BIOACTIVE MATERIAL

Abstract

A process and apparatus for manufacture of biocide products are described. The biocide properties arise from the caustic calcined powder, from carbonates such as such as magnesite and dolomite, and from hydroxides such as brucite. The method of manufacture is based on the production of high surface area oxide particles using an indirectly heated counterflow reactors for specifically calcining the carbonates and the hydroxides without significant sintering. The biocide products may be a powder or a hydrated slurry. A hydrated slurry is preferred for agricultural applications as a spray. For aquaculture applications, the products have a preferred particle size distribution to impact the aquatic and benthic ecosystems, and a Ca/Mg ratio that promotes the growth of the cultivates species when applied as a powder or a slurry. For applications such as a marine paint, the powder product or the slurry product is mixed with various agents to form a setting coating, and is applied to the infrastructure that is otherwise subject to biofilm growth.

Claims

1. A process for producing a biocide powder, comprising the steps of: a. selecting one or more carbonate compounds with a predetermined calcium/magnesium ratio; b. grinding the carbonate compounds to produce a carbonate powder with a first predetermined particle size distribution; c. selecting a magnesium hydroxide compound; d. grinding the hydroxide compound to produce a hydroxide powder with a second particle size distribution; e. calcining the carbonate powder in an externally heated counterflow flash calciner at a first temperature to produce a calcined mixture having a surface area sufficiently high enough to exhibit bioactivity; f. calcining the hydroxide powder in an externally heated counterflow flash calciner at a second temperature to produce a calcined oxide with a surface area sufficiently high enough to exhibit bioactivity; and g. blending the calcined mixture and the calcined oxide in a predetermined proportions.

2. The process of claim 1 further comprising the step of adding ground limestone, or lime or hydrated lime to the form the biocide powder.

3. The process of claim 1, wherein the carbonate compounds comprising Magnesite and Dolomite.

4. The process of claim 3, wherein the degree of calcination of the magnesium carbonate in the magnesite and dolomite is in the vicinity of 95% or more, and the degree of calcination of the calcium carbonate is in the vicinity of 5% or less.

5. The process of claim 1, wherein the calcined mixture and calcined oxide comprises magnesium oxide (MgO).

6. (canceled)

7. (canceled)

8. The process of claim 5, wherein the surface area of the oxide from the hydroxide powder is above 200 m.sup.2/gm of MgO, and preferably above 250 m.sup.2/gm of MgO and most preferably above 300 m.sup.2/gm of MgO.

9. (canceled)

10. (canceled)

11. (canceled)

12. (canceled)

13. The process of claim 2, wherein the proportion of limestone, lime or hydrated lime depends on the specification to achieve a desirable Ca/Mg ratio for the application and to achieve a desirable viscosity and stability of the slurry in conjunction with an amount of carboxylic acid added in the slurry production process.

14. (canceled)

15. (canceled)

16. (canceled)

17. The process of claim 1, further comprising the step of: a. hydrating the biocide powder with water at or near the boiling point of water until the hydration is completed; b. Applying a shear mixing, and c. Adding a carboxylic acid or salt as the thinning agent, in order to form a stable, readily thinned, slurry of the hydrated oxide with about 60% solids in the final product.

18. (canceled)

19. (canceled)

20. (canceled)

21. (canceled)

22. (canceled)

23. (canceled)

24. (canceled)

25. (canceled)

26. (canceled)

27. The process of claim 13, wherein the carboxylic acid is acetic acid, and the carboxylic salt is magnesium or calcium acetate.

28. The process of claim 17, wherein the slurry is mixed with one or more viscosity modifier and setting additives for manufacturing a coating to sewage pipes and manholes.

29. A reaction apparatus for producing biocide powder or a chemical detoxifier powder or a catalyst support from a carbonate mineral, comprising: a. a grinder for carbonate compounds b. a grinder for hydroxide compounds c. an externally heated counter flow flash calciner that produces high surface area oxides from the ground carbonate; d. an externally heated counter flow flash calciner that produces high surface area oxides from the ground hydroxide; and e. a blender in which the calcined solid powders arc mixed together, and or with other ground solids for the production of a biocide powder.

30. The reaction apparatus of claim 29, further comprising a hydration reaction vessel for the production of the slurry product having an inlet for the blended powder and a water inlet; and a shearing apparatus for shearing the reaction mixture; and a steam outlet for release of steam from the reaction vessel, such that in use the reaction is controlled by allowing heat of hydration to raise the temperature of the reaction mixture, allowing water to boil off from the reaction mixture as hydration proceeds, and removing steam via the steam outlet to remove excess heat and control reaction temperature at boiling point; and a means of quenching the slurry to below 60° C. and a means of cooling the slurry to ambient temperature; and a means of adding solid or liquid additives to the slurry.

31. The reaction apparatus of claim 29 further comprising a second reaction apparatus, wherein the second reaction apparatus is adapted to carrying out one or more steps of: sparging the powder or slurry with a gas adjuvent enhance bioactivity; adding and mixing liquid adjuvent compounds to the powder or slurry to enhance bioactivity; adding and mixing materials to the powder or slurry to make a biocidal coating product; or adding and mixing materials to the powder or slurry to make a biocidal emulsion or foam.

