Eutectic Hydrocarbon-Triglyceride Dust Binder for Mineral Wool
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Solution Overview
Problem
The production of mineral wool, such as glass wool, generates significant dust during processing and use, posing industrial hygiene issues due to the high congealing points of heavy hydrocarbon by-products from petroleum processing, which are difficult to utilize effectively, and triglycerides with high congealing points are limited in applications due to their solid state at ambient temperature.
Innovation Solution
A watery composition is developed comprising a surfactant and a mixture of hydrocarbon ingredients like Residual Aromatic Extract (RAE) and Foots Oil from petroleum, combined with triglycerides, creating a eutectic with a softer consistency that enhances dust binding properties by forming a more effective cover layer on fibers, reducing dust particle detachment and improving compatibility with binders.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If heavy hydrocarbon by-products from petroleum processing with high congealing points are used as dust binders, then dust binding capability is improved, but the materials are difficult to utilize effectively due to their solid state at ambient temperature
Solution Approach 1:
The patent changes the physical state parameter of heavy hydrocarbon by-products by mixing them with triglycerides to form a eutectic composition. This mixture lowers the congealing point from above ambient temperature to below ambient temperature, transforming the material from solid to liquid state at room temperature, thereby making it easy to apply while maintaining dust binding capability
Solution Approach 2:
The patent creates a composite material system by combining heavy hydrocarbon by-products (RAE or Foots Oil) with triglycerides in specific ratios. This composite forms a eutectic mixture that exhibits properties different from the individual components, specifically a lowered congealing point that enables liquid state at ambient temperature while retaining the high dust binding properties of the hydrocarbon component
2Object-affected harmful factors
If triglycerides with high congealing points are used, then dust binding properties are improved, but applications are limited due to their solid state at ambient temperature
Solution Approach 1:
The patent modifies the congealing point parameter of triglycerides by forming a eutectic mixture with heavy hydrocarbon by-products. This composition change lowers the congealing point below ambient temperature, enabling the material to remain liquid and expand its applicability beyond limited heated storage requirements
3Object-affected harmful factors
If heavy oil with high boiling point is used as dust binder, then dust binding effectiveness is improved, but viscosity is high making it difficult to process
Solution Approach 1:
The patent creates a composite emulsion system by mixing heavy hydrocarbon by-products with triglycerides and dispersing them in water with the aid of a surfactant. This composite formulation reduces viscosity and improves processability while maintaining the dust binding effectiveness of the hydrocarbon component
Solution Approach 2:
The patent introduces water as a continuous phase and surfactant as an intermediary to create an emulsion system. The surfactant mediates between the hydrophobic hydrocarbon/triglyceride mixture and water, enabling homogeneous dispersion and reducing viscosity, thereby improving ease of processing and application
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The composition effectively binds dust during mineral wool production and use, reducing dust formation and increasing the availability of the anti-dust agent, while also lowering the viscosity and congealing point of the mixture, making it more stable and easier to process, thus addressing the challenges of using high congealing point materials.
Implementation Method 1
a watery composition which comprises a surfactant as an emulsifier for the ingredients insoluble in water
Implementation Method 2
comprises a surfactant as an emulsifier for the ingredients insoluble in water
Implementation Method 3
creating a eutectic with a softer consistency that enhances dust binding properties
Implementation Method 4
lowering the viscosity and congealing point of the mixture
Implementation Method 5
The composition effectively binds dust during mineral wool production and use, reducing dust formation
Data Source
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AI summary
A watery composition is described which is suitable for binding dust in production of mineral wool, which comprises a surfactant substance as an emulsifier for the ingredients insoluble in water, and which furthermore comprises, on the basis of its dry substance content, (a) from 5 to 95% by weight of a hydrocarbon ingredient obtained from petroleum, and (b) from 95 to 5% by weight of a triglyceride, wherein the hydrocarbon ingredient obtained from petroleum and the triglyceride ingredient both have a congealing point of at least 23ºC. A method is also described for production of this composition, and the use thereof in the production of mineral wool. The use is also described of a composition of 5 to 95% by weight of a hydrocarbon ingredient obtained from petroleum and 95 to 5% by weight of a triglyceride, wherein at least one of these ingredients has a congealing point of at least 23ºC, as an aid in the production of mineral wool.