AU2014216039A1 - Composition, System and Method for Treating an Exhaust Gas - Google Patents

Abstract

-31 Abstract A composition including a first part which is combinable with a second part for the treatment of exhaust in a scrubber box, the first part including a surfactant, a solvent and an alkali and the second part including a defoaming agent. In some examples, the first part further includes an emulsifying surfactant and water. The first part may include from about 1 part to 20 parts of the surfactant, about 1 part to 30 parts of the emulsifying surfactant, about 1 part to 20 parts of the solvent and about 1 part to 15 parts of the alkali with the balance being the water to create a total of about 100 parts. The defoaming agent of the second part may include at least one of an oil, a silicone defoamer, an ethylene oxide compound and a propylene oxide compound and in some examples the silicone defoamer is a silicone emulsion. There is also disclosed a method of treatment of an exhaust gas utilising the composition as well as a system for combining the first part and the second part so as to form a treatment chemical for use within an exhaust treatment apparatus to treat the exhaust gas. Dosing Dosing Pressure FiIe Device A Device B Regulator Fle Pressurised Water Source Composition Composition Part A Part B Treatment Composition Header Tank Scrubber Box Figure 1

Description

-1 COMPOSITION, SYSTEM AND METHOD FOR TREATING AN EXHAUST GAS Technical Field [001] The invention relates to a chemical composition for the treatment of exhaust gases, a method for using a chemical composition to treat exhaust gases and a system utilising a chemical composition for the treatment of exhaust gases. Background [002] Motors or other exhaust emitting devices and processes are often used to power equipment in environments where there is restricted air supply or circulation. For example, diesel motors are often used in the underground environment and the diesel exhaust which includes particulate matter is emitted to the underground atmosphere. [003] Diesel exhaust gasses contain oily fuel residues, unburned fuel vapour and solid material including very fine, carbonaceous diesel particulate matter. Exposure to diesel exhaust particulate matter may be hazardous to humans. Some studies have even suggested that diesel particulate matter may be a carcinogen, although these studies are based on limited evidence of carcinogenicity from studies in humans and supporting evidence from studies in experimental animal and mechanistic studies. [004] Accordingly, it is desirable to reduce or control the particulate matter emitted from a diesel engine. One type of arrangement to control the emission of diesel particulate matter is a scrubber box. [005] Scrubber boxes generally include a cylindrical or rectangular shaped housing for containing a scrubbing fluid. The housing includes an inlet through which exhaust gasses enter the scrubber and an outlet through which the exhaust gasses leave the scrubber. The housing may also contain baffles to direct the flow of the exhaust gas through the scrubber.

-2 [006] The scrubber typically contains water through which the exhaust gases pass. The environment inside a diesel scrubber box is aggressive and very difficult to work with. The hot gasses bubbling through the water solution generate high temperatures and strong agitation, creating a difficult environment in which to maintain stability. [007] The primary purposes of scrubber boxes are: to act as a safety barrier against flame out from the motor; to cool the exhaust gasses and absorb any soluble gasses; and to precipitate the vapours and oily residues from the exhaust. [008] The oily residues captured by the water in the scrubber box, in particular oily hydrophobic material, settle on the exhaust system plates on the baffle and sides of the box creating inefficiencies in the operation of the scrubber and difficulties in maintaining the system. Accordingly, it is also necessary to maintain and clean the scrubber box. [009] In an attempt to maintain the cleanliness of the scrubber box additives may be introduced into the water. These additives are typically simple solutions of alkaline salts - commonly sodium metasilicate. These additives are generally not effective in the cleaning of the scrubber box. Accordingly, the scrubber box is required to be cleaned on a regular, often weekly basis. Furthermore, this configuration of a scrubber box including water with an alkaline salt additive is generally not effective in sufficiently reducing the diesel particulate matter which is emitted from the scrubber box. Accordingly, a diesel particulate filter is often fitted between the scrubber box and the exhaust to pre-filter the exhaust prior to the exhaust entering the scrubber box. [0010] Diesel particulate filters typically include an inlet which couples to the exhaust, an outlet which couples to the scrubber box and filter media located between the inlet and the outlet. The filter media is adapted to capture particulate matter from the exhaust gas. [0011] Diesel particulate filters, however, have several disadvantages. In particular, the particulate filter is a consumable item as the filter media becomes clogged or saturated in a relatively short period of time. Accordingly, the particulate filter is required to be changed on a regular basis, and in some instances may be changed -3 every shift, which results in a significant cost as well as a significant environmental waste. Furthermore, whilst the diesel particulate filter assists to reduce the particulate matter entering the scrubber box, the particulate filter plays no role in assisting to maintain the overall cleanliness and function of the scrubber box. As such, regular downtime is still required to maintain the cleanliness and functionality of the scrubber box. [0012] The invention described herein seeks to address or overcome the above problems and disadvantages or at least provide a useful alternative. Summary [0013] In a first aspect there is provided, a composition including a first part which is combinable with a second part for the treatment of exhaust in a scrubber box, the first part including a surfactant, a solvent and an alkali and the second part including a defoaming agent. [0014] In another aspect, the first part further includes an emulsifying surfactant. [0015] In another aspect, the first part includes water. [0016] In another aspect, the first part includes from about 1 part to 20 parts of the surfactant, about 1 part to 30 parts of the emulsifying surfactant, about 1 part to 20 parts of the solvent and about 1 part to 15 parts of the alkali with the balance being the water to create a total of about 100 parts. [0017] In another aspect, the surfactant includes at least one of a non-ionic surfactant, anionic surfactant and an amphoteric surfactant. [0018] In another aspect, the non-ionic surfactant includes at least one of a Cs-Cis alkyl compound, a Cs-Cis primary alcohol and a Cs-Cis fatty acid. [0019] In another aspect, the non-ionic surfactant includes a C 8

-C

16 alkyl polyglucoside.

