Patent Application
20180258599
The present invention relates to a collection kit for the removal of unwanted material from a surface or a workplace. The kit itself includes an apparatus having a magnetic source and ferromagnetic material. In operation, the ferromagnetic material is adapted to be spread over the unwanted material so as to absorb and/or adsorb that material. The kit is operable to remove that material for disposal. The apparatus may be adapted for both domestic and/or commercial use. The unwanted material may be oils, fats, chemicals, paints, abattoir wastes, wine and other materials.
The present invention also relates to ferromagnetic material that has been specifically formulated for use with the collection kit. The ferromagnetic material of the present invention is formulated to be substantially lighter than iron powder alone, which makes it suitable for use with the preferred magnetic source apparatus.
The present invention also relates to a method for cleaning unwanted material from an area of operation which involves spreading the ferromagnetic material across the unwanted material such that the ferromagnetic material absorbs and/or adsorbs the unwanted material. The ferromagnetic material is attracted to the magnetic source, and may be disposed of once the magnetic source is withdrawn from the area of operation, or the ferromagnetic material is moved from the vicinity of the magnetic source.
Oil spills of varying descriptions are a common occurrence in an industrialised world. The form of an oil spill varies from the somewhat catastrophic, for example as the result of oil rig or tanker accident, to everyday occurrences in the workplace or home, to the somewhat minor that may be associated with personalised oil spills from automotive engines. The manner in which such oil spills are cleaned up to any degree also substantially varies depending upon the size of the oil spill, availability of appropriate technology and immediate consequences that may have resulted from such an oil spill.
When oil spills occur in a water environment, the oil forms a thick slick that floats on the water. The oil eventually spreads out, so it is paramount to contain it as rapidly as possible allowing skimming to occur to clean up the oil slick.
An unfortunate consequence that occurs when oil spills occur in such environments is that bird and sea life become coated with the oil slick. Where possible, bird life, including penguins, may recover if the oil is removed in a prompt enough manner.
Generally, such bird life may be washed with detergents to remove the oil. This has been found to be relatively effective although the use of detergents may also have a detrimental effect upon the bird life. Further, cleansing facilities are hard to transport to remote areas.
The use of ferromagnetic material, such as gamma-iron oxide or iron powder to assist in the cleaning of wildlife has been used where the ferromagnetic material is spread onto the oiled wildlife to absorb and/or adsorb the oil and then removed by the use of a magnetic wand to remove the ferromagnetic material from the bird together with the absorbed and/or adsorbed oil. The hand held magnetic device needs to be wiped clean to remove the oil laden ferromagnetic material. This has proven to be an effective means to clean wildlife affected by oil spills without the detrimental effects of detergents.
U.S. Pat. No. 389,024 describes a similar process where a polymer material is used, together with a ferromagnetic material, to provide additional absorption for the oil.
Whereas the use of ferromagnetic material and a hand held magnetic device have proven to be an effective means in which to clean oil from wildlife, such devices are not generally applicable to a broader range of situations where oil may be at issue, such as roads, home or in the workplace. Further, such devices have not been developed to clean up other types of unwarranted matter such as domestic or industrial cooking fats, paints, abattoir wastes and the like.
Other magnetic devices have been used to clean up metallic objects from roads and like surfaces, where a magnet may be swept over the surface to attract metal objects such as tacks, scrap metal or the like, that may have been spread over the surface. Such devices generally take the form of a trolley having a magnetic source as part of the underside carriage. These are adapted to attract metallic objects, and not adapted for use to clean up oil spills or the like.
It is a desired feature of the present invention to provide a magnetic collection kit that is applicable to a broad range of environments and situations, both domestically and on a commercial or industrial scale, where unwanted material such as oil spills and the like, needs to be removed and disposed of safely. Such devices may simultaneously pick up metal scraps.
It is a further desired feature of the present invention to provide a collection kit including a magnetic device that may be operated in a convenient manner where disposal of the unwanted material is relatively simple.
