Patent Grant
7798743
The present disclosure relates to a soy-based material binder. More particularly, the disclosure is directed to a soy-based stabilizer for soil stabilization and dust suppression.
As an example, dirt and aggregate road surfaces may be adversely affected by weather and time. Specifically, exposure to various extreme weather conditions, such as temperature changes, precipitation, etc. may affect the quality of a dirt and aggregate road surface. Further, exposure to traffic may cause accelerated degradation of road surfaces. For example, improperly stabilized road surfaces may be subject to the formation of potholes, wash-boarding, frost-boils, dry weather flaking, wet weather leaching, erosion, as some examples. Moreover, use of such dirt and aggregate roads may result in loss of road bed material and high levels of dust being created.
Various compositions and products have been used on road surfaces in an attempt to minimize the effect of use and weather on such road surfaces and improve the durability and quality of the road surfaces.
Examples of dust suppressants and soil stabilizers are disclosed in U.S. Pat. Nos. 4,001,033; 4,571,116; 4,737,305; 4,801,635; 5,084,207; 5,412,007; and 5,824,725, the disclosures of which are incorporated by reference in their entirety for all purposes.
However, many of these products provide only short-term relief from the above-described conditions. Additionally, some of the products require frequent reapplication due to the loss of product on the road from traffic and/or weather conditions. For example, rainy weather may result in erosion of the products. Moreover, a wet winter may result in the leaching of the products, and products can thereby introduce contaminants into the local environment. Other issues in regards to current products include the stability and cost of the products. In some instances, the products may become unstable during storage and require remixing or other conditioning. Further, many of the known products become unstable over time. Another issue is a higher cost of the product. Further, there is waste of non-food grade soy product in the soy industry.
A soy-based material binder may be an effective use of non-food grade soy product. The use of non-food grade soy product in a soy-based material binder may substantially reduce the costs of stabilizing roadways and may have minimal environmental effect.
The present application is directed towards a soy-based material binder which may be used as a dust suppressant and soil stabilizer. A composition and methods for a soy-based material binder are provided to address the above issues. The inventors herein have recognized a method for increasing road stabilization with a soy-based material binder. The method may include creating a soy-based material binder including at least one of a soy protein isolate with a concentration in the range of 1 to 20% of soy protein isolate by weight. The method may further include adjusting the concentration of the soy protein isolate in the soy-based material binder based on road base attributes. Further still, the method may include determining the amount of soy-based material binder for a volume of application based on the concentration of soy protein isolate in the soy-based material binder and based on the road base attributes. Further still, the method may include applying the soy-based material binder to the road base.
The soy-based material binder may be selectively applied to a road base to improve hardness of a surface and/or suppress dust particles. For example, the soy-based material binder may aggregate fine particles such that the particles are retained along a surface, such as a roadbed. These binding and dust suppression characteristics may withstand environmental changes, including wind, snow, rain, heat, sunlight, etc. making the soy-based material binder a durable alternative to current stabilizers and dust suppressants.
In some embodiments, the binder may be used in other environments including hydroseeding, flowable fill, concrete additive, wood pelletization and/or feed pellet pelletization. The advantages of the present invention will be understood more readily after a consideration of the Detailed Description.
As described herein, a soy-based material binder may be produced using a soy base, such as a soy protein isolate or variant thereof derived from non-food grade soy product, in one example. The use of non-food grade soy product in a soy-based material binder may substantially reduce the costs of stabilizing roadways and may have minimal environmental effect.
Systems and methods for increasing road stabilization with a soy-based material binder are therefore described herein. In one example method, a soy-based material binder is generated. The desired concentration of the soy protein isolate (SPI) in the soy-based material binder may be determined by determining and/or assessing the road base attributes of the road base for application. For example, some attributes that may affect concentration of SPI in the soy-based material binder include chemical composition, hardness, and strength (e.g., shear strength). For example, when shear strength of a road base is less than a predetermined threshold, a higher concentration of SPI may be used in the soy-based material binder. The concentration of the SPI in the soy-based material binder may be adjusted based on road base attributes by being mixed into a solution, in one example. In other embodiments, the disclosed soy-based material binder may be applied in a solid form. Further, the amount of soy-based material binder for a volume of application may be determined based on the SPI concentration and road base attributes.
