Foam compositions for selective recovery of oil spills and other applications

Abstract

A polymer composition for use in the removal and recovery of oil slicks or spills floating on the surfaces of bodies or water or present on land, such as beaches comprising a foam of a blend of polyethylene and an ethylene-alkyl acrylate copolymer and a process for using such foams in the selective removal of oil from fresh water or salt water and the recovery of the absorbed oils from the foams is disclosed. The polymer composition is also for use in other applications in which absorption of liquids is desired.

What is claimed is: 
     
         1 . An open-cell cross-linked foam composition comprising:
 a blend of ingredients, wherein ethylene-alkyl acrylate copolymer comprises from about 40 to about 80 parts per hundred of the total resin content of the blend;   wherein the blend is processed to create an open-cell foam that has the following properties:
 i) open-cells with an average cell size of from 0.65 mm to 1.4 mm by ocular; and 
 ii) a density of at least 1.5 pounds per cubic foot. 
   
     
     
         2 . The composition of  claim 1  wherein the blend of ingredients further comprises an elastomer. 
     
     
         3 . The composition of  claim 2  wherein the blend of ingredients further comprises a chemical foaming agent that decomposes to form a gas when the blend is heated during processing in to the foam composition. 
     
     
         4 . The composition of  claim 3  wherein the blend of ingredients further comprises an organic peroxide cross-linker. 
     
     
         5 . The composition of  claim 4  wherein the blend of ingredients further comprises silicone oil. 
     
     
         6 . The composition of  claim 5  wherein the blend of ingredients further comprises a biodegradation initiator. 
     
     
         7 . The composition of  claim 5  wherein the blend of ingredients further comprises an inorganic filler. 
     
     
         8 . The composition of  claim 1  wherein the open-cell foam has a density of from 1.5 to 2.0 pounds per cubic foot. 
     
     
         9 . The composition of  claim 1  wherein the open cells are created at least in part by crushing the foamed blend. 
     
     
         10 . The composition of  claim 1  wherein the ethylene-alkyl acrylate copolymer has a melt index of between about 0.5 and about 4 g/10 minutes. 
     
     
         11 . The composition of  claim 1  wherein open-cell foam has an absorption weight capacity of SAE 90 oil of at least about 27 times the weight of the open-cell foam and an absorption weight capacity of SAE 10 W-30 oil of at least about 25 times the weight of the open-cell foam. 
     
     
         12 . A structure constructed and arranged to remove liquid hydrocarbons from a mixture of liquid hydrocarbons and water comprising the open-cell foam composition of  claim 1 . 
     
     
         13 . The structure of  claim 12  in the form of one or more separate pieces. 
     
     
         14 . The structure of  claim 13  in the form of a series of strips. 
     
     
         15 . The structure of  claim 14  wherein the strips are submerged using weights. 
     
     
         16 . The structure of  claim 13  wherein the separate pieces are held close together. 
     
     
         17 . The structure of  claim 16  wherein the separate pieces are held close together by netting. 
     
     
         18 . The structure of  claim 12  wherein liquid hydrocarbons are removed from the structure by squeezing. 
     
     
         19 . The structure of  claim 18  wherein liquid hydrocarbons are removed from the structure using wringing rollers. 
     
     
         20 . The structure of  claim 12  wherein the structure is placed on the surface of water in need of liquid hydrocarbon removal. 
     
     
         21 . The structure of  claim 12  wherein the structure is submerged below the surface of water in need of liquid hydrocarbon removal. 
     
     
         22 . The structure of  claim 12  wherein the structure is placed on land or rocks in need of liquid hydrocarbon removal. 
     
     
         23 . An open-cell cross-linked foam composition comprising:
 a blend of ingredients comprising: from about 40 to about 80 parts per hundred total resin content ethylene-alkyl acrylate copolymer; an elastomer; a chemical foaming agent that decomposes to form a gas when the blend is heated during processing into the foam composition;   
       and an organic peroxide cross-linker;
 wherein the blend is processed, at least in part by crushing the foamed blend, to create an open-cell foam that has the following properties:
 i) open-cells with an average cell size of from 0.65 mm to 1.4 mm by ocular; and 
 ii) a density of at least 1.5 pounds per cubic foot.