Formulations and method for controlling and mitigating dust in at least one industrial activity

Abstract

The present invention discloses formulations and a method for controlling and mitigating dust in at least one industrial activity. Specifically, the invention discloses a formulation for controlling and mitigating dust comprising, in wt.-%: 5 to 15% of sodium lauryl sulphate; 0.5 to 1.5% of at least one polysaccharide and / or a biopolymer; and 83.5 to 94.5% of water enriched with nanobubbles of at least one gas. The invention further discloses a formulation for controlling and mitigating dust comprising at least one dust suppressant composition and at least one mixture of water with at least one type of biopolymer, the water being enriched with nanobubbles of at least one gas. Lastly, the invention discloses a method for controlling and mitigating dust in accordance with the formulations of the invention.

Description

[0001] FORMULATIONS AND METHOD FOR DUST CONTROL AND MITIGATION IN AL

[0002] LESS THAN ONE INDUSTRIAL ACTIVITY

[0003] DESCRIPTIVE MEMORANDUM

[0004] The present invention relates to formulations for dust control and mitigation in at least one industrial activity. It also relates to a method for dust control and mitigation in at least one industrial activity and its related uses. In general, the invention aims at dust control processes in general, where airborne dust is generated that is desired or necessary to control.

[0005] The formulations and method of the invention operate on the principle of using biodegradable organic molecules dissolved in a solution enriched with nanobubbles. The main function of these nanobubbles is to facilitate the wetting of the dust through a more effective penetration process of the solutions and compounds onto the surface where dust propagation is to be controlled and mitigated, thus optimizing the effectiveness of the method and the formulations in reducing these dust particles.

[0006] Another problem addressed by the invention relates to the generation of a formulation based on compounds that are compatible with the different types of soils and surfaces where various industrial activities take place, such as mining, cement production, and construction, where dust generation is a problem that must be addressed. Furthermore, the aim is to obtain compound formulations that can maintain their effectiveness for as long as possible in contact with the surface or soil being treated.

[0007] In this regard, the invention describes a formulation for dust control and mitigation in at least one industrial activity, according to a first embodiment of the invention, comprising, by weight percentage: between 5 and 15% sodium lauryl sulfate; between 0.5 and 1.5% of at least one polysaccharide and / or biopolymer; and between 83.5 and 94.5% water enriched with nanobubbles of at least one gas. Furthermore, the invention describes a second formulation for dust control and mitigation in at least one industrial activity, according to a second embodiment of the invention, comprising at least one dust suppressant composition; and at least one mixture of water with at least one type of biopolymer enriched with nanobubbles of at least one gas.

[0008] Finally, a method for controlling and mitigating dust in at least one industrial activity is described, comprising the steps of: providing at least one first dispensing means for at least one first formulation for dust control and mitigation, according to the second embodiment of the invention; applying the at least one first formulation, by means of the at least one first dispensing means, to at least one surface where it is desired to control and mitigate the spread of dust; providing at least one second dispensing means for at least one second formulation for dust control and mitigation, according to the first embodiment of the invention; and applying the at least one second formulation, by means of the at least one second dispensing means, to the at least one surface where it is desired to control and mitigate the spread of dust.

[0009] Based on the formulations and method of the invention, it is possible to reduce the emission of dust caused by industrial activities carried out, for example, in mining processes, in the cement industry or construction in general, which usually spread large quantities of dust into the environment, where the quality of the resulting material, after the application of the formulations, meets all the requirements to continue with the operations related to the extraction of minerals, in the case of mining activities, and with all the environmental requirements, in the case of construction activities and the cement industry.

[0010] BACKGROUND OF THE INVENTION

[0011] In various industries that involve processes generating airborne dust, such as mining and construction, increasingly stringent regulations are impacting operations, not only to ensure practical viability but also to guarantee adequate working and environmental conditions. In the mining industry, for example, all stages of the process—including drilling, blasting, road transport, ore haulage lines, loading areas, and the operations and machinery in the dry section of the plant—generate dust emissions. Air pollution from fine particulate matter poses a serious problem, negatively impacting the health and quality of life of communities near mining operations.In the construction industry, the problem is even more complex, given that work sites are often located just meters from densely populated urban areas, where airborne dust can seriously affect people if control measures are not taken. Similar problems are also observed in the cement manufacturing industry.