32. A chemical composition as a powder adapted for use as a biocide, wherein the composition comprises: a powder of micron scale calcined particles which are formed from a mixture of carbonate compounds and hydroxide compounds, and which have additives to boost the biocide impact wherein the particles have a porosity of greater than 0.5 and wherein the pore surface is largely composed of nano-crystalline structures.

33. A chemical composition as a slurry adapted for use as a biocide, wherein the composition comprises a slurry produced by hydrating the powder of claim 31 with additives that stabilise the slurry.

34. A chemical composition as a coating material slurry adapted for use as a biocide, wherein the composition comprises a coating material produced by mixing the powder of claim 31 with additives that set the material when applied to a surface.

35. A chemical composition as a foam, spray or emulsion material slurry adapted for use as a biocide, biofilm inhibitor, or plant root repellant, wherein the composition comprises a foam, spray or emulsion material produced by mixing the powder of claim 31 with additives that form a foam, spray or emulsion when processed.

36. The reaction apparatus according to claim 30, wherein the means of quenching the slurry to below 60° C. is by transfer of the slurry to a cooled container.

37. The reaction apparatus of claim 31, wherein the gas adjuvant is ozone.

38. The reaction apparatus according to claim 32, wherein the additives to boost the biocide impact is ozone and/or hydrogen peroxide.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0078] FIG. 1 depicts a schematic drawing of a process for production of a powder or a slurry from powders of mineral magnesite, dolomite or brucite in which the powder particle size, porosity and surface area are optimised by calcination to form a biocide.

DESCRIPTION OF THE INVENTION

[0079] Preferred embodiments of the invention will now be described with reference to the accompanying drawings and non-limiting examples.

[0080] FIG. 1 depicts a schematic drawing of a process for production of a powder or a slurry from powders of mineral magnesite, dolomite or brucite in which the powder particle size, porosity and surface area are optimised by calcination to form a biocide.

[0081] One example form of manufacture of the product which can be described by consideration of the process flow of FIG. 1 for the mineral precursors of magnesite and dolomite as carbonate compounds and brucite as a hydroxide compound. Other minerals particulate impurities in a mined mineral may include sand, talcs, and clays. The desired material product is either a bioactive powder or a bioactive slurry. The desired solid product may be made solely from the carbonate materials, or the hydroxide materials, or a combination of either, and a by-product from the carbonate compound processing may be a pure carbon dioxide gas.

[0082] The hydroxide compound may be a mineral brucite or a synthetic brucite for example, produced from sea water or brines in the known art by precipitating the hydroxide from sea water or brines by the addition of limestone. The synthetic material is called herein brucite, although it may have a different crystalline structure from the mineral.

[0083] In this embodiment, the 10 comprises the following steps: [0084] Grinding the feedstocks (steps 12a, 12b); [0085] Calcining the ground materials (steps 14a, 14b); [0086] Blending the calcined materials (steps 16);

[0087] In another embodiment the process 10 may comprise a further step of adding ground limestone, or lime or hydrated lime to the form the biocide powder.

[0088] In yet another embodiment, the process 10 may comprise a further step of hydrating the blended powder to form a slurry product (step 18).

[0089] In yet another embodiment, the process 10 may further comprise a step of enhancing the bioactivity of the slurry with adjuvents as an option (step 20).

[0090] In one embodiment of the present invention, the first step of process 10 is one in which the desired particle size distribution is achieved by crushing and grinding the compounds (steps 12a, 12b). The magnesite and brucite are the primary sources of nano-active Mg(OH).sub.2 in the final product, whereas the dolomite is the primary source of calcium. These minerals may be found within a mine site and are selectively mined, or in the case of brucite, synthesised. In this embodiment the hydroxide compound are ground separately from the carbonate compound. It is known in the art that the brucite grinds very differently to the other minerals by virtue of its different crystal structure, which is such that the mineral rapidly flakes to during grinding give small particles in the range of 0.4-15 microns. In this embodiment, the process for production of brucite is taken to be unchanged from that used to make, for example, brucite for the manufacture of refractories, in which the process is optimised to facilitate ease of filtering, drying and compacting for subsequent calcination in a kiln. That is, the particle size distribution exceeds the preferred distribution of say 0.4-100 microns. In this embodiment, the dried particles are ground. This may preferably be done by first sieving the particles to remove the fraction above 100 microns, and then grinding the oversized fraction to produce particle with sizes in the range of 0.4-15 microns. A number of sieving and grinding stages can be performed to give the desired particle size distribution for the application.

[0091] In this embodiment, the desired particle size distribution of the ground carbonate compound may be achieved in a number of grinding stages, followed by mixing. For example, a single grinding process may not provide a sufficient number density of small particles, such that a fraction of the coarsely ground material may be finely ground, and remixed with the residual coarsely ground fraction. The art of obtaining a desired particle size distribution by such comminution processes is a known art per se. The desired particle size distribution is typically in the range of 0.4-100 microns.

[0092] In this embodiment, the fraction of dolomite in the ground material is set to give the desired calcium/magnesium ratio for the desired application. For example, in aquaculture, For aquaculture, a typical desirable Mg/Ca ratio on a molar basis is in the range of about 6:1-4:1. While it is possible to use ground limestone as the source of the calcium, the availability of the calcium carbonate from limestone is lower than that which is available from the calcined dolomite, described below, by virtue of the higher porosity and surface area of the calcined dolomite compared to ground limestone.

