Dust control composition

Abstract

A dust control composition for application on unpaved or gravel roads, particularly in environments with significant heavy vehicle traffic such as mining operations, which includes an organic by – product derived from fermentation of sugar containing organic materials and yielding a dust control composition having a solids content of between 5 and 50 % by mass.

Description

[0001]5 DUST CONTROL COMPOSITION Field of the Invention The invention relates generally to dust control technologies and, more specifically, to 10 a composition for controlling or suppressing dust particles generated on gravel or unpaved roads, particularly in mining and other heavy-duty industrial operations. The invention further relates to an environmentally friendly dust suppression solution suitable for use in areas where regulatory and ecological considerations restrict the use of conventional chemical suppressants. 15 Background to the invention Dust generation on gravel roads, haulage routes, and other unpaved surfaces within mining operations presents significant operational, environmental, and health challenges. Fine particulate matter, commonly referred to as fugitive dust, is generated 20 by vehicular traffic, drilling, blasting, and material handling. These airborne particles reduce visibility, contribute to road surface degradation, accelerate equipment wear, and pose health risks to workers and surrounding communities through inhalation of respirable dust particles. Various dust suppression techniques have been employed in the art, including 25 frequent water spraying, application of hygroscopic salts such as calcium chloride and magnesium chloride, and petroleum-based chemical suppressants. However, these methods suffer from numerous disadvantages. Water-based dust suppression requires repeated application, resulting in high operational costs and significant water consumption, which is increasingly unsustainable in arid mining 30 regions. Hygroscopic salts, while effective, are corrosive to vehicles and infrastructure, and they can contaminate surrounding soil and water bodies through leaching. 5 Petroleum-based products, such as emulsified oils or bituminous binders, are often environmentally hazardous, non-biodegradable, and subject to strict regulatory controls. Consequently, there is a growing demand for alternative dust control solutions that are effective, durable, cost-efficient, and environmentally responsible. Several attempts 10 have been made to develop biodegradable dust palliatives based on lignosulfonates, vegetable oils, and synthetic polymers. However, such products often exhibit limited dust suppression efficacy, reduced durability under heavy traffic conditions, and inconsistent performance in varying climatic conditions. 15 The applicant identified the need for an improved dust suppression composition that provides effective, long-lasting control of dust particles on gravel and unpaved roads in mining environments, while being non-toxic, biodegradable, and compliant with increasingly stringent environmental regulations and having considered the above proposes the invention disclosed hereunder. 20 In this specification, all percentages (%) are expressed by mass unless otherwise indicated. Disclosure of the Invention 25 According to the invention there is provided a dust control composition which includes an organic by – product derived from fermentation of sugar containing organic materials and yielding a dust control composition having a solids content of between 5 and 50 % by mass. 30 The organic by - product will preferably be rich in organic matter and minerals. The organic by-product can be selected from any of the group of a biosurfactant, lignosulfonates, molasses, distillers grains and solubles, spent wash, brewery spent yeast and corn steep liquor. 35 5 The biosurfactant can include vinasse. The biosurfactant can be vinasse. The organic by - product can comprise between about 30 % and 99% by mass of the 10 composition. The organic by-product can have a solids content in the region of between 5% and 20%, preferably about 12 %. 15 The dust control composition can further include a polyol selected from any of the group of glycerol, propylene glycol, sorbitol and polyglycerol, preferably glycerol. The glycerol can comprise between about 0.5 % and 15 % by mass of the composition. 20 The polyol can have a solids content of between 40 % and 90 %, preferably about 70 % The ratio between the organic by-product : polyol can be between 30 - 99 : 0.5 – 15. 25 In one embodiment the organic by-product is vinasse and the polyol is glycerol, yielding a dust control composition having a solids content of between 10 % and 35 %. The vinasse can comprise about 99% by mass of the composition, and the glycerol in 30 the region of about 1 % by mass of the total composition, and may yield a composition having a solids content of about 12 %, and exhibiting an infrared (IR) absorption spectrum substantially corresponding to that illustrated in Figure 1. The vinasse can also comprise about 98% by mass of the composition, and the 35 glycerol in the region of 2.5 % by mass of the total composition, and may yield a composition having a solids content in the region of 13 %, and exhibiting an infrared (IR) absorption spectrum substantially corresponding to that illustrated in Figure 2. 