-4 [0020] In another aspect, the surfactant includes between about 1 part and 3 parts of the C 8

-C

16 alkyl polyglucoside. [0021] In another aspect, the emulsifying surfactant includes at least one of a C 8

-C

2 2 fatty acid ester type emulsifier, a C 8

-C

2 2 fatty acid condensed with 3-12 mole ethylene oxide and a fatty amine ethoxylate. [0022] In another aspect, the C 8

-C

2 2 fatty acid ester type emulsifier is a polyethylene glycol ester. [0023] In another aspect, the emulsifying surfactant includes between about 5 parts and about 15 parts of the polyethylene glycol ester. [0024] In another aspect, the solvent includes at least one of a co-solvent glycol ether and an ester solvent. [0025] In another aspect, the co-solvent glycol ethers include at least one of alkyl glycol ethers, dialkyl glycol ethers and alkyl glycol ethers esters. [0026] In another aspect, the ester solvent includes methyl methoxy butanol. [0027] In another aspect, the solvent includes between about 8 parts and 10 parts of the methyl methoxy butanol. [0028] In another aspect, the alkali includes at least one of an alkali salt and an organic alkali. [0029] In another aspect, the organic alkali includes an organic alkanolamine. [0030] In another aspect, the alkanolamine includes at least one of monoethanolamine, diethanolamine, triethanolamine or isopropanolamine. [0031] In another aspect, the alkali includes between about 2 parts and about 5 parts monoethanolamine.

-5 [0032] In another aspect, the defoamer of the second part includes at least one of an oil, a silicone defoamer, an ethylene oxide compound and a propylene oxide compound. [0033] In another aspect, the silicone defoamer is a silicone emulsion. [0034] In another aspect, the silicone emulsion is based on polydimethylsiloxane. [0035] In another aspect, the second part includes about 20 parts to about 30 parts of the silicone emulsion with the balance being water to create a total of about 100 parts. [0036] In accordance with yet another aspect there is provided, a two part chemical product including a first part and a second part as defined above. [0037] In accordance with yet another aspect there is provided, a method for treating exhaust gas to reduce particulate matter carried by the exhaust gas using a first part and a second part as defined above, the method including the steps of combining the first part and second part to form a treatment composition and introducing the treatment composition to an exhaust treatment apparatus such that the exhaust gas passing through the exhaust treatment apparatus contacts treatment composition so as to the reduce particulate matter carried by the exhaust gas. [0038] In another aspect, the first part and second part are combined prior to being introduced into the exhaust treatment apparatus. [0039] In another aspect, the first part and second part are combined prior after being introduced into the exhaust treatment apparatus. [0040] In another aspect, the first part is diluted with water at a ratio of about 1:25 to about 1:250. [0041] In another aspect, the second part is diluted with water at a ratio of about 1:2000 to about 1:3000.

-6 [0042] In still yet another aspect there is provided a system for combing a first part and a second part as defined above so as to form a treatment chemical used in an exhaust treatment apparatus, wherein the system includes a first dosage unit and a second dosage unit which configured to output to the exhaust treatment apparatus, the first dosage unit being configured to provide a diluted first part by mixing the first part with a first fluid at a ratio of about 1:25 to about 1:250 and the second dosage unit being configured to provide a diluted second part by mixing the second part with a second fluid at a ratio of about 1:2000 to about 1:3000 such that the diluted first and second parts are outputted to the exhaust treatment apparatus so as to form the treatment chemical. [0043] In another aspect, the first dosage unit and the second dosage unit are arranged in series with the second dosage unit feeding the first dosage unit, wherein the second fluid is water and the first fluid is the diluted second part. [0044] In another aspect, the first fluid is water and the second fluid is water. [0045] In another aspect, the system includes a first container in communication first dosage unit and containing the first part, and a second container in communication second dosage unit and containing the second part. [0046] In another aspect, the exhaust treatment apparatus is a scrubber, the scrubber having a header and the first dosage unit and second dosage unit are in communication with the header so as to deliver the diluted first part and diluted second part to the header so as to form the treatment chemical within header. Brief Description of the Figures [0047] The invention is described, by way of non-limiting example only, by reference to the accompanying figures, in which; [0048] Figure 1 is a schematic diagram of a dosing system for introducing the composition into the scrubber box; and -7 [0049] Figure 2 is a side view illustrating an exhaust treatment system including a scrubber box in which the composition is received in use. Detailed Description [0050] The example forms of a treatment composition disclosed herein have been developed to capture fine diesel particulate matter and oily vapours which enter an exhaust cleaning apparatus, such as a scrubber box compartment. [0051] During development of the examples of the treatment composition disclosed herein it was determined that effective capture of the particulate matter could be achieved by wetting and emulsifying of the exhaust particulate matter as the exhaust matter as it enters the scrubber box compartment. The wetting was accomplished by using one or more surfactants, also known as wetting agents, and the emulsifying was accomplished by using one of more emulsifying surfactants. The surfactants and the emulsifying surfactants may be considered as a surfactant blend. [0052] However, when introducing the surfactant blend into the scrubber box significant foam was generated. The foam generated may be at least partially attributed to the turbulent environment within the scrubber box. The generation of foam is found to have a negative effect on the operation of the surfactants blend in capturing the particulate matter from the exhaust. [0053] Accordingly, it was deemed necessary to introduce a de-foaming agent into the surfactant blend. However, the defoaming agents were not stable in the surfactant blend solution and there were difficulties incorporating the defoaming agent within the surfactant blend to maintain effectiveness at the envisaged dilution rate necessary for practical operation. [0054] As such, the composition, in particular, the chemical treatment composition for treatment of particulate matter from exhaust gas, was developed so as to include a first part or Part A including the surfactant blend which is combinable, during, prior to or immediately prior to use, with a second part or Part B including a defoaming agent. A method and system were also developed to combine the first part and the second -8 part at the appropriate dilutions to form a treatment composition and introduce the treatment composition into the scrubber box. [0055] As will be further detailed below, in some examples, the first part includes one or more surfactants (wetting agents), one or more solvents which may be soluble in water and in mineral oils and one or more alkali or alkaline ingredients. The first part may also include one or more emulsifying surfactants and water. The second part may be a defoaming agent which is combined with the first part prior to, immediately prior to or during the exhaust treatment. [0056] The examples and data provided herein provide the constituents or ingredients of the composition using "parts per 100" nomenclature. In particular, a mass per volume basis has been used with the parts being kg per 100 Litres. Accordingly, within this specification, for example, 5 parts means about 5 kg of about 100 Litres. It is also noted that the S.G. (Specific Gravity) of the ingredients is typically close to 1. Therefore, the 5 parts may also be considered substantially equal to 5 litres and hence a volume % of about 5%. Likewise, the 100 Litres may be considered about 100 kg and therefore the wt% may, in this example, be considered about 5%. [0057] The amounts and ratios of the various ingredients in the first part and the second part may vary. However, in the examples provided herein the ingredients are generally in the following ratios and volumes. The first part includes from about 1 part to about 20 parts of the surfactant, about 1 part to about 30 parts of the emulsifying surfactant, about 1 part to about 20 parts of the solvent and about 1 part to about 15 parts of the alkali with the balance being the water to create a total of about 100 parts. [0058] The first part has been developed as an optimised blend of ingredients designed to provide efficient wetting and emulsification of the oily residues and gasses in the diesel exhaust and the second part provides optimisation of the formula and effective defoaming of the system once blended at the proposed dilution rates. The system and method of incorporation the first part and the second part is important to the success of the exhaust gas treatment and is also proposed.

