Note: Descriptions are shown in the official language in which they were submitted.
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TITLE
MANUFACTURED GRANULAR SUBSTRATE
AND METHOD FOR PRODUCING THE SAME
BACKGROUND OF THE INVENTION
This invention relates to a manufactured granular
substrate suitable for use as a carrier for chemical
agents, as well as a method for producing a granular
substrate. More particularly, this invention relates to a
water dispersable, light weight manufactured granular
substrate.
Generally, manufactured granular substrates are
utilized as carriers for active chemical agents, such as
for example herbicides or other pesticides. The carriers,
with the active chemical agents, are utilized to distribute
the active agent over a broad area. The carriers are
generally inert compounds that, upon application, break
down over time. Existing water dispersable carrier
compositions have larger than desired particles sizes
accompanied by high bulk densities of greater than 60
pounds per cubic foot. It is preferable to utilize a
carrier with smaller granules and a lower bulk density in
order to efficiently transport and distribute the required
amount of active chemical agent without utilizing excessive
amounts of inert carrier compounds.
In addition, conventional manufactured granular
substrates often have a tendency to break apart thus
creating handling and distribution problems. Granular
substrates that resist attrition are preferred because they
will not degrade and therefore maintain their particle size
during handling. While resistance to attrition is
important, the carrier compound must however breakdown or
disintegrate upon exposure to water.
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U.S. Patent No. 5,078,779 discloses a binder
composition for the granulation of dry, stable, particulate
fertilizers. The composition generally includes a reactive
carbonate and a reactive sulfate, in combination with a
silicate strengthening agent and a water dispersing agent.
Dolomite is disclosed as a carbonate source for the binder
composition. The binder is used in conjunction with
ammonium sulfate to provide a granulated fertilizer. In
order to form the granulated fertilizer, the patent teaches
the use of a reactive acid to initiate a reaction between
the sulfate salt and the metal ion of the carbonate to form
a complex salt.
A manufactured granular substrate having 10% to 100%
plant fiber and 0% to 90% of a mineral filler is disclosed
in U.S. Patent No. 5,019,564. The substrate is formed by
the agitated agglomeration of a fibrous slurry without the
use of a binder. The plant fibers are generally 1mm to
10mm in length. The resulting substrate has a bulk density
of about 20 to 42 pounds per cubic foot. The substrate is
utilized as a carrier for active chemical agents. However,
the substrate does not readily breakdown upon exposure to
water. Additionally, the fibrous nature of the substrate
can reduce the ability of the substrate to flow in bulk
form.
U.S. Patent Nos. 4, 015, 973, 4, 954, 134, and 5,228,895
all generally disclose the use of either limestone or
dolomite in conjunction with a lignosulfonate binder in the
formation of manufactured granular substrates. The
agglomerated particles produced in accordance with the
patents are either outside the preferred size and bulk
density or are susceptible to degradation during handling.
Additionally, U.S. Patent No. 5,242,690 discloses an
inert manufactured granular substrate as a carrier for
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chemical agents. The granular carrier composition includes
grain dust and a binder of either calcium or sodium
lignosulfonate. The finished granular carrier exhibits a
bulk density between 30 and 35 lbs per cubic foot.
Thus, existing manufactured granular substrates
utilize either limestone or dolomite with other binding or
reactive components to produce granular substrates as
carriers for active chemical agents. The existing
manufactured granular substrates are not of the desired
size or bulk density. Also, some of the existing
manufactured granular substrates have a tendency to
breakdown during handling thereby changing the bulk density
or creating distribution problems during application.
Other granular substrates, produced from primarily plant
fiber, have some desirable physical properties but fail to
readily disintegrate upon exposure to water.
It would be an advantage to produce a manufactured
granular substrate for use as a carrier compound for active
chemical agents that has a bulk density of less than about
55 pounds per cubic foot at a relatively small particle
size. A manufactured granular substrate having the noted
properties is capable of delivering an appropriate amount
of active chemical agent to a desired area while utilizing
less inert material. Furthermore, smaller particle sizes
provide a greater surface area for the chemical agent and
result in an improved distribution or coverage of the
desired area of application.