5 The vinasse can comprise about 90% by mass of the composition, and the glycerol in the region of 10 % by mass of the total composition, and may yield a composition having a solids content of about 18 %, and exhibiting an infrared (IR) absorption spectrum substantially corresponding to that illustrated in Figure 3. 10 The composition can further include a water-soluble anionic polyelectrolyte polymer. The ratio between the organic by-product : polyol : water soluble anionic polyelectrolyte polymer can be in the region of 30 - 99 : 0.5 – 15 : 0.5 – 15. 15 The water-soluble anionic polyelectrolyte polymer can include lignosulfonate. The water-soluble anionic polyelectrolyte polymer can be in the form of lignosulfonate. The lignosulfonate can have a solids content in the region of between 30 % and 60 %, 20 preferably about 48 %. The lignosulfonate can comprise between about 30 % and 90 % by mass of the composition. 25 The composition comprising vinasse, glycerol and lignosulfonate can have a solids content of between about 25 % and 45 %. In this form of the invention the vinasse can comprise about 20% by mass of the composition, the glycerol may be included in the region of 0.5 % by mass of the 30 composition, and the lignosulfonate in the region of 80 % of the total composition, and may yield a composition having a solids content of about 41 %, and exhibiting an infrared (IR) absorption spectrum substantially corresponding to that illustrated in Figure 4. 35 In another form the vinasse can comprise about 49% by mass of the composition, the glycerol in the region of 1.5 % by mass of the composition, and the lignosulfonate in the region of 50 % by mass of the total composition, and may yield a composition 5 having a solids content of about 30 %, and exhibiting an infrared (IR) absorption spectrum substantially corresponding to that illustrated in Figure 5. In another form of the invention the dust control composition includes an organic by – product derived from fermentation of sugar containing organic materials, and 10 a synthetic polymer. The organic by - product will preferably be rich in organic matter and minerals. The organic by-product can be selected from any of the group of a biosurfactant, 15 lignosulfonates, molasses, distillers grains and solubles, spent wash, brewery spent yeast and corn steep liquor. The biosurfactant can include vinasse. 20 The biosurfactant can be vinasse. The organic by - product can comprise between about 60 % and 99% by mass of the composition. 25 The organic by-product can have a solids content in the region of between 5% and 20%, preferably about 12 %. The synthetic polymer can include any of polyacrylic acid (PAA), polymethyl methacrylate (PMMA), and sodium polyacrylate. 30 The synthetic polymer can have a solids content in the region of between 50% and 90%, preferably about 70%. The synthetic polymer can comprise between about 1 % and 20% by mass of the 35 composition. The ratio between the organic by-product : synthetic polymer can be between 30 - 99 : 0.5 – 15. 5 In one embodiment the organic by-product is vinasse and together with the synthetic polymer, yields a dust control composition having a solids content of between 10 % and 35 %. In this form of the invention the vinasse can comprise about 99% by mass of the 10 composition, and the synthetic polymer in the region of about 1 % by mass of the total composition, and may yield a composition having a solids content of about 12 %, and exhibiting an infrared (IR) absorption spectrum substantially corresponding to that illustrated in Figure 6. 15 In another form the vinasse can comprise about 97% by mass of the composition, and the synthetic polymer in the region of about 3 % by mass of the total composition, and can yield a composition having a solids content of about 14 %, and exhibiting an infrared (IR) absorption spectrum substantially corresponding to that illustrated in 20 Figure 7. In a further form the vinasse can comprise about 90% by mass of the composition, and the synthetic polymer in the region of about 10 % by mass of the total composition, 25 so as to yield a composition having a solids content of about 18 %, and exhibiting an infrared (IR) absorption spectrum substantially corresponding to that illustrated in Figure 8. The composition can further include black liquor, a lignin-containing by-product 30 obtained from the kraft pulping of lignocellulosic biomass. The ratio between the organic by-product : synthetic polymer : black liquor can be in the region of 70 – 79 : 1- 10 : 15-20. 35 In this form the vinasse can comprise about 80% by mass of the composition, and the synthetic polymer in the region of about 1 % by mass of the total composition, and the 5 black liquor about 20 % by mass of the composition, yielding a dust control composition having a solids content of about 17 %, and exhibiting an infrared (IR) absorption spectrum substantially corresponding to that illustrated in Figure 9. The vinasse can also comprise about 77% by mass of the composition, and the 10 synthetic polymer in the region of about 3 % by mass of the total composition, and the black liquor about 20 % by mass of the composition, any may yield a dust control composition having a solids content of about 17 %, and exhibiting an infrared (IR) absorption spectrum substantially corresponding to that illustrated in Figure 10. 