-9 [0059] As detailed above the composition includes a first part and a second part. Within the text below the first part is referred to as Part A and the second part is referred to as Part B. Details for each of the ingredients of Part A and Part B are now provided below followed by examples of specific forms of Part A and Part B along with experimental results. Composition - Part A (First Part) Surfactants [0060] Part A may include one or more surfactants. The primary surfactants (wetting agents) may be from about 1 part to about 20 parts of Part A and may be non-ionic, anionic or amphoteric in nature or a combination of non-ionic and anionic or non ionic and cationic. [0061] Suitable non-ionic surfactants may comprise: * Cs-C1 7 Alkyl Ethoxylated and Alkylphenol Ethoxylated compounds condensed with 3-16 moles ethylene oxide * Cs-Cis primary alcohols condensed with 3-16 moles of ethylene or propylene oxide; * C 8

-C

16 alkyl polyglucosides; * Mono-, di-, or tri- ethanolamine salts of Cs-Cis fatty acids. [0062] Suitable anionic surfactants may comprise: * Alpha olefin sulphonates; * Alkaline salts of sulphuric or sulphonic acid esters of C 8

-C

16 fatty alcohols; (e.g sodium Lauryl ether sulphate); * Sodium salts of sulphonated vegetable oils (e.g sulphonated castor oil); * Alkali neutralised alkylaryl sulphonates (e.g. Sodium dodecylbenzene sulphonate isopropylamine dodecylbenzene sulphonate); * Secondary alkyl sulphonates; and -10 Alkali salts of sulphosuccinate ester (eg sodium dioctyl sulphosuccinate). [0063] Suitable amphoteric surfactants may comprise: * C 8

-C

16 amidopropyl betaine * Sodium salts of alkyl aminoacetate and aminoproprionates * Hydroxyethyl, aminoethyl, and amidoethyl imidazoline [0064] It is preferable that the surfactant is a non-ionic surfactant that Part A includes between about 1 part and 10 parts of the non-ionic surfactant. It is more preferable that the non-ionic surfactant includes a C 8

-C

16 alkyl polyglucoside and that Part A includes between about 1 part and 3 parts of the C 8

-C

16 alkyl polyglucoside. Emulsifying surfactants [0065] Part A may also include one or more emulsifying surfactants. The emulsifying surfactants may comprise from about 1 part to about 30 parts of Part A and may include: * Glycerol, ethylene, diethylene and polyethylene glycol esters of fatty acids with a carbon chain length ranging from 8-22. Some examples may be PEG 200 mono oleate, diethylene glycol mono oleate, PEG 400 mono oleate, PEG 400 mono laurate, PEG 400 di oleate, PEG 600 mono oleate, glycerol mono stearate; * C 12 -Cis Fatty acids condensed with 3-12 mole ethylene oxide; * Fatty amine ethoxylates. [0066] Preferably, the emulsifying surfactant is a C 8

-C

2 2 fatty acid ester type emulsifier. More preferably, the C 8

-C

2 2 fatty acid ester type emulsifier is a polyethylene glycol ester and Part A includes between about 5 parts and about 15 parts of the polyethylene glycol ester.