It would also be an advantage to produce a
manufactured granular substrate that does not degrade
during handling but breaks down when exposed to moisture or
water. The resistance to attrition ensures the proper
distribution of the active chemical agent upon application.
Furthermore, the ability to disintegrate upon exposure to
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water is needed to provide the active chemical agent to the
soil.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is
provided a novel manufactured granular substrate
composition that is suitable for use as a carrier for
active chemical agents. The present invention also
includes a method for forming the manufactured granular
substrate.
The manufactured granular substrate composition of the
present invention includes one or more mineral components,
one or more light weight additives, and one or more
binders. The mineral component in the granular substrate
is 65 wt% or more of at least one mineral compound,
preferably selected from the group consisting of dolomite
and limestone. The light weight additive is included in
the substrate at about 5 wt% to about 25 wt%, and is
preferably of one or more compounds selected from the group
consisting of expanded silica, fly ash, hydrated lime,
wheat flour, wood flour, ground wheat straw, cellulose and
soy flour. The binder is included in an amount up to about
20 wt%, and may preferably be one or more materials
selected from the group consisting of brewers condensed
solubles, lignosulfonate, sodium carbonate lignin, cane
molasses, beet syrup, beet molasses, desugared beet
molasses, whey, starch, soy solubles with cane molasses or
the like, hydrolyzed collagen, amino acid solutions,
cellulose derivatives, or cellulose based polymer binders.
Optionally, a coating, at about 1 wt% or less, may be added
to the outer surface of the manufactured granular
substrate.
CA 02310955 2008-01-18
The granular substrate of the present invention has a
bulk density of less than about 55 pounds per cubic foot at
a particle size guide number ranging from about 100 to
about 230. The granular substrate should have a
5 sufficiently high bulk density to provide the desired
ballistics upon application of the finished product. The
preferred bulk density is between 40 pounds per cubic foot
and 55 pounds per cubic foot, and is most preferably
greater than 42 pounds per cubic foot to about 52 pounds
per cubic foot. Additionally, the substrates have a
uniformity index at a minimum of 40. The particle size and
bulk density are desirable properties for use of the
granular substrate as a carrier for active chemical agents,
such as herbicides or other pesticides. Additionally, the
granular substrate resists attrition during handling but is
capable of breaking down once exposed to water.
The process of the invention involves the mixing and
pelletizing of the noted manufactured granular substrate
composition. The mixing of the present inventive
composition occurs at relatively low shear forces to
prevent the degradation of the mix components. The
pelletizing of the mixture composition may be accomplished
through conventional pelletizing equipment such as
pelletizing pans or drum granulators. The manufactured
granular substrate, in pellet form, is then generally dried
at a temperature of about 240 F to about 300 F to remove
excess moisture and produce the manufactured substrate of
the present invention.
It is an aspect of the present invention to provide a
manufactured granular substrate, produced from at least one
mineral component and additional additives, that has a bulk
density of about 40 pounds per cubic foot to about 55
pounds per cubic foot at a particle size in accordance with
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particle size guide number standards of about 100 to about
230. A manufactured granular substrate having the noted
characteristics is desirable for use as a carrier for
chemical agents because the granular substrate, in bulk
form, has a greater surface area for receiving the chemical
agent while reducing the amount of inert material required
for application. Additionally, the smaller particle size
and lower bulk density of the present invention result in
an improved distribution of active chemical agents over a
specified area.
It is also an aspect of the present invention to
provide a manufactured granular substrate that does not
degrade during handling yet disintegrates upon application
and exposure to water.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In accordance with the present invention, it has been
discovered that a combination of specific mineral
components, light weight additives, and binders results in
a preferred manufactured granular substrate which is
suitable for use as a carrier for active chemical agents.
Additionally, the present invention involves a process for
manufacturing the granular substrate.