It is a further desired feature to provide a method for cleaning up unwanted material with a magnetic collection kit that is able to be applied to a variety of different environments.
It is a further desired feature to provide a ferromagnetic material that is formulated to be substantially lighter than iron powder yet still suitable for use with a magnetic device for the removal of unwanted material.
The present invention aims to provide a collection kit, including formulated ferromagnetic material suitable for use with the collection kit, and a method that meets these desired features.
A reference herein to a patent document or other matter which is given as prior art is not to be taken as an admission that that document or matter was known or that the information it contains was part of the common general knowledge as at the priority date of any of the claims.
Where the term “comprising” or variations thereof such as “comprises” has been used in the present specification, it will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.
The present invention relates to a collection kit that generally includes a magnetic source and ferromagnetic material that is able to absorb and/or adsorb unwanted material such as oil, fats and the like. The kit is generally operable when the ferromagnetic material is spread over the unwanted material to create an area of operation. The term, an area of operation as used herein is intended to refer to that area, such as a hard surface, where unwanted material such as oil and the like has spread. That is, the surface to be cleaned. The area of operation is created when the ferromagnetic material is spread over the unwanted material to absorb and/or adsorb that material. The collection kit is then able to remove the ferromagnetic material from the area of operation by the magnetic source. The attracted ferromagnetic material is then able to be dislodged from the magnetic source generally by removing the magnetic source from the vicinity of the ferromagnetic material, or removing the attracted ferromagnetic material from the vicinity of the magnetic source.
In a first embodiment, the present invention provides a collection kit for the removal of unwanted material from a surface, said kit comprising:
The magnetic source itself may simply be a magnet or magnets that are able to directly contact the ferromagnetic material, or be associated with an operable surface that covers the magnetic source with the magnetic source being operable through the operable surface. The operable surface itself may preferably be in the form of a ferromagnetic material when the device is placed near the area of operation. The device would then be operated to remove the attracted ferromagnetic material from the area of operation so that the ferromagnetic material together with the absorbed and/or adsorbed unwanted material is transferred to a collection site. The ferromagnetic material is released from the magnetic source by removing the magnetic source, moving the operable surface to a position away from the magnetic source, or scraping the ferromagnetic material from the magnetic source if the magnetic source has moved with the drum. The ferromagnetic material together with the absorbed and/or adsorbed material is then collected for disposal.
In one embodiment, the magnetic source is generally associated with an operable surface that may itself be magnetised when the magnetic source is touching or in the vicinity of the operable surface. Alternatively, the magnetic source may operate directly to attract the ferromagnetic material. For example, the operable surface itself could move with the magnetic source, for example in a rotating belt like arrangement and essentially the ferromagnetic material, together with the absorbed and/or adsorbed waste material is removed from the operable surface by removing the magnetic source from the operable surface, or removing the operable surface itself. Alternatively, the magnetic source may be in a fixed position while the operable surface rotates around the magnetic source moving the ferromagnetic material to a position away from the fixed magnetic source.
In an alternative embodiment, the operable surface is a collection belt that is fitted on a roller, with magnets located on the inside of the collection belt and able to rotate with the roller. The collection kit is able to be rotated over the unwanted material and ferromagnetic material, which form the area of operation. The collection belt may be moulded silicon or another appropriate material. Any ferromagnetic material attracted to the magnetic source may be dislodged from the operable surface by scraping or brushing the ferromagnetic material from the operable surface when it is rotated to a point away from the area of operation. Once dislodged, the ferromagnetic material, together with any absorbed and/or adsorbed unwanted material may be disposed of in an appropriate manner.
In a preferred embodiment, the drum is a rotating cylinder able to rotate around the bank of magnets that are internal of the drum and have an influence over part of the drum. The magnets are in a position to attract the contaminant-laden ferromagnetic material when the drum is in the vicinity of the area of operation, that is the surface to be cleaned. The ferromagnetic material is released when the drum is rotated to a position where the ferromagnetic material is not in the vicinity of the magnetic source and will be dislodged from the outer surface of the drum.