In one specific example described in detail herein, the soy-based material binder may be applied to a road base. In another example, the soy-based material binder may be used to prevent erosion of banks or fields. The soy-based material binder may operate to bind the aggregate particles and retain them in a form which creates a substantially durable hard surface, suppress dust particles and/or limit erosion, as some examples. These binding and dust suppression characteristics may withstand environmental changes, including wind, snow, rain, heat, and sunlight, as some examples, thus making the soy-based material binder a durable alternative to current stabilizers and dust suppressants. By mixing the soy-based binder into the road base, it may be possible to cost-effectively stabilize and improve the durability and life expectancy of the road. The mixture may provide a “concrete-like” or “paved-type” surface.
In contrast to prior stabilizers and dust suppressants, the soy-based material binder may reduce costs of the product to approximately as an eighth or a tenth of the cost for prior products. For example, known systems may use stabilizers which cost 70 cents per square yard, while use of the soy-based material binder may reduce the cost to 5 to 10 cents per square yard. In addition to the significant reduction in costs, the soy-based material may have high levels of binding capabilities and hardening capabilities.
The soy-based material binder may be configured to be applied to dirt and aggregate roadbeds and other similar surfaces. Although described primarily in regard to use as a soil stabilizer and/or dust suppressant in the present application, it should be appreciated that the soy-based material binder disclosed herein may be used as soil, road aggregate, coal ash aggregate, animal feed, wood chip/sawdust binder that may be used for fugitive dust control, road base and in-depth stabilization, erosion control, hydroseeding, flowable fill, concrete additive, wood pelletization and/or feed pellet pelletization.
Example methods to create and use the soy-based material binder and the composition of the soy-based material binder are provided below. It should be appreciated that such examples are provided for illustration and the invention is not so limited. References to weight percentages and mixtures are only examples and the examples are provided for illustrative purposes.
As illustrated in
The soy-based material binder in the following examples may be combined with one or more of a road surface aggregate to form a road base. The soy-based material binder may be included in the road base in the range of 0.0001-5 gallons per pound of road base in some examples.
In a first example, SPI alone, may be modified by heating and/or denaturing by acid or alkali pH modification, such as by use of cationic, non-ionic, or anionic surfactants or detergents, and/or the addition of an amino containing compound. Further, in some embodiments, the soy protein isolate, or modified soy protein isolate, may be used as an additive to: calcium, sodium, and/or ammonium lignosulfonates or calcium, magnesium, and/or sodium chloride (or a combination of) and used as described above.
In another example, soy protein concentrate alone, may be modified by heating and/or denaturing by acid or alkali pH modification, such as by use of cationic, non-ionic, or anionic surfactants, and/or the addition of an amino containing compound. Further, in some embodiments, the soy protein concentrate, or modified soy protein concentrate, may be used as an additive to: calcium, sodium, and/or ammonium lignosulfonates or calcium, magnesium, and/or sodium chloride (or a combination of) and used as described above.
Likewise, in another example, defatted soy (such as flakes, meal, and flour), or modified defatted soy, such as through modification by heating and/or denaturing by acid or alkali pH modification, such as by use of cationic, non-ionic, or anionic surfactants, and/or the addition of an amino containing compound, may be used. Further, in some embodiments, the defatted soy or modified defatted soy may be used as an additive to: calcium, sodium, and/or ammonium lignosulfonates or calcium, magnesium, and/or sodium chloride (or a combination of) and used as described above.
In yet additional examples, full fat soy flour soy, low fat soy flour, or high fat soy flour and/or modified full fat soy flour soy, modified low fat soy flower, or modified high fat soy flour, such as through modification by heating and/or denaturing by acid or alkali pH modification, such as by use of cationic, non-ionic, or anionic surfactants, and/or the addition of an amino containing compound, may be used alone or in combination. Further, in some embodiments, the full fat soy flour soy, low fat soy flour, or high fat soy flour and/or modified full fat soy flour soy, modified low fat soy flower, or modified high fat soy flour, may be used as an additive to: calcium, sodium, and/or ammonium lignosulfonates or calcium, magnesium, and/or sodium chloride (or a combination of) and used as described above.