[0012] Given that dust control is a relatively new challenge in industry, there is a shortage of commercially available solutions that effectively mitigate fine particles dispersed in the air during industrial processes, especially those that emit the largest quantities of particulate matter into the environment, such as some mining and construction activities. Furthermore, simply irrigating the land or surface with water or other substances is ineffective, as these tend to accumulate on the surface of desert soils without adequate penetration, leading to highly inefficient water use. This is exacerbated by the fact that water is an extremely limited resource in mining areas, for example.

[0013] To understand the above, the surface of the land where dust emissions need to be controlled and mitigated must be studied in detail. For example, the dust present in mining operations, such as blasting areas, or in desert areas where construction work is carried out, is extremely dry, which creates a phenomenon that hinders the absorption and penetration of water into the soil, causing it to accumulate on the surface. Likewise, the surface of mining terrain contains extremely fine dust that is easily suspended in the air.

[0014] The inability of water to penetrate extremely dry soils, such as those found in some of these mining and construction operation areas, is due to several physicochemical factors, such as:

[0015] 1) Surface tension of water: Water has a high surface tension, which means that water molecules attract each other more strongly than they do dry soil, causing the water to form droplets instead of dispersing and penetrating.

[0016] 2) Capillarity: The structure of the soil influences its ability to conduct water. Soils with large pore spaces (macropores) allow water to filter through quickly, but if those pores are dry, the water may not have enough energy to overcome surface tension and air resistance in the pores to infiltrate properly.

[0017] 3) Differences in matric pressure: Dry soil can have a very high negative matric pressure (matric potential), which means that the soil particles hold water very strongly, preventing the penetration of water applied to the surface.

[0018] Therefore, there is a growing need for an effective solution to control and mitigate airborne dust generated in processes such as those in the mining, construction, and cement industries, in order to contribute to the safety of operations and the reduction of particulate matter in the environment, which is extremely harmful to people living near construction sites, and to glaciers located in areas close to mining operations, for example, where the dust that settles on their surface causes a temperature increase that accelerates their melting, with the consequent climate damage that it entails.

[0019] In the field of patents, there are solutions that address methods or formulations for dust control and mitigation. For example, Chinese patent CN 100523115C describes a foam powder bonding agent prepared from the following raw materials by weight: 10 to 40% foaming agent, 4 to 25% wetting and foam stabilizing agent, with the remainder being water. The main components of the foam powder adhesive and its composite products are non-toxic, readily soluble in water, easy to obtain, and relatively inexpensive. The resulting foam has characteristics such as low density, large surface area, and stability, and can significantly reduce dust and noise pollution. The patent also provides a method for preparing the foam powder adhesive and its application in building blasting.

[0020] In this regard, in document CN 100523115C, the foaming agent is selected from one or more mixtures of sodium soap, sodium alkyl sulfate, tetrahydroglyoxal, or trimethylglycine. For their part, the foam-stabilizing wetting agents are selected from one or more mixtures of polyvinyl alcohol, methylcellulose gum, hydroxypropylcellulose, urea, sodium dodecylbenzenesulfonate, sodium laurylsulfonate, xanthan gum, mannuronic acid, 2-hydroxypropylbutrylic ether, ethylene glycol, lauryl alcohol, diethylene glycol, dimethyl ether, a secondary sodium heptadecyl sulfate, or the water-soluble ammonium salt of metaphosphoric acid.

[0021] Comparing these characteristics with the formulations and method of the present invention, it is observed that one of its formulations for dust control and mitigation comprises sodium lauryl sulfate, a polysaccharide and / or a biopolymer, and water as main components. In this regard, while document CN 100523115C also describes the use of water, sodium lauryl sulfonate, and xanthan gum, it does not describe or suggest the application of a first formulation based on a dust suppressant composition and a mixture of water with at least one type of biopolymer enriched with nanobubbles, and the application of a second formulation that also comprises nanobubbles, which improves the penetration of these substances into the surface to be treated, thereby enhancing the effectiveness of dust control and mitigation.

