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 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 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, it may also be preferable that
the carrier compound 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 lmm 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
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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 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
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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 preferably 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 water is preferred to
provide the active chemical agent to the soil.
SUNIIMARY 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 preferably selected from the group
consisting of dolomite and limestone. The light weight
additive 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 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
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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.
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
sufficiently high bulk density to provide the desired
ballistics upon application of the finished product. In
a first embodiment, 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 preferably capable of breaking down once exposed to
water.
In alternate embodiments, the granular substrate
preferably has a bulk density of 40 pounds per cubic
foot or less. Depending upon the desired application,
the granular substrate may or not be readily water
dispersible. In those applications where water
dispersibility is desired, it is preferred that the
granular substrates according to these embodiments of
the invention have a water dispersibility of about 5
minutes or less.
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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 object 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 55 pounds per cubic
foot or less at a particle size in accordance with
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 object of the present invention to
provide a manufactured granular substrate that does not
degrade during handling, yet preferably disintegrates
upon application and exposure to water.
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DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
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. In certain preferred
embodiments, 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 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. In these embodiments, 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
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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. In
these embodiments, 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 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
dispersibility 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,
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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. In these embodiments, 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 is such that the resulting
granular substrate has a resistance to attrition (RTA)
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,
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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 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 thoroughly mixed at conditions
which prevent degradation or compaction of the
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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 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 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
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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.
The size of particles is determined by the size
guide number/uniformity index system used in the
fertilizer industry. The substrates of the present
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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 dispersibility 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 every minute, the container is
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inverted. The granular substrate of the present
invention has a dispersibility 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, in these embodiments, 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.
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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 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,
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and total moisture content. The results of each sample
are listed in Table I.
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 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.
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 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
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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%.
The finished product was collected and tested to
obtain bulk density, particle size, crush strength, RTA,
angle of repose, water dispersibility, and total
moisture content. The results are listed in Table I.
Example 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 Screwt" 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
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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 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
dispersibility, 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.
TABLE I
EXAMPLE 1 2 3 4 5 6
POUNDS OF INGREDIENTS DOLOMITE 83.2 83.2 83.2 83.2 83.2 83.2
PER -100 POUND BATCH WHEAT FLOUR 7.6 7.6 11.4 11.4 11.4 7.6
WOOD FLOUR 0 7.6 7.6 7.6 11.4 7.6
FLY ASH 0 0 0 0 0 0
EXPANDED SILICA 9.2 0 0 0 0 0
LIQUID BINDERS(MILLILITER BREWERS CON-
PER -100 POUND BATCH) DENSED SOLUBLES 0 0 8256 8256 0 8256
LIGNOSULFONATE 8256 8256 0 0 8751 0
DILUTION 18% 18% 0% 10% 18% 0%
APPROX. FEED RATE TO PAN (POUNDS/HOUR) 503 360 600 570 600 600
WEIGHT % <14 AND >40 MESH 21.9 41.7 39.6 44 55.7 37.6
BULK DENSITY POUNDS/CUBIC FOOT (14 x 40 MAT'L) 47.8 48.8 49.2 45.2 41.5 47.1
% RESISTANT'PD A'ITRfI1ON (RrA) (14 x 40 MA'IERIAL) 87.5 96.2 97.6 92.5 87.5
93.1
CRUSH STRENGTH(POUNDS)(8 MESH PELLETS) 2 3.1 3.2 2.5 2.7 3
% MOISTURE DRY PELLETS 1.5 -1.5 1.5 -1.5 -1.5 -1.5
DISPERSABILITY (MINUTES) NA NA NA NA NA NA
ANGLE OF REPOSE NA NA NA NA NA NA
El{AMPLE 7 8 9 10 11 12
POUNDS OF INGREDIENTS DOLOMITE 83.2 83.2 90 83.2 83.2 85
PER -100 POUND BATCH WHEAT FLOUR 7.6 7.6 0 11.4 7.6 0
WOOD FLOUR 0 0 10 7.6 7.6 15
FLY ASH 7.6 7.6 0 0 0 0
EXPANDED SILICA 9.2 9.2 0 0 0 0
LIQUID BINDERS(MB,L[IlTER BREWERS CON-
PER -100 POUND BATCII) DENSED SOLUBLES 0 0 0 8256 0 8256
LIGNOSULFONATE 8884 8884 8256 0 8256 0
DILUTION 10% 10% 18% 0% 18% 0%
APPROX FEED RATE TO PAN (POUNDS/HOUR) 384 608 540 460 NA -400
WEIGHT % <14 AND >40 MESH 58 62 62.5 32.1 56.3 -10
BULK DENSITl' POUNDS/CUBIC FOOT (14 x 40 MATL) 47.5 50 49.9 48.4 50.9 46.9
% RESISTANT'PO AITRPIION (RTA) (14 x 40-MATERIAL) 94.5 92 92.6 97 97.4 97
CRUSH STRENG"IH(POUNDS)(8 MESH PELLETS) 1.5 2 NA NA NA NA
% MOISTTJRE DRY PELLETS -1.5 0.3 1.1 1.2 1.7 0.41
DISPERSABQ.fTY (MINUTES) NA <2 -1 <3 <3 <2
ANGLE OF REPOSE NA <35 NA 319 NA NA
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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 O. 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.