[0093] The second step of the sample embodiment is calcination. The ground carbonate compound is processed by calcination, as described by Sceats and Hodgson to create the nano-scale crystallites that are believed to be the source of the bioactivity. This step of the process is that of calcination of the carbonate in which the MgCO.sub.3 in the magnesite and dolomite is calcined. It is important that the processed particles exhibit minimal sintering during the calcination process, and achieve a degree of calcination of the MgCO.sub.3 sites, in the magnesite and dolomite, that is preferably in excess of 95%. The most fundamental measure of the deleterious impact of sintering is the specific surface area The experimental results show that the calcination of the dolomite MgO site does not generate nano-scale crystallites of MgO with super-oxide formation to create a biocide. Without being limited by theory, it is reasonable to assume that the uncalcined CaCO.sub.3 moieties in the dolomite prevents the formation of MgO nano-crystallites because there is insufficient time during flash calcination for diffusion and aggregation of nano-structured MgO to occur, as reasoned by Sceats and Haley in AU2006904553. Extending the time leads to sintering and phase separation with no nano-scale crystallites. The surface area that provides the bio-activity of the calcined product is that of the MgO from magnesite alone. This can be deduced from surface area and calcination measurement, and should be 200 m.sup.2/gm of MgO from magnesite, and preferably greater than 250 m.sup.2/gm of MgO and more preferably greater than 300 m.sup.2/gm of MgO. The type of calciner is critical to achieving the properties described above. The basic requirement is that the process is very fast to eliminate the effect of sintering, and this should be preferably several seconds. This means that the process is flash calcination. The second requirement is that the particles experience the lowest possible temperature during this time. Conventional flash calciners drop the particles into a very hot combustion gas, and from that time, the temperature of the gas decreases as the react on extract energy from the gas stream. Further, not all particles experience the same conditions. The net result is that the outer surfaces of the particles are extensively sintered, and it is difficult to achieve surface areas in excess of 50 m.sup.2/gm of MgO. The small particles are most extensively sintered. The preferred calciner is that described by Sceats and Horely, for example in WO2007/112496 (incorporated herein by reference). In this case, the temperature of the particles flowing through the calciner steadily increases for all particles, and the maximum temperature they experience is the exhaust temperature. During the calcination, there is generally some decrepitation of the input particles, and often a shoulder appears on the particle size distribution in the region of 0.1-1 microns. Control of the external burners along the calciner provides the desired heat transfer to the particles, and the degree of calcination and surface area can be controlled. This system is known per se, and is capable of operating at production levels of about 5 tonnes per hour for particles that are 95% calcined for the Mg site, with a surface area of greater than 200 m.sup.2/gm of MgO from magnesite. The important factor which determines the biocidal impact is the high surface area of the MgO from the magnesite in the calcined powder. For the calcination of magnesite and dolomite the exhaust temperature from the calciner is preferably about 750° C., at which temperature about 95% calcination of the MgCO.sub.3 is achieved, less than about 3% calcination of the CaCO.sub.3 is achieved.

[0094] The calcination process for the ground hydroxide compound is similar to that described above for the ground carbonate compounds, except that the temperature of the exhaust of the calciner is preferably lower than about 450° C., at which temperature 95% calcination of the Mg(OH).sub.2 to nano-active MgO is achieved with a surface area greater than 120 m.sup.2/gm of MgO. This process has not previously be described. Generally, multiple hearth furnaces can produce MgO from magnesium hydroxide with a surface area of typically 50-100 m.sup.2/gm, and such MgO does not display the required nano-active properties required for biocidal activity. At higher exhaust temperatures of above about 450° C., for a given calciner, the sintering of the particles dramatically reduces the surface area.

[0095] It highly desirable that the calciner design, of the type, for example, described by Sceats and Horely, is its capability for processing either the hydroxide compound at about 450° C. or the carbonate compound at about 760° C. That is, in the embodiment of FIG. 1, the two calciners shown can mean the same equipment operating under different settings at different times.

[0096] The third stage of the embodiment of FIG. 1 shows that the powder streams from the two calcination processes being mixed to form the biocide powder product. This product has the desired particle size distribution and the Ca/Mg ratio to suit the application. This powder is a biocide, and can be used in application where a powder form is used, either directly or indirectly as a feed for the manufacture of products such as coatings.

[0097] Where a slurry product is desirable, the fourth stage of the process is to hydrate the slurry. This process is well described by Sceats and Vincent for example in AU 2013904096 (incorporated herein by reference), as a process that can produce tonnes of slurry per hour to match the production rate of the calciner described above. The high surface area of the particles is such that the hydration reaction, when mixed vigorously, liberates a large amount of heat and boils the water. This establishes a set point and the thermally activated hydration occurs at the boiling point and the excess heat is liberated by boiling. The application of a shear mixer provides the agitation required for a uniform controlled process. During the course of the reaction, acetic acid is added to the slurry to provide thinning necessary for the shear mixer to operate. The reaction is complete when the temperature starts to drop from the heat losses. It is preferred to quench the slurry quickly below 60° C., and then let the slurry cool to ambient for the next processing step. The net result is a slurry that has hydrated, and which is stable over many months with regard to sedimentation, and which is readily shear thinned to allow pouring and processing. This slurry has the same intrinsic biocide activity as has nano-particles when diluted in water for application as a foliar spray. Importantly, there is no significant loss of biocide activity during over the slurry lifetime of several months.