-11 Solvents [0067] Part A may also include solvents in the range of about 1 part to about 20 parts. The solvents may be chosen so as to be water-soluble and oil soluble and act to increase the efficiency of the solubilisation of the oily components in the scrubber box. Suitable solvents may include: Alkyl glycol ethers; o Ethylene glycol monomethyl ether; o Ethylene glycol monoethyl ether; o Ethylene glycol monopropyl ether; o Ethylene glycol monoisopropyl ether; o Ethylene glycol monobutyl ether; o Ethylene glycol monophenyl ether; o Ethylene glycol monobenzyl ether; o Propylene glycol monomethyl ether; o Diethylene glycol monomethyl ether; o Diethylene glycol monoethyl ether; o Diethylene glycol mono-n-butyl ether; o Dipropylene glycol monomethyly ether; * Dialkyl glycol ethers; o Ethylene glycol dimethyl ether; o Ethylene glycol diethyl ether; o Ethylene glycol dibutyl ether; * Alkyl glycol ethers esters; o Ethylene glycol methyl ether acetate; o Ethylene glycol monethyl ether acetate; and o Ethylene glycol monobutyl ether acetate; * Estersolvents o Methyl methoxy butanol [0068] In one example form, the solvent includes at least one of a co-solvent glycol ether and an ester solvent. Where the co-solvent glycol ethers are utilised, these may -12 include at least one of alkyl glycol ethers, dialkyl glycol ethers and alkyl glycol ethers esters. Preferably, within Part A the co-solvent glycol ethers are the range of about 5 parts to about 15 parts. In other example forms, ester solvents are utilised and may include methyl methoxy butanol. Most preferably, Part A includes between about 8 parts and about 10 parts of the methyl methoxy butanol solvent. Alkaline ingredients [0069] Part A also includes an alkali ingredient that is used to increase the emulsification and saponification of any oils coming into the scrubber system from the exhaust gasses. Part A may include about 1 part to about 15 parts of the alkali. [0070] The alkali may be an inorganic alkali salt such as: Sodium hydroxide, potassium hydroxide, sodium silicate, sodium or potassium phosphates, sodium carbonate, alkali salts of ethylendiaminetetraacetic acid, Nitrilotriacetic acid or diethylenetriaminepentaacetic acid; and/or organic alkalis including: Monoethanolamine, diethanolamine, triethanolamine or isopropanolamine. [0071] Preferably, the alkali is an organic alkali and Part A includes between about 1 part and about 10 parts of the organic alkali. In some examples, the organic alkali includes an organic alkanolamine. The alkanolamine may include at least one of monoethanolamine, diethanolamine, triethanolamine or isopropanolamine. In a most preferred form, the Part A includes between about 2 parts and about 5 parts monoethanolamine. Composition - PART B (Second Part) [0072] During initial experimental testing of Part A, the foam generated in the system was found to be difficult to quell. Surprisingly, it was found that a separate Part B including a defoamer was required to be added to Part A, prior to, immediately prior to or during the composition being introduced in the scrubber box. [0073] Accordingly, Part B includes agents designed to de-foam the scrubber box contents effectively throughout its cycle of use, agents to stabilise the emulsion in its -13 concentrated form and agents to optimise the compositions. It was found that suitable defoamers were hydrophobic entities that were solubilised or emulsified to allow them to blend in the system. Examples of these defoamers are provided below. [0074] Suitable defoamers may be: a range of vegetable oils, mineral oils, white oil or any other oil that is insoluble in the system except silicone oils. To these oil may be added waxes such as: ethylene bis stearamide (EBS), paraffin waxes, ester waxes and fatty alcohol waxes. These products may also have surfactants to improve emulsification and spreading in the foaming medium or solvents such as 2-Ethylhexanol, Dipropyleneglycol Monomethylether, 2 Butoxyethanol, Propylene Glycol. * Silicone defoamers based on Polydimethylsiloxane with viscosities from 50-60,000, and emulsified to allow even dispersion throughout the system * Ethylene oxide or propylene oxide compound containing polyethylene and polypropylene glycol delivered as water based emulsions; * Ethoxylated Acetylenic Diols such as Tetramethyl-5-decyne-4,7-diol, 2,4,7,9-, either in its pure form or blended with solvents such as 2 Ethylhexanol, Dipropyleneglycol Monomethylether, 2-Butoxyethanol, Propylene Glycol. [0075] In a preferred example form, the silicone defoamer is a silicone emulsion and Part B includes between about 20 parts to about 30 parts of the silicone emulsion with the balance being water to create a total of about 100 parts. In more preferred forms, the silicone emulsion is based on polydimethylsiloxane and Part B includes about 25 parts of polydimethylsiloxane. [0076] Example compositions are now described in further detail below. Experimental test results which demonstrate be advantageous properties of the examples are provided in the section after the example section.

-14 Composition Example 1 [0077] Referring to Table 1, Part A may include about 80.5 parts water, about 2 parts of Cs-Cio Alkyl Poly Glucosides, about 1 part of C 1 2 Alcohol Ethoxylate, about 1 part of Laureth 4 (Laureth-4 is a synthetic polymer composed of lauryl alcohol and PEG (polyethylene glycol) with a molecular formula of C 2 0

H

4 2 0 5 ), about 3 parts Monoethanolamine, about 6.5 parts of Ethylene Glycol Monobutyl ether and about 6 parts of sodium Metasilicate Pentahydrate. [0078] In Example 1, the surfactants are provided in the form of Cs-Cio Alkyl Poly Glucosides, and the C 12 Alcohol Ethoxylate, the emulsifying surfactant is provided in the form of Laureth 4, the solvent is provided in the form of Ethylene Glycol Monobutyl ether and the alkali is provided in the form of monoethanolamine and Sodium Metasilicate Pentahydrate. [0079] In Example 1, Part B includes about 75 parts water and about 25 parts silicone emulsion which in this example is based on polydimethylsiloxane. COMPONENT PARTS PER 100 Part A Water 80.50 Cs- CIO Alkyl Poly Glucoside 2.00

