PRODUCT FOR OIL POLLUTION REMEDIATION

Abstract

The invention is both a product and a method for the safe, harmless and effective remediation of oil spills on water and on land. The oil can then be successfully recovered from the product for use. The invention also allows for the reuse of two waste products—post consumer plastics and coal combustion product—into a material that is used for the clean-up of oil spills and for site remediation. Furthermore, the used product can be reprocessed post use into more usable product.

Claims

1. A method of making an oil remediation product comprising: heating a petroleum or crude oil until bubbling; adding plastic to the heated oil and melting the plastic until a paste-like viscosity is achieved; adding a coal combustion product to the mixture of oil and melted plastic; mixing the oil, melted plastic, and coal combustion product until a uniform distribution is achieved; and cooling the final mixture until the mixture is substantially solid.

2. A method of making an oil remediation product according to claim 1 and her comprising mechanically reducing the cooled substantially unitary mixture.

3. A method of making an oil remediation product according to claim 2 and further comprising mechanically reducing the product into particle sizes of 1 mm to 100 mm.

4. A method of making an oil remediation product according to claim 1 and further comprising melting the plastic at a temperature of between about 165° F. and 600° F.

5. A method of making an oil remediation product according to claim 1 and further comprising adding the coal combustion product to the melted plastic until the ratio of plastics to coal combustion products is between 70:30 (plastic to coal combustion product) and 80:20 (plastic to coal combustion product).

6. A method of making an oil remediation product according to claim 1 and further comprising cooling the mixture by removing the mixture from heat and allowing the temperature of the mixture to drop to the ambient room temperature.

7. A method of making an oil remediation product according to claim 1 wherein the cooling step comprises adding water to the mixture of melted plastic and coal combustion product to thereby solidify the mixture.

8. A method of making an oil remediation product according to claim 1 wherein the cooling step comprises placing the mixture of melted plastic and coal combustion product into a cooling or refrigerated chamber to thereby solidify the mixture.

9. A method of recycling plastic and coal combustion products comprising: placing post-consumer plastics in a heat-resistant receptacle; feeding coal combustion products into the receptacle; heating the receptacle at a temperature high enough to melt the plastics; thoroughly mixing the contents of the receptacle; and cooling the mixed contents of the receptacle.

10. A method of recycling plastic and coal combustion products according to claim 9 and further comprising cooling the mixed contents of the receptacle by removing the mixture from heat and allowing the temperature of the mixture to drop to the ambient room temperature.

11. A method of recycling plastic and coal combustion products according to claim 9 wherein the cooling step comprises adding water to the mixed contents of the receptacle to thereby solidify the mixture.

12. A method of recycling plastic and coal combustion products according to claim 9 wherein the cooling step comprises placing the mixed contents of the receptacle into a cooling or refrigerated chamber.

13. A method of remediating oil spills comprising: placing a solidified mixture of plastic and coal combustion product on an oil spill to thereby absorb the oil; and retrieving the solidified mixture with the oil entrapped in it.

14. A method of remediating oil spills according to claim 13 and further comprising removing the oil from the retrieved solid mixture.

15. A method of remediating oil spills according to claim 14 and further comprising applying the solidified mixture from which oil has been removed to a subsequent oil spill remediation after removing the oil from the solidified mixture from the first remediation.

16. A method of remediating oil spills according to claim 14 and further comprising burning the retrieved solidified mixture with the oil entrapped in it.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0025] FIG. 1 represents the process of making and use of the product. Number 1 is the melting of the post-consumer plastics in a vat with oil and the subsequent addition of CCPs, followed by cooling and solidification to form the product. Number 2 represents the shredding of the product into the appropriate sizes for oil absorption. Number 3 represents the addition of the product to an oil spill and the absorption of the oil into the product. Number 4 is the recovery of the oil from the product. Number 5 is the subsequent remelting of the used product, and solidification to form new product.

[0026] FIG. 2 schematically illustrates the particle ranges of the product that will absorb oils. The size of the particles increases from left to right. Due to the limitations of the page width, there is a discontinuum in the size scale represented by two diagonal lines and the number 9 on the figure represents a jump in the length of the size diagram. The size product particles in oval 6 are too small to be used for oil absorption and recovery in waters, but may be used for oil recovery on land. The particles sizes in oval 7 represent the optimal, but not only, usable size product particles for oil absorption and recovery on both water and land. The product size particles in oval 8 are generally too large to be used for oil absorption and recovery.

DETAILED DESCRIPTION

[0027] The product is made from recycled post-consumer plastics and coal combustion products combined to form a new product that safely, efficiently, and effectively remediates oil spills. The product involves the reuse and recycling of CCPs and plastics, and more particularly the recycling of coal ash (both fly and bottom ash) into a plasticized material.

[0028] The preferred embodiment is composed of pre and post-consumer plastics, including but not limited to polyester (PES), polyethylene terephthalate (PET), polyethylene (PE), high-density polyethylene (HDPE), polyvinyl chloride (PVC), Polyvinylidene chloride (PVDC), low-density polyethylene (LDPE), polypropylene (PP), polystyrene (PS), high-impact polystyrene (HIPS), polyamides also known as nylons (PA), acrylonitrile butadiene styrene (ABS), polycarbonate (PC), and polyurethanes (PU).

[0029] Any type of coal combustion products (CCPs) may be used, including coal ash (fly ash and bottom ash), boiler slag, and flue-gas desulphurization products.

[0030] Referring to FIG. 1, number 1, a petroleum or crude oil is heated until it is bubbling (at approximately 425° F.). The added oil can be petroleum or crude oil, since the initial mixture of the coal ash and plastic require a catalyst to form a uniformly distributed mixture rather than allowing the shredded plastic to burn due to the heat which will be a loss of one of the constituents of the final mixture.