In another example, lecithinated soy flour or modified lecithinated soy flour, such as through modification by heating and/or denaturing by acid or alkali pH modification, such as by use of cationic, non-ionic, or anionic surfactants, and/or the addition of an amino containing compound, may be used. Further, in some embodiments, lecithinated soy flour or modified lecithinated soy flour may be used as an additive to: calcium, sodium, and/or ammonium lignosulfonates or calcium, magnesium, and/or sodium chloride (or a combination of) and used as described above.
As another example, rapeseed protein isolate or modified rapeseed protein isolate, such as through modification by heating and/or denaturing by acid or alkali pH modification, such as by use of cationic, non-ionic, or anionic surfactants, and/or the addition of an amino containing compound, may be used. Further, in some embodiments, rapeseed protein isolate or modified rapeseed protein isolate may be used as an additive to: calcium, sodium, and/or ammonium lignosulfonates or calcium, magnesium, and/or sodium chloride (or a combination of) and used as described above.
In yet another example, fava bean protein concentrate or modified fava bean protein concentrate, such as through modification by heating and/or denaturing by acid or alkali pH modification, such as by use of cationic, non-ionic, or anionic surfactants, and/or the addition of an amino containing compound, may be used. Further, in some embodiments, fava bean protein concentrate or modified fava bean protein concentrate, may be used as an additive to: calcium, sodium, and/or ammonium lignosulfonates or calcium, magnesium, and/or sodium chloride (or a combination of) and used as described above.
The soy-based material binder 100 may be comprised of a variety of components as described above. For example, the soy-based material binder may include a variety of secondary stabilizers 112 including clay, powdery fly ash, bottom ash, ammonium lignosufonates, and a resin product, as examples.
The following experimental results of soy-based material binders have been observed. Mixture A: 6.2% SPI material binder by weight produced a hard mixture. Mixture B: 20.0 g of 6.2% SPI material binder by weight mixed with 100.1 g of dry heavy clay produced a mixture which set up hard. Mixture C: 50 g 6.2% SPI material binder by weight mixed with 100 g of powdery fly ash produced a very hard mixture. Mixture D: 20 g of 6.2% SPI material binder by weight mixed with 100.1 g of sand-like bottom ash produced a very hard mixture. Mixture E: 50 g of 6.2% SPI material binder by weight mixed with 50 g 50% lignin solute (e.g., obtained by mixing 50 g ammonium lignosulfonate and 50 g water) produced a very hard mixture with darkened color.
The soy-based material binder may further be combined with a resin product. As an exemplary resin product, and not as a limitation, one product which may be mixed with the soy-based material binder is EARTHBIND® 100 manufactured by EnviRoad®. The combined binding materials may provide a high-level binder and dust suppression agent. The following experimental results have been observed. Mixture F: 0.25 gallons of concentrated EARTHBIND® 100 mixed with 1.25 gallons of H20 to obtain a 4:1 EARTHBIND® 100 solution. Then, 20.3 g of the 4:1 EARTHBIND® 100 solution was mixed with 105.9 g of sand and gravel to form a hard/very hard mixture. Mixture G: 50 g of the 4:1 EARTHBIND® 100 solution was mixed with 200 g 6.2% SPI material binder and a hard/very hard mixture with lighter color compared to Mixture F was produced.
It may be appreciated that the experimental mixtures described above are exemplary in nature and other embodiments of the soy-based material binder 100 combined with secondary stabilizers 112 including, as some examples, clay, powdery fly ash, bottom ash, lignins (e.g., ammonium lignosufonates), resin, and surfactants in different proportions may be included in the scope of the present application, for example as described in U.S. Publication No. 2006/0011105 A1 entitled “Composition and Method for Stabilizing Road Base”, hereby incorporated by reference for all purposes.