C

12 Alcohol Ethoxylate 1.00 Laureth 4 1.00 Monoethanolamine 3.00 Ethylene Glycol Monobutyl ether 6.50 Sodium Metasilicate Pentahydrate 6.00 Part B Parts per 100 Water 75 Silicone emulsion (30%) 25 Table 1 - Composition Example 1 Composition Example 2 [0080] Referring to Table 2, in Example 2, Part A may include about 71 parts water, about 4 parts of 244 PEG 400 di Oleate, about 9 parts of 241 PEG 400 mono Oleate, about 2 parts of Cs- CIO Alkyl Poly Glucoside, about 1 part of C 12 Alcohol -15 Ethoxylate, about 10 parts of Methyl Methoxy Butanol and about 3 parts of Monoethanolamine. [0081] In Example 2, the surfactants are provided in the form of C 8 -Cio Alkyl Poly Glucosides and the C 12 Alcohol Ethoxylate, the emulsifying surfactant is provide in the form of PEG 400 di Oleate and PEG 400 mono Oleate, the solvent is provided in the form of Methyl Methoxy Butanol and the alkali is provided in the form of monoethanolamine. [0082] Similar to Example 1, in Example 2, Part B includes about 75 parts water and about 25 parts silicone emulsion which in this example is based on polydimethylsiloxane. COMPONENT PARTS PER 100 Part A Water 71.00 244 PEG 400 di Oleate 4.00 241 PEG 400 mono Oleate 9.00 Cs- CIO Alkyl Poly Glucoside 2.00

C

12 Alcohol Ethoxylate 1.00 Methyl Methoxy Butanol 10.00 Monoethanolamine 3.00 Part B Parts per 100 Water 75 Silicone emulsion (30%) 25 Table 2 - Composition Example 2 Experimental Results [0083] Experimental results of Example 1 and Example 2 of the treatment composition are now provided. The experimental results highlight the surprising and advantageous properties of the treatment composition including Part A and Part B as have been described above.

-16 Testing Setup [0084] Experimental testing of the subject compositions was performed with a scrubber box fitted to the exhaust of diesel motor powered vehicle. In this experiment, the vehicle was a DMS Coaltram (Model No. #CT907) which is powered by a typical diesel motor used in underground coal operations. The approved gas test that is performed on all diesels (as governed by Australian Department of Resources) is called a 'Rev Change Test'. [0085] In this test, an analysis probe is placed near the exhaust pipe and records the emission levels. The test runs through a 60 second cycle, 20 seconds at idle RPM, 20 seconds at 'full load' (high RPM) and then again 20 seconds at idle RPM. From this a Maximum, Minimum and Average particulate level in mg/m 3 is provided. [0086] For the testing conducted a controlled approach was undertaken, this was achieved by keeping the RPM steady at 1500 for the 60 second test. This results in a 'worst case' scenario for particulate emissions. The probe remained in the same position for all tests. The machine was run for 10 minutes after the test composition was added. This was to ensure maximum exposure within the scrubber box. Test 1 (Control) [0087] The scrubber and header tank water were evacuated and both were cleaned with fresh water prior to commencing the test. This was conducted to ensure there was no cross contamination from previous scrubber additives. Fresh water was then introduced into the header and scrubber tank with no chemical additives. A first control exhaust gas test was then performed at 1500 PRM for 60 seconds. [0088] Referring to Table 3, for Test 1 the average particulate emission from the scrubber using the control was 54.6 (mg/m 3

).

-17 Test 2 to 5 (Example 1 and Example 2 Treatment Chemical Compositions) [0089] Test Number 2 to 5 were conducted using Example composition 1, Part A and Part B, and Example composition 2, Part A and Part B. Part A and Part B were then diluted using water. [0090] The compositions were mixed in 20L drums to the correct dosage/ concentration and then poured into both the scrubber tank (40L) and header tank (60L) to give a total of 1OOL in the exhaust scrubbing system. After each test, the water was dumped from the system to ensure no cross contamination. [0091] Test 2 included Example 1 Part A being diluted at 1:100 with water and Part B being diluted at 1:2500 with water. The diluted Part A and Part B were then introduced into the scrubbed box and the test was conducted. Referring to Table 3, for Test 2, the average particulate emission from the scrubber using the control was 20.8 (mg/m 3 ). [0092] Test 3 included Example 2 Part A being diluted at 1:100 with water and Part B being diluted at 1:2500 with water. The diluted Part A and Part B were then introduced into the scrubbed box and the test was conducted. Referring to Table 3, for Test 3, the average particulate emission from the scrubber using the control was 18.9 (mg/m 3 ). [0093] In Test 4 and 5, the Example 2 Part A and Part B were again tested. However, in Test 4 Part A was diluted at 1:80 and in Test 5 Part A was diluted at 1:50. In both cases, Part B remained at a dilution of 1:2500. From Table 3, Test 4 produced an average particulate emission from the scrubber of 17.6 (mg/m 3 ) whilst Test 5 produced an average particulate emission from the scrubber of 16.7 (mg/m 3 ). Test 6 (Example 2 - Rev Change Test) [0094] Test 6 was a Rev Change test (as detailed above in the 'Testing Setup') using the Example 2 composition with Part A diluted 1:50 and Part B diluted at 1:2500. The -18 results of Test 6 were used to compare with quarterly emissions results data as shown below in Table 6. Results Test Notes Max (mg/m 3 ) Min (mg/m 3 ) Avg (mg/mn) Clean water, No Additives, No Test 1 (control) Particulate filter, 78 21.1 54.6 1500 rpm 60 seconds Example 1: Part A Test 2 1:100, Part B (Ex. 1) 1:2500, 10 33.0 9.9 20.8 Minute warm up, 1500 rpm 60 Example 2 Part Test 3 A 1:100, Part B (Ex.2) 1:2500, 10 Minute 36.7 8.9 18.9 warm up, 1500 rpm 60 seconds Example 2, Part A Test 4 (Ex. 2 1:80, Part B 1:2500, 10 30.8 7.2 17.6 Minute warm up, 1500 rpm 60 Example 2, Part A Test 5 (Ex.2 1:50, Part B 1:2500, 10 26.4 6.7 16.7 Original @ 1:50) Miuewrup Minute warm up, 1500 rpm 60 Test 6 (Ex. 2 @ Part A 1:50, Part B 1:50 1:2500, 20 19.1 2.5 7.4 Rev Change Test) soead, 20 se Idle Table 3 - Experimental Results [0095] From Table 3 it may be appreciated that Example 2 of the composition produced the lowest diesel particulates using the 1500 rpm 60 second test. From Test result 3, the concentration of Part A was then increased to see whether a greater reduction could be achieved. Test 4 and 5 were mixed at 1:80 and 1:50 respectively.