In one embodiment, the magnetic source may be fixed magnets located within the drum. The magnetic source may be arranged in a concentric wheel or part wheel within the drum and fixed in that position so as to have a magnetic influence over part of the drum. The ferromagnetic material will be attracted to the magnetic source where the magnetic source is operable through the drum and will move with the rotating drum to a location removed from the magnetic influence of the magnetic source. When the ferromagnetic material has reached a point removed from the magnetic source, it will be dislodged from the drum, preferably with the use of a scraper or more simply through gravity or centripetal force.
In a most preferred form the magnets may be arranged so as to assert graduation in the magnetic field, such that the stronger magnetic influence on or through the drum is near the area of operation, that is near the surface to be cleaned. This may be achieved in a number of different ways. In one preferred embodiment, stronger magnets, such as rare earth magnets, are used at or near the area of operation. The stronger magnets here are able to attract a greater proportion of the contaminant-laden ferromagnetic material, and act as lifter magnets.
As the drum is rotated around the bank of magnets, ceramic magnets, which are not as powerful, may be positioned at stations slightly removed from the area of operation. These magnets act as carrier magnets.
As an alternative, or in conjunction, the carrier magnets may simply be positioned further away from the inner surface of the drum. This will assist in reducing the magnetic force and optimise release of the ferromagnetic material from the drum as the drum rotates. That is the lifter magnets will be positioned either touching, or close to the inner surface of the drum, while carrier magnets may also be touching but generally are positioned further away from the inner surface of the drum. It is preferred that there is at least some distance, say at least 2 mm in gap between both the lifter and carrier magnets and the inner surface of the drum. In this embodiment, the magnets may either be of the same or different types of magnets, but preferably different types of magnets.
In a preferred embodiment, the operable surface such as a drum is fitted with cups or fins on its outer surface to assist in trapping and holding the contaminant-laden ferromagnetic material. The cups or fins also assist in releasing the ferromagnetic material when combined with the centripetal force achieved with rotation of the drum. The cups or fins may be in any configuration including being rounded to form a scoop, or angled forward to trap the ferromagnetic material as it lifts it from the surface. In a preferred form, the drum has fins angled at 90° from the surface and of a length of 1 to 50 mm, and spaced 20 to 100 mm apart. It should be appreciated however that other angles, fin sizes and spacing could be used.
In an alternative embodiment, the drum may be a stationary cylinder and the magnetic source is a concentric wheel or part wheel or a bank of magnets internal of the drum that is able to rotate within the drum. The wheel or bank of magnets may be positioned such that it has a magnetic influence over part or the whole of the drum, but is positioned so that it is able to rotate to drive the attracted ferromagnetic material around the surface of the drum until it reaches a point where the ferromagnetic material is dislodged from the surface, preferably with a scraper or the like, or more simply through gravity or centripetal force, where it is collected for disposal purposes or recycle.
In yet a further preferred embodiment, both the drum and magnetic source each rotate. The apparatus may include either a motor or appropriate gearing to drive the outer cylinder and magnetic source in the same direction, or opposite directions. In a preferred embodiment, the drum and inner wheel of magnets will rotate in the same direction, but will be geared to rotate at different rates. It is believed that the speed differential may optimize the efficiency of the pick-up of the ferromagnetic material.
The drum and the concentric inner magnetic source are preferably mounted on a transport means that will allow the apparatus to be moved over the surface to be cleaned. The transport means is preferably a trolley or chassis having its own set of outer driving wheels that will allow the drum or alternative operable surface such as a rotating belt, to be moved across the area of operation. The trolley or chassis serves the purpose of maintaining the drum at an operating height above the ferromagnetic material that has been spread across the surface to be cleaned, such that the magnetic source is able to assert a magnetic influence on the ferromagnetic material and attract it to the outer surface of the drum while still being clear of the material for ease of being able to move the apparatus over the ferromagnetic material. Preferably, the drum is not at a level to touch the ferromagnetic material when spread across the contaminated area, but is at a height just above that level. The trolley or chassis may have means to be able to adjust the height of the outer cylinder in operation.
