Use of spent bleaching earth from edible oil processing in the formulation of salt and mineral feed blocks or pellets for livestock

Abstract

Spent bleaching earth from edible oil processing can be used in the formulation of salt and mineral lick blocks and pellets for livestock to enhance the health and nutritional value of the feed supplements. Because of the ignition hazard inherent with spent bleaching earth, landfill has been and continues to be the dominant disposal method. By adding salt or brine to the spent bleaching earth upon discharge from the process filters, the hydroscopic property will keep the material safe for handling and economic use as described.

Claims

1. A method for disposing of spent bleaching earth consisting of: providing a spent bleaching earth composition consisting essentially of 35 wt. % of spent bleaching earth obtained from edible oil processing with 50 wt. % sodium chloride and 15 wt. % of a binding agent comprising Portland cement; mixing the spent bleaching earth, sodium chloride, and binding agent with water to form a mixture; allowing the mixture to set; and curing the mixture for 7 to 10 days to form a stable crystal matrix block; wherein the spent bleaching earth contains 30 wt. % to 50 wt. % oil; wherein the mixture is not spontaneously combustible at atmospheric temperatures.

2. The method of claim 1, wherein the spent bleaching earth is selected from the group consisting of attapulgite, montmorillonite, Na-montmorillonite, Ca-montmorillonite, bentonite, Na-bentonite, Ca-bentonite, beidellite, nontronite, saponite, hectorite, or combinations of thereof.

3. A method for preparing animal feed supplements consisting of: providing a spent bleaching earth composition consisting essentially of 35 wt. % of spent bleaching earth obtained from edible oil processing with 50 wt. % sodium chloride and 15 wt. % of a binding agent comprising Portland cement; mixing the spent bleaching earth, sodium chloride, and binding agent with water to form a mixture; allowing the mixture to set; and curing the mixture for 7 to 10 days to form a stable crystal matrix block; wherein the spent bleaching earth contains 30 wt. % to 50 wt. % oil; wherein the mixture is not spontaneously combustible at atmospheric temperatures.

4. The method of claim 3, wherein the spent bleaching earth is selected from the group consisting of attapulgite, montmorillonite, Na-montmorillonite, Ca-montmorillonite, bentonite, Na-bentonite, Ca-bentonite, beidellite, nontronite, saponite, hectorite, or combinations of thereof.

5. The method of claim 3, wherein said Portland cement is Type I/II.

6. The method of claim 3, wherein said animal feed supplement is a lick block.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a flowchart demonstrating one of the invention methods for utilizing spent edible oil bleaching earth.

(2) FIG. 2 is a flowchart demonstrating one of the invention methods for utilizing spent edible oil bleaching earth.

(3) FIG. 3 is a flowchart demonstrating an invention method for production of salt and mineral lick blocks enhanced with edible oil contained in spent bleaching clay.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

(4) The embodiments of this invention are not limited to particular animal lick block and pellet compositions and methods of use thereof, which can vary and are understood by skilled artisans. It is further to be understood that all terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting in any manner or scope. For example, as used in this specification and the appended claims, the singular forms a, an and the can include plural referents unless the content clearly indicates otherwise. Further, all units, prefixes, and symbols may be denoted in their SI accepted form. Numeric ranges recited within the specification are inclusive of the numbers defining the range and include each integer within the defined range.

(5) So that the present invention may be more readily understood, certain terms are first defined. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which embodiments of the invention pertain. Many methods and materials similar, modified, or equivalent to those described herein can be used in the practice of the embodiments of the present invention without undue experimentation, the preferred materials and methods are described herein. In describing and claiming the embodiments of the present invention, the following terminology will be used in accordance with the definitions set out below.

