WO2002088026A1 - A method of preparing calcium silicate hydrate granules and use thereof - Google Patents

A method of preparing calcium silicate hydrate granules and use thereof Download PDF

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Publication number
WO2002088026A1
WO2002088026A1 PCT/EP2002/004333 EP0204333W WO02088026A1 WO 2002088026 A1 WO2002088026 A1 WO 2002088026A1 EP 0204333 W EP0204333 W EP 0204333W WO 02088026 A1 WO02088026 A1 WO 02088026A1
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WO
WIPO (PCT)
Prior art keywords
water
calcium silicate
silicate hydrate
moulds
hydrate granules
Prior art date
Application number
PCT/EP2002/004333
Other languages
French (fr)
Inventor
Dietmar Lange
Original Assignee
Mars Incorporated
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Mars Incorporated filed Critical Mars Incorporated
Priority to US10/475,467 priority Critical patent/US20040151650A1/en
Priority to CA002443227A priority patent/CA2443227A1/en
Priority to EP02747288A priority patent/EP1381564A1/en
Publication of WO2002088026A1 publication Critical patent/WO2002088026A1/en

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B33/00—Silicon; Compounds thereof
    • C01B33/20—Silicates
    • C01B33/24—Alkaline-earth metal silicates
    • A—HUMAN NECESSITIES
    • A01—AGRICULTURE; FORESTRY; ANIMAL HUSBANDRY; HUNTING; TRAPPING; FISHING
    • A01K—ANIMAL HUSBANDRY; AVICULTURE; APICULTURE; PISCICULTURE; FISHING; REARING OR BREEDING ANIMALS, NOT OTHERWISE PROVIDED FOR; NEW BREEDS OF ANIMALS
    • A01K1/00—Housing animals; Equipment therefor
    • A01K1/015—Floor coverings, e.g. bedding-down sheets ; Stable floors
    • A01K1/0152—Litter
    • A01K1/0154—Litter comprising inorganic material

