Note: Descriptions are shown in the official language in which they were submitted.
Wa~te red-mud is the residual product of the alu~inu~
; ~ndustry. It is obta~ned fro~ Bauxlte after the extraction of
alumlnum oxlde wlth alkall solution. Since the resldue still
contalnq about 10% alkali, the disposal o~ red-mud may pollute
the envlronment. A typical ~amp~ o~ the red-mud has shown
the follo~in~ analysis:
SiO2 14.6% T~02 7
23 22.6~ Fe203 35.6
Na20 9.1~ Others 10.9~
The cQ~position ~111 vary dependlng ~pon the purity Or the ore,
t~pe and concentrat10n Or alkal~, typ~ o~ extraction process,
~-1 efiiclency of ~xtraction, etc. The foregolng analysls 18 for
demonstration purpo3es only and 1~ not mean~ to limlt the
composltion of the red-mud.
Tlle disposal of ~aste PVC ht~s proren to be an enYlrc~n-
: mental problem. Burning the mater~al produce3 ~mo~e and
hazardou3 gases sueh as H~l. The pr~ent ln~ention reduce~
~ ~,
the~e pro~lems. The processes o~ the pre~ent inYent$on
utllize the convenlence of the Banbury mixer, but other
prscessing equip~ent can be u~ed such a~ $nternal ml~ers, roll
mills, extruders or O~her processlng equipment familiar to
those skllled in the art.
: .
A plastic material ls obtained by compounding poly-
vinylchloride (PVC) in the form o~ waste material or as ~resh
plas~lc~ with waste red-mud. It is thought that degrqdation
products in the PVC are neutrallzed b~ free alkall in the
red-~ud. Prefersbly another waste product such as waste
..; . .
` ~ motor oil is added a~ an lnexpensive processing aid thereby
performing a worthwhi~ function while also eliminating a
pollution problem. The waste oil softens the P~C while
. mlxing to aid in the dlsper~lon of lngredients, e.g. cut
;;
~: r. down power consumption~ shorten mixing time, etc. The
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]plastl~ material may contain other additives such as fillers
~, ,, ,;~
and plastic~zers to obtain deslred physical properties.
Di-octyl phthalate is a possible optional
ingredient. It serves as a plasticizer to soften P~C so that
it will be flexible
.. .. .
-: ~ The following tables show the percentages of ingredi-
ents found in the present compositions. All percentages are on
a weight percent basis.
Table 1 - Percent Ranges
INOREDIENT BROAD RA~TGE PREFERRED RANGE
Red-mud 5~ - 80% 10% - 55%
Waste oil 0~ - 20~ 3% - 15%
Di-octyl Phthalate 0% - 50% 5% - 10
Other Flller 0~ - 20% 0% - 6~
PVC 20~ - 85~ 25% - 80%
Table 2 - Optimum Compositions
GREDIENTHARD (Shore D-78)SOFT ~Shore A-77)
~VC 20-30% (25~) 30-50% (40~)
o :~ DOP ~10~ (7%) 20-40~ (38~)
~: Red-mud 7 3% (60~) 5-25% ~12%)
Waste Oil 3-10~ (4%) 3-10% (5%)
Others 2-6~ (4%) 2-6~ (5~)
Fillers such as designated below may be used ln
~ 25 amounts o~ up to 20~ to increase tensile strength and hardness.
: ~ ~ Cheap material byproducts, such as plant ~ibers, e.g. slsal,
bagasse are preferred.
Plant Flbers Synthetic Fibers
j~ .,~ ~
Sisal Glas~
Bamboo . Polyester
' Bagasse Polyamide
~ . " ~
~ Polyvinylalcohol
- ~ Polyacrylics
~ '
~,~
Typtcally, the present compositions are non-trans-
~i parent, heat stable to 180C, and self extinguishing ~rom a
fLammabilit~J standpoint. Typical hardnesses are Shore D 78
for hard materials and Shore A-77 for soft material compositions.
Compounded material shows geod outdoor stability.
; The processes of the present invention provide a
novel, highly effective method for the conversion of used
lubricating oil, waste red-mud and new or waste P~C material
into useful and durable products. Since all of the raw materials
employed may be waste materials, this will reduce the cost
of the products as well as reduce the waste disposal problems
.
and ensuing environmental pollutlon. The current state of the
art for the compounding of PVC uses costly stabllizers and
; ~ processing aids. The present invention utilizes the stabllizing
. _~
~ 15 properties of the red-mud and the softening effect of the wast~
._ .
oil in PVC materials. The present invention reduces both the
cost of the product and increases the thermal stability and
weather resistance. Another advantage of the present invention
is that compounded PV~ materlal maintains a large amount o~
~ 20 the ini~ial tensile strengbh and elongat~on upon prolonged
exposur~ to Ultraviolet irradiation. These effects may be
due to the existence o~ the red-mud increasing the thermal
stability o~ the compounded material by absorbing the resulting
degradation products.
The compounded mater~al ma~ be ~ormed into films,
sheets, leathers, plates, et~, either of a ~lexible or hard
type. me flexible material can be m~de into waste digesters,
portable rice warehouses, fermentation vess~ls, containers for
agricultural water, storage silos for grass and hay, hot bed
llners, storage tanks for methane generated from animal wastes,
`:~ liners for salt water e~aporators and reser~oir~, outside
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~ - 3 -
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storage buildings, liners to protect beaches ~rom wave action3
wire and cable protective coatlngs, etcO The hard material
can b~ used ~or durable conduits, corrugated roofin~ and
siding, surfacing material for ~edestrian sidewalks, con-
i 5 struction panels, etc.
When waste PVC is used in the cDmpositlons of the
~'1
present invention, it ~s often not necessary to add a plasti-
cizer, since the waste PVC already contains plasticizer.