[0098] The fifth stage is the option, if required, to add adjuvants to either the powder or the intrinsic slurry product described in order to increase the biocide properties above that of the intrinsic biocide response considered below. There are many such adjuvants. Examples are hydrogen peroxide, or ozone, which can be added to saturate the crystalline binding sites on the Mg(OH).sub.2 surfaces with the radical species being the superoxide ion, the hydroperoxide anion, and oxygen radical, and the hydroxyl radical. Magnesium peroxide MgO.sub.2 is a stable compound. In addition, the acetate ions may be further converted to the peroxyacetate ion, which is stable at the pH of the slurry, at about 10.4. Impurity ions, such as Fe.sup.2+ and Fe.sup.3+ are removed from the slurry as particles for ferric oxide. The use of hydrogen peroxide or ozone supplements the intrinsic radicals developed during calcination and hydration. Ozone is added by sparging the slurry with ozonated air. Other adjuvents include a large number of established biocides, including all those listed in U.S. Pat. No. 6,827,766 B2 or nano-particles such as AgO and ZnO. Depending on the specific adjuvant and the amount added, the stability of the slurry may have to be re-established by the addition of dispersion agents. The use of adjuvants is not generally preferred because it may make the product toxic to humans, and increase the cost of production compared to the intrinsic biocide developed in the previous stages.

[0099] If required, impurities in the mineral such as sand, talc and magnetic particles are extracted during this process at any stage. The process to be used depends on the mineral source, whether macrocrystal line or cryptocrystalline, the impurities, the grinder and the grinder settings. Generally, for aquaculture applications, no such separation step is required.

[0100] Most importantly, it is noted that there is an expectation that there are no nanocrystalline particles present (i.e. with a diameter less than 0.1 microns) in the powder or slurry, and generally such particles are undesirable because, as fines, they are difficult to filter from the grinder air, and also to process in the steps described below, and to meet customer and community concerns about the toxicity of nanoparticles in general. The grinders are preferably grinding mills that entrains the ground particles in air, and which removes particles above about 0.5-1 micron before they can be further ground. This is a known art per se.

[0101] The intrinsic biocide for aquaculture produced using steps 1-5 described above produces either a powder or a 60% solids slurry of particles with a range of particle sizes from 0.1 microns to 100 microns as measured by a particle size analyser, and a Mg/Ca ratio in the range of 4-6.

[0102] The biocide activity of the intrinsic powder and slurry in aquaculture has been established in preliminary aquaculture trials on crayfish, prawns, salmon, tilapia, sea bass, silver perch, trout and milkfish.

[0103] The milkfish trials were conducted on fingerlings over 13 weeks in a 4 ha pond of 0.85 ML stocked with 250,00 fingerlings that are fed 3 times per day. The water is drained every 2 weeks. Weekly doses of 60 kg of the slurry were used. The pH was about 8.0-8.5. The odour of H.sub.2S was not present, compared to the control, and samples of the pond bottom were more solid, had less odour, and were lighter in colour. The fingerling mortality was 55% compared to 65% in the control, and the weight of the fingerlings was 34.9 g, compared to 22.4 g in the control. Thus the yield improvement was 84%. The fingerlings were transferred to sea pens (without further treatment), and at the harvest, the average fish weight was 7.3 kg, compared to 6.6 kg for the control. The quantity of premium fish, with the highest weight increased by a factor of 4. The economic impact was estimated to be ten times higher than the cost of dosing.

[0104] The biocide activity of the intrinsic powder slurry for agriculture and other applications has also been established, and are the same as described by Sceats, and Sceats and Hodgson.

[0105] In one embodiment of the present invention, the nano-activity is demonstrated when brucite is used as a starting material. Brucite is the mineral of Mg(OH).sub.2 which is formed in a slow process where the grain size or crystallite size is in the region of microns and larger, and when ground, the particles exhibit no bioactivity. Brucite may be synthesised from sea water or brines by treating such with lime of hydrated lime to precipitate the Brucite. This brucite also exhibits no substantial bioactivity. When the brucite is flash calcined to give a very high surface area MgO, the MgO is formed as nano-scale crystallites within the particle, and hydration creates nano-scale Mg(OH).sub.2 within the particles. There is no observable change in the particle size, so that the process has transformed the structure of the brucite from macrocrystalline to nanocrystalline, and the defect density is accordingly very high, and the nano-activity is accordingly high.

[0106] The sprayed slurry of the hydrated nano-active Mg(OH).sub.2 has the effect of a disease preventative contact biocide, and is not a systemic biocide. The implication is that it has a broad spectrum response, typical of other biocides such as sulphur and copper compounds, and hydrogen peroxide, but without the toxic effects on all the biota on the leaf ecosystem. An advantage of the nano-active particles is that the potentially adverse toxic impact of nano-particles on humans is mitigated because the particles cannot be breathed into the lung, and cannot diffuse through the skin into the human blood and lymph systems because the particles are too large. If ingested into the human gut, the particles are rapidly dissolved by the acids in the stomach. At high concentrations, the release of magnesium ions in the human or animal gut has the mild muscle relaxant effect of Milk of Magnesia.

[0107] In one embodiment of this invention, the materials described by Sceats and Hodgson are extended to include marine applications generally, in combination with other materials to form a setting material that, as a biocide, inhibits the formation of biofilms.