(6) The term about, as used herein, refers to variation in the numerical quantity that can occur, for example, through typical measuring and liquid handling procedures used for making concentrates or use solutions in the real world; through inadvertent error in these procedures; through differences in the manufacture, source, or purity of the ingredients used to make the compositions or carry out the methods; and the like. The term about also encompasses amounts that differ due to different equilibrium conditions for a composition resulting from a particular initial mixture. Whether or not modified by the term about, the claims include equivalents to the quantities.

(7) The terms weight percent, wt-%, wt % percent by weight, % by weight, and variations thereof, as used herein, refer to the concentration of a substance as the weight of that substance divided by the total weight of the composition and multiplied by 100. It is understood that, as used here, percent, %, and the like are intended to be synonymous with weight percent, wt-%, etc.

Ingredients

(8) Spent Bleaching Earth

(9) The terms spent bleaching earth, spent bleaching clay, edible oil bleaching earth, edible oil bleaching clay, and variations thereof, as used herein, refer to spent bleaching earth resulting from the production of edible vegetable oil, i.e., oils used chiefly in foodstuffs. Examples of preferred spent bleaching earth are: attapulgite, bentonite, montmorillonite, Na-montmorillonite, Ca-montmorillonite, Na-bentonite, Ca-bentonite, beidellite, nontronite, saponite, hectorite, and combinations thereof. Typical attributes of edible oil bleaching earth are presented in Table 1.

(10) Salt Component

(11) The terms salt, salt component, salt composition, and variations thereof, as used herein, refer to edible salts, which can serve as nutrient sources. Suitable examples of salts include the alkaline earth metal salts (e.g., calcium chloride and magnesium chloride), alkali earth metal salts (e.g., sodium chloride, sodium sulfate, and potassium chloride), copper salts, cobalt salts, chromium salts, selenium salts, manganese salts, and iron salts.

(12) The terms brine, brine solution, and variations thereof, as used herein, refer to salt dissolved in water at between about 10 wt % and 50 wt %, preferably between about 10 wt % and 30 wt %, more preferably between about 20 wt % and 30 wt %, most preferably about 24%. The amount and nature of impurities in brine can vary from about 100 to 6,000 ppm. Examples of common impurities are aluminum, iron, magnesium, and sodium compounds.

(13) TABLE-US-00001 TABLE 1 Typical Attributes of Edible Oil Bleaching Earth Physical Properties Apparent Bulk Density (g/cc) 0.99 Free Moisture (%) [2 hours, 110 C.] 10 to 12 Loss on Ignition (%) [pre dried for 2 hours at 1,000 C.] 6 to 8 Ph [10% suspension filtered] 5 to 5.3 Acidity (mg KOH/g) <1 Surface Area (m.sup.2/g) 210 Micro Pore Volume 0-80 nm (mg/l) 0.46 Chemical Analysis (Mineral Composition by Percentage) Silicon Oxide 64 Aluminum Oxide 16 Iron (III) Oxide 1.20 Magnesium Oxide 2.10 Calcium Oxide 1.20 Sodium Oxide 0.00 Loss on Ignition (%) 7.90 Others 7.60 Particle Size Distribution (Based on Standard Screen Sizes) 100 2 200 9 240 21 300 18 350 12 350 38 Source: Fuller's Earth (Clay), Activated Edible Oil Bleaching

(14) Binding Agent

(15) The terms binding agent, binding agent composition, and any variations thereof, as used herein, describe a material used to solidify the mixture of spent bleaching earth and salt or brine. Those skilled in the art will be familiar with various binding agents for differing animal feed supplements, i.e., for making lick blocks, pellets, etc. A binding agent including a mineral component is preferred. Examples of suitable binding agents containing a mineral component include Portland cement, particularly Type I/II. Portland cement is commonly used as the binding agent in lick blocks containing soy protein meal and other nutritional ingredients. Methods of making Portland cement and places for purchasing Portland cement are well-known by those skilled in the art. Portland cement contains significant amounts of calcium, which provides nutritional benefits to the animals. The mineralogical composition of Type I/II Portland cement is presented in Table 2. Water may be added to the binding agent composition, as necessary, so that the mixture of spent bleaching earth, salt component, and binding agent may be poured into molds.