15 In addition, the vinasse may comprise about 70% by mass of the composition, and the synthetic polymer in the region of about 10 % by mass of the total composition, and the black liquor about 20 % by mass of the composition, so as to yield a dust control composition which may have have a solids content of about 22 %, and exhibiting an 20 infrared (IR) absorption spectrum substantially corresponding to that illustrated in Figure 11. The aforementioned IR values are generated by a Fourier Transform Infrared (FTIR) spectroscopy system produced by PerkinElmer, a company specializing in analytical 25 instrumentation. The invention seeks to optimise the solids concentration in the formulation through systematic variation of the aforementioned components, enabling precise tailoring of physical properties such as viscosity, adhesion, or mechanical strength. The high-organic-load effluent derived from the anaerobic fermentation or distillation 30 of sugarcane or molasses, such as commonly known Vinasse, can be the primary base ingredient, present in high concentrations in most formulations. The polyol or alcohol such as trihydroxy alcohol or glycerol and the acrylic based polymer are used as modifiers, either alone or in combination, to influence the solids 35 concentration, which ranges between 10% and 50 % across tested formulations, preferably between approximately 12% and 42% across tested formulations. 5 The natural polymer such as lignosulphonate and the lignin rich spent pulping liquor / lignocellulosic biomass byproduct such as for example commonly known black liquor, serve as further solid-content enhancers or texture-modifying agents, introduced in certain formulations at concentrations up to 80% and 20%, respectively. 10 Use of the composition as claimed in any one of the preceding claims as a binder or soil conditioner, wherein the blend is biodegradable and derived at least in part from agro-industrial waste. Key findings of the formulation testing reveal: 15^That the solids concentration increases with rising amounts of high-solids components such as acrylic based polymer, lignosulphonate and black liquor. ^ That compositions with vinasse on combination with either of acrylic based polymer or glycerol, one in the absence of the other, result in a dust control composition having a solids content by mass of between about 12 % and 18%. 20 ^ That incorporation of black liquor significantly increases the solids percentage indicating its role as a solid enhancer. ^ That lignosulphonate used as a major component leads to the highest recorded solids levels The invention allows for the preparation of compositions with targeted solids 25 concentrations for use in various industrial applications. It provides flexibility in formulation while maintaining predictable performance characteristics. In use, the composition is delivered in a ready-to-use form and is specifically developed for permanent road application (mining and rural) as it produces a durable 30 smooth and dust free surface that eliminates the need for frequent maintenance. The dust control composition is water-soluble and easy to apply. It improves tyre grip, improves rolling resistance and reduces the need for constant grading and watering of the roads, thereby saving on precious water resources and overall costs. 5 For haulage roads which are newly established, the composition could be incorporated into the wearing course layer of the road. This happens through the process of scarifying, spraying, mixing, brooming, and 10 rolling.50-100mm of scarifying is recommended which provides excellent dust control and sealing properties for the wearing course of the road. Alternatively, temporary roads require a series of light dilution, spray-on applications. Once applied the need for reapplication depends on reapplications based on factors 15 like climatic conditions, traffic volume, frequency, and soil types (Sand, Clay, Loam, Chalk, etc.) Dilution 20 A dilution rate of 2% up to 50% depending on the specific requirement. For initial establishment, a dosage rate of + / -20% composition diluted with 80% water, with an application rate of 500-800ml / m2 is recommended. The dosage rate will be influenced by soil specifications, high / low soil EC and CEC, vehicle traffic 25 volume, frequency. Results After 28 days with 4 applications on a 50 / 50 spray-on airborne dust level reduction of 80% was maintained. 30 Rejuvenation and Maintenance Subsequent application at a dosage rate of 0.5-3%. Composition diluted with 99.5-97% water can be applied for maintenance. 35 The Applicant considers the invention advantageous in that a biodegradable organic based dust suppressant composition is provided which can be manufactured and 5 supplied in a cost effective manner with an efficiency index matching / exceeding that of conventional products of the kind. 10 15 20 25 30 35