[0108] A first aspect of this invention may include the extension of the precursors that can be used for the production of the nano-active Mg(OH).sub.2 biocide described by Sceats and Hodgson, and the variation of the process conditions to achieve the biocidal properties. The prior art of Sceats and Hodgson claims a production process of carbonate minerals with the first step being grinding the precursor to produce a powder with a broad particle size distribution. The specification of the nano-active Mg(OH).sub.2 material was a particle size in the range of 0.5-100 microns. The feedstock for this prior art was generally magnesite, which is not abundant and is usually found with mineral impurities. In this invention, the range of preferred mineral precursors is increased from carbonatites such as magnesite MgCO.sub.3 and dolomite MgCO.sub.3.CaCO.sub.3 to include brucite, Mg(OH).sub.2, where brucite include the mineral as well as synthetic magnesium hydroxide produced from brine, as a known art per se. Subsequent experiments have shown that magnesium hydroxide crystals made from brine itself are not nano-active because their surface area is too low. However, nano-activity can be induced by flash calcination of brucite to a nano-active MgO, followed by rehydration to form a nano-active Mg(OH).sub.2 material in the process described herein. The invention requires significantly different processing conditions that are disclosed herein. The synthetic brucite typically has a broad distribution of crystal sizes with a significant fraction above 100 microns, such that further grinding, wet or dry, is required to give a preferred distribution. The synthetic brucite material has been developed for ease of processing and for applications such as refractory manufacture in which the crystal size is generally as large as possible. For this invention, smaller crystal sizes are required, and the invention recognises that the synthetic process for brucite can be modified to yield a crystal size distribution that meets the requirements for this invention. Therefore, the first step in this modified process is one in which the size distribution may be achieved by either grinding or synthesising the precursors to give the desired particle size distribution. The first step can include grinding different fractions of the raw materials in a number of fractions to a number of different degrees of grinding and remixing the fractions to give the desired distribution, or including within a grinder segmentation of the materials to achieve the desired particle size distribution. The first step can include synthesising the precursor in a number of stages to give the desired distribution. For example, with synthetic brucite, boron can be used to control the crystallite distribution as described by Chisholm in U.S. Pat. No. 3,232,768.

[0109] A second aspect of the present invention may include the production of a nano-active product that can simultaneously provide bioactivity in the aqueous and the benthic ecosystems of an aquaculture pen or pond. In order to achieve a simultaneous impact, the product must be provided to both these ecosystems in doses that enable them to respectively impact on pathogenic species in each ecosystem. The general means of dosing used in aquaculture ponds is to deliver the product from a spray in a liquid form, or a metered spray of the liquid form or a powder form on the surface of the pond or pen. It has been found that the most advantageous distribution between ecosystems can be achieved by controlling the particle size distribution. It has been observed that very small particles, say below 10 microns in diameter have a very long residence time in the aqueous ecosystem. This is because their settling hydrodynamics is dominated by Brownian motion from the water, such that the settling velocity of such fine particles from the aqueous ecosystem is very low. This gives a prolonged residence time, so that the encounter of the particles with a pathogen is sufficiently probable that the bioactivity of the particles can exert themselves in this ecosystem. The fine nano-active particles can adhere onto the pathogen for direct bio-impact or the cultured species or algae for indirect bio-impact. It has been observed that larger particles, say above 50 microns, have a shorter residence time in the aqueous environment because their hydrodynamics is dominated by gravitation, offset by turbulence of the water, such that they quickly fall into the benthic environment where they can exert their bio-impact Intermediate sized particles have intermediate residence time. The most desired residence time depends on the location of the pathogen and the life-cycle of the pathogen. For example, some pathogens initially grow in benthic layer, before making an impact on the cultivated species. Therefore, the most effective means of controlling the residence time is to control the particle size distribution of the particles so that a sufficient fraction of the particles fall directly into the benthic ecosystem. Thus there is a preferred fraction of fines in the range of 0.4-10 microns that have a long residence time in the aqueous ecosystem, and course larger particles in the range of 50-100 microns that have a short residence time in that ecosystem, so that they act to improve the benthic ecosystem.

[0110] The specification of 0.5-100 microns was developed by Sceats and Hodgson to be such that the calcination process and the formation of a stable slurry could be readily achieved. For aquaculture, experiments have shown that the particle size distribution is preferably further specified to meet the residence time distribution of the particles in the aqueous ecosystem and the benthic ecosystem so as to have maximum bio-impact for the health of the cultivated species, as well as meeting the requirements for calcination and slurry stability. The preferred range of the particle size for aquaculture applications is within the 0.5-100 micron range claimed by Sceats and Hodgson, and is herein further specified for use in aquaculture. Thus key feature of this innovation is that the particle size distribution has become a parameter to optimise the biocidal impact of the nano-structured particles, rather than just a specification for the ease of calcination and stable slurry production. For example, for controlling the parasite vibrio in prawns, for an aquaculture pond that was 2 metres deep, the desirable particle size was such that at least 30% of the particles were less than 5 microns.