(16) TABLE-US-00002 TABLE 2 Mineralogical Composition of Type I/II Portland Cement Compound Chemical Percent by weight Name Formula Range Average Tricalcium Silicate Ca.sub.3SiO.sub.5 50-70 60 Dicalcium Silicate Ca.sub.2SiO.sub.4 10-30 20 Tricalcium Aluminate Ca.sub.3Al.sub.2O.sub.6 3-13 6 Tetracalcium Aluminoferrite Ca.sub.4Al.sub.2Fe.sub.2O.sub.10 5-15 8 Calcium Sulfate CaSO.sub.42H.sub.2O 3-7 5 Anhydrous Calcium Sulfate CaSO.sub.4 0.2-2.0 1 Source: H. G. van Oss, 2005, Background Facts and Issues Concerning Cement and Concrete Data, U.S. Geological Survey Open-File Report 2005-1152: Version 1.2, available at http://pubs.usgs.gov/of/2005/1152/2005-1152.pdf

(17) Optional Ingredients

(18) The animal feed supplement mixture may also include other optional ingredients. Optionally, other edible fats may be added to the mixture. Optional edible fat sources include, but are not limited to, fatty acids (e.g., stearic, palmitic, oleic, linoleic, and lauric acid), complex lipids (e.g., phospholipids). Sources of edible fats may include, but are not limited to, coconut oil, corn oil, cottonseed oil, fish oil, olive oil, palm oil, sesame oil, soybean oil, canola oil, sunflower seed oil, tallow, greases, beef fat, restaurant fats, and mixtures thereof.

(19) Optionally, other feedstuffs may be added to the mixture, including but not limited to, cottonseed meal, soy bean meal, mill run, lupins, molasses, dunder, other molasses byproducts (dried); grains, cereals, legumes, straw, hay, soy flakes, dried alfalfa, soy meal, wheat middlings, corn; barley meal, blood meal, dried buttermilk, linseed meal, meat and bone meal, peanut meal, rice meal, and sunflower meal.

(20) Optionally, dietary nitrogen may be included in the mixture. Optional dietary nitrogen sources include, but are not limited to, ammonia, ammonium polyphosphate, animal protein products, oilseed meals, synthetic amino acids, and urea.

(21) Optionally, various vitamins may be added to the mixture. Examples of such vitamins include, but are not limited to, vitamins A, E, K, and the B group vitamins.

(22) Optionally, various trace minerals and elements may be added to the mixture. Examples of such trace minerals and elements include, but are not limited to, cobalt sulfate, copper sulfate, ferrous sulfate, ferrous oxide, iodines, manganese sulfate, potassium iodate, selenium and its compounds, sulphur, zinc oxide, and zinc sulfate, etc.

(23) Optionally, various drugs, medicaments, insecticides, enzymes, antimicrobials, probiotics and the like may be added to the mixture.

(24) Optionally, water may be added to the mixture, as necessary, so that the mixture may be poured into molds.

(25) Depending on the optional ingredients added, it may be beneficial to include optional emulsifying agents to stabilize the composition and prevent separation of the mixture, particularly of the fat ingredient(s). A preferred, although not exclusive, example of emulsifying agents are colloidal clay gellants, such as, attapulgite, bentonite, and sepiolite. One of skill in the art will be familiar with the use of emulsifying agents, including when they are helpful and how to incorporate them.