Claims

5 Claims 1. A dust control composition which includes an organic by – product derived from fermentation of sugar containing organic materials and yielding a dust control composition having a solids content of between 5 and 50 % by mass. 10 2. The dust control composition as claimed in claim 1 wherein the organic by - product is rich in organic matter and minerals.

3. The dust control composition as claimed in claim 1 or 2 wherein the organic by- product is selected from any of the group of a biosurfactant, lignosulfonates, molasses, distillers grains and solubles, spent wash, brewery spent yeast and corn steep liquor.

4. The dust control composition as claimed in claim 3 wherein the biosurfactant includes vinasse.

5. The dust control composition as claimed in claim 3 wherein the biosurfactant is is vinasse.

6. The dust control composition as claimed in any preceding claim wherein the organic by - product comprise between about 30 % and 99% by mass of the composition.

7. The dust control composition as claimed in any of claims 1 to 5 wherein the organic by-product have a solids content in the region of between 5% and 20%, preferably about 12 %.

8. The dust control composition as claimed in claim 6 wherein the organic by- product have a solids content in the region of between 5% and 20%, preferably about 12 %.5 9. The dust control composition as claimed in any of the preceding claims which further includes a polyol selected from any of the group of glycerol, propylene glycol, sorbitol and polyglycerol.

10. The dust control composition as claimed in claim 9 wherein the polyol has a 10 solids content of between 40 % and 90 %.

11. The dust control composition as claimed in claim 10 wherein the polyol has a solids content of about 70 %.

12. The dust control composition as claimed in any preceding claim where the ratio of the organic by-product : polyol is between about 30 - 99 : 0.5 – 15.

13. The dust control composition as claimed in any of claims 9 to 12 wherein the polyol is glycerol.

14. The dust control composition as claimed in claim 13 wherein the glycerol comprises between about 0.5 % and 15 % by mass of the composition.

15. The dust control composition as claimed in any of the preceding claims wherein the organic by-product is vinasse, and the polyol is glycerol, yielding a dust control composition having a solids content of between 10 % and 35 %.

16. The dust control composition as claimed in claim 15 wherein the vinasse comprise about 99% by mass of the composition, and the glycerol in the region of about 1 % by mass of the total composition.

17. The dust control composition as claimed in claim 15 or 16 having a solids content of about 12 %, and exhibiting an infrared (IR) absorption spectrum substantially corresponding to that illustrated in Figure 1.5 18. The dust control composition as claimed in claim 15 wherein the vinasse comprise about 98% by mass of the composition, and the glycerol in the region of 2.5 % by mass of the total composition.

19. The dust control composition as claimed in claim 18 having a solids content in 10 the region of 13 %, and exhibiting an infrared (IR) absorption spectrum substantially corresponding to that illustrated in Figure 2.

20. The dust control composition as claimed in claim 15 wherein the vinasse comprise about 90% by mass of the composition, and the glycerol in the region of 10 % by mass of the total composition.

21. The dust control composition as claimed in claim 20 having a solids content of about 18 %, and exhibiting an infrared (IR) absorption spectrum substantially corresponding to that illustrated in Figure 3.

22. The dust control composition as claimed in any of the preceding claims which further includes a water-soluble anionic polyelectrolyte polymer.

23. The dust control composition as claimed in claim 22 wherein the ratio of the organic by-product : polyol : water soluble anionic polyelectrolyte polymer is in the region of 30 - 99 : 0.5 – 15 : 0.5 – 15.

24. The dust control composition as claimed in claim 23 wherein the water-soluble anionic polyelectrolyte polymer is lignosulfonate.

25. The dust control composition as claimed in claim 24 wherein the lignosulfonate has a solids content in the region of between 30 % and 60 % by m.

26. The dust control composition as claimed in claim 25 wherein the lignosulfonate has solids content of 48 % by mass.5 27. The dust control composition as claimed in any of claims 22 to 26 wherein the lignosulfonate comprises between about 30 % and 90 % by mass of the composition.

28. The dust control composition as claimed in any of claims 22 to 27 having a 10 solids content of between about 25 % and 45 % by mass.

29. The dust control composition as claimed in any of claims 22 to 28 wherein the vinasse comprises about 20% by mass of the composition, the glycerol in the region of 0.5 % by mass of the composition, and the lignosulfonate in the region of 80 % of the total composition.

30. The dust control composition as claimed in claim 29, yielding a composition having a solids content of about 41 % by mass, and exhibiting an infrared (IR) absorption spectrum substantially corresponding to that illustrated in Figure 4.

31. The dust control composition as claimed in any of claims 22 to 28 wherein the vinasse comprises about 49% by mass of the composition, the glycerol in the region of 1.5 % by mass of the composition, and the lignosulfonate in the region of 50 % by mass of the total composition.

32. The dust control composition as claimed in claim 31, yielding a composition having a solids content of about 30 % by mass, and exhibiting an infrared (IR) absorption spectrum substantially corresponding to that illustrated in Figure 5.

33. The dust control composition as claimed in claim 1 which additionally includes a synthetic polymer.

34. The dust control composition as claimed in claim 33 wherein the synthetic polymer comprises between about 1 % and 20% by mass of the composition.