[0111] A third aspect of the invention is associated with the ingestion of the particles by the cultivated species. The prior art described by Sceats and Hodgson is focused on the use of nano-structured particles in agricultural crops, where the ingestion of the particles through the leaf stomata provides an additional benefit of enhancing the growth of the plant by the adsorption of magnesium for the production of chlorophyll. However, by analogy, the ingestion of the particles by the cultivated species in aquaculture provides a means of providing minerals for growth. The cultivated species have specific requirements for calcium for the growth of bones or shells, and the aqueous ecosystem may not be able to supply the required amounts. Further, calcium is also important in fish hatchery water supplies, because eggs tend to hydrate at low calcium concentrations and may not develop or hatch if the calcium concentration is too low. The cultivated species may ingest the calcium from the ions in the water (ie through the calcium hardness, which varies from lakes, rivers, estuaries and the sea) and from food, either directly or from algae that grow in the pond, or from additives such as calcium sulphate. The nano-active material is generally Mg(OH).sub.2 produced from hydration of MgO from calcining magnesite ores. Most magnesite ore, dominantly MgCO.sub.3 contains some dolomite MgCO.sub.3.CaCO.sub.3. When the dolomite ore is processed, the product is a semi dolime MgO.CaCO.sub.3, and the formation of dolime MgO.CaO is suppressed at low calcination temperatures by the high partial pressure of CO.sub.2. This process is described by Sceats and Horely (AU 2006904553), incorporated herein for reference. The dolomite crystallites are often found within the ground mineral feedstock particles along with magnesite and silica. Experiments have shown that the high porosity and surface area of the semidolime produced in the flash calciner is such that the hydrated material, Mg(OH).sub.2.CaCO.sub.3 exhibit a very fast acid decomposition which releases the calcium ions. In the gut of the fish, the acids in the stomach quickly release the calcium which can be ingested and can assist in the growth of the fish. It is preferable that the conditions of the calcination is such that the CaCO.sub.3 is not calcined to lime. The absence of lime CaO, as dolime MgO.CaO, is such that the pH within the particle is maintained at about 10.4, and experiments have shown that the intake of the hydrated semi dolime in the hydrated product has no adverse effects from stress that otherwise may have occurred had quicklime been formed. The desirable Mg/Ca balance in the product can be optimised to meet the requirements of the cultivated species, taking into account the calcium and magnesium in the water and in the food. Generally, the use of a mixture of Magnesite and dolomite as feed into the calciner can be varied so as to deliver the required Ca/Mg dose for growth of the cultivated species. More generally, mineral deposits of magnesite are found in layers, usually accompanied with dolomite layers, and the magnesite rich layers have some Dolomite as granular impurities and substitutional impurities. This benefit of specifying a Ca/Mg ratio is an important feature for aquaculture, but relatively unimportant for plants. Thus the specification for the production of the bioactive material by Sceats, and Sceats and Hodgson, failed to teach the benefits of controlling the input mineral to provide the desired bioactivity, and the desired Mg/Ca ratio in aquaculture applications to promote the health of the cultivated species, specifically with respect to the growth of bones and the hatching of eggs. This capability relies on the lack of toxicity of the nano-active species for ingested particle's because the acids in the stomach dissolve the particles and the released ROS is at sufficiently low doses that they are rapidly reduced in the digestive tract. The animal cells are capable of handling intense bursts of ROS because the release of ROS is a primary mechanism developed to combat infection. Thus nano-active particles have no toxicity to the cultivated species when ingested, and it is desirable that the calcium required for bones and shells is provided as CaCO.sub.3, in particles with a high surface area so that ingestion is rapid. Thus calcined dolomite is preferable to the addition of ground limestone because the calcium is more accessible from semidolime because of the higher surface area arising from calcination of the magnesium site.

[0112] A fourth aspect of the invention relates to the ability of the particles that are suspended for a short time to remove heavy metals, and excess phosphate and nitrogen, from the aquatic ecosystem. The specification provided by Sceats and Hodgson uses the surface area and porosity of the magnesium oxide as indicators of the nano-crystallinity of the powder, and therefore as indicators of the propensity of the particles to generate ROS at the nano-grain boundaries, and to retain these species as oxidants after hydration. However, experiments in aquaculture have revealed that the surface area of the magnesium hydroxide itself enables the controlled removal of heavy metals and phosphorous and nitrogen from the aquatic ecosystem during their passage to the floor of the pen. The accumulation of heavy metals, such as cadmium, copper, lead, chromium, arsenic, barium, cobalt, manganese and vanadium in the cultivated species may make the product unsuitable for human consumption. Very high concentrations of iron, from pyrites oxidation, are toxic to the fish. Magnesium hydroxide is well established as a product for removing iron and heavy metals from soils and water, where the metals precipitate to form insoluble hydroxides. Experiments have shown that the extraction efficiency is enhanced by the high porosity and surface area of the Mg(OH).sub.2 particles. Without being bound by theory, the reason for this is two-fold. Firstly, the reaction kinetics for the precipitation of insoluble hydroxides scales with the surface area of the Mg(OH).sub.2, and secondly, within the pores of the particle, the concentration of hydroxide ions is that of water saturated by the dissolution of Mg(OH).sub.2 at the pH of 10.4, rather than the pH of the water itself, which is preferably in the range of 7.0-7.6 for aquaculture. Thus the particles, falling through the water, efficiently extract the heavy metals from the aqueous ecosystem without the need for the particles to raise the pH to the levels required for heavy metal precipitation. These larger particles, having accumulated the metals, fall into the sludge of the benthic ecosystem. It is now current practice to extract the sludge from the pen after a number of days, and in this case, the heavy metals ions are removed from the pen. In the sludge, the larger particles sequester the heavy metals in the same way as Mg(OH).sub.2 is used to sequester heavy meals in soils, with a very low rate of leaching. It is preferable that there is a sufficient fraction of particles move through the aqueous ecosystem and fall into the benthic ecosystem to remove heavy metals from the aqueous system, and that there is a sufficient amount of such particles in the sludge, when removed, such that the heavy metals are extracted from the benthic ecosystem. Experiments have shown that the use of low surface area, low porosity Mg(OH).sub.2 is not as efficient for heavy metal extraction. The invention is that the high porosity and surface area increases the yield of heavy metal ions that would be expected on the basis of the pH of the aqueous ecosystem.

