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US-12618179-B2 - Dedust compositions for treatment of mineral fibers

US12618179B2US 12618179 B2US12618179 B2US 12618179B2US-12618179-B2

Abstract

Dedust compositions suitable for use as dedust oil for mineral wool applications comprise a) from 95 percent by weight to 99.99 percent by weight of a triacyl glyceride sourced from a plant or animal oil, the triacyl glyceride having an IV of from 45 to 70, a viscosity at 30 C of from 30 mPa·s to 80 mPa·s, and a Solid Fat Content of 15% w/w or less at 10 C; and b) from 100 ppm to 2,500 ppm of an antioxidant. The dedust composition exhibits a flash point of at least 280 C. In aspects, the dedust composition is liquid at 23 C. In aspects, the triacyl glyceride is palm super olein.

Inventors

  • Ryan L. FLYNN
  • Frank P. Lochel
  • Peter James Tollington

Assignees

  • CARGILL, INCORPORATED

Dates

Publication Date
20260505
Application Date
20190221

Claims (19)

  1. 1 . A method of making a bonded mineral fiber-containing product comprising mixing a dedust composition exhibiting a flash point of at least 280° C. with a binder composition to form a binder/dedust mixture, wherein the dedust composition comprises: a) from 95 percent by weight to 99.99 percent by weight of a triacyl glyceride sourced from a plant or animal oil, the triacyl glyceride having an IV of from 45 to 70, the triacyl glyceride has an Oxidation Induction Time (OIT) of at least 22 minutes at 130 C, a viscosity at 30° C. of from 30 mPas to 80 mPas, and a Solid Fat Content of 15% w/w or less at 10° C., wherein the triacyl glyceride has not been chemically reacted to form a modified chemical compound per se; and b) from 100 ppm to 2,500 ppm of an antioxidant; applying the binder/dedust mixture to mineral fibers; collecting and compressing the mineral fibers in the shape of the desired product; and curing the binder, thereby forming the bonded mineral fiber-containing product.
  2. 2 . The method of claim 1 , wherein the dedust composition is liquid at 23° C.
  3. 3 . The method of claim 1 , wherein the triacyl glyceride is palm super olein.
  4. 4 . The method of claim 1 , wherein the dedust composition comprises from 98 percent by weight to 99.99 percent by weight of a triacyl glyceride.
  5. 5 . The method of claim 1 , wherein the triacyl glyceride has an IV of from 50 to 70.
  6. 6 . The method of claim 1 , wherein the triacyl glyceride has a Slip melting point of 21° C. or less.
  7. 7 . The method of claim 1 , wherein the triacyl glyceride has a viscosity at 30° C. of from 40 mPa's to 70 mPa's and the triacyl glyceride has a viscosity at 40° C. of from 30 mPa's to 60 mPa·s.
  8. 8 . The method of claim 1 , wherein the triacyl glyceride has a Solid Fat Content of 10% w/w or less at 10° C.
  9. 9 . The method of claim 1 , wherein triacyl glyceride has a Solid Fat Content of 25% w/w or less at 0° C.
  10. 10 . The method of claim 1 , wherein from 30 to 45 percent of the fatty acids of the triacyl glyceride are saturated fatty acids.
  11. 11 . The method of claim 1 , wherein the dedust composition comprises from 150 ppm to 2000 ppm of an antioxidant.
  12. 12 . The method of claim 1 , wherein the antioxidant comprises a hindered phenol.
  13. 13 . The method of claim 1 , wherein the antioxidant is selected from the group consisting of 2,4-dimethyl-6-octyl-phenol; 2,6-di-t-butyl-4-methyl phenol (i.e., butylated hydroxy toluene-BHT); 2-t-butyl-4-methoxyphenol and 3-t-butyl-4-methoxyphenol (BHA); 2,6-di-t-butyl-4-ethyl phenol; 2,6-di-t-butyl-4-n-butyl phenol; 2,4-dimethyl-6-t-butyl phenol; 4-hydroxymethyl-2,6-di-t-butyl phenol; n-octadecyl-beta (3,5-di-t-butyl-4-hydroxyphenyl) propionate; 2,6-dioctadecyl-4-methyl phenol; 2,4,6-trimethyl phenol; 2,4,6-triisopropyl phenol; 2,4,6-tri-t-butyl phenol; 2-t-butyl-4,6-dimethyl phenol; 2,6-methyl-4-didodecyl