-19 [0096] While the composition mixture for Test 6 was still present in the scrubber box, a Rev Change test was carried out. This resulted in an average particulate level of 7.4 mg/m 3 . See 'Rev Change Test Comparison Results' page 4 of this report. Results Comparison [0097] The table below represents a comparison of each test against the control test. The percentage reduction is calculated in the following way. Avg (mg/n 3 ) Difference (mg/m3) % Reduction Test 1 (Control) 54.6 0 0 Test 2 20.8 33.8 61.90% Test 3 18.9 35.7 65.38% Test 4 17.6 37 67.77% Test 5 16.7 37.9 69.41% Table 4 - Result Comparison [0098] From the comparison table the results show that there is a trend in the diesel particulate readings. After Test 3, the results begin to level out, with only an approximately 4% reduction from Test 3 to Test 5. Accordingly, whilst the Example 2 with Part A diluted at 1:50 with water performed the best, the difference between with Part A diluted at 1:100 was relatively minor and, depending on a cost analysis and the particular circumstance, it may be preferable to use Example 2 with Part A diluted at 1:100. Rev Change Test Comparison [0099] The Results in the table below show the Baseline with no additive and the results for Test 6 as outlined above. The testing conducted demonstrates a significant reduction of 58% or 10.3mg/m 3 using the treatment composition Example 2 at the concentration as specified in Test 6 above.

-20 Test Type Result (mg/m 3 ) % Reduction Baseline Test 17.7 0 Test 6 7.4 58.19% Decrease Table 5 - Rev Change Test Results System and Method [00100] The Part A and Part B as described above are formulated to be diluted and then combined with one another to form a treatment composition for use within an exhaust treatment apparatus. Accordingly, in addition to the specific formulation of Part A and Part B as has been described above, a system is also proposed and associated method for combining Part A and Part B in an exhaust treatment apparatus as is further detailed below. [00101] Referring to Figure 1, there is shown a dosage system 100 for delivering a quantity of a treatment chemical to an exhaust treatment apparatus or device 110. The system 100 includes a first dosage unit 102 and a second dosage unit 104 which are configured to output to the exhaust cleaning apparatus 110. In this example, the first dosage unit 102 and the second dosage unit 104 are arranged inline or in series with the output of the second dosage unit 104 being the feed or input to the first dosage unit 102. The output of the first dosage unit 102 then feeds or provides input to the exhaust treatment apparatus 110. In other examples, the first dosage unit 102 and the second dosage unit 104 may also be arranged in a reverse arrangement with the output of the first dosage unit 102 being the input to the second dosage unit 104. [00102] The second dosage unit 104 is configured to provide a diluted second part by mixing the second part, Part B, with water at a ratio of about 1:2000 to about 1:3000 such that the diluted second part is outputted to first dosage unit 102. The second dosage unit is then configured to add the first part, Part A, to the diluted second part so as to form the treatment composition or chemical. The first dosage unit 102 is configured to provide a diluted treatment composition by mixing the first part, Part A, with the diluted second part at a ratio of about 1:50 to about 1: 200. The -21 diluted treatment chemical or composition then enters the exhaust cleaning apparatus 110. [00103] The system 100 includes a first container 106 in communication first dosage unit 102 and containing the first part, and a second container 108 in communication second dosage unit 104 and containing the second part. The communication between the dosage units 102, 104 and the containers 106, 108 may be by fluid conduits or pipes. The system 100 may also include a pressurised water supply which is introduced to each of the dosage units to dilute Part A and Part B, as appropriate. The system 100 may also include a filter 112 fitted to the pressurised water supply and a pressure regulator 114 connected to the filter 112 to ensure the dosage devices 102, 104 are provided with filtered water at the correct pressure. [00104] In this example the dosage devices 102, 104 may be provided in the form of commercially available Dosatron T m units. However, other dosage unit technologies may also be used. These units are typically water powered and include a water inlet, a composition or additive inlet and a single outlet. The units include an adjustable dosage piston which alters the size or volume of an internal cavity of the device in which the composition is introduced and mixed with the water. The dosage piston is coupled to a hand operable dial to adjust the size of the internal cavity and hence the amount of composition that is drawn or injected into the unit. The unit is configured such that the dose of the composition or additive is directly proportional to the volume of water entering the unit. [00105] In use, water flows through the unit and the composition, being in this example either Part A or Part B, is introduced or drawn into the unit at the desired rate to provide the desired concentration or dilution. The composition then mixes with the water and flows from the outlet with the water. This provides the composition diluted to the desired amount. [00106] Referring to Figure 2, there is illustrated an exhaust treatment system 200 including an exhaust treatment apparatus 110 in the form of a scrubber 210 and the dosage system 100 may be configured to output to the scrubber 210.