Another advantage o~ the present in~ention is that compounded
materials are self-extinguishing when sub~ected to a flamma-
.'1.~
bility test. This test consisted o~ igniting the compounded
material with a bunson burner; ~hen the bunson burner was re-
moved, the burning of the material ceased. Yet another advan-
~;~ tage of the present invention is the incorporation of waste
and/or used machine3 engine or motor lubricating oil as aprocessing ~id with no adverse effect on the quality of the
~ .
final product or its response to environme~ al aging. The
addition elim~nates costly proces~ing oils and reduces the
pollut~on caused by dumping the used oil.
In the following examples, the following standard test
procedures were used:
Aging ASTM D 1573-61
Tensile and
Elongation ASTM D 638-72
All percentages are w~lght percent unless otherwise
`~ indicated,
-~ ~ Re~erring to the drawings, Figures 1 and 2 compare
the results o~ adding red-mud ~o ~omposition~ not conta~ning
red-mud. Figures 3 and 4 compare the present compositions
with those employing CaCo3 rather than red-mud.
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~ - - 4 -
-.,,.. ,,9 EXAMPLE 1
This example demonstrates the formation of a flexible
film which is then assembled into a marsh digest~r and which
has good weather resistance. The following ingredients were
charged into a Banbury mixer at 175C: -
200 parts waste PVC
20 parts whste oll
,, --~.....
55 parts predried red-mud
The mlx obtained was processed on a roll mill and then sheeted
out on a calander. ~ilms of 1.0 mm thickness were heat welded
together to construct a cylindrical animal waste digester three
meters long ~nd 1.5 meters ~n diameter. The digester wa~ buried
~lth the cylindrical axls parallel to the ground surface with
. . .
-- half the volume above ground. The digester was then filledwith ~ater to ground level and the air space above the water
was p~essurized to 15 cm water.
Over the course of one year3 air has been pumped ln
and out o~ the digester ~or six thousand cycles wlth no damage
,~
to the surface o~ the digester. Air pressure was maintained
over long periods of time. The ~ilm hardness was Shore A-T7.
EXAMPLE 2
This example demonstrates the ~ormation o~ a hard
sheet which has good environmental resistance. The composit~on
used was:
260 parts waste PVC
5~ 87 pQrts di-octyl phthalate (DOP)
`~j` 527 parts predried rea-mud
. ~.....
40 parbs waste oil
4~ parts sisal ~iber
These ingredients were mixed ~ell and then put lnto a
orming press under a pressure Or 50kg/cm at 170C for 5
minutes,
:. ;., ~.,?-` `;
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~h~
The sheet obtai~ed had a bending stren~th (ASTM
I3790-74) of 420kg/c~ ; arter four years exposure to Taiwan's
weather, the bending strength was 382kgicm2. A large portlon
of the bending ~trength has been retained a~ter long en~iron-
~ental exposure. This is in contrast to the present state
~"~ of the art where PV~ becomes embrittled and useless ln one to
two years exposure to the out-of-door~ environment.
, ......
The sisal ~iber is an inexpensive ~elnforcing
agent used to increase the tensile strength and hardness. The
hardness was Shore D-78.
.. . ...
( EXAMPLE 3
: ~; ~
;, ~ ~ This example demonstrates the increase in tensila
i strength and the retention of elongation of materlals of the
present invention after prolonged exposure to ultraviolet light.
Table 3
;;; EXAMPLE ~ PVC % RED-MUD % WASTE OIL %
3 A 78 12 lO
3 B 100 0 0
It i5 noted that lO0 hours of ultraviolet irradiation
is equi~alent to one year of out door testing.
~, Results are shown in Figures l and 2. As shown in
the ~igures, addition o~ red-mud and waste lubricatlng oil
pursuant to the present in~ention yields products which have
bet~er tensile strength and elongation after prolonged W
irradiatlon. All ~est resu~ts are the average of 5-10 samples
according to the China National Standards Statistlcal procedures.
,` EXAMPLE 4
"
;~ ~ This example demonstratos the superlority of using
~ ~ red-mud pursuant to the present lnvention as compared to the
..,~ ......
~ 30 use of conventional ~illers, e~g. CaC03.
~ .
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:;'",'? EXAMPLE ~ PVC ~ FILLER_ PROCESSING AID
4 C 160 g CaC03 60 g Process Oil 60 g
4 D 160 g red-mud 60 g Waste Oil 60 g
A3 shown in Figures 3 and 4~ the present invention
ga~e improved elongation retention and retained tensile
strength. This demonstrates a substantial improvement over
p~or ar~ composit~ons.
~` EXAMPIES 5-7
The ~ollowing examples demonstrate that the addi~ion
o~ ~aste lubricating oil as a process~ng aid does not adversely
, ~, . ...
affect the lnitial physical properties of the co~pounded materials
or the physica~ properties after aging tests. The composltion
consisted o~ 160 g PVC ~ 160 g of di-octyl phthalate plus
~arying amounts o~ filler and processing aid. In the ta~le
below "FINAL" refers to 1000 hours W lrradiation.
Table 4
.-......
ELONGATION
EXAMPLE RED-MUD PROCESSING AID INITIAL % FINA~
$(Control) 60 g 20 g Process Oil 324 284
;~ ~ 5 60g 20 g Wa~te Oil 4 318
6 5 g 30 g Waste 011 346 318
7 40 g 40 g Waste Oil 334 3~6
TENSILE STRENGTH ~G~CM
X(Control) 79.6 82.1
80.2 76.5
80.0 83.6
. ~.... ... .
~- ~ 7 76.2 67.1
. ~ .,. ,. ~
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