[0022] Other examples within the technical field of the invention correspond to patent applications CN107224816A, CN101125335A, and CN102408875A, which describe different methods and formulations for reducing dust emissions in various applications. While these documents fall within the technical field of the present invention, they also fail to provide a solution to the problems raised in this application, since none of them improves the efficiency of dust emission control and mitigation on surfaces with low permeability, such as those found in mining deposits. This is made possible by injecting nanobubbles into the solutions and compounds used, which drastically improves surface permeability.

[0023] Therefore, it is necessary to have a formulation and method that not only control and mitigate dust emissions in industrial processes, such as those associated with the mining, construction, and cement industries, but also improve this mitigation by enhancing the permeability of the surfaces or soils being treated. Furthermore, there is a need for a solution that does not increase the cost or delay the mining processes in which the invention is used, given the resulting economic losses from halted operations. Finally, there is also a need for a solution that is environmentally friendly to the surfaces being treated, without any harmful effects, considering the potential proximity to urban communities or the flora and fauna of the area where the industrial activities take place.

[0024] This and other advantages associated with other aspects of the technology are described in more detail below.

[0025] DESCRIPTION OF THE INVENTION The invention relates to formulations and a method for controlling and mitigating dust in at least one industrial activity, which improves the efficiency of control and mitigation by improving the permeability of the surfaces to be treated.

[0026] According to a first preferred embodiment of the invention, a formulation for the control and mitigation of dust in at least one industrial activity is described, comprising, in % by weight:

[0027] - between 5 and 15% sodium lauryl sulfate;

[0028] - between 0.5 and 1.5% of at least one polysaccharide and / or biopolymer; and

[0029] - between 83.5 and 94.5% water enriched with nanobubbles of at least one gas.

[0030] The formulation of the first embodiment of the invention creates a biopolymeric matrix that stabilizes the soil and prevents the dispersion of fine dust generated by mining, construction, and cement production activities. Furthermore, the use of water with nanobubbles modifies the water's surface tension, allowing the solution to penetrate more deeply into the surface being treated. This creates a deeper, stabilizing polymer network, improving the efficiency of dust control and mitigation. In this sense, the function of this first embodiment of the invention is to prevent dust dispersion during industrial activities.

[0031] According to another embodiment of the invention, the at least one polysaccharide and / or biopolymer corresponds to at least one of the following: guar gum, methylcellulose gum, hydroxypropylcellulose, and xanthan gum. Preferably, the at least one polysaccharide and / or biopolymer corresponds to guar gum.

[0032] According to another embodiment of the invention, the at least one gas corresponds to at least one of the following: oxygen, air, nitrogen, and carbon dioxide. Preferably, the at least one gas corresponds to oxygen. However, the type of gas can be any other that allows the generation of nanobubbles in water.

[0033] According to another embodiment of the invention, the nanobubbles have a concentration in the range between 10E3 and 10E9 nanobubbles per mi of water.

[0034] According to another embodiment of the invention, the nanobubbles have an average diameter in the range between 100 and 1000 nm, preferably between 100 and 300 nm.

[0035] According to another embodiment of the invention, the formulation is a foam. According to another preferred embodiment, the formulation is a liquid.

[0036] According to another embodiment of the invention, the formulation is biodegradable. This characteristic is of vital importance, for example, in mining activities, where the ore carried downstream during the extraction process cannot contain external chemical components. In this respect, the formulations of the invention are biodegradable, so they do not affect the quality of the ore, as they degrade rapidly. According to another embodiment of the invention, the formulation is harmless. This is also an important characteristic in cases where industrial activities are carried out in areas near urban centers or habitats of flora or fauna. Furthermore, according to a second preferred embodiment of the invention, a formulation for dust control and mitigation in at least one industrial activity is described, comprising:

[0037] - at least one dust suppressant composition; and

[0038] - at least a mixture of water with at least one type of biopolymer enriched with nanobubbles of at least one gas.

[0039] The formulation of this second embodiment of the invention, as in the case of the formulation of the first embodiment described, creates a biopolymeric matrix that stabilizes the soil and prevents the fine dust generated in mining and construction activities from dispersing, with the same advantages associated with the use of nanobubbles. In this sense, the function of this second embodiment of the invention is to transform the dust deposited on the surface or soil to be treated into hard clods (compaction).