As described above, ash may be combined with the soy-based material binder and used in constructing a road base. The ash may be a byproduct/waste product of burning coal, including bottom ash, boiler slag, fly ash, and mixtures of such ashes. As an example, the fly ash is typically a fine powder-like substance formed from the mineral matter in some coal, including the noncombustible matter in coal plus a small amounts of carbon that remain from incomplete combustion. In some embodiments, fly ash may comprise mostly silt-sized and clay-sized glassy spheres, with a consistency somewhat like talcum powder. Properties of fly ash may vary with coal composition and plant-operating conditions. For example, the properties of fly ash may vary on different operations within the coal plant, such as selection, carbon reduction, classification, grinding, blending and homogenization.
As described above, the mixture may also include a secondary stabilizer, such as a liquid lignin, such as lignin sulfonate. Lignin sulfonate, as used herein, is a metallic sulfonate salt made from the lignin of sulfite pulp-mill liquors. Such lignin sulfonate may be approximately 20 wt. % to 60 wt. % of the overall composition. Lignin sulfonate may act as a watering agent and as a soil stabilizer to bind to various types of soils and ash. The combination of the petroleum resin and the lignin sulfonate result in a composition that is adapted to provide effectively binding of various types of soils particles and/or ash together. Further, it may also generate a substantially waterproof surface. This binding may further function to mitigate airborne particles and prevent the soil or ash from dispersing over time from roadway use.
It should be appreciated that various types of lignin sulfonates may be used. For example, both ammonium lignin sulfonate and/or a calcium lignin sulfonate are suitable lignin sulfonates. It should be appreciated that other types of lignin sulfonates may be used, including, but not limited to sodium lignin sulfonate. The type of lignin sulfonate used may depend on the specific application of the composition. Thus, in the exemplary composition, ammonium lignin sulfonate is identified as a suitable lignin sulfonate; however it should be appreciated that for other road surfaces or conditions a different lignin sulfonate may be used. The ammonium lignin sulfonate of the exemplary composition is shown as being generally 15 wt. % to 45 wt. % of the composition.
In addition to a petroleum resin and the lignin sulfonate, the composition further may include approximately 1 wt. % to 20 wt. % of a surfactant, also referred to herein as the emulsifier. The surfactant in the composition may optionally be a non-ionic surfactant. For example, alkylphenols, such as a nonylphenol (C9H19C6H4OH), may be used as the non-ionic surfactant. The present surfactant functions as an emulsifier which is adapted to wet out various types of soil surfaces (regardless of charge). Unlike an oppositely-charged surfactant system, which is configured to wet only a specific surface type, the present emulsifier may be adapted to wet a variety of surfaces making the overall composition extremely versatile.
In an oppositely-charged surfactant system, the type of particles and/or soil may require use of a different charged emulsifier. For example, with limestone aggregates (having a positive charge on the surface), a negatively-charged emulsifier (anionic) may be used to obtain a desired level of wetting of the particles. Similarly, a granite surface (having a negative charge on the surface), may be suitable for a positively-charged emulsifier (cationic) to get the best wetting of the particles. In the present composition, the non-ionic emulsifier enables maximum wetting of the different types of particles, such as soil. Thus, the non-ionic emulsifier is adapted to wet out both cationic and anionic soils (e.g., limestone and granite, respectively) quickly and more efficiently than using an oppositely-charged surfactant system. It should be appreciated that the wetting of the soil enables the petroleum resin to come into closer contact with individual particles. The ability to come into closer contact may result in more thoroughly coated particles, creating a more weatherproof surface once compacted.
Another consideration regarding the emulsifier is the overall stability of the emulsifier. A good emulsifier for the present composition may be a stable product that is easily useable in the field. Further, the emulsifier should be easy to store and transport, such that there are no difficulties in transporting or handling the composition or its components.
It should be appreciated that the soy-based material binder, including or not including the EARTHBIND® 100 may be stored in a concentrated form and diluted prior to application. For example, the product may be used at water-to-product concentrations of 3:1 to 20:1 depending on the soil type, traffic flow, amount of ash and other environmental factors.
Several exemplary methods for increasing road stabilization with a soy-based material binder are illustrated in
A method for increasing road stabilization is illustrated in
An exemplary experimental series of the hardness and shear strength observations of soy protein isolates and variants when mixed with coarse sand, dirt and/or gravel, as described above, is provided in Chart A below. Controls are also listed in the chart below and are italicized.