Definitions

  • the invention relates to a method of preparing calcium silicate hydrate granules by reacting crystalline and optionally amorphous silica or materials containing same with calcium oxide or materials containing same by homogenising them in water, moulding, autoclave curing, comminuting, drying and classifying, the homogenisation during the reaction being performed by dispersing the solid starting materials in water while adding an anionic surfactant that has previously been converted in water into a microporous stable foam; the invention also relates to a product obtainable by this method and its use.
  • Known materials for animal litter are usually natural products of mineral or organic origin, such as pumice stone, clay minerals, moler earth, wood dust, peat and diatomaceous earth, which, because of their porous structure, possess the ability to absorb liquids.
  • DE-AS 2902079 discloses an animal litter for which calcium silicate hydrate granules manufactured as specified above are used.
  • DE 3121403 discloses a further development of this animal litter in which, in order to bind odours, the pH is lowered to a level between about 5.8 and 6.2 using acidic materials.
  • EP 0 109 267 Al teaches treating various solid absorbent materials with water- soluble salts of transition metals from Groups lb or lib of the periodic table
  • EP 0 204 152 Cl teaches treating with zinc salts, while adjusting a particular zinc content and pH level, in both cases likewise in order to improve odour binding
  • DE 41 09 590 Cl discloses an animal litter in which, in order to improve odour binding, the water activity is adjusted to about 0.95 or less by treating it with a salt or salt mixture taken from the group of alkali metal and earth alkali metal chlorides.
  • the object of the present invention is to improve this known absorbent material in such a way that the properties of the material which are relevant to its use as animal litter, especially its absorbtivity, are improved at least in part.
  • this problem is solved in that, in the method described in the preamble, the homogenised mixture is filled, to a maximum depth of 60 cm, into moulds which are at least 5 square metres in area.
  • the mouldings - with or without the moulds - are autoclaved without being divided or comminuted beforehand.
  • moulds are at least 10 square metres in area.
  • the mouldings are comminuted in two stages after autoclaving, a particle fraction of up to 15 cm being obtained in the first stage, and a particle fraction of up to 5 mm being obtained in the second stage.
  • the invention also relates to calcium silicate hydrate granules obtainable according to the method of the invention and the use of such calcium silicate hydrate granules as or in animal litter.
  • the two main starting materials - as in the prior art - are preferably pure, finely ground quartz sand (SiO 2 ) and burnt white fine lime (CaO).
  • the two materials are blended into a sufficient quantity of water, the weight ratio of CaO:SiO 2 being between 0.4 and 0.6, preferably between 0.46 and 0.51.
  • Mixing is preferably carried out in a blade mixer at a relatively low stirring speed.
  • a foam gun After stirring for a short time (e.g. 60 sec), a foam gun is used to add a microporous stable foam obtained by foaming an anionic surfactant.
  • Surfactants preferably used are anionic, biodegradable surfactants, e.g. mixtures of alkene sulphonates and hydroxyalkane sulphonates, such as the product HOSTAPUR-OS ® .
  • an anion- active stabiliser can be added, e.g. an alkyl triglycol ether sulphate, such as the product Zeliquid LP-2.
  • the mixture is poured into casting moulds which are at least 5 square metres, preferably 10 square metres, in size, such as 6 m x 2 m.
  • the relatively large area of the casting moulds - conventionally, the maximum size of the casting moulds used is 2.5 square metres - and the fact that the homogenised mixture is filled, to a maximum depth of 60 cm - conventionally, the depth is at least 90 cm - leads - especially if the autoclaving is performed without the mouldings' being divided or comminuted before- hand - to mouldings with a more homogeneous, finer porosity, which leads to a distinct improvement in and greater uniformity of the above-mentioned material properties, especially water absorption, i.e. absorbtivity, bulk density and surface area.
  • the mouldings are preferably autoclaved in the following cycle:
  • vacuum 0.75 to 1.5 h, preferably 1 h, to 0.3 to 0.5 bar, preferably 0.4 bar heating: 0.75 to 1.5 h, preferably 1 h, to 2.5 to 4 bar, preferably 3 bar heating: 1.25 to 2 h, preferably 1.5 h, to 12 to 16 bar, preferably 15 bar holding time: 0.75 to 1.5 h, preferably 1 h, at 12 to 16 bar, preferably 15 bar heating: 5 to 15 min, preferably 8 min, to 14 to 18 bar, preferably 16 bar holding time: 3 to 6 h, preferably 4.5 h, at 14 to 18 bar, preferably 16 bar cooling time: approx. 3 h.
  • the mouldings are comminuted to the desired particle size, preferably in two stages, a particle fraction of up to 15 cm being obtained in the first stage, and a particle fraction of up to 5 mm being obtained in a second stage.
  • the comminuted material is preferably subjected to sifting between the two comminution stages. In this way, the amount of dust in the final product can be reduced.
  • the water was introduced into an Ekato mixer, type EM2100, with a mixer blade diameter of 1,700 mm.
  • the starting materials i.e. quartz powder and lime, were mixed in while stirring continued at 90 r.p.m.
  • a microporous stable foam 80 parts water, 1 part HOSTAPUR-OS ® , 1 part Zeliquid ® LP-2
  • HOSTAPUR-OS anionic surfactant
  • Zeliquid ® LP-2 foam stabiliser
  • a recirculation pump VASA G 120234-50 was used in order to improve the blending.
  • the mouldings come out of the autoclave with a residual moisture of approx. 28 - 35 % (preferably 32 %) and are then initially comminuted with a roll crusher to a particle size of up to 15 cm. Following that, the fraction ⁇ 0.5 mm is removed. The remaining material is comminuted to a maximum particle size of 5 mm in a second stage and is then dried to approx. 3 % residual moisture.
  • a material produced in accordance with Example 1 of DE-AS 29 02 079 has substantially the same composition as the material produced in accordance with the example of the invention.
  • the production process differs essentially in the fact that, in the state of the art, considerably smaller moulds (maximum size: 2.5 square metres) with a great depth (minimum of 90 cm) were used, which were subdivided into individual chambers by means of separating walls. This means that the casting process gave rise to blocks with a very much smaller base area but of greater height, which were subjected to autoclaving.
  • the further processing was performed essentially in the same way as described in the example of the invention.
  • the average figures for the material parameters were as follows:
  • the product produced in accordance with the method of the invention is characterised by a substantially lower bulk density, i.e. a substantially lower bulk weight, a larger surface area, and considerably higher water absorption. It is therefore better suited for use as or in animal litter than the known calcium silicate hydrate granules.