[0040] According to another embodiment of the invention, the at least one dust suppressant composition corresponds to at least one commercial dust-killing composition.

[0041] According to another embodiment of the invention, the at least one biopolymer corresponds to at least one of: guar gum, methylcellulose gum, hydroxypropylcellulose, and xanthan gum.

[0042] According to another embodiment of the invention, the at least one gas corresponds to at least one of the following: oxygen, air, nitrogen, and carbon dioxide. Preferably, the at least one gas corresponds to oxygen. However, the type of gas can be any other that allows the generation of nanobubbles in water.

[0043] According to another embodiment of the invention, the nanobubbles have a concentration in the range between 10E3 and 10E9 nanobubbles per mi of water.

[0044] According to another embodiment of the invention, the nanobubbles have an average diameter in the range between 100 and 1000 nm, preferably between 100 and 300 nm.

[0045] According to another embodiment of the invention, the formulation is a foam. According to another preferred embodiment, the formulation is a liquid.

[0046] According to another embodiment of the invention, the formulation is biodegradable and harmless, which entails the same advantages mentioned above for the formulation of the first embodiment.

[0047] Additionally, according to a third embodiment of the invention, a method for controlling and mitigating dust in at least one industrial activity is described, comprising the steps of: a) providing at least one first dispensing means for at least one first formulation for dust control and mitigation, according to the second embodiment of the invention; b) applying the at least one first formulation, by means of the at least one first dispensing means, to at least one surface where it is desired to control and mitigate the spread of dust; c) providing at least one second dispensing means for at least one second formulation for dust control and mitigation, according to the first embodiment of the invention; and d) applying the at least one second formulation, by means of the at least one second dispensing means, to the at least one surface where it is desired to control and mitigate the spread of dust.

[0048] The method of the invention is not only compatible with soils used in all types of industrial activities, such as mining, construction, or cement production, but it also maintains its effectiveness for a longer period in contact with the soil or surface being treated, compared to prior art solutions, thanks to its improved permeability. In this respect, the method of the invention provides a two-phase approach for its application to the surfaces to be treated. Initially, the surface is prepared by applying a first formulation, according to the second embodiment of the invention, before beginning the work related to the mining activity or process.Subsequently, the second phase is carried out, which consists of applying a second formulation, according to the first embodiment of the invention, through at least one second dispensing means. Both formulations are prepared using water enriched with nanobubbles, which promotes more efficient penetration into the soil of the work area.

[0049] Regarding the first formulation, it can be applied by irrigation to the surface to be treated. Once this first formulation has dried on the surface, the ground is prepared, if necessary, before starting industrial activity. Subsequently, the second formulation is applied to the area where the greatest dust generation is expected, ensuring uniform distribution across the entire surface to be treated. This ensures better dust control and mitigation.

[0050] According to another embodiment of the invention, the method further comprises, before step d), waiting until the drying of at least a first formulation on at least one surface.

[0051] According to another embodiment of the invention, the method further comprises, prior to step c), removing at least one first dispensing means.

[0052] According to another embodiment of the invention, the method further comprises, after step d), removing at least a second dispensing means.

[0053] According to another embodiment of the invention, the method further comprises applying between 250 and 2,000 ml of at least a first formulation per square meter, preferably between 750 and 1,250 ml per square meter.

[0054] According to another embodiment of the invention, the method further comprises waiting between 15 and 120 minutes, after the application of at least one first formulation, before applying at least one second formulation, preferably between 45 and 75 minutes. According to another embodiment of the invention, the method further comprises applying between 250 and 2,000 ml of at least one second formulation per square meter, preferably between 750 and 1,250 ml per square meter.

[0055] According to another embodiment of the invention, the method further comprises waiting between 0 and 60 minutes, after the application of at least one second formulation, before initiating at least one industrial activity. Preferably, one should wait between 0 and 10 minutes, after the application of at least one second formulation, before initiating at least one industrial activity.

[0056] Finally, it is noted that, although the industries and activities related to mining, construction and cement manufacturing are mentioned as exemplary applications for the formulations and method of the invention, the modalities described by the present invention can be adapted and used in any work and operation that involves the generation and dispersion of dust in the environment.