The present invention provides a granular carrier in
pellet form that has a bulk density of less than about 55
pounds per cubic foot at a nominal product sizing, in
accordance with the size guide numbering system, of about
100 to about 230. The preferred bulk density is between
about 40 pounds per cubic foot to about 55 pounds per cubic
foot, and is most preferably greater than 42 pounds per
cubic foot to about 52 pounds per cubic foot.
The manufactured substrate has an appropriate crush
strength and resistance to attrition to prevent significant
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degradation of the substrate during handling. Additionally,
the manufactured granular substrate quickly disperses when
exposed to water. The granular substrate also has the
appropriate spherocity, absorption, and solubility to
enable the use of the substrate as a carrier for active
chemical agents such as herbicides or other pesticides.
The manufactured granular substrate of the present
invention includes one or more mineral components
preferably selected from the group consisting of dolomite
and limestone. The mineral components make up about 65 wt%
or more of the manufactured granular substrate. In
general, the mineral components have a sizing of 100%
passing through a 30 mesh screen and 50% or more passing
through a 200 mesh screen. The mineral components have a
preferred sizing of about 100% through a 50 mesh screen and
80% or more through a 200 mesh screen. The noted mesh
sizes and all those mentioned hereafter conform with U.S.
standard sieve sizes. Additionally, the mineral components
have a bulk density of greater than about 70 pounds per
cubic foot, and preferably have a bulk density of about 75
to about 90 pounds per cubic foot. The sizing of the
mineral components may vary with respect to other
ingredients utilized in the agglomerated substrate. In
addition to the preferred mineral components, other stone
or mineral dust compounds conforming with the size and bulk
density parameters may be suitable for use with the present
invention.
One or more light weight additives are utilized with
the present inventive composition to obtain the desired
bulk density of the finished substrate. The manufactured
granular substrates include about 5 wt% to about 25 wt% of
the additives. The light weight additives are generally
inert compounds having a bulk density of less than 35
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pounds per cubic foot and a sizing of at least 20% passing
through a 40 mesh screen. It is preferred that the
additives have a sizing of 100% passing through a 40 mesh
screen. Additionally, the light weight material should be
a non-fibrous material as indicated by the sizing
parameters. Fibrous material can adversely impact the
dispersability and the flow characteristics of the finished
granular substrate. The light weight additives are
preferably selected from the group consisting of expanded
silica, fly ash, hydrated lime, wheat flour, wood flour,
ground wheat straw, cellulose and soy flour. However,
other inert compounds meeting the bulk density and sizing
specifications may be suitable for use in the present
inventive composition.
A preferred embodiment includes the use of wood flour
resulting from finely milled wood particle board. The wood
particle board contains approximately 10 wt% of a urea-
formaldehyde resin. Another preferred embodiment includes
the use of wheat straw flour resulting from finely milled
wheat straw particle board. The wheat straw particle board
contains a diphenylmethane diisocyanate resin. In both
cases, the additional resin assists in producing a granular
substrate that does not degrade during handling but breaks
down upon exposure to water.
A binder is utilized to agglomerate the ingredients of
the present invention. The binder is utilized at an amount
up to about 20 wt% (dry basis) of the granular composition.
The preferred amount of binder is generally 2 wt% to 20
wt%. The binder utilized will bind the ingredients into a
granular substrate which resists attrition, will not
degrade and therefore maintain their particle size during
handling. The binder must be such that the resulting
granular substrate has a resistance to attrition (RTA)
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value, in accordance with ASTM E 728-91 Volume 11.04, of
at least 85%. In addition, the selected binder needs to be
sufficiently water soluble that the resulting granular
substrate disperses quickly in water.
The binder is preferably selected from the group
consisting of brewers condensed solubles, lignosulfonate,
sodium carbonate lignin, cane molasses, beet syrup, beet
molasses, desugared beet molasses, whey, starch, soy
solubles with cane molasses or the like, hydrolyzed
collagen, amino acid solutions, cellulose derivatives, or
cellulose based polymer binders. Other water soluble
binders having equivalent properties to, for example, the
brewers condensed solubles, may be suitable for use in the
present inventive composition, although economics may
mitigate against their use.