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  • Life Sciences & Earth Sciences (AREA)
  • Chemical & Material Sciences (AREA)
  • Inorganic Chemistry (AREA)
  • Environmental Sciences (AREA)
  • Organic Chemistry (AREA)
  • Zoology (AREA)
  • Animal Husbandry (AREA)
  • Biodiversity & Conservation Biology (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Geology (AREA)
  • Silicates, Zeolites, And Molecular Sieves (AREA)
  • Housing For Livestock And Birds (AREA)

Abstract

A method of preparing calcium silicate hydrate granules by reacting crystalline and optionally amorphous silica or materials containing the same with calcium oxide or materials containing the same by homogenising them in water, moulding, autoclave curing, comminuting, drying and classifying, the homogenisation being performed by dispersing the solid starting materials in water while adding an anionic surfactant that has previously been converted in water into a microporous stable foam, wherein the homogenised mixture is filled, to a maximum depth of 60 cm, into moulds which are at least 5 square meters in area; a product obtainable by this method and its use in animal litter.

Description

"A method of preparing calcium silicate hydrate granules and use thereof
The invention relates to a method of preparing calcium silicate hydrate granules by reacting crystalline and optionally amorphous silica or materials containing same with calcium oxide or materials containing same by homogenising them in water, moulding, autoclave curing, comminuting, drying and classifying, the homogenisation during the reaction being performed by dispersing the solid starting materials in water while adding an anionic surfactant that has previously been converted in water into a microporous stable foam; the invention also relates to a product obtainable by this method and its use.
Known materials for animal litter are usually natural products of mineral or organic origin, such as pumice stone, clay minerals, moler earth, wood dust, peat and diatomaceous earth, which, because of their porous structure, possess the ability to absorb liquids.
DE-AS 2902079 discloses an animal litter for which calcium silicate hydrate granules manufactured as specified above are used.
DE 3121403 discloses a further development of this animal litter in which, in order to bind odours, the pH is lowered to a level between about 5.8 and 6.2 using acidic materials.
Furthermore, EP 0 109 267 Al teaches treating various solid absorbent materials with water- soluble salts of transition metals from Groups lb or lib of the periodic table, and EP 0 204 152 Cl teaches treating with zinc salts, while adjusting a particular zinc content and pH level, in both cases likewise in order to improve odour binding. Finally, DE 41 09 590 Cl discloses an animal litter in which, in order to improve odour binding, the water activity is adjusted to about 0.95 or less by treating it with a salt or salt mixture taken from the group of alkali metal and earth alkali metal chlorides.
Whereas different methods have therefore been adopted to improve absorbent materials for animal litter with regard to odour binding by means of an appropriate treatment, one of the commercially most important absorbent materials itself, namely artificially produced calcium silicate hydrate granules, is essentially still produced in exactly the same way as described in DE-AS 29 02 079.
The object of the present invention is to improve this known absorbent material in such a way that the properties of the material which are relevant to its use as animal litter, especially its absorbtivity, are improved at least in part.
According to the invention, this problem is solved in that, in the method described in the preamble, the homogenised mixture is filled, to a maximum depth of 60 cm, into moulds which are at least 5 square metres in area.
In a preferred embodiment, the mouldings - with or without the moulds - are autoclaved without being divided or comminuted beforehand.
It is particularly preferred for the moulds to be at least 10 square metres in area.
In a preferred embodiment of the invention, the mouldings are comminuted in two stages after autoclaving, a particle fraction of up to 15 cm being obtained in the first stage, and a particle fraction of up to 5 mm being obtained in the second stage.
In accordance with the invention, it is particularly preferred for particles with a size of less than 0.5 mm to be removed between the two comminution stages. The invention also relates to calcium silicate hydrate granules obtainable according to the method of the invention and the use of such calcium silicate hydrate granules as or in animal litter.
It has now surprisingly been found that, with the new production method, a material with improved properties can be obtained, in particular with improved water absorption, i.e. absorbtivity, lower bulk density (and thus lower bulk weight) and a larger surface area. In this way, a material can be provided which is superior to the known materials for use as or in animal litter.
The two main starting materials - as in the prior art - are preferably pure, finely ground quartz sand (SiO2) and burnt white fine lime (CaO). The two materials are blended into a sufficient quantity of water, the weight ratio of CaO:SiO2 being between 0.4 and 0.6, preferably between 0.46 and 0.51. Mixing is preferably carried out in a blade mixer at a relatively low stirring speed.
After stirring for a short time (e.g. 60 sec), a foam gun is used to add a microporous stable foam obtained by foaming an anionic surfactant. Surfactants preferably used are anionic, biodegradable surfactants, e.g. mixtures of alkene sulphonates and hydroxyalkane sulphonates, such as the product HOSTAPUR-OS®. If necessary, in order to stabilise the foam, an anion- active stabiliser can be added, e.g. an alkyl triglycol ether sulphate, such as the product Zeliquid LP-2.