[0057] Based on the foregoing, it is possible to observe that a significant difference between the present invention and prior art solutions relates to the improved efficiency of the formulations used, as they are capable of penetrating low-permeability surfaces, such as those found in mining operations located in desert areas. This, in turn, allows for the use of a smaller quantity of these formulations, since they can permeate the surfaces to be treated more effectively.

[0058] DETAILED DESCRIPTION OF THE PREFERRED OPTIONS

[0059] The following describes an exemplary embodiment of the invention, in which the method for controlling and mitigating dust has been implemented in blasting operations.

[0060] Process Description (Work Methodology)

[0061] 1) Transfer of at least one first means of dispensing

[0062] At least a first formulation is transferred in a first means of dispensing, such as a water truck, to the area where the surface or surfaces to be treated are located.

[0063] 2) Download of at least a first formulation

[0064] The ground around and above the truck's tank must be checked. Then, the driver or operator must position the truck with its rear end in the unloading area, ensuring it stops a safe distance from edges and equipment in the unloading zone.

[0065] Then, the operator must position themselves at the rear of the truck to unload at least the first formulation, activating a valve and waiting, maintaining a safe distance, out of the line of fire, until the operation is finished.

[0066] In some cases, depending on the size of the surfaces to be treated, hoses or dispersion media will be used to apply at least a first formulation.

[0067] Once the unloading is complete, the truck will be removed from the area. After applying at least the first coat, it should ideally dry for one hour before allowing the trucks that will dig the blast holes and install the explosives in each hole to proceed.

[0068] 3) Transfer of at least one second means of dispensing

[0069] At least a second formulation is transferred in a second dispensing vehicle, such as a 3 / 4 truck, to the area where the surface(s) to be treated are located.

[0070] 4) Projection of at least a second formulation

[0071] The ground around and above the truck's tank must be checked. Then, the driver or operator must position the truck with its rear end in the unloading area, ensuring it stops a safe distance from edges and equipment in the unloading zone.

[0072] Subsequently, the driver or operator must connect hoses from the truck to a foam blower, if the at least one second formulation is in foam form, to extend a plastic sleeve to the area where the at least one second formulation is being emptied. Then, the operator must position themselves at the rear of the truck to unload the at least one second foam formulation. To do this, they must start the generator that powers the blower and then wait, maintaining a safe distance and clear of the line of fire, until the operation is complete.

[0073] Once the unloading is complete, the removal from the area will proceed.

[0074] In this respect, the fact that at least one of the secondary formulations is in foam form has the advantage of trapping ambient dust particles across a larger surface area than using a liquid alone. Furthermore, the foam dries quickly, which helps to compact the dust into clumps of soil.

[0075] Through the study of drone-captured images during blasting processes, showing the explosion columns at their peak, it has been demonstrated that, when comparing blasts under standard conditions with blasts using the method and formulations of the invention, dust emissions caused by blasting are reduced by up to 87%. Similarly, it has been demonstrated that the quality of the resulting material, after applying the dust control and mitigation formulations, meets all the requirements for continuing mineral extraction operations.

Claims

CLAIMS 1. A formulation for dust control and mitigation in at least one industrial activity, CHARACTERIZED in that it comprises, in % by weight: - between 5 and 15% sodium lauryl sulfate; - between 0.5 and 1.5% of at least one polysaccharide and / or biopolymer; and - between 83.5 and 94.5% water enriched with nanobubbles of at least one gas.

2. The formulation according to claim 1, CHARACTERIZED in that the at least one polysaccharide and / or biopolymer corresponds to at least one of: guar gum, methylcellulose gum, hydroxypropylcellulose and xanthan gum.

3. The formulation according to any of claims 1 to 2, CHARACTERIZED in that the at least one gas corresponds to at least one of: oxygen, air, nitrogen and carbon dioxide.

4. The formulation according to any of claims 1 to 3, CHARACTERIZED in that the nanobubbles have a concentration in the range between 10E3 and 10E9 nanobubbles per mi of water.