The binder is generally added to the composition as a
solution. The solution is typically provided as a water
based slurry having about 40% to 50% solids by weight and
weighing about 10 pounds per gallon. The binder may also
be added and mixed with the other dry ingredients,
subsequently mixing in an amount of water.
Optionally, a coating may be included with the
manufactured granular substrate to provide a harder outer
shell. The coating is generally added to the composition
at 1 wt% or less. The coating material is added directly
to the dried, finished pellets and enhances the strength of
the granular substrate to prevent degradation. The
preferred coating material is polyvinyl alcohol. However,
other coating compositions capable of strengthening the
substrate without adversely affecting the desired
properties are suitable for use with the present invention.
The composition of the present invention is generally
produced by first creating an admixture of the noted
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components within the specified ranges. The mixing of the
components may occur in either a batch or continuous mixing
process. Conventional mixing devices are suitable for use
with the present invention. The components should be
5 thoroughly mixed at conditions which prevent degradation or
compaction of the materials. During the mixing step, the
binder composition is generally added to the mixture as a
solution. Optionally, at least part of the water soluble
binder may be added to the pelletizing apparatus during
10 pelletizing. Additional water, up to about 15% by weight,
may be necessary for agglomeration of the materials in the
inventive composition.
The admixture is then fed into a pelletizing apparatus
to produce the manufactured granular substrate of the
present invention. Conventional pelletizing equipment is
suitable for use in producing the substrate in pellet form.
The preferred pelletizing equipment is a pelletizing pan.
Additionally, drum granulators or other types of
granulation equipment may be used to produce the granular
substrate of the present invention.
Water may be added to the mixture during the
pelletizing step of the process to assist in granulation of
the material. The water is generally added at an amount
which results in no greater than 35% by weight in the
substrate.
In accordance with the present invention, the
operation of a pelletizing pan may vary with the specific
formulation or ingredients in order to produce a granular
substrate with the preferred properties. For example, feed
rates and locations of the admixture or the water, the
angle of the pan, the speed of rotation of the disc, or the
depth of the pan may be varied to produce the desired
product. One skilled in the art of pelletizing is capable
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of recognizing the variables and making adjustments to
obtain the granular substrate in pellet form.
The manufactured granular substrate is then dried to a
temperature of about 240 F to about 300 F to remove excess
water utilized during the agglomeration of the components.
The pellet is dried to a total moisture content of 8% or
less in accordance with ASTM standard D 5033 Volume 11.04.
The substrates have a preferred total moisture content of
2.0% or less. The upper temperature limitation during the
drying step prevents the degradation or burning of the
organic binder in the granular substrate. The substrates
may be dried in conventional drying units such as for
example a fluid bed dryer or a rotary dryer.
The resulting granular substrates are then screened to
remove oversized and undersized granular substrates. The
improperly sized material may be recycled to the mixing
stage or milled to the appropriate size and rescreened.
Optionally, the finished product may be sprayed with a
light weight mineral oil to prevent dusting of the product
in bulk form.
The sizing and bulk density are important finished
product specification for the present invention. The
composition of the present invention results in a
relatively low bulk density while having a smaller particle
size distribution. This is contrary to conventional,
mineral based granular substrates, where typically larger
particles have bulk densities in excess of 60 pounds per
cubic foot. The resulting manufactured granular substrates
of the present invention have a bulk density, as measured
by ASTM E 727 Volume 11.04 standards, of less than about 55
pounds per cubic foot, and preferably from about 40 pounds
per cubic foot to about 55 pounds per cubic foot.
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The size of particles is determined by the size guide
number/uniformity index system used in the fertilizer
industry. The substrates of the present invention have a
size guide number between 100 and 230 and a uniformity
index of at least 40. The size guide number describes the
relative particle size and is obtained by multiplying the
average particle size, in millimeters, by 100. The
uniformity index is a comparison of large particles to
small particles. The index is expressed as a whole number
between 1 and 100 with higher numbers indicating better
uniformity and tighter size range. Additionally, the
sizing may be determined in accordance with ASTM E 728-91
Volume 11.04 wherein the sizing is preferably 20% or more
passing through a 14 mesh screen and retained on a 40 mesh
screen.