phenol; benzenepropanoic acid, 3,5-bis(1,1-dimethylethyl)-4-hydroxy-, C7-9-branched alkyl ester (Irganox L-135); 2,2′-methylene-bis(4-methyl-6-t-butyl phenol); 2,2′-methylenebis(4-ethyl-6-t-butyl phenol); 4,4′-methylene-bis(2,6-di-tert-butylphenol); 4,4′-bis(2,6-di-tert-butylphenol); 4,4′-bis(2-methyl-6-tert-butylphenol); 4,4′-butyldene-bis(3-methyl-6-tert-butyl phenol); 4,4′-isopropylidene-bis(2,6-di-tert-bulylphenol); 2,2′-methylene-bis(4-methyl-6-nonylphenol); 2,2′-isobutylidene-bis(4,6-dimethylphenol); 2,2′-methylene-bis(4-methyl-6-cyclohexylphenol); bis(3,5-di-tert-butyl-4-hydroxybenzyl); tris(3,5-di-t-butyl-4-hydroxy isocyanurate; tris(2-methyl-4-hydroxy-5-t-butylphenyl) butane; pentaerythritol tetrakis(3-(3,5-di-tert-butyl-4-hydroxyphenyl) propionate); hexamethylene bis[3-(3,5-di-tert-butyl-4-hydroxyphenyl) propionate]; thiodiethylene bis[3-(3,5-di-tert-butyl-4-hydroxyphenyl) propionate; 2,6-di-tert-dimethylamino-p-cresol; 2,6-di-tert-4-(N,N′-dimethylaminomethylphenol); 4,4′-thiobis(2-methyl-6-tert-butylphenol); 2,2′-thiobis(4-methyl-6-tert-butylphenol); and bis(3-methyl-4-hydroxy-5-tert-butylbenzyl)-sulfide.
  14. 14 . The method of claim 1 , wherein the antioxidant is selected from the group consisting of octadecyl-3,5-di-t-butyl-4-hydroxy-hydrocinnamate (NAUGARD 76, Uniroyal Chemical; IRGANOX 1076, Ciba-Geigy); tetrakis {methylene (3,5-di-t-butyl-4-hydroxy-hydrocinnamate)}methane (NAUGARD 10, Uniroyal Chemical; IRGANOX 1010, Ciba-Geigy); 2,2′-oxamido bis {ethyl-3-(3,5-di-t-butyl-4-hydroxyphenyl)}propionate (NAUGARD XL-1, Uniroyal Chemical); 1,2-bis(3,5-di-t-butyl-4-hydroxyhydrocinnamoyl) hydrazine (IRGANOX MD 1024,Ciba-Geigy); 1,3,5-tris(3,5-di-t-butyl-4-hydroxybenzyl)-s-triazine-2,4,6 (1H,3H,5H) trione (IRGANOX 3114,Ciba-Geigy); 1,3,5-tris(4-t-butyl-3-hydroxy-2,6-dimethylbenzyl)-s-triazine-2,4,6-(1H,3H,5H) trione (CYANOX 1790, American Cyanamid Co.); 1,3,5-trimethyl-2,4,6-tris(3,5-di-t-butyl-4-hydroxybenzyl)benzene (ETHANOX 330, Ethyl Corp.); 3,5-di-t-butyl-4-hydroxyhydrocinnamic acid triester with 1,3,5-tris(2-hydroxyethyl)-5-triazine-2,4,6 (1H,3H,5H)-trione, and bis(3,3-bis(4-hydroxy-3-t-butylphenyl) butanoic acid)glycolester.
  15. 15 . The method of claim 1 , wherein the dedust composition has a flash point of at least 285° C.
  16. 16 . The method of claim 1 , wherein the dedust composition further comprises an emulsifying agent.
  17. 17 . The method of claim 16 , wherein the emulsifying agent comprises a non-ionic emulsifier.
  18. 18 . The method of claim 1 , wherein the triacyl glyceride has a Slip melting point of from 10° C. to 21° C.
  19. 19 . The method of claim 1 , wherein the dedust composition has a flash point of from about 280° C. to about 400° C.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS This application is a national phase of International Application No. PCT/US2019018923, filed Feb. 21, 2019, which is hereby incorporated by reference herein in its entirety. FIELD The present invention relates to mineral fiber processing and dedust compositions. BACKGROUND Conventional fibers are useful in a variety of bonded fiber-containing products (i.e. products where fibers are bonded together by a binder composition), such as reinforcements, textiles, and acoustical and thermal insulation materials. Various fibers may be used in these products, including glass fibers; organic fibers such as polypropylene, polyester; and multi-component fibers may be used alone or in combination in forming the fiber-containing product. Fiberglass is a composite material comprising glass fibers. Glass fibers are hydrophilic, unless the fibers are modified by a surface treatment. Mineral wool is a composite material comprising mineral fibers. Mineral fibers are compositionally different from glass fibers material, and are also used in the above noted applications. Mineral fibers