5. The formulation according to any of claims 1 to 4, CHARACTERIZED in that the nanobubbles have an average diameter in the range between 100 and 1000 nm, preferably between 100 and 300 nm.

6. The formulation according to any of claims 1 to 5, CHARACTERIZED in that it is a foam.

7. The formulation according to any of claims 1 to 5, CHARACTERIZED in that it is a liquid.

8. The formulation according to any of claims 1 to 7, CHARACTERIZED in that it is biodegradable.

9. The formulation according to any of claims 1 to 8, CHARACTERIZED in that it is harmless.

10. A formulation for dust control and mitigation in at least one industrial activity, CHARACTERIZED in that it comprises: - at least one dust suppressant composition; and - at least a mixture of water with at least one type of biopolymer enriched with nanobubbles of at least one gas.

11. The formulation according to claim 10, CHARACTERIZED in that the at least one gas corresponds to at least one of: oxygen, air, nitrogen and carbon dioxide.

12. The formulation according to any of claims 10 to 11, CHARACTERIZED in that the nanobubbles have a concentration in the range between 10E3 and 10E9 nanobubbles per mi of water.

13. The formulation according to any of claims 10 to 12, CHARACTERIZED in that the nanobubbles have an average diameter in the range between 100 and 1000 nm, preferably between 100 and 300 nm.

14. The formulation according to any of claims 10 to 13, CHARACTERIZED in that it is a foam.

15. The formulation according to any of claims 10 to 13, CHARACTERIZED in that it is a liquid.

16. The formulation according to any of claims 10 to 15, CHARACTERIZED in that it is biodegradable.

17. The formulation according to any of claims 10 to 16, CHARACTERIZED in that it is harmless.

18. A method for controlling and mitigating dust in at least one industrial activity, CHARACTERIZED in that it comprises the steps of: a) providing at least one first dispensing means for at least one first formulation for dust control and mitigation, according to any one of claims 10 to 17; b) applying the at least one first formulation, by means of the at least one first dispensing means, to at least one surface where it is desired to control and mitigate the spread of dust; c) providing at least one second dispensing means for at least one second formulation for dust control and mitigation, according to any one of claims 1 to 9; and d) applying the at least one second formulation, by means of the at least one second dispensing means, to the at least one surface where it is desired to control and mitigate the spread of dust.

19. The method according to claim 18, CHARACTERIZED in that it further comprises, before step d), waiting until the drying of at least a first formulation on at least one surface.

20. The method according to any of claims 18 to 19, CHARACTERIZED in that it further comprises, prior to step c), removing at least one first dispensing means.

21. The method according to any of claims 18 to 20, CHARACTERIZED in that it further comprises, after step d), removing at least a second dispensing means.

22. The method according to any of claims 18 to 21, CHARACTERIZED in that it further comprises applying between 250 and 2,000 ml of at least one first formulation per square meter, preferably between 750 and 1,250 ml per square meter.

23. The method according to any of claims 18 to 22, CHARACTERIZED in that it further comprises waiting between 15 and 120 minutes, after the application of at least a first formulation, to apply at least a second formulation, preferably between 45 and 75 minutes.

24. The method according to any of claims 18 to 23, CHARACTERIZED in that it further comprises applying between 250 and 2,000 ml of at least a second formulation per square meter, preferably between 750 and 1,250 ml per square meter.

25. The method according to any of claims 18 to 24, CHARACTERIZED in that it further comprises waiting between 0 and 60 minutes, after the application of at least a second formulation, to start at least one industrial activity, preferably between 0 and 10 minutes.

26. Use of a formulation according to any of claims 1 to 9, CHARACTERIZED in that it is used in mining activities.

27. Use of a formulation according to any of claims 10 to 17 CHARACTERIZED in that it is used in mining activities.

28. Use of a formulation according to any of claims 1 to 9, CHARACTERIZED in that it is used in construction activities.

29. Use of a formulation according to any of claims 10 to 17, CHARACTERIZED in that it is used in construction activities.

30. Use of a formulation according to any of claims 1 to 9, CHARACTERIZED in that it is used in the cement manufacturing industry.

31. Use of a formulation according to any of claims 10 to 17, CHARACTERIZED in that it is used in the cement manufacturing industry.