The manufactured granular substrate must be strong
enough so that the particle does not degrade during normal
conveying and handling operations. The degradation of
granular substrates would result in an increase in fine
material which in turn would increase the bulk density.
Additionally, dust or powder material absorbs more chemical
agent and therefore would result in the improper
distribution of the active chemical agent upon application.
It is preferred that the granular substrate not
degrade until subject to water. However, it is also
equally important that the substrate not degrade with high
humidity. The ability of the granular substrate of the
present invention to degrade with water is generally
measured in a water dispersability test. The test involves
placing about 10 grams of the granular substrate into 100
ml of water at room temperature in a closed glass
container. The container is then inverted and the time is
observed until the material completely disperses. After
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every minute, the container is inverted. The granular
substrate of the present invention has a dispersability
time of generally less than 3 minutes.
The strength of the granular substrate is determined
through the crush strength test, ASTM E 382 Volume 3.06,
and resistance to attrition (RTA) test, ASTM E 728-91
Volume 11.04. The manufactured granular substrate of the
present invention has a crush strength between 2 and 8
pounds on an 8 mesh pellet. Additionally, the granular
substrate has an RTA value of at least 85%.
The resulting granular substrate of the present
invention generally has a smooth surface and is spherical
in shape. The spherocity lends to desired flow
characteristics of the substrates in bulk form. The angle
of repose is a test utilized to measure the ability of a
substrate to flow in bulk form. The test is conducted on a
14 x 30 mesh sample. The granular substrates of the
present invention all have an angle of repose of 35 degrees
or less.
The granular substrate must have the capability of
absorbing the active chemical agent in order to function as
a carrier. The active agent is generally absorbed in the
carrier up to about five percent by weight. The substrate
is also water soluble and therefore degrades upon exposure
to moisture or water.
The manufactured granular substrate of the present
invention is suitable for use as a carrier for active
chemical agents. For example, active chemical agents could
include herbicides or other pesticides that are commonly
distributed through the use of a carrier in bulk form.
The following examples, which constitute the best mode
presently contemplated by the inventors for practicing the
present invention, are presented solely for the purpose of
CA 02310955 2000-06-05
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further illustrating and disclosing the present invention,
and are not to be construed as a limitation on the
invention:
Examples 1-7
A series of examples were produced in the lab to
demonstrate the composition of the present invention. The
specified dry based raw materials for each example were
weighed out and placed in a Forberg type mixer made by
Paul 0. Abbe, Inc. Of Little Falls, New Jersey. The mixer
was run for about one minute in order to thoroughly mix the
materials before adding the binder composition. The binder
composition, in solution form, was added to the materials
over a one minute time period and then mixed for another
minute.
The resulting wet mixture was then fed into a 36"
rotating pelletizing pan through a Vibra Screwtm feeder.
The feed rates to the pelletizer for each example are
listed in Table I. The pan angle was 50 (from
horizontal). The pan depth was maintained at 6 inches
while the pan speed was 26 rpm. Additional water was
sprayed into the pelletizer to assist in the agglomeration
process. The substrates, in pellet form, were collected
from the pelletizing pan and placed in a conventional lab
oven. The granular substrates were then heated to a
temperature of about 240 F to about 300 F to remove excess
water.
The finished substrates where then tested to obtain
the bulk density, particle size, crush strength, RTA, and
total moisture content. The results of each sample are
listed in Table I.
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Example 8
The example was produced to demonstrate the
manufactured granular substrate and process of the present
invention on large scale production equipment. The noted
5 amounts of dry ingredients were mixed in a two cubic foot
Forberg type mixer for about 1 minute. The binder
composition was then added to the mixing vessel and
thoroughly mixed with the materials for about another
minute.
10 The mixture was then transferred to an AccuRatetm
surge hopper having a 2" feeder screw. The feeder screw
was used to continuously feed the mixture to a three foot
diameter pelletizing disc at a rate of 608 pounds per hour.