In one example, 10 g of SPI is the primary ingredient and is dissolved in water such that the SPI is 6.7% by weight. There is no secondary ingredient in this example. The observations include very hard hardness, excellent shear strength, and no odor. Further, it has a high level of bonding and stabilization potential. Further still, it was observed to be close to colorless when dry. In another example, Ticagel (a gum) was the primary ingredient, used here as a hydrocolloid to help a mixture of soy stay in suspension. Each of the other examples in Chart A may be similarly understood.
Additional tests were completed to identify the effects of overnight soaking of the various soy-based material binders in bonded form. The materials remained in a bonded form after overnight soaking. In some embodiments, the soy-based material remained relatively hard. For example, the hydrated lime and soy protein isolate combination was observed to be moderately hard after a 24 hour soaking. As another example, the soy protein isolate in the dry form was observed to be less hard than the hydrated lime and soy protein isolate combination after a 24 hour soak but the materials remained in a bonded form. Similarly, the soy protein isolate and calcium chloride combination was observed to be less hard than the hydrated lime and soy protein isolate combination after a 24 hour soak but the materials remained in a bonded form. The remaining example materials, as illustrated in Chart A, remained in a bonded form after an overnight soaking and were less hard than the three above described examples.
Thus, it may be appreciated that the hardness and shear strength measures of the soy-based material binder may depend on the composition of the soy-based material binder. Further, it may be appreciated that said measures may be affected by, at least, road base attributes. Referring now to
If the answer is yes at 310 (e.g., the road base is hard gravel), the method may include combining an SPI and secondary stabilizers with water (H20) to create a 5.0% SPI material binder, as depicted in this example at 316. This may involve diluting a 6.2% SPI material binder, in one example. Thus, the 5.0% SPI material binder may be combined with the road base at 318. As one example, 10.1 g of 5.0% SPI material binder may be combined with 100.1 g of sand, dirt, and/or gravel to create a mixture. In another example, a low concentration soy-based material binder, such as a 5.0% SPI material binder may be used as a dust palliative. It may be appreciated that the soy-based material binder may include SPI in the range of 1% to 100%.
Thus, it may be appreciated that as the strength of the road base decreases, the concentration of soy protein isolate in the soy-based material binder may increase. Further, as the strength of the road base increases, the concentration of soy protein isolate in the soy-based material binder may be decreased.
In other embodiments, the soy-based material binder, such as soy protein isolate, defatted soy, etc., alone or in combination with other additives, may be applied to the surface of the soil in a solid form, such as in a flake form.
To create a mixture including the soy-based material binder, ready for use in a roadbed, an example method flowchart for preparing the soy-based material binder is shown in
Another example method flowchart for preparing the soy-based material binder ready for use in a road base is shown in
In other example methods, the soy-based material binder may or may not be heated. Further, with respect to
Soy-based material binder may be mixed and applied to a road base in a variety of ways. As noted above, a durable, stabilized road base may be obtained using a process that uses the existing roadbed soils. Exemplary method flowcharts are shown in
Referring now to
Referring now to
An exemplary experiment to determine the density of sand, dirt, and gravel including a soy-based material binder in a quantity of water was conducted. As an example, 318.7 cubic centimeters of H20 was combined with 476.1 g of sand, dirt, and gravel, including a soy-based material binder, such that the density was 1.49 g/cubic centimeter. Subsequent unit conversion examples were conducted to determine that 380 lbs of the sand, dirt, and gravel including a soy-based material binder may be used for a cubic yard with a depth of 4 inches. Thus, one embodiment of the soy-based material binder may include creating 1.25 gallons of a 4:1 EARTHBIND® 100 mixture, such as that of mixture G described above including 0.25 gallons of concentrated EARTHBIND® 100 and 1 gallon of 6.2% SPI material binder for 1 cubic yard with a depth of 4 inches. In one example, 1 cubic yard with a depth of 4 inches may include 380 lbs of soil. Thus, 0.00329 gallons of the 4:1 EARTHBIND® 100 mixture may be used for 1 lb of soil.