35. The dust control composition as claimed in claim 33 or 34 wherein the ratio of the organic by-product : synthetic polymer is between 30 - 99 : 0.5 – 15.5 36. The dust control composition as claimed in any of claims 33 to 35 wherein the organic by - product is rich in organic matter and minerals. 10 37. The dust control composition as claimed in any of claims 33 to 36 wherein the organic by-product is selected from any of the group of a biosurfactant, lignosulfonates, molasses, distillers grains and solubles, spent wash, brewery spent yeast and corn steep liquor.

38. The dust control composition as claimed in claim 37 wherein the organic by - product comprises between about 60 % and 99% by mass of the composition.

39. The dust control composition as claimed in claim 38 wherein the organic by- product has a solids content in the region of between 5% and 20% by mass.

40. The dust control composition as claimed in claim 39 wherein the organic by- product has a solids content of about 12 % by mass.

41. The dust control composition as claimed in any of claims 33 to 40 wherein the biosurfactant includes vinasse.

42. The dust control composition as claimed in any of claims 33 to 40 wherein the biosurfactant is vinasse.

43. The dust control composition as claimed in any of claims 33 to 42 wherein the synthetic polymer is selected from any of the group of polyacrylic acid (PAA), polymethyl methacrylate (PMMA), and sodium polyacrylate.

44. The dust control composition as claimed in any of claims 33 to 43 wherein the synthetic polymer has a solids content in the region of between 50% and 90% by mass.

45. The dust control composition as claimed in claim 44 wherein the synthetic polymer has a solids content of about 70% by mass.5 46. The dust control composition as claimed in claim 45 wherein the the organic by- product is vinasse and in combination with the synthetic polymer, yields a dust control composition having a solids content of between 10 % and 35 % by mass. 10 47. The dust control composition as claimed in claim 46 wherein the vinasse comprise about 99% by mass of the composition, and the synthetic polymer in the region of about 1 % by mass of the total composition.

48. The duct control composition as claimed in claim 47 having a solids content of about 12 % by mass, and exhibiting an infrared (IR) absorption spectrum substantially corresponding to that illustrated in Figure 6.

49. The dust control composition as claimed in claim 46 wherein the vinasse comprise about 97% by mass of the composition, and the synthetic polymer in the region of about 3 % by mass of the total composition.

50. The dust control composition as claimed in claim 49 having a solids content of about 14 % by mass, and exhibiting an infrared (IR) absorption spectrum substantially corresponding to that illustrated in Figure 7.

51. The dust control composition as claimed in claim 46 wherein the vinasse comprise about 90% by mass of the composition, and the synthetic polymer in the region of about 10 % by mass of the total composition.

52. The dust control composition as claimed in claim 51 having a solids content of about 18 % by mass, and exhibiting an infrared (IR) absorption spectrum substantially corresponding to that illustrated in Figure 8.

53. The dust control composition as claimed in any of claims 33 onwards further including black liquor, a lignin-containing by-product obtained from the kraft pulping of lignocellulosic biomass.5 54. The dust control composition as claimed in claim 53 wherein the ratio of the organic by-product : synthetic polymer : black liquor is in the region of 70 – 79 : 1- 10 : 15-20.

55. The dust control composition as claimed in claim 54 wherein the organic by- 10 product is vinasse, which comprises about 80% by mass of the composition, and the synthetic polymer in the region of about 1 % by mass of the total composition, and the black liquor about 20 % by mass of the composition,.

56. The dust control composition as claimed in claim 55 having a solids content of about 17 % by mass, and exhibiting an infrared (IR) absorption spectrum substantially corresponding to that illustrated in Figure 9.

57. The dust control composition wherein the organic by-product is vinasse, which comprises about 77% by mass of the composition, and the synthetic polymer in the region of about 3 % by mass of the total composition, and the black liquor about 20 % by mass of the composition.

58. The dust control composition as claimed in claim 57 having a solids content of about 17 % by mass, and exhibiting an infrared (IR) absorption spectrum substantially corresponding to that illustrated in Figure 10.

59. The dust control composition as claimed in claim 54 wherein the organic by- product is vinasse which comprises about 70% by mass of the composition, and the synthetic polymer in the region of about 10 % by mass of the total composition, and the black liquor about 20 % by mass of the composition.

60. The dust control composition as claimed in claim 59 yielding a dust control composition having a solids content of about 22 %, and exhibiting an infrared (IR) absorption spectrum substantially corresponding to that illustrated in Figure 11.

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