After the foam has been added and worked in, the mixture is poured into casting moulds which are at least 5 square metres, preferably 10 square metres, in size, such as 6 m x 2 m. The relatively large area of the casting moulds - conventionally, the maximum size of the casting moulds used is 2.5 square metres - and the fact that the homogenised mixture is filled, to a maximum depth of 60 cm - conventionally, the depth is at least 90 cm - leads - especially if the autoclaving is performed without the mouldings' being divided or comminuted before- hand - to mouldings with a more homogeneous, finer porosity, which leads to a distinct improvement in and greater uniformity of the above-mentioned material properties, especially water absorption, i.e. absorbtivity, bulk density and surface area.
The mouldings are preferably autoclaved in the following cycle:
vacuum: 0.75 to 1.5 h, preferably 1 h, to 0.3 to 0.5 bar, preferably 0.4 bar heating: 0.75 to 1.5 h, preferably 1 h, to 2.5 to 4 bar, preferably 3 bar heating: 1.25 to 2 h, preferably 1.5 h, to 12 to 16 bar, preferably 15 bar holding time: 0.75 to 1.5 h, preferably 1 h, at 12 to 16 bar, preferably 15 bar heating: 5 to 15 min, preferably 8 min, to 14 to 18 bar, preferably 16 bar holding time: 3 to 6 h, preferably 4.5 h, at 14 to 18 bar, preferably 16 bar cooling time: approx. 3 h.
Following the autoclaving, the mouldings are comminuted to the desired particle size, preferably in two stages, a particle fraction of up to 15 cm being obtained in the first stage, and a particle fraction of up to 5 mm being obtained in a second stage.
In order to remove particles with a particle size of less than 0.5 mm, the comminuted material is preferably subjected to sifting between the two comminution stages. In this way, the amount of dust in the final product can be reduced.
The invention will now be described in more detail with reference to the following example.
EXAMPLE 1 The following starting materials were used to prepare the calcium silicate hydrate granules of the invention:
40.3 % by weight quartz powder 20.1 % by weight lime 39.6 % by weight water
The water was introduced into an Ekato mixer, type EM2100, with a mixer blade diameter of 1,700 mm. The starting materials, i.e. quartz powder and lime, were mixed in while stirring continued at 90 r.p.m. After they had been dispersed, a microporous stable foam (80 parts water, 1 part HOSTAPUR-OS®, 1 part Zeliquid® LP-2) prepared in an active foam generator from water and an anionic surfactant (HOSTAPUR-OS ") with the addition of a foam stabiliser (Zeliquid® LP-2) was worked in by means of a foam gun (2-3 % by weight relative to the dispersion). A recirculation pump (VASA G 120234-50) was used in order to improve the blending.
After that, the finished mixture was poured through a pipe into mouldings measuring 600 x 200 x 53 cm. The mouldings were then cured in autoclaves, adhering to the following cycle:
vacuum: 1 h to 0.4 bar heating: 1 h to 3 bar heating: 1.5 h to 15 bar holding time: 1 h at 15 bar heating: 8 min to 16 bar holding time: 4.5 h at 16 bar cooling time: approx. 3 h. The mouldings come out of the autoclave with a residual moisture of approx. 28 - 35 % (preferably 32 %) and are then initially comminuted with a roll crusher to a particle size of up to 15 cm. Following that, the fraction < 0.5 mm is removed. The remaining material is comminuted to a maximum particle size of 5 mm in a second stage and is then dried to approx. 3 % residual moisture.
The average figures for the material parameters of the calcium silicate hydrate granules obtained (standard fraction: fraction 0.5 to 2 mm: 25 %; fraction 2 - 4 mm: 60 %; fraction 4 - 5 mm: 15 %) were as follows:
bulk density (g/1): 470 to 480
bulk weight (g/1) : 270 to 310
surface area (BET) according to DIN 66131 (m2/g): 90 to 100
water absorption: ~ 140 %
water absorption (after spraying with MgCl2): 72 to 75 %
EXAMPLE 2 (COMPARATIVE EXAMPLE
A material produced in accordance with Example 1 of DE-AS 29 02 079 has substantially the same composition as the material produced in accordance with the example of the invention. The production process differs essentially in the fact that, in the state of the art, considerably smaller moulds (maximum size: 2.5 square metres) with a great depth (minimum of 90 cm) were used, which were subdivided into individual chambers by means of separating walls. This means that the casting process gave rise to blocks with a very much smaller base area but of greater height, which were subjected to autoclaving. The further processing was performed essentially in the same way as described in the example of the invention. The average figures for the material parameters (standard fraction as in Example 1) were as follows:
bulk density (g/1): 510 to 520
bulk weight (g/1): 315 to 345
surface area (BET) according to DIN 66131 (m2/g): 40 to 60 (with considerably greater fluctuations than in the material of the invention)
water absorption: 120 %
water absorption (after spraying with MgCl ): 66 to 68 %.
It is therefore clear that the product produced in accordance with the method of the invention is characterised by a substantially lower bulk density, i.e. a substantially lower bulk weight, a larger surface area, and considerably higher water absorption. It is therefore better suited for use as or in animal litter than the known calcium silicate hydrate granules.
The features of the invention disclosed in the above description and in the claims may be essential either individually or in any combination in order to carry out the invention in its various embodiments.