In a most preferred embodiment, the outer driving wheels of the trolley rotate in the opposite direction to the drum, while the bank of magnets remains fixed. This may be achieved through appropriate gearing between the drum and driving wheels. Rotation of the drum in the opposite direction allows the ferromagnetic material to be released to a collection tray at the back of the trolley. This has the advantage that the collection tray will not interfere with the forward movement of the trolley allowing for greater access to the area to be cleaned.
A preferred gearing arrangement is such that at least one of the outer driving wheels has a gear moulded within the inner surface of that wheel. This gear engages with and turns a one-way bearing. This may include a clutch type arrangement if desired. The one-way bearing turns a smaller gear which rotates the drum in the opposite direction to the outer driving wheels when in a forward motion.
The one-way bearing will allow the drum to spin in one direction only. A brake mechanism is not needed as the friction of the gears will slow the drum as necessary. A clutch type arrangement may be incorporated to allow the drum to spin freely in the same direction (opposite the forward moving driving wheels) or remain stationary. The one-way bearing or clutch arrangement will allow the driving wheels to be able to be moved backward and forward without affecting the rotation of the drum, which will rotate in the one direction only.
Maintaining the reverse direction of the drum will allow the collection kit to continue to pick-up the ferromagnetic material and distribute it to a collection tray which is located at the rear of the trolley. The rotation of the drum should continue in a reverse direction regardless of whether the direction of the driving wheels of the trolley is in a forward or backward direction. This will allow the centripetal momentum of the rotation of the drum to continue allowing continued distribution of the ferromagnetic material to the collection tray at the rear of the trolley.
The speed of the drum or the concentric magnetic source will generally be controlled to maintain the ferromagnetic material on the surface of the drum. The rotational speed of the drum may be generated by the movement of the trolley anywhere from just below walking pace to more high speed, if for example, trailed behind a car or incorporated into a mobile device. The rotational speed may also be controlled by the internal gearing ratios, and may be designed to be variable. The ideal speed of rotation will depend on factors such as the magnetic strength used, and the composition of the ferromagnetic material and the clean-up scenario.
The drum itself may be made from any suitable material that is able to permit the magnetic source to operate through the cylinder and where the material from which the drum is comprised does not itself have any significant affinity for the contaminated material that is to be picked up. Suitable materials include certain plastics, stainless steel and aluminium.
The collection kit includes ferromagnetic material, which is preferably zero valent iron powder or a composite of zero valent iron powder with other powdered magnetic materials such as magnetite or magnetised material. In one preferred form, the iron powder is combined with another material such as a non-magnetic absorbent and/or adsorbent material that will significantly reduce the weight of the ferromagnetic material when compared to iron powder alone, without significant loss of magnetic qualities.
It is preferred that the iron powder particles are spongy grade, but other grades are possible including atomised or annealed particles. The particles themselves may be course, fine or super-fine but preferably have an average particle size of between 5 and 500 microns, preferably between 5 and 200 microns, but most preferably with an average particle size of between 30 to 50 microns. The shape of the particles is preferably irregular and the density, surface features, surface area and porosity may vary depending upon the final intended use. The ferromagnetic material is able to absorb and/or adsorb unwanted materials such as oils, fats, paints, chemicals, abattoir wastes, wine, detergents, and the like. The ferromagnetic material itself may be optimised depending upon the use to which it is likely to be put.
In a further embodiment, the present invention resides in a ferromagnetic material suitable for use with the collection kit of the invention. In this embodiment, the ferromagnetic material is preferably iron powder that has been blended or reacted with a non-magnetic absorbent and/or adsorbent material such that the non-magnetic material is able to integrate with the ferromagnetic material. The non-magnetic absorbent material may be any form of absorbent and/or adsorbent material and could include paper or plastic particles or commercial products including clays and zeolite based products for example, a kitty litter type product. Most preferably, the non-magnetic absorbent material is a zeolite product.