-22 [00107] In this example, the scrubber 210 includes a header or header tank 220 and the first dosage unit 102 and second dosage unit 104 are in communication with the header 220 so as to deliver the diluted first part and diluted second part to the header 220 so as to form the treatment chemical within header. The diluted first part and diluted second part may be combined prior to or within head tank 220 or the scrubber 210. [00108] In use, the treatment composition flows from the header 220 via an inlet 224 and into the body of the scrubber 212. The exhaust gas carrying the particulate matter enters the scrubber 210 via an inlet 214. Exhaust gas then travels upwardly through the body of the scrubber 210 which contains the treatment composition which is generally located in the area indicated by numeral 218. Accordingly, it may be appreciated that the flow of the treatment composition into the body of the scrubber 212 is at least partially counter flow to the exhaust gas travelling upwardly and through the scrubber. [00109] The hot exhaust gas travelling through the treatment composition creates a relatively turbulent mixing environment in which the treatment composition interacts with the exhaust gas to remove at least a portion of the particulate matter carried by the exhaust gas. Once the exhaust gas has travelled through the body of the scrubber 212 the scrubbed exhaust gas proceeds upwardly through the scrubber 212 and emits to the external atmosphere via outlet 216. [00110] A method of utilising or using the Part A and Part B composition as disclosed herein with the system 200 for the treatment of exhaust gas may be as follows. The method including the steps of combining the Part A and Part B to form a treatment composition and introducing the treatment composition to the exhaust gas treatment system such that the exhaust gas passing through the scrubber contacts treatment composition so as to the reduce particulate matter carried by the exhaust gas. [00111] The steps of combining Part A and Part B may include utilising a dosage system 100 as has been described above. The method may further include diluting Part A with water at a ratio of about 1:50 to about 1:200 and diluting Part B -23 with water at a ratio of about 1:2000 to about 1:3000. The diluting of Part A and Part B may be carried out utilising the dosage devices 102, 104 of the dosage system 100. The diluted Part A and the diluted Part B may be combined prior to entering the exhaust treatment device 110. Alternatively, the diluted Part A and the diluted part B may be separately introduced into the exhaust treatment device 110 and allowed to intermix and combine within the exhaust treatment device 110 thereby forming the treatment composition within the exhaust treatment device 110. Utility and Advantages [00112] From the testing it has been established that the treatment composition having a Part A combinable with a Part B have the following advantageous properties: Reduces Diesel Particulate; Reduces harmful un-burnt gases; Absorbs and disperses carbon, oil, grease, sludge; Prevents carbon adhering to the internal surfaces; Improves heat transfer; and Reduces scrubber box maintenance. [00113] In view of the above, it may be appreciated that treatment composition disclosed herein having a Part A combinable with a Part B provides a scrubber technology which utilises surfactants and emulsifying surfactants specifically blended to capture diesel particulate and suspend it in solution. The two-part system, Part A and Part B, thereby provides an advanced method of dealing with diesel particulate and toxic gases. [00114] The surfactants and emulsifying surfactants of Part A increase the viscosity of hydro-based systems, increases its stability, and provides body without modifying its other properties. Part A behaves as a wetting and dispersing agent, promoting miscibility and facilitates even dispersion. It acts by combining with dissolved substances in water and binding them together, allowing detergent surfactants to act effectively. [00115] When diluted and introduced into the scrubber, the unique ingredients of the treatment composition create an environment within the scrubber that captures particulate matter and holds the particulate matter in suspension. The synergistic effect of bringing a group of ingredient chemicals together has a dramatic effect on -24 improving air quality, creates a clean scrubber box, reduces scrubber maintenance and provides a safer and cleaner working environment. [00116] The two-part treatment composition described herein provides a diesel particulate reducing additive that is safe to use, is non-flammable, does not give off toxic fumes, and contains no acids or caustic alkalis. The two-part treatment composition provides a greater margin of protection and greater dispersion capacity, without the fear of releasing airborne diesel particles within the surrounding environment that may be an underground mine site. [00117] Unlike detergent based products, the two-part treatment composition described herein formulated to emulsify and disperse condensed, carbonaceous and oily residues in scrubber box exhaust cleaning systems during operation. Accordingly, the two-part treatment composition described herein provides a significant point of difference to currently available alkali/detergent cleaning systems and doesn't have the associated DPM (diesel particulate matter) capture and disposal problems associated with filters. [00118] Furthermore, in use, the two-part treatment composition described herein absorbs preferentially onto the oily surface of the precipitated exhaust particles carrying the polymer dispersant directly onto the molecule. The strong dispersing power of the polymer inhibits coagulation of the oily particles and inhibits adherence of the oily particles to the baffles, the walls or internal surfaces of the scrubber box. Accordingly, in addition to providing a high level of DPM capture, the two-part treatment composition described herein also assist with maintaining a clean scrubber box. [00119] Although the chemical composition product described herein may find uses in many applications, use of the chemical composition product within wet scrubber boxes in underground mining operations have the greatest need for the solutions provided herein. [00120] The reference in this specification to any known matter or any prior publication is not, and should not be taken to be, an acknowledgment or admission or -25 suggestion that the known matter or prior art publication forms part of the common general knowledge in the field to which this specification relates. [00121] While specific examples of the invention have been described, it will be understood that the invention extends to alternative combinations of the features disclosed or evident from the disclosure provided herein. [00122] Many and various modifications will be apparent to those skilled in the art without departing from the scope of the invention disclosed or evident from the disclosure provided herein.