Claims

Claims
1. A method of preparing calcium silicate hydrate granules by reacting crystalline and optionally amorphous silica or materials containing same with calcium oxide or materials containing same by homogenising them in water, moulding, autoclave curing, comminuting, drying and classifying, the homogenisation being performed by dispersing the solid starting materials in water while adding an anionic surfactant that has previously been converted in water into a microporous stable foam, characterised in that the homogenised mixture is filled, to a maximum depth of 60 cm, into moulds which are at least 5 square metres in area.
2. The method as claimed in Claim 1, characterised in that the mouldings - with or without the moulds - are autoclaved without being divided or comminuted beforehand.
3. The method as claimed in either of Claims 1 or 2, characterised in that the minimum area of the moulds is at least 10 square metres.
4. method as claimed in any of Claims 1, 2 or 3, characterised in that the mouldings are comminuted in two stages after autoclaving, a particle fraction of up to 15 cm being obtained in the first stage, and a particle fraction of up to 5 mm being obtained in the second stage.
5. The method as claimed in Claim 4, characterised in that particles with a size of less than 0.5 mm to be removed between the two comminution stages.
6. Calcium silicate hydrate granules obtainable according to any of the preceding claims.
7. Use of calcium silicate hydrate granules as claimed in Claim 6 as or in animal litter.
PCT/EP2002/004333 2001-04-27 2002-04-19 A method of preparing calcium silicate hydrate granules and use thereof WO2002088026A1 (en)