[0031] Once the oil is bubbling, a quantity of solid plastics is melted with the oil at temperatures between about 165° F. and 600° F., dependent upon the types of plastics used at the time of production.

[0032] Once the solid plastics are thoroughly melted and the mixture has thickened to a paste-like viscosity, CCPs are stirred into the mixture, with the ratio of oil to plastics to CCP's at approximately 2:1:1 (oil:plastics:CCPs) or 45%-55% oil to 20%-30% plastics to 20%-30% CCP.

[0033] In the preferred embodiment, the CCP is stirred into the melted plastic in small batches until it is thoroughly and evenly mixed. The result of this being a large solid piece of the product.

[0034] Still referring to FIG. 1, number 1, the mixture is then removed from the heat and allowed to cool and solidify. This solidification may occur slowly with the natural temperature drop of the mixture to ambient temperatures, or the solidification process may be sped up by the cooling of the mixture, through the addition of water (the water will not become part of the mixture and can be reused) or by placing the mixture into a cooling or refrigerated chamber.

[0035] In an experiment of the present disclosure, the inventor successfully utilized a propane burner and container to preheat motor oil to 425° F. until bubbling, then added plastic to the hot oil to melt the plastic at a temperature of approximately 275° F. to 300° F. until the mixture reached a liquid paste. The inventor subsequently added coal ash while mixing, and evenly distributed the ash into the mixture. The container was removed from the heat, water was added to cool the mixture, and the mixture was shaved for reuse.

[0036] Once the product is solidified, it may then be mechanically shredded or pelletized into useful sizes, typically from 1 mm to 100 mm.

[0037] Particle sizes less than one millimeter after shredding of the product are too small to be used for oil spill remediation on waters because particles less than one millimeter typically disperse and sink in the water. Particles of the product less than one millimeter, however, may be used for spills on terrestrial and hard surfaces. Particle sizes greater than 500 mm×100 mm are typically too large to be used for successful oil recovery and site remediation.

[0038] In the preferred embodiment, referring to FIG. 1, number 3, the shredded product is used to absorb oils, both low density oils and high density oils. Oil spilled on waters tends to float because its density is lower than that of the water, the density/specific gravity of pure fresh water at 4° C. is 1.0 g/cm3, while the density of sea water at 25° C. is typically 1.028 g/cm3. Oils, both those termed low density and those termed high density, tend to have a density of less than 1.0 g/cm3 and thereby float on waters. The product in its shredded form has a density of less than 1.0 g/cm3 and also floats on the surface of water.

[0039] Still referring to FIG. 1, number 3, the shredded product is spread on the spilled oil, either on the water or on the ground or on a hard surface and the oil is absorbed into the product. The spill may have been contained by booms or berms, prior to the addition of the product, to prevent spread. As the oil is absorbed into the product the product coalesces and draws the oil inward and decreases the spill area as it absorbs the oil. The perimeter of the spill decreases as the oil is absorbed. Once all of the oil is absorbed into the product, the product with oil can be physically retrieved.

[0040] No matter the surface to which the invention is applied, as the oil is absorbed into the product, the product coalesces and draws the oil inward to decrease the spill area as it absorbs the oil.

[0041] Other spill containment methods incorporating booms or berms may optionally be used in conjunction with the product prior to the addition of the product, to prevent spread. As the oil is absorbed into the product the product coalesces and draws the oil inward and decreases the spill area as it absorbs the oil. The perimeter of the spill decreases as the oil is absorbed.

[0042] Once the oil is absorbed into the product, the oil-laden product may be scooped from the surface of the waters, or picked up from hard surfaces and the spilled oil recovered and reclaimed for subsequent usage. After the product has been used to remediate oil spills, it may be reprocessed into usable product and reused for subsequent spilled oil site remediation and oil reclamation.

[0043] In the preferred embodiment, referring to FIG. 1, number 4, the oil is recovered from the product for reprocessing. This recovery can be achieved mechanically; e.g., by pressing the oil filled material, or chemical means, thereby releasing the oil for recovery and reprocessing of the oil. After oil recovery is completed, the used product may be reprocessed to produce a new product.

[0044] After the product is applied to capture the spilled oil and after the oil is extracted, the product naturally retains some of the oil due to its wettability property. Therefore, the mixture can be recycled without the need for additional oil.

[0045] To reprocess the product into a freshly usable form, the used product is melted at 165 to 600° s Fahrenheit, and if needed to increase the volume more plastics and more CCPs can be added. The melting, mixing, solidification and shredding occur as described above.

[0046] Referring to FIG. 2, oval number 6 represents the particle size after shredding of the product that is too small to be used for oil spill remediation on waters, typically less than one millimeter. Product particles smaller than this will tend to disperse in the water and may sink. However, particles of the product in oval number 6, less than one millimeter, may be used for spills on terrestrial and hard surfaces.

[0047] In the preferred embodiment, referring to FIG. 2, oval number 7 represents the optimal, although more sizes maybe used, size range of the product to be used for oil recovery and site remediation. This shredded product size range is typically between 1 and 100 millimeters.

[0048] Referring to FIG. 2, number 9 represents a discontinum of the number/size line in the Figure. Still referring to FIG. 2, number 8 represents the size of the product that is too large to be used for successful oil recovery. This is typically greater than 500 mm, by 100 mm, although this too may occasionally be used for oil spill recovery and site remediation.

[0049] While the invention has been described with reference to an exemplary embodiment(s), it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. Therefore, it is intended that the invention not be limited to the particular embodiment(s) but that the invention will include all embodiments falling with the scope of the specification, claims, and figures.