are made from rock (primarily basalt) and/or slag, and, unless modified by a surface treatment, are hydrophobic. Mineral fibers made from rock are also called “stone fibers.” Specific types of mineral wools include stone wool and slag wool (which are made from stone fiber or slag fiber, respectively). Dust is often liberated or generated during the formation of products made from glass fibers or from mineral fibers, such as products used for insulation, filtration, soundproofing, and the like. A dedust fluid is often applied to the glass or mineral fibers during the process to reduce this dust. The dust controlling oil remains on the fibers and continues to control dust during transport and installation of the product. Mineral-oil based fluids are often utilized as dedust fluids. In particular, a category of solvent-extracted mineral base oils known as “bright stock” has been used as a dedust composition in stone fiber processing. The use of polymerized oil as a dust control agent is described in US Patent Application Publication No. 2007/0004811 to Bruner et al. SUMMARY Historically, dedust fluids have been prepared from petroleum sources, and in particular mineral-oil based fluids are often utilized as dedust fluids. It is desirable to identify dedust fluids that are sourced from renewable resources, such as plant-based oils or animal-based oils. In an aspect of the present invention, a dedust composition is provided that is suitable for use as dedust oil for mineral wool applications. In an aspect, the dedust composition comprises a) from 95 percent by weight to 99.99 percent by weight of a triacyl glyceride sourced from a plant or animal oil, the triacyl glyceride having an IV of from 50 to 70, and a viscosity at 30° C. of from 30 mPa·s to 80 mPa·s; and b) from 100 ppm to 2,500 ppm of an antioxidant; wherein the dedust composition exhibits a flash point of at least 280° C. In an aspect, a dedust composition suitable for use as dedust oil for mineral wool applications is provided comprising a) from 95 percent by weight to 99.99 percent by weight of a triacyl glyceride, the triacyl glyceride having an IV from 50 to 70, and a viscosity at 30° C. of from 30 mPa·s to 80 mPa·s; and b) from 100 ppm to 2,500 ppm of an antioxidant; wherein the dedust composition exhibits a flash point of at least 280° C., and wherein the dedust composition is liquid at 23° C. In an aspect, a dedust composition suitable for use as dedust oil for mineral wool applications is provided comprising a) from 95 percent by weight to 99.99 percent by weight palm super olein; and b) from 100 ppm to 2,500 ppm of an antioxidant. The dedust compositions as described herein advantageously are compatible with and very effective for use with mineral wool. Moreover, the present dedust compositions may be prepared from readily available materials that require little or no additional processing or chemical reaction that may introduce undesirable byproducts or contaminants. Because the present triacyl glycerides may be made using animal or plant-based oils (which are a renewable resource), the present dedust compositions are natural in origin and more readily biodegradable. DETAILED DESCRIPTION The aspects of the present invention described below are not intended to be exhaustive or to limit the invention to the precise forms disclosed in the following detailed description. Rather a purpose of the aspects chosen and described is by way of illustration or example, so that the appreciation and understanding by others skilled in the art of the general principles and practices of the present invention can be facilitated. For purposes of the present invention, “Flash Point” or “Flash Point Temperature” is a measure of the minimum temperature at which a material will initially flash with a brief flame. It is measured according to the method of ASTM D-92