Methods of the Invention and Preferred Embodiments

(26) Prepartion of the Mixture

(27) A mixture is prepared of spent bleaching earth, containing about 30-50 wt % oil, and a salt component. The spent bleaching earth may be present at about 10-35 wt %, preferably about 20-35 wt %, more preferably about 35 wt %. The salt component is present at about 5-85 wt %, preferably 50-85 wt %, and more preferably about 50 wt %. The mixture of spent bleaching earth and salt component is then mixed with a binding agent. The binding agent may be present at about 5-15 wt %, preferably about 15 wt %. Preferably the binding agent includes a mineral component. Most preferably, the binding agent is Type I/II Portland cement. Any suitable mixer can be used to combine and thoroughly mix the ingredients. Examples of suitable mixers include, but are not limited to, variable-speed shop drill motors with a mixer bit, paddle-mixers, etc. One of skill in the art will be familiar with various mixers and can select an appropriate mixer for their particular production needs. Once thoroughly mixed, the mixture is transferred to a mold with the desired size and shape. The mixture should be allowed to set until it has hardened. One of skill in the art will recognize how long the mixture must set to harden.

(28) The methods, products, and compositions of the invention may be followed to provide nutritional supplements in the form of pellets and lick blocks. One of skill in the art may produce pelletized nutritional supplements following the disclosure herein and using pelletizing techniques well-known in the art. Lick blocks, however, are preferred because they provide free-choice feeding to the animals on a self-demand basis and reduce labor and expenses resulting from rationing and mixing granular materials in the animal feed. Additionally, lick blocks can be weather resistant, which removes the need to provide sheltered feeding locations. The lick blocks are also easily transported from one location to another without the risk of spilling.

(29) Additionally, the lipid content in the spent bleaching clay has health benfits for the livestock. In cases where livestock producers have leased pasture land to edible oil processors for disposal of spent bleaching earth, it has been observed that cattle immediately lick on any small quantities spilled. There is no question that livestock will not be attracted to and nutritionally benefit from this incorporation of spent bleaching earth in salt and mineral lick blocks or pellets.

(30) Spontaneous Combustion Suppression Tests

(31) Spontaneous combustion suppression tests were conducted to ensure that the hazards associated with the combustion of spent bleaching earth were eliminated. The tests were conducted as discussed below and the data from the tests is contained in Table 3. Five pound samples of spent bleaching earth containing about 30% oil by weight were mixed with salt component as presented in Table 3, and under the procedures described below.

(32) TABLE-US-00003 TABLE 3 Spontaneous Combustion Suppression Test Formulations Amount of Spent Weight Percentage Salt Component Form Bleaching Earth of Salt and Composition 5 lbs 0% (reference) No Salt Added 5 lbs 5% 24% (wt) brine, NaCl 5 lbs 5% Dry NaCl 5 lbs 7.5% 24% (wt) brine, NaCl 5 lbs 7.5% Dry NaCl 5 lbs 10% 24% (wt) brine, NaCl 5 lbs 10% Dry NaCl 5 lbs 15% Dry NaCl 5 lbs 18% Dry NaCl

(33) All of the five-pound samples were placed outside on a gravel roadway in the direct sunlight for five days. To retain the heat produced from oil oxidation and protect the samples from moisture, the sample bags were closed and tied at the end of each test day and opened again each morning. The temperature of each sample was taken by means of a non-contact infrared thermometer. The temperature recordings are provided in Table 4 by sample.

(34) TABLE-US-00004 TABLE 4 Temperature Profile of Spent Bleaching Earth Samples with Salt Addition over Five-Day Period Date Jul. 24, 2012 Jul. 25, 2012 Jul. 26, 2012 Jul. 27, 2012.sup. Jul. 28, 2012 Time 1100 1500 1100 1500 1100 1500 1100 1500 1100 1500 Temperature ( F.) Reference Sample 119 130 154 167 169 170 163 151 148 152 (0% Salt) Sample with 5% 86* 111 121 128 130 133 121 128 126 129 Salt (Brine) Sample with 5% 96 132 140 147 150 142 137 135 140 Dry Salt Sample with 7.5% 94 118 125 128 130 117 124 121 125 Salt (Brine) Sample with 7.5% 95 129 137 142 145 139 134 132 137 Dry Salt Sample with 10% 86* 94 113 121 124 128 115 121 119 121 Salt (Brine) Sample with 10% 87 124 133 139 142 136 131 129 133 Dry Salt Sample with 15% 84* 115 126 135 136 131 126 124 129 Dry Salt Sample with 18% 84* 113 124 133 135 129 124 122 126 Dry Salt Ambient 88 92 89 91 87 89 86 84 89 92 Temperature % Humidity 94 94 97 94 91 (High) % Humidity 73 79 83 79 78 (Low) *The temperature recording reflects the sample temperature at the conclusion of preparation and being placed outside for observation. .sup.Rain occurred on Jul. 27, 2012, which resulted in an ambient temperature drop. The samples were protected from rain exposure.