Claims (35)

1. A composition including a first part which is combinable with a second part for the treatment of exhaust in a scrubber box, the first part including a surfactant, a solvent and an alkali and the second part including a defoaming agent.

2. The composition according to claim 1, wherein the first part further includes an emulsifying surfactant.

3. The composition according to claim 2, wherein the first part includes water.

4. The composition according to claim 3, wherein the first part includes from about 1 part to 20 parts of the surfactant, about 1 part to 30 parts of the emulsifying surfactant, about 1 part to 20 parts of the solvent and about 1 part to 15 parts of the alkali with the balance being the water to create a total of about 100 parts.

5. The composition according to claim 4, wherein the surfactant includes at least one of a non-ionic surfactant, an anionic surfactant and an amphoteric surfactant.

6. The composition according to claim 5, wherein the non-ionic surfactant includes at least one of a C 8 -C 16 alkyl compound, a Cs-Cis primary alcohol and a Cs Cis fatty acid.

7. The composition according to claim 6, wherein the non-ionic surfactant includes a C 8 -C 16 alkyl polyglucoside.

8. The composition according to claim 7, wherein the surfactant includes between about 1 part and 3 parts of the C 8 -C 16 alkyl polyglucoside.

9. The composition according to any one of claims 4 to 8, wherein the emulsifying surfactant includes at least one of a Cs-C 2 2 fatty acid ester type emulsifier, a Cs-C22 fatty acid condensed with 3-12 mole ethylene oxide and a fatty amine ethoxylate. -27

10. The composition according to claim 9, wherein the Cs-C 2 2 fatty acid ester type emulsifier is a polyethylene glycol ester.

11. The composition according to claim 9, wherein the emulsifying surfactant includes between about 5 parts and about 15 parts of the polyethylene glycol ester.

12. The composition according to any one of claims 4 to 11, wherein the solvent includes at least one of a co-solvent glycol ether and an ester solvent.

13. The composition according to claim 12, wherein the co-solvent glycol ethers include at least one of alkyl glycol ethers, dialkyl glycol ethers and alkyl glycol ethers esters.

14. The composition according to claim 12, wherein the ester solvent includes methyl methoxy butanol.

15. The composition according to claim 14, wherein the solvent includes between about 8 parts and 10 parts of the methyl methoxy butanol.

16. The composition according to any one of claims 4 to 15, wherein the alkali includes at least one of an alkali salt and an organic alkali.

17. The composition according to claim 16, wherein the organic alkali includes an organic alkanolamine.

18. The composition according to claim 17, wherein the alkanolamine includes at least one of monoethanolamine, diethanolamine, triethanolamine or isopropanolamine.

19. The composition according to claim 18, wherein the alkali includes between about 2 parts and about 5 parts monoethanolamine. -28

20. The composition according to any one of the previous claims, wherein the defoaming agent of the second part includes at least one of an oil, a silicone defoamer, an ethylene oxide compound and a propylene oxide compound.

21. The composition according to claim 20, wherein the silicone defoamer is a silicone emulsion.

22. The composition according to claim 21, wherein the silicone emulsion is based on polydimethylsiloxane.

23. The composition according to claims 21 or claim 22, wherein the second part includes between about 20 parts to about 30 parts of the silicone emulsion with the balance being water to create a total of about 100 parts.

24. A two part chemical product including a first part and a second part as defined in any one of the previous claims.

25. A method for treating exhaust gas to reduce particulate matter carried by the exhaust gas using a first part and a second part as defined in any one claims 1 to 23, the method including the steps of combining the first part and second part to form a treatment composition and introducing the treatment composition to an exhaust treatment apparatus such that the exhaust gas passing through the exhaust treatment apparatus contacts treatment composition so as to the reduce particulate matter carried by the exhaust gas.

26. The method according to claim 25, wherein the first part and second part are combined prior to being introduced into the exhaust treatment apparatus.

27. The method according to claim 25, wherein the first part and second part are combined after being introduced into the exhaust treatment apparatus.

28. The method according to any one of claims 25 to 27, wherein the first part is diluted with water at a ratio of about 1:25 to about 1:250. -29

29. The method according to any one claims 25 to 27, wherein the second part is diluted with water at a ratio of about 1:2000 to about 1:3000.

30. The method according to claim 29, wherein the first part is diluted with the second part at a ratio of about 1:25 to about 1:250. 30. A system for combining a first part and a second part as defined in any one of claims 1 to 23 so as to form a treatment chemical for use within an exhaust treatment apparatus, wherein the system includes a first dosage unit and a second dosage unit which configured to output to the exhaust treatment apparatus, the first dosage unit being configured to provide a diluted first part by mixing the first part with a first fluid at a ratio of about 1:25 to about 1:250 and the second dosage unit being configured to provide a diluted second part by mixing the second part with a second fluid at a ratio of about 1:2000 to about 1:3000 such that the diluted first and second parts are outputted to the exhaust treatment apparatus so as to form the treatment chemical.

31. The system according to claim 30, wherein the first dosage unit and the second dosage unit are arranged in series with the second dosage unit feeding the first dosage unit, wherein the second fluid is water and the first fluid is the diluted second part.

32. The system according to claim 30, wherein the first fluid is water and the second fluid is water.

33. The system according to any one of claims 30 to 32, including a first container in communication first dosage unit and containing the first part, and a second container in communication second dosage unit and containing the second part.

34. The system according to claim 33, wherein the exhaust treatment apparatus is a scrubber, the scrubber having a header and the first dosage unit and second dosage unit are in communication with the header so as to deliver the diluted first part and diluted second part to the header so as to form the treatment chemical within header. -30

35. A composition, method and system as defined herein with reference to the Figures and/or examples.