The blending or reacting of the ferromagnetic material with the non-magnetic material may be in any ratio, dependent upon the need. For example it may be in a volume ratio of from 5% to 95% ferromagnetic material with 5% to 95% non-magnetic material, dependent upon the particular application but such that the non-magnetic material is sufficiently integrated with the ferromagnetic material to also be attracted to the magnetic source and achieving an effective contaminant absorption and/or adsorption. Preferably, a relatively even volume ratio of between 40% to 60% of each material is used, and most preferably in an approximately equivalent ratio by volume.
The benefit of blending or reacting a non-magnetic absorbent material is that the ferromagnetic material itself may not satisfactorily pick up oil from a surface. In some circumstances the non-magnetic material, such as zeolite, may not bind sufficiently to the iron powder, even in the presence of oil. It is now considered by the Applicants that the efficiency of blending a non-magnetic material with the ferromagnetic material is improved if the non-magnetic material, such as a zeolite-based product is soaked, for example in a solution of, for example ferric chloride or other salts, so as to impart a charge to the zeolite. Preferably, the zeolite material is soaked in a saturated aqueous solution of ferric chloride for several days for maximum absorption and/or adsorption of ions onto or into the zeolite. A period of anywhere from 12 hours to 5 days may occur, preferably 2 days to 4 days. The resulting material may then be filtered and oven dried at around 50° C. to 70° C. The resultant charge on the non-magnetic material assists it in being integrated with the ferromagnetic material allowing for a consolidated blend such that the blend itself will be attracted to the magnetic source.
It is believed that a modified zeolite of this type has a greater attraction for the surface of the iron particles forming a more coherent blend. For a 50/50 blend of the treated (charged) zeolite with iron powder, a significant improvement in the integrity of the mixture was observed upon oil pick-up. Furthermore, most of the oil could be harvested from this blend.
Further, the zeolite/iron powder blend is significantly lighter than the iron powder alone. A weight reduction of up to 65% may be achieved without significant loss of magnetic character.
The non-magnetic absorbent and/or adsorbent material may take any form and would include such material as absorbent and/or adsorbent clay; zeolites; aluminium silicates and minerals; recycled waste wood products; paper products; grain by-products or other naturally occurring absorbent material such as pelletised corn cobs or wheat grass or straw products. Preferably, the non-magnetic material includes paper, clays and zeolite products. Most preferably the non-magnetic material is a modified zeolite where the characteristics of the zeolite have been modified by soaking the zeolite in a ferric chloride solution or other salts. The particle size of the non-magnetic material depends upon the material which is used but may vary from 5 microns to 100 microns and then blended or reacted with the ferromagnetic material. The blended or reacted material may be subject to grinding to achieve particle-size consistency.
In a most preferred embodiment, the operable surface is a drum, with a bank of fixed magnets within the drum and housed in a trolley. The drum is geared so that it rotates in the opposite direction to the driving wheels of the trolley. Preferably the bank of magnets includes lifter magnets, preferably rare earth magnets at or near the area of operation, and carrier magnets of lesser strength away from the area of operation. The carrier magnets may be magnets that are of a lesser strength such as ceramic magnets, or may simply be positioned further away from the inner surface of the drum creating a lesser magnetic field strength. The carrier magnets allow for easier removal of the ferromagnetic material from the drum, together with the centripetal force of the rotating drum, when the drum is away from the area of operation. A collection basket or tray at the rear of the trolley may be provided to catch the released ferromagnetic material.
The collection device is useful for cleaning up oils and it is anticipated that it will also be useful for cleaning up fats, paints, chemicals, abattoir wastes, wine, detergents or any other material that is able to be adsorbed and/or absorbed by the ferromagnetic material.
The present invention is described with reference to the accompanying drawings. It is to be understood that these drawings are merely illustrative of preferred embodiments, and the invention as described and claimed herein should not be considered to be limited thereto.
The present invention is illustrated with reference to
In a preferred embodiment illustrated with reference to
Ferromagnetic material is placed over the spilled unwanted material to be absorbed and/or adsorbed by the ferromagnetic material. In use, the trolley type device will roll over the ferromagnetic material that has been spread over the unwanted material such that the collection belt operates just above the ferromagnetic material, while the driving wheels (2) run on the surface to be cleaned.