[0113] In a similar manner, excess phosphorus, as the phosphate ion, and nitrogen as the ammonium ion, precipitate magnesium phosphate and magnesium ammonium phosphate in the particle pores at the pH of 10.4 and at a concentration of magnesium that is or order unity (directly from a surface site), and these materials are collected in the sludge. It is preferable that there is a sufficient fraction of particles move through the aqueous ecosystem and fall into the benthic ecosystem to remove excess phosphorous and nitrogen from the aqueous system, and that there is a sufficient amount of such particles in the sludge, when removed, such that the excess phosphorous nitrogen are extracted from the benthic ecosystem. It is noted that excess nitrogen is extracted when there is excess phosphate. In the case that the heavy metal ions are sufficiently low, the sludge is a useful plant fertilizer. Experiments have shown that the use of low surface area, low porosity Mg(OH).sub.2 is not as efficient for excess phosphorous and nitrogen extraction. The invention is that the high porosity and surface are increases the yield of excess phosphorus and nitrogen that would be expected on the basis of the pH and magnesium concentration in the aqueous ecosystem.

[0114] Therefore, in this innovation, the high surface area and porosity of the Mg(OH).sub.2 particles have been shown to control the extraction of heavy metal ions, phosphorous and nitrogen from the aqueous ecosystem, such that the cultivated species can grow healthily in a clean ecosystem, and the cultivated species can be consumed without adverse health impacts to humans.

[0115] A fifth aspect of the invention is associated with the capability of the Mg(OH).sub.2 particles to induce the flocculation of the particles in the aqueous phase. These particles may be suspended clays from soils following run off or disturbance, or organic matter such as faeces or uneaten food. In aquaculture practice, the optimum turbidity of the pond is dependent on the needs of the cultivated species, and generally it should not be too high to induce health problems, or too low to facilitate the capture by predators, such as birds. Magnesium hydroxide is an established flocculant because its high charge density causes the collapse of ionic boundary layers which others keeps the particles in suspension. Without being bound by theory, the Mg(OH).sub.2 particle have a point of zero charge at a pH of 10.4, and are thus negatively charged in an aqueous ecosystem with a pH in the ideal range of 7.5-7.0, whereas the particles that cause the turbidity and health problems have a point of zero charge below a pH of 7.0 and are charged positively. This is the basis of why Mg(OH).sub.2 is an excellent flocculant. However, the high surface area is such that the local response of these particles is fast, and the floc forms quickly through the charge neutralisation. Experiments have shown that the efficiency and rate of flocculation of a high porosity high surface area Mg(OH).sub.2 particle is larger than a comparable Mg(OH).sub.2 particles that have a lower surface area and lower porosity. Generally, this process removes the Mg(OH).sub.2 particles as well as the target particles, and they fall to the floor of the pen and are removed from the aqueous ecosystem. The larger particles trap a large number of smaller suspended particles that cause the turbidity. The flocculated particles are part of the sludge removed from the pens on a regular basis in many aquaculture practices.

[0116] It follows that the first and second aspects are optimised for small particles that have a long residence time, while the third and fourth aspects are optimised by larger particles that are sufficiently large that they pass through the aqueous ecosystems. The control of the particle size allows for such control.

[0117] The aspects considered above are concerned with the health of the aqueous ecosystem. Experiments have shown that the larger particles that move into the benthic ecosystem play a significant role in the health of that ecosystem, whether or not the particles have sequestered heavy metal ions or have deposited other particles. A sixth aspect is associated with the benefits of a healthy benthic ecosystem arising from the presence of nano-active Mg(OH).sub.2. It is often observed that the sludge at the base of an untreated aquaculture pen is septic, with a characteristic small of H.sub.2S, it is acidic and anaerobic. This generally arises from the anaerobic bacterial decomposition of organic matter, from faeces and uneaten food, as a result of the high population density of the cultivated species. It is a known art that the dosing of sewage systems by Mg(OH).sub.2 is a means of raising the pH to a level that the decomposition is suppressed. Further, the use of nano-active Mg(OH).sub.2 may suppress the growth of pathogenic organisms in this benthic ecosystem, and mitigate their growth such that they do not significantly move into the aquatic ecosystem and infect the cultivated species. Experiments have shown that the sludge that is removed from the base of the pond or pen in which the nano-active Mg(OH).sub.2 has been added has very little sulphide smell, and is more compact compared to an untreated sludge. The degree of compaction is related to the same factors as flocculation, so that high surface area, and high porosity lead to more compact sludge. The practices in agriculture associated with sludge vary widely. In some cases, the sludge is decomposed in anaerobic digesters to produce a fuel, and experiments have shown that the presence of nano-active Mg(OH).sub.2 decreases the H.sub.2S, and increases the methane content. In one practice, the sludge is sold as a fertilizer, and the absence of the H.sub.2S odour is benefit In another practice, the water is drained before being refilled and restocked, allowing a time for regeneration of the pond bed in aerobic conditions. The time for regeneration is significantly reduced if the anaerobic conditions of the sludge have previously been reduced and the sludge is compact as a result of dosing with nano-active Mg(OH).sub.2.