(35) In the combustion suppression test, none of the spent bleaching earth samples exhibited any visible ignition over the five-day test period. The reference sample did reach a maximum temperature of 170 F. on the second day of observation and reflected a color change from yellow-tan to brown with some ashen-colored spots. The next highest sample temperature recorded was 150 F. on the second day of observation. This sample had been treated with 5% by weight of dry salt. With salt being hydroscopic, moisture is absorbed from the air to aid in keeping the spent bleaching earth cool. Additionally, the encapsulation of spent bleaching earth within a salt-Portland cement crystal matrix essentially eliminates air exposure and the risk of spontaneous combustion of the entrained edible oil. Thus, the addition of the salt component to the spent bleaching earth prevents significant increases in the temperature of the spent bleaching earth and eliminates the problem of spontaneous combustion.

(36) Spent bleaching earth was disposed of according to the methods disclosed herein and animal nutritional supplements were produced. Four illustrative examples are discussed below. These examples are not to be deemed exclusive embodiments of the methods for disposing of spent bleaching earth, methods of producing the animal nutritional supplements, or compositions of animal nutritional supplement, disclosed herein.

Example 1

(37) Two animal lick block samples were prepareda 1.573 liter rectangular-shaped block and a 4.732 liter bell-shaped block. A blend of attapulgite and bentonite spent bleaching earth from edible oil processing was obtained and combined with salt, Portland cement Type I/II, and water. The proportions combined were: 10 wt % spent bleaching earth, 85 wt % salt, 5 wt % Portland cement Type I/II, and 300 mL of water for the 1.573 liter block and 900 mL of water for the 4.732 liter block. A variable-speed shop drill motor with a mixer bit was used to thoroughly mix the ingredients. After thorough mixing, each mixture was transferred to a lick block mold. At this point, the mixtures had the color and consistency of concrete or mortar. The mixtures were allowed to set overnight in the molds. After setting overnight, the mixtures hardened and white salt crystals dominated their appearance. The 4.732 liter block was cured for ten days. The 1.573 liter block was cured for one week. During the curing period, the temperature of the blocks was monitored with a non-contact infrared thermometer. The blocks exhibited stable temperatures over the curing period. After the curing period, the lick blocks were off-white in color and had typical attributes of a salt lick block. The blocks were firm and structurally stable. The 4.732 liter lick block was provided to a cattle producer for consumption by a herd of cattle. The block was placed in an outdoor serving dish and observed by personnel onsite. The 4.732 liter lick block exhibited no abnormal or deleterious characteristics. The 1.573 liter block was retained for longer observation. The 1.573 liter lick block exhibited no abnormal or deleterious characteristics.