In the cut through illustration of
When the magnets are in the lower position (7), they are able to attract the ferromagnetic material that has been spread over the unwanted material (not shown), such as oil, to the collection belt. The ferromagnetic material rotates with the collection belt as the belt wheels and magnets rotate. The ferromagnetic material remains on the collection belt until it reaches Point (8) where cleaning bristles (9) (see
The collection belt together with the magnets continues to be rotated and collect further ferromagnetic material together with the adsorbed and/or absorbed unwanted material.
The height of the collection belt may be adjusted through the collection belt height adjustor (11). Stability casters (12) may also be provided. There is also a gear box assembly (13) that allows rotation of the main driving wheels to translate the rotation of the belt wheels and hence the rotation of the collection belt.
The apparatus is able to be rolled over ferromagnetic material (1) such that the ferromagnetic material will be attracted to the magnets and will become fixed to the rotating drum when in the vicinity of the magnets. The drum will rotate in the direction of arrow (17) while the wheel of magnets will remain in a fixed position.
The rotating drum may also be operated to rotate in the opposite direction and at a controlled rotation rate, sufficient to maintain the ferromagnetic material on the surface of the drum. The apparatus may include a motor or gearing mechanism (not shown) to control the direction and rate of rotation of the rotating drum. The ferromagnetic material will be dislodged from the rotating drum when it is no longer in the vicinity of the magnets and will fall into collection tray (10).
A further embodiment is shown in
In a comparable arrangement, both the drum and inner magnetic source may be geared to rotate either in the same direction or in opposite directions and at the same or differing speeds. The apparatus may be designed to allow for variation in the set-up of the movement, both direction and speed, of the drum on the inner concentric magnetic source dependent on the need.
As an alternative, or in conjunction with different magnet types being used, the magnets themselves may be placed at a graduation of distances from the surface to be cleaned. As illustrated in
The ferromagnetic material is picked up at the surface to be cleaned, and is rotated with the assistance of cups or fins (28) to a position away from the surface to be cleaned, where the contaminant-laden ferromagnetic material is then released to collection tray (29), assisted by the centripetal force. The ferromagnetic material (30) may then be disposed of or potentially recycled.
The zeolite used was commercial grade “SpillZorbe”.
The iron powder was supplied by Hoganas AB Grade MH300.29 spongy annealed superfine (average particle size 37 microns).
A quantity of the zeolite material was soaked in a saturated aqueous solution of ferric chloride, FeCl3, allowing several days for maximum absorption and/or adsorption of ions into the zeolite to occur. The resulting material was then dried in an oven (to constant weight) at around 60° C. This is referred to as the “modified zeolite”.
The modified zeolite was ground to a finer powder using a mortar and pestle and intimately mixed (with stirring) with an equivalent amount (by solid volume) of the iron powder.
A vigorous exothermic solid-state reaction ensued and appeared to be complete after several hours. This reaction appeared to produce two products: (1) a dark, rusty-brown product that is highly magnetic and around 26% lighter than the iron powder (on a solid volume basis) and (2) a dark yellow powder that is slightly magnetic and that is 65% lighter than the iron powder. Due to their differences in magnetic susceptibility, products (1) and (2) could be magnetically separated from one another.
To make a Mark II version that is 50% lighter than the iron powder, product (1) and product (2) from Example 1 were recombined in equivalent proportion by solid volume and the mixture was ground using a mortar and pestle to produce a grey-brown powder. This blend is 50% lighter than the original pure iron powder and appears to be equally effective.
The effectiveness of this blend is shown in
The invention described herein is illustrative of the invention and provides examples of the best method of performing the invention. The invention described should be considered to be inclusive of minor modifications that may be made without departing from the spirit or ambit of the invention described.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2015903770 | Sep 2015 | AU | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/AU2016/050854 | 9/13/2016 | WO | 00 |