[0118] A seventh aspect of the invention is the use of the nano-Mg(OH).sub.2 application in aquaculture is as a coating on aquaculture infrastructure. Experiments have shown the nano-active Mg(OH).sub.2 minimises the formation of biofilms. The result is that secondary growth of barnacles is also suppressed. Without being bound by theory, the mode of action of the nano-Mg(OH).sub.2 is believed to arise from the encapsulation of the particles by the extracellular extrusions of biofilm forming organisms, and the subsequent release of ROS and increase of the pH in the biofilms degrades the films, and leads to the disruption of the colonies of the biofilm forming organisms. This aspect is applicable to the maritime industry, as well as the aquaculture industry. For shipping, the presence of a biofilm causes a roughness on the hull, and the higher expenditure of energy. For aquaculture, the biofilm causes destruction of the pond enclosures, and fouling of equipment used to manage the cultivation. Depending on the application, the strength of the nano-Mg(OH).sub.2 coating can be enhanced by using additives. These include acrylic materials used in paints, and other stabilising materials. For example, the use of graphene fibres is particularly useful in such applications.

[0119] In this specification, the word ‘comprising_ is to be understood in its ‘open_ sense, that is, in the sense of ‘including_, and thus not limited to its ‘closed_ sense, that is the sense of ‘consisting only of_. A corresponding meaning is to be attributed to the corresponding words ‘comprise_, ‘comprised_ and ‘comprises_ where they appear.

[0120] While particular embodiments of this invention have been described, it will be evident to those skilled in the art that the present invention may be embodied in other specific forms without departing from the essential characteristics thereof. The present embodiments and examples are therefore to be considered in all respects as illustrative and not restrictive, with all changes which come within the meaning and range of equivalency therefore intended to be embraced therein. It will further be understood that any reference herein to known prior art does not, unless the contrary indication appears, constitute an admission that such prior art is commonly known by those skilled in the art to which the invention relates.

[0121] In one embodiment of the present invention, there is provided a reaction apparatus for producing biocide powder or a chemical detoxifier powder or a catalyst support from a carbonate mineral, comprising: a first grinder for carbonate compounds and a second grinder for hydroxide compounds; an externally heated counter flow flash calciner that produces high surface area oxides from the ground carbonate; an externally heated counter flow flash calciner that produces high surface area oxides from the ground carbonate; and a blender in which the calcined solid powders are mixed together, and or with other ground solids for the production of a biocide powder.

[0122] In another embodiment the reaction apparatus further comprising a hydration reaction vessel for the production of the slurry product having an inlet for the blended powder and a water inlet and a shearing apparatus for shearing the reaction mixture; and a steam outlet for release of steam from the reaction vessel, such that in use the reaction is controlled by allowing heat of hydration to raise the temperature of the reaction mixture, allowing water to boil off from the reaction mixture as hydration proceeds, and removing steam via the steam outlet to remove excess heat and control reaction temperature at boiling point and a means of quenching the slurry to below 60° C., preferably by transfer of the slurry to a cooled container and a means of cooling the slurry to ambient temperature; and a means of adding solid or liquid additives to the slurry.

[0123] In a further embodiment, the reaction apparatus is adapted for post-processing the bioactive power or slurry from the apparatus by one or more of the following steps: [0124] sparging the powder or slurry with a gas adjuvent such as ozone to enhance bioactivity; [0125] adding and mixing liquid adjuvent compounds to the powder or slurry to enhance bioactivity; [0126] adding and mixing materials to the powder or slurry to make a biocidal coating product or [0127] adding and mixing materials to the powder or slurry to make a biocidal emulsion or foam.

[0128] In one embodiment of the present invention, there is provided a chemical composition as a powder adapted for use as a biocide, wherein the composition comprises: a powder of micron scale calcined particles which are formed from a mixture of carbonate compounds and hydroxide compounds, and which have additives to boost the biocide impact such as ozone, hydrogen peroxide wherein the particles have a porosity of greater than 0.5 and wherein the pore surface is largely composed of nano-crystalline structures.

[0129] The chemical composition as a slurry is adapted for use as a biocide, wherein the composition comprises a slurry produced by hydrating the powder of mentioned above with additives that stabilise the slurry.

[0130] In another embodiment, the chemical composition is presented as a coating material slurry adapted for use as a biocide, wherein the composition comprises a coating material produced by mixing the powder or the slurry mentioned above with additives that set the material when applied to a surface.

[0131] In another embodiment, the chemical composition is presented as a foam, spray or emulsion material slurry adapted for use as a biocide, biofilm inhibitor, or plant root repellant, wherein the composition comprises a foam, spray or emulsion material produced by mixing the powder or the slurry mentioned above with additives that form a foam, spray or emulsion when processed.

[0132] Although the invention has been described with reference to specific examples, it will be appreciated by those skilled in the art that the invention may be embodied in many other forms, in keeping with the broad principles and the spirit of the invention described herein.

[0133] The present invention and the described preferred embodiments specifically include at least one feature that is industrial applicable.