Dust control formulations

Abstract

This disclosure describes formulations and methods for dust control, for example, coal topping, a term which refers to the application of liquid products to the top of coal loads, such as those in open topped coal hopper railcars as commonly used today to transport coal. Disclosed herein are wax-based emulsion formulations that accomplish dust control during industrial operations in which dust handling is required.

What is claimed: 
     
       1. A method for controlling dust on a surface of a bulk material, comprising:
 (I) preparing a dust control formulation (DCF) comprising a dust reduction additive (DRA) emulsion comprising colloidally-protected wax-based (CPWB) microstructures; and 
 (II) applying said dust control formulation to said surface of said bulk material in an amount effective for dust control,
 wherein said CPWB microstructure comprises: 
 (A) a wax core,
 wherein said wax core comprises a paraffin component and a non-paraffin component,
 wherein said paraffin component comprises at least one linear alkane wax defined by the general formula CnH2n+2, where n ranges from 13-80, 
 wherein said non-paraffin component comprises at least one wax selected from the group consisting of animal-based wax, plant-based wax, mineral wax, synthetic wax, a wax containing organic acids and/or esters, anhydrides, an emulsifier containing a mixture of organic acids and/or esters, and combinations thereof; and 
 
 
 (B) a polymeric shell,
 wherein said polymeric shell comprises at least one polymer selected from poly-vinyl alcohol, polyvinyl alcohol copolymers, polyvinyl alcohol terpolymers, polyvinyl acetate, polyvinyl acetate copolymers, polyvinyl acetate terpolymers, cellulose ethers, polyethylene oxide, polyethyleneimines, polyvinylpyrrolidone, polyvinylpyrrolidone copolymers, polyethylene glycol, polyacrylamides and poly (N-isopropylamides), pullulan, sodium alginate, gelatin, starches, and combinations thereof. 
 
 
 
     
     
       2. The method as recited in  claim 1 , wherein said polymeric shell comprises polyvinyl alcohol. 
     
     
       3. The method as recited in  claim 1 , wherein said DCF further comprises a binder; a preservative; a rheology modifier; and/or a surfactant. 
     
     
       4. The method as recited in  claim 1 , wherein said binder is selected from polyvinyl acetate, polyvinyl alcohol, ethylene vinyl acetate co-polymer, vinylacrylic copolymer, styrenebutadiene, polyacrylamide, acrylic polymers, latex, natural starch, synthetic starch, casein, and combinations thereof. 
     
     
       5. The method as recited in  claim 1 , wherein said dust-reduction additive emulsion further comprises a second water; a base; and a dispersant. 
     
     
       6. The method as recited in  claim 4 , wherein said dispersant is selected from a dispersant having sulfur; a dispersant having a sulfur-containing group in the compound; sulfonic acid (R—S(═O) 2 —OH); sulfonic acid salts, wherein the R groups is functionalized with hydroxyl, or carboxyl; lignosulfonate; lignosulfonic acid; naphthalene sulfonic acid; sulfonate salt of lignosulfonic acid; sulfonate salt of naphthalene sulfonic acid, derivatized lignosulfonic acid, derivatized naphthalene sulfonic acid, functionalized lignosulfonic acid; functionalized naphthalene sulfonic acid; magnesium sulfate; polycarboxylate; ammonium hepta molybdate; combination of ammonium hepta molybdate and starch, alkyl quaternary ammonium; montmorillonite clay; non-ionic surfactants; ionic surfactants; zwitterionic surfactants; and mixtures thereof. 
     
     
       7. The method as recited in  claim 4 , wherein said base is selected from monoethanol amine; diethanol amine; triethanol amine; imidazole; potassium siliconate; and combinations thereof. 
     
     
       8. The method as recited in  claim 1 , wherein the weight of said dust reduction additive emulsion is in the range of from about 0.01% to about 20% by weight of said dust control formulation. 
     
     
       9. The method as recited in  claim 1 , wherein the weight of said dust reduction additive emulsion is in the range of from about 0.1% to about 10% by weight of said dust control formulation. 
     
     
       10. The method as recited in  claim 1 , wherein said dust control formulation further comprises at least one component from a silicone, a siliconate, a fluorinated compound, a stearate, or a combination thereof. 
     
     
       11. The method as recited in  claim 10 , wherein the silicones, siliconates, fluorinated compounds, or stearates are selected from the group consisting of metal siliconate salts, potassium siliconate, poly hydrogen methyl siloxane, polydimethyl siloxane, stearate-based salts, and combinations thereof. 
     
     
       12. The method as recited in  claim 1 , wherein said dust control formulation is applied to the surface of said bulk material at the rate of from about 0.001 to about 5.0 gallon per square yard for controlling dust. 
     
     
       13. The method as recited in  claim 1 , wherein said bulk material is coal, limestone, fly ash, cement, carbon black, coke, or mineral material. 
     
     
       14. The method as recited in  claim 1 , wherein said bulk material is coal, and said dust control formulation is applied the top of said coal load in an open-topped, coal-hopper railcar, used for transporting coal. 
     
     
       15. The method as recited in  claim 1 , wherein said dust control formulation is applied by sprinkling, and/or a spray nozzle. 
     
     
       16. The method as recited in  claim 1 , wherein said dust control formulation further comprises a first water.