Compositions and Methods for Dust Control and for the Manufacture of Construction Materials

Abstract

Compositions and methods for producing materials for construction and for dust control utilizing enzyme producing cells, an amount of a nitrogen source such as urea, and an amount of calcium such as calcium chloride. Calcium contributes to the formation of calcium carbonate which creates a solid structure, layer or shield. Compositions of the invention can be sprayed or otherwise applied to surfaces for erosion control, foundation support, prevention of sink hole formation or other applications. Ammonia, water and other by-products of the process can be recycled and re-utilized for the same or other purposes including, for example, as fertilizers and energy sources, or independently fermented from selectively cultivated microorganisms.

1 . A composition comprising a support material to which is applied urease-producing cells or cell spores and a transport medium. 
     
     
         2 . The composition of  claim 1 , wherein the support material comprises organic or inorganic material, rock, glass, wood, paper, metal, plastic, polymers, fibers, minerals or combinations thereof. 
     
     
         3 . The composition of  claim 1 , which is a liquid or dry powder. 
     
     
         4 . The composition of  claim 1 , wherein the support material is in the form of beads, grains, rods, strands, fibers, flakes, fibers, pulverized or crushed stone, crystals, or combinations thereof. 
     
     
         5 . The composition of  claim 1 , wherein the support material is sand, glass, fiberglass, paper, ash, wood, metal, waste material or combinations thereof. 
     
     
         6 . The composition of  claim 1 , wherein the urease-producing cells or cell spores comprise yeast, algae, bacteria or eukaryotic cells or cell spores. 
     
     
         7 . The composition of  claim 6 , wherein the bacteria are  Sporosarcina pasteurii, Sporosarcina ureae, Proteus vulgaris, Bacillus sphaericus, Myxococcus xanthus, Proteus mirabilis, Helicobacter pylori,  or variants, serotypes, mutations or combinations thereof. 
     
     
         8 . The composition of  claim 6 , wherein the yeast, algae, bacteria or eukaryotic cells or cell spores are genetically engineered. 
     
     
         9 . The composition of  claim 1 , wherein the support material and the cells are coupled via hydrophobic bonds, hydropyllic bonds, ionic bonds, non-ionic bonds, covalent bonds, van der Waal forces, or a combination thereof. 
     
     
         10 . The composition of  claim 1 , wherein the support material is at least partially encompassed by a film that promotes binding of the urease-producing cells. 
     
     
         11 . The composition of  claim 10 , wherein the film comprises a polymer or a cell nutrient. 2 5 12. The composition of  claim 1 , which contains a coloring agent. 
     
     
         13 . The composition of  claim 1 , which contains an identifying agent or a detectable marker. 
     
     
         14 . The composition of  claim 1 , wherein the transport medium comprises ingredients for cell growth. 
     
     
         15 . The composition of  claim 14 , wherein the ingredients for cell growth comprise one or more of water, nutrients, vitamins, minerals, amino acids, proteins, oils, fatty acids, saccharides and polysaccharides. 
     
     
         16 . A kit for manufacturing solid forms comprising:
 the composition of  claim 1 ;   a second composition containing nutrients for proliferation of the ureases-producing cells and/or germination of the cell spores;   a plurality of sets of formworks wherein each set encloses the shape of at least one solid form and contains one or more porous panels; and   a third composition comprising calcium, nitrogen or both calcium and urea.   
     
     
         17 . The kit of  claim 16 , wherein the solid forms are rectangular, square, rounded, oval or an irregular shape. 
     
     
         18 . The kit of  claim 16 , wherein the solid forms are blocks, boards, bricks, pavers, panels, tiles, or veneer. 
     
     
         19 . The kit of  claim 18 , wherein the blocks are concrete masonry, cinder blocks, foundation blocks, breeze blocks, hollow blocks, solid blocks, besser blocks, clinker blocks, high or low density blocks, or aerated blocks. 
     
     
         20 . The kit of  claim 16 , wherein the nutrients include amino acids, proteins, polysaccharides, fatty acids, vitamins and minerals. 
     