The three foot diameter pelletizing disc utilized a 5 inch
15 deep pan and was operated at a 56 degree (from horizontal)
pan angle and a speed of 26 RPM. Additional water was
introduced near the feed inlet through spray nozzles to
assist in the agglomeration. Then the resulting pellets
were collected from the disc outlet. The moisture content
of the pellets was about 21%.
The pellets produced from the pelletizing disc were
transferred to TecWeightm feeder surge hopper having a 3"
feeder screw. The pellets were then continuously fed into
a 24 inch diameter by 20 foot long rotary dryer. The
granular substrates were fed into the dryer at about 1000
pounds per hour. The dryer was a co-current gas fired
dryer with internal lifters and rotating at about 11 rpm.
The combustion temperature in the dryer was controlled at
about 1400 F while the outlet temperature was monitored at
220 F. The outlet product temperature was controlled at
about 175 F. The total moisture content of the finished
pellet was less than 0.5%.
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The finished product was collected and tested to
obtain bulk density, particle size, crush strength, RTA,
angle of repose, water dispersability, and total moisture
content. The results are listed in Table I.
Examples 9-12
The specified amounts of dry ingredients were mixed in
a Forberg type mixer, having a four cubic foot capacity,
for about one minute. For diluted binders, the binder
solution was previously prepared in a 3.5 cubic foot rotary
drum mixer. The binder solution was then added to the
Forberg type mixer and then allowed to mix for another
minute.
The mixture was transferred to a Vibra Screwtm live
bin feeder having three cubic foot hopper and three inch
diameter screw. The material was continuously fed into a
36" diameter disc pelletizer at a rate as indicated in
Table I. For Examples 9-11, the pelletizer was operated at
a pan angle of 50 degrees from horizontal and a pan speed
of 26 rpm. For Example 12, the pelletizer was operated at
a pan angle of 59.5 degrees (from horizontal) and a pan
speed of 24 rpm.
The wet pellets were then fed into a continuous
vibrating fluidized bed dryer having a 9' x 1' perforated
tray. The fluidized bed utilized an oscillating tray to
convey the material. Hot air was blown through the
perforated tray at a rate of 1400 cfm and a temperature of
about 500 F to about 550 F. The hot air was utilized to
dry a 3"-4" deep bed (when fluidized) of granular
substrate. For Examples 9-11, the granular substrate was
fed to the fluidized bed at a rate of about 1200 pounds per
hour. For Example 12, the granular substrate was fed at a
CA 02310955 2000-06-05
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rate of about 400 pounds per hour. The granular substrates
were heated to a temperature of about 270 F to 300 F.
The finished product was collected and tested to
obtain bulk density, particle size, water dispersability,
RTA, and total moisture content. Additionally, the angle
of repose was measured for the resulting granular substrate
of Example 10. The results of each sample are listed in
Table I.
15
25
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18
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CA 02310955 2000-06-05
19
Examples 13-32
A series of examples were produced in the lab to
demonstrate the use of a variety of binders in the
composition of the present invention. In this series of
examples, the mineral component was 82.5 pounds of #60 dry
dolomite and the light weight additive was 17.5 pounds of
minus 40 mesh particle wood particle flour, except for the
example using the Polybind 300Mtm binder, in which 80
pounds of #60 dry dolomite and 20 pounds of minus 40 mesh
wood particle board flour were used. These dry based raw
materials were weighed out and placed in a Forberg type
mixer, having a four cubic foot capacity, made by Paul 0.
Abbe, Inc. of Little Falls, New Jersey. The mixer was run
for about 30 seconds in order to thoroughly mix the dry
materials before adding the specified binder composition.
The binder composition, in solution form, was added to the
materials over a 30 second time period and then mixed for
another 30 seconds.
