosphorous oxychloride, alkyl phosphites, phosphorous trichloride, phosphorus pentachloride, alkyl phosphites, diisopropyl methylphosphonate, and phosphamidon.

21. The composition of claim 5, wherein the organosulfur agent comprises one or more of 2-chloroethylchloromethylsulfide, bis(2-chloroethyl)sulfide, sulfur dichloride, and thionyl chloride, carbon disulfide, carbonyl sulfide, disulfoton, endosulfan, hydrogen sulfide, sulfur dioxide, sulfur trioxide, sulfuric acid, bis(2-chloroethylthio)methane, 1,2-bis(2-chloroethylthio)ethane, 1,3-bis(2-chloroethylthio)-n-propane, 1,4-bis(2-chloroethylthio)-n-butane, 1,5-bis(2-chloroethylthio)-n-pentane, bis(2-chloroethylthiomethyl)ether, and bis(2-chloroethylthioethyl)ether, dialkyl aminoethane-2-thiols, thiodiglycols, sulfur monochloride, ethion, ethylparathion, fenthions, malathion, methylparathion, and methyl mercaptan.

22. The composition of claim 5, wherein the pesticide and/or insecticide comprises one or more of parathion, paraoxon and malathion.

23. The composition of claim 5, wherein the industrial chemical or warfare agent comprises one or more of VX, mustard compounds, Lewisites, 2-chlorovinyldichloroarsine, bis(2-chlorovinyl)chloroarsine, tris(2-chlorovinyl)arsine, bis(2-chloroethyl)ethylamine, bis(2-chloroethyl)methylamine, saxitoxin, ricin, amiton, 1,1,3,3,3-pentafluoro-2-(trifluoromethyl)-1-propene, 3-quinuclidinyl benzilate, diphenyl hydroxyacetic acid, quinuclidin-3-ol, dialkyl aminoethyl-2-chlorides, dialkyl aminoethane- 2-ols, pinacolyl alcohols, phosgene, cyanogen chloride, hydrogen cyanide, chloropicrin, acetaldehyde, acetone, acrolein, acrylamide, acrylic acid, acrylonitrile, aldrin, dieldrin, ammonia, aniline, atrazine, barium, benzidine, 2,3-benzofuran, beryllium, 1,1′

-biphenyl, bis(2-chloroethyl)ether, bis(chloromethyl)ether, bromodichloromethane, bromoform, bromomethane, 1,3-butadiene, 1-butanol, 2-butanone, 2-butoxyethanol, butraldehyde, carbon tetrachloride, chlordane, chlorfenvinphos, chlorinated dibenzo-p-dioxins (CDDs), chlorine, chlorobenzene, chlorodibenzofurans (CDFs), chloroethane, chloroform, chloromethane, chlorophenols, chlorpyrifos, cobalt, copper, creosote, cresols, cyanide, cyclohexane, DDT, DDE, DDD, DEHP, di(2-ethylhexyl)phthalate, diazinon, dibromochloropropane, 1,2-dibromoethane, 1,4-dichlorobenzene, 3,3′

-dichlorobenzidine, 1,1-dichloroethane, 1,2-dichloroethane, 1,1-dichloroethene, 1,2-dichloroethene, 1,2-dichloropropane, 1,3-dichloropropene, dichlorvos, diethyl phthalate, di-n-butylphtalate, dimethoate, 1,3-dinitrobenzene, dinitrocresols, dinitrophenols, 2,4-- dinitrotoluene, 2,6-dinitrotoluene, 1,2-diphenylhydrazine, di-n-octylphthalate (DNOP), 1,4-dioxane, dioxins, endrin, ethylbenzene, ethylene oxide, ethylene glycol, formaldehyde, freon 113, heptachlor and heptachlor epoxide, hexachlorobenzene, hexachlorobutadiene, hexachlorocyclohexane, hexachlorocyclopentadiene, hexachloroethane, hexamethylene diisocyanate, hexane, 2-hexanone, HMX (octogen), hydraulic fluids, hydrazines, iodine, isophorone, MBOCA, methamidophos, methanol, methoxychlor, 2-methoxyethanol, methyl ethyl ketone, methyl isobutyl ketone, methyl t-butyl ether, methylchloroform, methylene chloride, methylenedianiline, methyl methacrylate, methyl-tert-butyl ether, mirex, chlordecone, monocrotophos, N-nitrosodimethylamine, N-nitrosodiphenyl amine, N-nitrosodi-n-propylamine, naphthalene, nitrobenzene, nitrophenols, perchloroethylene, pentachlorophenol, phenol, polybrominated biphenyls (PBBs), polychlorinated biphenyls (PCBs), polycyclic aromatic hydrocarbons (PAHs), propylene glycol, phthalic anhydride, pyrethrins and pyrethroids, pyridine, RDX (cyclonite), selenium, styrene, 1,1,2,2-tetrachloroethane, tetrachloroethylene, tetryl, thallium, tetrachloride, trichlorobenzene, 1,1,1-trichloroethane, 1,1,2-trichloroethane, trichloroethylene (TCE), 1,2,3-trichloropropane, 1,2,4-trimethylbenzene, 1,3,5-trinitrobenzene, 2,4,6-trinitrotoluene (TNT), vinyl acetate, and vinyl chloride.

24. The composition of claim 5, wherein the industrial chemical comprises fluoride.

25. The composition of claim 5, wherein the industrial chemical comprises a material having an anionic functional group selected from the group consisting of phosphates, sulfates, and nitrates.

26. The composition of claim 25, wherein the anionic functional is phosphate.

27. The composition of claim 25, wherein the anionic functional group is sulfate.

28. The composition of claim 25, wherein the anionic functional group is nitrate.

29. The composition of claim 5, wherein the industrial chemical comprises arsenic.