Depending on the application and the soil material, various tilling depths may be used, such as 1-3 inches, 0.5-5 inches, 5-10 inches, etc. Further, various blends of soy-based material binder may be introduced such as 1-5%, 5-50%, 20-30%, 10-40%, 25-50%, 35-45%, etc. By varying the amount of soy-based material binder, water and tilled soil and other additives (fly ash, bottom ash, lignin, surfactants, etc.) the strength of the mixture and the mixed composition may be tailored to the specific needs of the roadway.
Further still, it should be appreciated that the amount of SPI, or variant thereof (soy protein concentration, defatted soy, etc.) in the soy-based material binder described in the present application may be varied between 1-100% depending on the application and other factors, including the type of road base or road surface material that the product is to be bonded. Moreover, the amount and concentration of SPI may further be based on the strength of a road base, the moisture content of the road base, or the specific type of road base (e.g. sand, dirt, gravel). Further, the amount and concentration of SPI may be varied depending on the type of road surface. For example, for a hard gravel surface, a reduced amount of binder may be used, while on a sand surface, a more concentrated solution may be used.
For illustrative purposes, in some embodiments, the SPI may be mixed in water in a 6.2% solution or 5.0% solution by weight. As described above, such weight percentages are provided for illustrative purposes only and are not intended to be limiting in any sense. Thus, it may be appreciated that one or more protein isolates or variants thereof may comprise the soy-based material binder alone.
The soy-based material binder and mixture compositions herein described may be used for a variety of applications other than road base stabilization and dust abatement. For example, the composition further may be applied to bare soil surfaces to control erosion and aid in vegetation establishment. For example, the composition may be added to a hydroseeding mix as a seed tackifier. Hydroseeding is a planting process that includes application of a mixture to a soil surface. The hydroseeding mix may include a mix of seed, fertilizer, tackifier, and a fiber medium, such as a cellulose fiber or wood fiber. Once combined, the hydroseeding mix may be applied to a soil surface. For example, the mix may be sprayed onto the surface to form a blanket or mat that protects and stimulates the seeds to begin growing.
Newly planted seeds are vulnerable to wind and rain. The present composition functions as a tackifier in the hydroseeding mix by preventing erosion of the soil surface. The composition further prevents the seeds within the hydroseeding mix from being washed away in a heavy rain. The present composition further functions to minimize subsurface water loss once the hydroseeding mix is applied. Specifically, the composition aids in retaining moisture within the soil and further protects the soil surface from winds, which may dry the soil surface.
In some embodiments, the mixtures of the soy-based material binder also may effectively aid in seed growth. For example, application of the soy-based material binder in a mixture with lignin may, in addition to providing an erosion protected surface, may also operate to darken the soil surface, thereby causing the soil surface to absorb more radiant energy. The absorption of more radiant energy within the soil may result in an increased soil temperature, which may accelerate seed germination.
In addition, the soy-based mixture may be used to generate pellets, including animal and feed pellets, as well as wood or fuel pellets. The binder may bind the feed product or wood product to form pellets. The pellets may be of a select hardness to maintain form regardless of environmental conditions, storage conditions, etc.
It is believed that the disclosure set forth above encompasses multiple distinct inventions with independent utility. While each of these inventions has been disclosed in its preferred form, the specific embodiments thereof as disclosed and illustrated herein are not to be considered in a limiting sense as numerous variations are possible. The subject matter of the inventions includes all novel and non-obvious combinations and subcombinations of the various elements, features, functions and/or properties disclosed herein. Similarly, where the claims recite “a” or “a first” element or the equivalent thereof, such claims should be understood to include incorporation of one or more such elements, neither requiring, nor excluding, two or more such elements.
Inventions embodied in various combinations and subcombinations of features, functions, elements, and/or properties may be claimed in a related application. Such claims, whether they are directed to a different invention or directed to the same invention, whether different, broader, narrower or equal in scope to any original claims, are also regarded as included within the subject matter of the inventions of the present disclosure.
This application claims priority from U.S. Provisional Patent Application No. 60/999,947 of Donald Blackmon and Swayne Walther, entitled “COMPOSITION AND METHODS FOR MATERIAL BINDER” filed Oct. 22, 2007, the disclosure of which is hereby incorporated by reference in its entirety and for all purposes.
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| 60999947 | Oct 2007 | US |