The resulting wet mixture was then fed into a 36"
rotating pelletizing pan through an AccuRatetm volumetric
feeder. The feed rates to the pelletizer for each example
are listed in Table II. The pan angle was 56 (from
horizontal). The pan depth was maintained at about 4.5
inches, while the pan speed was 24 rpm. Additional water
was sprayed into the pelletizer to assist in the
agglomeration process. The substrates, in pellet form,
were collected from the pelletizing pan and placed in a Ty-
Labtm sieve shaker having several heat guns connected
thereto. The Ty-Labtm sieve shaker uses square sieves
approximately 16 inches on a side. The shaker was equipped
with four sieves for granular substrate conditioning-
6 mesh, 8 mesh, 16 mesh, and 30 mesh. The shaker was
operated to subject approximately a 4 pound batch of the
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granular substrates to approximately 5 vertical
oscillations per second, of an amplitude of about 1-i inch,
for a total of from 20-40 seconds and at a temperature of
about 220 F. The granular substrates were then heated to a
5 temperature of about 240 F to about 300 F in a conventional
lab oven to remove excess water.
The finished substrates where then tested to obtain
the bulk density, particle size, RTA, water dispersability,
and particle size distribution. The results of each sample
10 are listed in Table II.
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21
Table II.
Binder Ex. Pounds of Feed Bulk Density RTA Dispers- Wt. % Weight%
Binder Solids Rate Pounds/Cubic ability 12X30 Passing
Per 100 Lbs. Pnds Foot (12X30 (Minutes) 30
of Dry Ingred Per Material)
Hour
Brewers 13 11.5 540 44 90 1 20 30
condensed
solubles
Cane Molasses 14 12 600 48 -91.5 1 30 25
Cane Molasses 15 8 360 52 87.5 1 34 45
Cane Molasses 16 6 400 47 86 1 to 2 33 55
Beet Syrup 17 12 600 -56 -94 1 30 30
50 cane mol./ 18 10 480 57 93 1 35 35
50 beet syrup
Beet Molasses 19 12 900 50 -94 1 20 40
Beet Molasses 20 7 300 44 86 1 23 55
Desugared Beet 21 12 580 -53 -92 1 35 40
Mol.
Hydrolyzed 22 5 320 -47 93 1 37 35
Collagen
75 Soy 23 12 550 -49 -90 1 17 65
Solubles/
Cane Mol
60 Whey/ 24 12 500 51.5 -90 1 30 40
40 Cane Mol
60 Whey/ 25 10 360 54 96 2 35 25
25 40 Cane Mol
50 Whey/ 26 12 600 -50 95.5 1 35 40
50 Cane Mol
50 Whey/ 27 10 400 55 88 1 30 40
50 Cane Mol
Flambinder' 28 10 400 -48.5 97 1 60 10
Flambinder 29 8 400 -52 -94.5 1 47 33
Polybind 300MZ 30 10.3 600 -45 97 1 60 10
Cellubind 31 10 300 49.5 97 1 50 15
2000'
Polybind HC" 32 8 480 52 -92 2 50 35
1. Calcium Lignosulfonate from Fraser Papers, Inc. of Park Falls, Wisconsin.
2. Sodium carbonate lignin from Northway Lignin Chemical of Sturgeon Falls,
Ontario.
3. By-product of grain processing with about 75 weight % crude protein amino
acids, commercially available from Northway Lignin Chemical of Sturgeon
Falls, Ontario.
4. Hemi-cellulose extract commercially available from Northway Lignin Chemical
of Sturgeon Falls, Ontario.
CA 02310955 2000-06-05
22
Examples 33-34
Examples 33 and 34 were produced in the lab to
demonstrate the use of dry binders in the composition of
the present invention. In Example 33, the mineral
component was 82.5 pounds of #60 dry dolomite and the light
weight additive was 17.5 pounds of minus 40 mesh wood
particle board flour. In Example 34, the mineral component
was 84 pounds of #60 dry dolomite and the light weight
additive was 16 pounds of minus 40 mesh wood particle board
flour. These dry based raw materials, including the
specified dry binder, were weighed out and placed in a
Forberg type mixer, having a four cubic foot capacity, made
by Paul 0. Abbe, Inc. of Little Falls, New Jersey. The
mixer was run for about 30 seconds in order to thoroughly
mix the dry materials. Twenty pounds of water was added to
the dry materials over a 30 second time period and then
mixed for another 30 seconds. The resulting wet mixture
was then pelletized, conditioned and dried as with Examples
13-32.