Example 2

(38) Again, two animal lick block samples were prepareda 1.573 liter rectangular-shaped block and a 4.732 liter bell-shaped block. A blend of attapulgite and bentonite spent bleaching earth from edible oil processing was obtained and combined with salt, Portland cement Type I/II, and water. The proportions combined were: 15 wt % spent bleaching earth, 75 wt % salt, 10 wt % Portland cement Type I/II, and 300 mL of water for the 1.573 liter block and 900 mL of water for the 4.732 liter block. A variable-speed shop drill motor with a mixer bit was used to thoroughly mix the ingredients. After thorough mixing, each mixture was transferred to a lick block mold. At this point, the mixtures had the color and consistency of concrete or mortar. The mixtures were allowed to set overnight in the molds. After setting overnight, the mixtures hardened and white salt crystals dominated their appearance. The 4.732 liter block was cured for ten days. The 1.573 liter block was cured for one week. During the curing period, the temperature of the blocks was monitored with a non-contact infrared thermometer. The blocks exhibited stable temperatures over the curing period. After the curing period, the lick blocks were off-white in color and had typical attributes of a salt lick block. The blocks were firm and structurally stable. The 4.732 liter lick block was provided to a cattle producer for consumption by a herd of cattle. The block was placed in an outdoor serving dish and observed by personnel onsite. The 4.732 liter lick block exhibited no abnormal or deleterious characteristics. The 1.573 liter block was retained for longer observation. The 1.573 liter lick block exhibited no abnormal or deleterious characteristics.

Example 3

(39) Again, two animal lick block samples were prepareda 1.573 liter rectangular-shaped block and a 4.732 liter bell-shaped block. A blend of attapulgite and bentonite spent bleaching earth from edible oil processing was obtained and combined with salt, Portland cement Type I/II, and water. The proportions combined were: 20 wt % spent bleaching earth, 65 wt % salt, 15 wt % Portland cement Type I/II, and 300 mL of water for the 1.573 liter block and 900 mL of water for the 4.732 liter block. A variable-speed shop drill motor with a mixer bit was used to thoroughly mix the ingredients. After thorough mixing, each mixture was transferred to a lick block mold. At this point, the mixtures had the color and consistency of concrete or mortar. The mixtures were allowed to set overnight in the molds. After setting overnight, the mixtures hardened and white salt crystals dominated their appearance. The 4.732 liter block was cured for ten days. The 1.573 liter block was cured for one week. During the curing period, the temperature of the blocks was monitored with a non-contact infrared thermometer. The blocks exhibited stable temperatures over the curing period. After the curing period, the lick blocks were off-white in color and had typical attributes of a salt lick block. The blocks were firm and structurally stable. The 4.732 liter lick block was provided to a cattle producer for consumption by a herd of cattle. The block was placed in an outdoor serving dish and observed by personnel onsite. The 4.732 liter lick block exhibited no abnormal or deleterious characteristics. The 1.573 liter block was retained for longer observation. The 1.573 liter lick block exhibited no abnormal or deleterious characteristics.

Example 4

(40) Again, two animal lick block samples were prepareda 1.573 liter rectangular-shaped block and a 4.732 liter bell-shaped block. A blend of attapulgite and bentonite spent bleaching earth from edible oil processing was obtained and combined with salt, Portland cement Type I/II, and water. The proportions combined were: 35 wt % spent bleaching earth, 50 wt % salt, 15 wt % Portland cement Type I/II, and 350 mL of water for the 1.573 liter block and 1050 mL of water for the 4.732 liter block. A variable-speed shop drill motor with a mixer bit was used to thoroughly mix the ingredients. After thorough mixing, each mixture was transferred to a lick block mold. At this point, the mixtures had the color and consistency of concrete or mortar. The mixtures were allowed to set overnight in the molds. After setting overnight, the mixtures hardened and white salt crystals dominated their appearance. The 4.732 liter block was cured for ten days. The 1.573 liter block was cured for one week. During the curing period, the temperature of the blocks was monitored with a non-contact infrared thermometer. The blocks exhibited stable temperatures over the curing period. After the curing period, the lick blocks were off-white in color and had typical attributes of a salt lick block. The blocks were firm and structurally stable. The 4.732 liter lick block was provided to a cattle producer for consumption by a herd of cattle. The block was placed in an outdoor serving dish and observed by personnel onsite. The 4.732 liter lick block exhibited no abnormal or deleterious characteristics. The 1.573 liter block was retained for longer observation. The 1.573 liter lick block exhibited no abnormal or deleterious characteristics.