Mineral Granulate for Animal Litter with Low Bulk Density
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Solution Overview
Problem
Existing mineral granulates for animal litter lack a balance of high adsorption capacity, strength, abrasion stability, odor control, and cost-effectiveness, with high bulk density and potential for dust and abrasion issues.
Innovation Solution
A granulate produced by granulating calcium silicate hydrate material with flour-shaped or granular forms, combined with magnesium oxide, calcium oxide, or their hydroxides, and bentonite, which promotes a low bulk density, high water absorption, and improved odor control, using waste materials and inexpensive granulation aids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If bentonite-based granules are used for animal litter, then adsorption capacity and odor control are improved, but bulk density increases and cost increases
Solution Approach 1:
The patent creates composite granules consisting of calcium silicate hydrate core material (70-90 wt%) combined with bentonite shell (10-30 wt%). This composite structure allows the product to achieve the high adsorption capacity of bentonite while maintaining the low bulk density of calcium silicate hydrate, resolving the contradiction between adsorption performance and weight.
Solution Approach 2:
The patent applies a thin shell of bentonite (10-30 wt%) on the surface of calcium silicate hydrate granules. This local application of bentonite provides the necessary adsorption capacity and odor control at the surface where liquid contact occurs, while the bulk of the granule remains lightweight calcium silicate hydrate, thus achieving high adsorption without high bulk density.
2Weight of stationary object
If aerated concrete granules are used for animal litter, then bulk density is reduced, but adsorption capacity and odor control are insufficient
Solution Approach 1:
The patent combines lightweight aerated concrete granules (calcium silicate hydrate) with bentonite to create a composite material that inherits the low bulk density of aerated concrete while gaining the high adsorption capacity of bentonite, thus resolving the contradiction between weight and adsorption performance.
Solution Approach 2:
The patent applies a surface layer of bentonite (10-30 wt%) on aerated concrete granules. This local enhancement provides the necessary adsorption functionality at the surface where liquid contact occurs, while the aerated concrete core maintains the low bulk density, achieving both lightweight and high adsorption capacity.
3Ease of operation
If flour-shaped calcium silicate hydrate material is used, then granulation and flowability are improved, but dust formation and abrasion increase
Solution Approach 1:
The patent changes the particle size parameter by using flour-shaped calcium silicate hydrate material with specific grain size distribution (maximum grain size 0.63-1.25 mm). This parameter optimization improves granulation and flowability while reducing dust formation by eliminating excessively fine particles that cause abrasion.
Solution Approach 2:
The patent creates composite granules where flour-shaped calcium silicate hydrate (70-90 wt%) forms the core and bentonite (10-30 wt%) forms the shell. This composite structure maintains the good flowability of the flour-shaped core material while the bentonite shell reduces dust formation and abrasion, resolving the contradiction between ease of operation and harmful factors.
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 granulate achieves high adsorption capacity, strength, abrasion resistance, and odor control with a low bulk density, making it suitable for animal litter while being environmentally friendly and cost-effective, with improved flowability and compactability.
Implementation Method 1
The granulate achieves high adsorption capacity
Implementation Method 2
high water absorption
Data Source
Figure 1
AI summary
The invention relates to a mineral granulate essentially consisting of agglomerated granules, at least microporous, preferably having micropores and macropores, calcium silicate hydrate material grains with a bulk density according to DIN EN 1097-3: 1998, less than 700 g/l, wherein the matrix of the granules contains MgO particles and/or CaO particles or particles of the hydroxides of these oxides and/or bentonite particles and/or starch, in particular cold water-soluble potato starch and/or starch derivatives such as glucose syrup and/or dextrin solution in amounts exceeding 1 wt.-%, based on the calcium silicate hydrate material, wherein the calcium silicate hydrate material is a flour and is present with flour particle sizes < 1200 µm, in particular < 1000 µm, and with a particle size distribution maximum below 500 µm, or the calcium silicate hydrate material is present with both flour fraction particle sizes with a particle size distribution maximum of below 500 µm and with granular particle fractions up to 8 mm, in particular up to 6 mm, and Gaussian particle size distribution with a particle size distribution maximum between 2.5 and 4 mm, and in particular the flour fraction and the granular fraction each have a distinguishable Gaussian particle size distribution due to precipitation, wherein particle fractions between the flour fraction and the granular particle fraction are absent or are present only in subordinate quantities of less than 10 wt.%, preferably less than 5 wt.%, and the flour fraction does not contain less than 20 wt.% in the Calcium silicate hydrate material is present.