The finished substrates where then tested to obtain
the bulk density, particle size, RTA, water dispersability
(disp.), and particl size distribution. The results of
each sample are listed in Table III.
Table III.
Binder Ex. Binder Feed Rate Bulk Density RTA Disp. Wt. 8 Weight%
Solids Pounds Pounds/Cubic (Min.) 12X30 Passing
Lbs./100 Per Hour Foot (12X30 30
Lbs. Dry Material)
Ingred
Peridur' 33 1.4 550 40 88 2 25 45
50 Peridur/ 34 2.8 200 49 -87 1 -50 -37
50 corn
starch
1. Sodium carboxymethyl cellulose based, water soluble polymer, commercially
3 5 available from Dreeland, Inc. of Denver, Colorado.
CA 02310955 2000-06-05
23
Examples 35-41
A series of examples were produced in the lab to
demonstrate the use of a variety of light weight additives
in the composition of the present invention. The samples
were prepared using the specified raw materials, which
were weighed out and placed in a Forberg type mixer, having
a 4 cubic foot capacity, made by Paul 0. Abbe, Inc. of
Little Falls, New Jersey. The mixer was run for about 30
seconds in order to thoroughly mix the dry materials before
adding the specified amount of the binder, brewers
condensed solubles. The binder composition, in solution
form having 4.5 pounds of solids per gallon, was added to
the materials over a 30 second time period and then mixed
for another 30 seconds.
The resulting wet mixture was then fed into a 36"
rotating pelletizing pan through an AccuRatetm volumetric
feeder. The feed rates to the pelletizer for each example
are listed in Table IV. The pan angle was 56 (from
horizontal). The pan depth was maintained at about 4.5
inches, while the pan speed was 24 rpm. Additional water
was sprayed into the pelletizer to assist in the
agglomeration process. The substrates, in pellet form,
were collected from the pelletizing pan and placed in a Ty-
Labtm sieve shaker having several heat guns connected
thereto. The granular substrates were conditioned in the
Ty-Labtm sieve shaker as in Examples 13-32, except that for
Examples 35-41, an approximately 2 pound batch was shaken
for about 90 seconds. The granular substrates were then
heated to a temperature of about 240 F to about 300 F in a
conventional lab oven to remove excess water.
CA 02310955 2000-06-05
24
The finished substrates where then tested to obtain
the bulk density, particle size, RTA, water dispersability,
and particle size distribution. The results of each sample
are listed in Table IV.
Table IV.
Examples 35 36 37 38 39 40 41
#60 Dolomite, Pounds 85 80 88 86.5 86.5 85 82.5
Oak Wood Dust (-40 Grade), 15 20 0 0 0 0 0
Pounds
Ground Wheat Straw, Pounds 0 0 12 13.5 0 0 0
Wood Particle Board Flour 0 0 0 0 0 0 15
(-40 Grade), Pounds
Wheat Straw Particle Board 0 0 0 0 13.5 15 0
Flour, Pounds
Omnicell, Pounds 0 0 0 0 0 0 5
Gallons of Brewer's Condensed 2.2 2.2 3 3 2.4 2.5 0
Solubles Per 100 Lbs. of Dry
Ingredients
Cane Molasses, Pounds of Solids 0 0 0 0 0 0 8
Per 100 Lbs. of Dry Ingredients
Feed Rate Pounds Per Hour 600 650 540 450 400 400 420
Bulk Density Pounds/Cubic Foot 52.6 47.6 48.8 54.5 48.4 47 -52
(12X30 Material)
RTA 96 83 97 79 90.8 87.4 92.6
Dispersability (Minutes) 1 1 1 NA 5 1 1
Weight % 12X30 48 43 NA 53.4 21.8 40 -46
Weight% Passing 30 18 12 NA 27 1.1 35 -46
1. Microcrystalline cellulose commercially available from Functional Foods of
Englishtown, New Jersey.