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The resulting wet mixture was then fed into a 36"
rotating pelletizing pan through an AccuRatet" 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 granular substrates to
approximately 5 vertical oscillations per second, of an
amplitude of about 1/2 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 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
dispersibility, and particle size distribution. The
results of each sample are listed in Table II.
CA 02385273 2002-05-07
Table II.
Binder Ex. Pounds of Binder Feed Rate Bulk Density RTA Dispersibility Wt. %
Weight%
Solids Per 100 Lbs. Pnds Per Pounds/Cubic (Minutes) 12X30 Passing 30
of Dry Ingred. Hour Foot(12X30
Material)
Brewers condensed 13 11.5 540 44 90 1 20 30
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./ 50 beet 18 10 480 57 93 1 35 35
syrup
Beet Molasses 19 12 900 50 -94 1 20 40
Beet Molasses 20 7 300 44 86 I 23 55
Desugared Beet Mol. 21 12 580 -53 -92 1 35 40
Hydrolyzed Collagen 22 5 320 -47 93 1 37 35
75 Soy Solubles/ 25 Cane 23 12 550 -49 -90 1 17 65
Mol
60 Whey/40 Cane Mol 24 12 500 51.5 -90 I 30 40
60 Whey/40 Cane Mot 25 10 360 54 96 2 35 25
50 Whey/50 Cane Mol 26 12 600 -50 95.5 I 35 40
50 Whey/50 Cane Mol 27 10 400 55 88 1 30 40
Flambinder (note 1) 28 10 400 -48.5 97 1 60 10
Flambinder 29 8 400 -52 -94.5 1 47 33
Polybind 300M (note 2) 30 10.3 600 -45 97 1 60 10
Cellubind 20003 (note 3) 31 10 300 49.5 97 1 50 15
Polybind HC (note 4) 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 02385273 2002-05-07
21
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 O. 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-
34.
The finished substrates where then tested to obtain
the bulk density, particle size, RTA, water
dispersibility (disp.), and particl size distribution.
The results of each sample are listed in Table III.
Table III.
Binder Ex. Binder Solids Feed Rate Bulk Density RTA Disp. Wt. % Weight%
Lbs./100 Lbs. Pounds Per Pounds/Cubic (Min.) 12X30 Passing
Dry Ingred. Hour Foot (12X30 30
Material)
Peridur (note 1) 33 1.4 550 40 88 2 25 45
50 Peridur/50 corn 34 2_8 200 49 -87 1 -50 -37
starch
1. Sodium carboxymethyl cellulose based, water soluble polymer, commercially
available from
Dreeland, Inc. of Denver, Colorado.
CA 02385273 2002-05-07
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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.
In each of these examples, light weight additive was
minus 40 mesh wood particle board flour. The dry based
raw materials 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-Lab" sieve shaker having several heat
guns connected thereto. The granular substrates were
conditioned in the Ty-Lab" sieve shaker as in examples
13-32, except that for examples 35-40, 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.
The finished substrates where then tested to obtain
the bulk density, particle size, RTA, water
dispersibility, and particle size distribution. The
results of each sample are listed in Table IV.