     
         21 . A method for manufacture of solid forms comprising:
 mixing the composition of  claim 1  with an aggregate material and water to form a mixture, wherein the aggregate material is largely composed of particulates of less than 50 mm in diameter;   apportioning the mixture into multiple form works wherein each form work contains at least one porous panel;   adding a second composition to the mixture, wherein the second composition contains nutrients that promote proliferation of the urease-producing cells;   adding a third composition to the mixture, wherein the third composition is a liquid that contains calcium;   incubating the mixture for a period of time to form covalent bonds between the particulates; and   removing the solid forms from the form works.   
     
     
         22 . The method of  claim 21 , wherein the aggregate material comprises rock, glass, wood, paper, metal, plastic, polymers, minerals or combinations thereof. 
     
     
         23 . The method of  claim 21 , wherein mixing comprising spraying the composition as a liquid onto the aggregate material. 
     
     
         24 . The method of  claim 21 , wherein the form works are substantially submerged during the incubating. 
     
     
         25 . The method of  claim 24 , wherein air is bubbled to the submerged form works. 
     
     
         26 . The method of  claim 21 , wherein additional third composition is added to the mixture repeatedly during incubating which drains through the bottom panel and, optionally, is recycled. 
     
     
         27 . The method of  claim 21 , wherein the incubating is performed under ambient conditions. 
     
     
         28 . The method of  claim 21 , wherein the incubating is performed between 5° C. and 50° C. 
     
     
         29 . The method of  claim 21 , wherein the third composition contains calcium chloride, calcium acetate, calcium phosphate, calcium carbonate, calcium lactate, calcium nitrate, or a calcium salt. 
     
     
         30 . The method of  claim 21 , wherein the pH of the mixture is monitored during the incubating. 
     
     
         31 . The method of  claim 21 , wherein the solid forms are blocks, boards, bricks, pavers, panels, tiles, or veneer. 
     
     
         32 . The method of  claim 21 , wherein the mixture further contains fibers or nanofibers. 
     
     
         33 . The method of  claim 32 , wherein the fibers or nanofibers are composed of wood, glass, plastic, metal or a polymer. 
     
     
         34 . The method of  claim 21 , wherein additional nutrients are added during incubating. 
     
     
         35 . The method of  claim 21 , wherein the solid forms removed from the form works are dried. 
     
     
         36 . A composition containing urease producing cells or cell spores that are encapsulated, microencapsulate or coated with nutrient, proteins, polysaccharides, polymers or other media. 
     
     
         37 . The composition of  claim 36 , wherein the nutrient media further contains additional urease producing cells or cell spores. 
     
     
         38 . A composition comprising urease and/or urease-producing cells, a nitrogen source, a calcium source and water. 
     
     
         39 . The composition of  claim 38 , further comprising aggregate materials which have an average diameter of less than 0.05 mm. 
     
     
         40 . The composition of  claim 38 , further comprising aggregate materials which have an average diameter of from 1 nm to 40 nm. 
     
     
         41 . The composition of  claim 38 , further comprising aggregate materials which have an average diameter of from 1.0 mm to 50 mm. 
     
     
         42 . The composition of  claim 38 , wherein the nitrogen source is urea and the calcium source is calcium chloride. 
     
     
         43 . The composition of  claim 38 , which contains an amount of the urease and/or urease-producing cells, an amount of the nitrogen source, an amount of the calcium source and an amount of the water that provides for solidification of the composition within a set time. 
     
     
         44 . The composition of  claim 38 , which contains urease-producing cells and further comprises nutrients that promote cell growth. 
     
     
         45 . A method of layering a solid object with calcium carbonate comprising:
 contacting the solid object with the composition of  claim 38  and promoting the formation of calcium carbonate.   
     
     
         46 . The method of  claim 45 , wherein contacting comprises spraying the solid object with the composition and/or maintaining a desired vapor pressure. 
     
     
         47 . The method of  claim 45 , wherein contacting comprises immersing, spraying, misting or exposing to vapor the solid object with the composition. 
     
     
         48 . A method of dust control comprising spraying the composition of  claim 38  on a surface. 
     
     
         49 . The method of  claim 48 , wherein the sprayed surface is more resistant to erosion as compared to an unsprayed surface. 
     
     
         50 . The method of  claim 48 , wherein the surface is a walking path, a pile, a cliff or vehicle roadway.