Priority Applications (3)

Application Number Priority Date Filing Date Title
US10/475,467 US20040151650A1 (en) 2001-04-27 2002-04-19 Method of preparing calcium silicate hydrate granules and use thereof
CA002443227A CA2443227A1 (en) 2001-04-27 2002-04-19 A method of preparing calcium silicate hydrate granules and use thereof
EP02747288A EP1381564A1 (en) 2001-04-27 2002-04-19 A method of preparing calcium silicate hydrate granules and use thereof

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE10121098.1 2001-04-27
DE10121098A DE10121098A1 (en) 2001-04-27 2001-04-27 Process for the preparation of calcium silicate hydrate granules and use thereof

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WO2002088026A1 true WO2002088026A1 (en) 2002-11-07

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US (1) US20040151650A1 (en)
EP (1) EP1381564A1 (en)
CA (1) CA2443227A1 (en)
DE (1) DE10121098A1 (en)
WO (1) WO2002088026A1 (en)
ZA (1) ZA200300683B (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2008007963A1 (en) * 2006-07-14 2008-01-17 Sivomatic Bv Particulate clumping animal litter material and process for the production thereof

Families Citing this family (4)

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Publication number Priority date Publication date Assignee Title
DE102009044521B4 (en) 2009-11-13 2018-04-26 Cirkel Gmbh & Co. Kg Method for producing an animal litter
CN104955551B (en) * 2012-08-30 2017-03-01 恩清公司 For removing compositionss and the method for phosphate and other pollutant from aqueous solution
US10239022B2 (en) * 2016-06-02 2019-03-26 C-Crete Technologies, Llc Porous calcium-silicates and method of synthesis
DE102019105573A1 (en) 2018-03-05 2019-09-05 Cirkel Gmbh & Co. Kg Process for the preparation of a granular animal litter

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US4275684A (en) * 1979-01-19 1981-06-30 Effem Gmbh Animal litter
US4395357A (en) * 1979-01-19 1983-07-26 Mars Inc. Calcium silicate granules forming a microporous structure
JPH0342096A (en) * 1989-04-21 1991-02-22 Shigenobu Kasamatsu Method for removing phosphate ion and sulfate ion in water
JPH0515731A (en) * 1991-07-11 1993-01-26 Mitsubishi Materials Corp Deodorizing treatment using calcium silicate type porous cured body

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SE461203B (en) * 1983-01-24 1990-01-22 Svanholm Engineering Ab G PROCEDURE AND EQUIPMENT FOR MANUFACTURE OF GAS CONCRETE ELEMENTS

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US4275684A (en) * 1979-01-19 1981-06-30 Effem Gmbh Animal litter
US4395357A (en) * 1979-01-19 1983-07-26 Mars Inc. Calcium silicate granules forming a microporous structure
JPH0342096A (en) * 1989-04-21 1991-02-22 Shigenobu Kasamatsu Method for removing phosphate ion and sulfate ion in water
JPH0515731A (en) * 1991-07-11 1993-01-26 Mitsubishi Materials Corp Deodorizing treatment using calcium silicate type porous cured body

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Title
DATABASE CA [online] CHEMICAL ABSTRACTS SERVICE, COLUMBUS, OHIO, US; KASAMATSU, NOBUSHIGE: "Preparation of adsorbents for removal of phosphate and sulfate ions from water in textile industries", XP002210093, retrieved from STN Database accession no. 114:234843 *
DATABASE WPI Section Ch Week 199309, Derwent World Patents Index; Class C04, AN 1993-070293, XP002210094 *

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2008007963A1 (en) * 2006-07-14 2008-01-17 Sivomatic Bv Particulate clumping animal litter material and process for the production thereof

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Publication number Publication date
CA2443227A1 (en) 2002-11-07
EP1381564A1 (en) 2004-01-21
DE10121098A1 (en) 2002-12-19
ZA200300683B (en) 2004-03-10
US20040151650A1 (en) 2004-08-05

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