CA 02385273 2002-05-07
23
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), Pounds 15 20 0 0 0 0 0
Ground Wheat Straw, Pounds 0 0 12 13.5 0 0 0
Wood Particle Board Flour (-40 Grade), Pounds 0 0 0 0 0 0 15
Wheat Straw Particle Board Flour, Pounds 0 0 0 0 13.5 15 0
Omnicel, Pounds (note 1) 0 0 0 0 0 0 5
Gallons of Brewer's Condensed Solubles Per 100 Lbs.
of Dry Ingredients 2.2 2.2 3 3 2.4 2.5 0
Cane Molasses, Pounds of Solids Per 100 Lbs. of Dry
0 0 0 0 0 0 8
Ingredients
Feed Rate Pounds Per Hour 600 650 540 450 400 400 420
Bulk Density Pounds/Cubic Foot (12X30 Material) 52.6 47.6 48.6 54.5 48.4 47 -
52
RTA 96 83 97 79 90.8 87.4 92.6
Dispersibility (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.
In further alternate embodiments of the granular
substrate of the invention preferably has a bulk density
of about 40 pounds per cubic foot or less. In these
embodiments, there is typically a lower weight
percentage of the mineral component and a higher weight
percentage of the light weight additive and/or binder.
There is still preferably 10 wt. % or more of the
mineral component.
Depending on the desired application, these
granular_substrates preferably have a water
dispersibility of about 5 minutes or less, and more
preferably of about 3 minutes or less. In other desired
applications, for example as a carrier for certain
CA 02385273 2002-05-07
24
insecticides, it may be preferred that these granular
substrates not be readily water dispersible, with a
water dispersibility greater than 5 minutes and
preferably greater than 10 minutes. In addition, the
resulting granular substrate has an RTA value of at
least 80%, and most preferably of at least 85%.
Examples 42-46
A series of examples were produced in the lab to
demonstrate making pellets with reduced mineral
composition and lower bulk density. The samples were
prepared using the specified raw materials
(ingredients), which were weighed out and placed in a
Forberg type mixer, having a 4 cubic foot capacity, made
by Paul 0. Abbe, Inc. The mixer was run for about 30
seconds in order to thoroughly mix the dry materials and
then was run continuously during the addition of the
specified amount of liquid binder or water, which
required 40 to 60 seconds. The mixer was then run an
additional 30 seconds to thoroughly blend all
ingredients.
The resulting wet mixture was then fed into a 36
inch diameter rotating pelletizing pan through an
AccuRateTM volumetric feeder. The rates to the
pelletizer were adjusted to effect a high proportion of
12 mesh by 30 mesh pellets and were generally between
200 and 400 pounds per hour. The pan angle was about
55 from horizontal. The pan depth was maintained at
about 4.5 inches, while the pan speed was about 24 rpm.
Additional water was sprayed into the pelletizer to
assist in the agglomeration process. The substrates, in
pellet form, were then conditioned and dried as with
examples 13-32.
CA 02385273 2002-05-07
The finished substrates were then tested to obtain
the bulk density, RTA, and water dispersibility. The
results of each example are listed in Table V.
Table V.
Examples 42 43 44 45 46
#60 Dolomite, Pounds 34 37 25 25 10
Wood Particle Board Flour (-40 Grade), Pounds 25 25 25 25 35
Cane Molasses/CA Lignin (note 1) , Pounds 0 30 30 30 30
Warm Water (note 2) 25 3 0 0 6
Peridur 700 (note 3) 3 0 0 0 0
Peridur 730 (note 4) 9 0 0 0 0
Baka-Snak (note 5) 0 0 0 3.65 5
7
Bulk Density Pounds/Cubic Foot (12X30 Fraction) 22.1 26.3 25.15 26.3 17.2
8 RTA (12X30 Fraction) 96.8 86.4 81.6 91.6 91.8
Dispersibility (Minutes) 5 1 1 >10 >10
1. The cane molasses/calcium lignin blend is a liquid binder having 50% solids
overall, with 1/4 of the solids attributable to cane molasses and 3/4 of the
solids
attributable to Flambinder Calcium Lignosulfonate.
2. In examples 43 and 46, the water was first added to the liquid binder and
then
mixture was added to the Forberg mixer.
3. A dry sodium carboxymethyl cellulose based, water soluble polymer,
commercially
available from Dreeland, Inc. of Denver, Colorado.
4. A dry mixture of 7 parts Peridur sodium carboxymethyl cellulose based,
water
soluble polymer and 3 parts sodium carbonate.
5. A dry, pregelantinized, modified food starch available from National Starch
and
Chemical of Bridgewater, New Jersey.
