ANTI-DUST ADDITIVE COMPOSITION FOR CONSTRUCTION MATERIAL

Abstract

An anti-dust additive composition for industrial mortars, dry coatings, cements and tile adhesives, includes at least a hydrocarbon fluid, a surfactant and 0.01% to 5% wt of water, preferably from 0.01% to 2% wt, more preferably from 0.01% to 1% wt and even more preferably from 0.05% to 0.5% wt of water. A process of preparation of construction material includes the step of adding the anti-dust additive composition to a material powdery binder. The use of the anti-dust additive composition for decreasing the dust emission during the fabrication of construction material with a material powdery binder and/or during the use of the construction material is also disclosed.

Claims

1. An anti-dust additive composition for industrial mortars, dry coatings, cements and/or tile adhesives, comprising at least a hydrocarbon fluid selected from a group consisting of hydrotreated hydrockracked hydrocarbon fluid and hydrotreated hydrodewaxed hydrocarbon fluid, alone or in combination, a surfactant and from 0.01% to 5% wt of water.

2. The anti-dust additive composition according to claim 1, wherein the hydrocarbon fluid comprises at least one hydrotreated hydrodewaxed hydrocarbon fluid.

3. The anti-dust additive composition according to claim 1, wherein the hydrocarbon fluid is a dearomatised and/or desulfurized hydrocarbon fluid.

4. The anti-dust additive composition according to claim 1, wherein the hydrocarbon fluid is originated from crude oil and/or biomass.

5. The anti-dust additive composition according to claim 1, wherein the hydrocarbon fluid has a distillation range comprised between 230° C. and 410° C., according to ASTM D86.

6. The anti-dust additive composition according to claim 1, wherein the hydrocarbon fluid has a kinematic viscosity at 40° C. comprised between 2 and 22 mm.sup.2/s, according to ASTM D445.

7. The anti-dust additive composition according to claim 1, wherein the hydrocarbon fluid contains less than 0.1% wt of aromatics, measured by UV spectrometry.

8. The anti-dust additive composition according to claim 1, wherein the hydrocarbon fluid has: a naphthenic content below 50% wt, and/or a paraffinic content above 60% wt, and/or an isoparaffinic content above 50% wt, and a normal paraffinic content below 20% wt.

9. The anti-dust additive composition according to claim 1, wherein the surfactant is a nonionic surfactant.

10. The anti-dust additive composition according to claim 9, wherein the non-ionic surfactant is selected from a group consisting of sorbitan oleate, triblock copolymers derived from ethylene oxide and propylene oxide, fatty alcohol and ethylene oxide condensate on fatty acids, alone or in combination.

11. The anti-dust additive composition according to claim 1, wherein the additive comprises 95 to 99% wt of hydrocarbon fluid.

12. The anti-dust additive composition according to claim 1, wherein the additive comprises between 0.1% to 10% wt of one or more surfactants.

13. A process of preparation of a construction material comprising adding an anti-dust additive composition for industrial mortars, dry coatings, cements and/or tile adhesives to a material powdery binder, the anti-dust additive composition comprising at least a hydrocarbon fluid selected from a group consisting of hydrotreated hydrockracked hydrocarbon fluid and hydrotreated hydrodewaxed hydrocarbon fluid, alone or in combination, a surfactant and from 0.01% to 5% wt of water.

14. The process according to claim 13, wherein the anti-dust additive composition is added by vaporisation on a material powdery binder.

15. The process according to claim 13, wherein the anti-dust additive composition is added by blending with a material powdery binder.

16. The process according to claim 13, wherein the construction material comprises between 0.01% and 10% wt of the anti-dust additive composition.

17. The anti-dust additive composition according to claim 1, decreasing the dust emission during the fabrication of construction material with a material powdery binder and/or during use of the construction material.

18. The anti-dust additive composition according to claim 17, wherein the material powdery binder is selected from the group consisting of industrial mortars, dry coatings, cements and tile adhesives.

Description

DETAILED DESCRIPTION

[0023] The additive according to the invention concerns a dust-binder additive composition which presents very good anti-dust properties. The anti-dust additive composition for industrial mortars, dry coatings, cements, and tile adhesives according to the invention comprises at least a hydrocarbon fluid, a surfactant and 0.01% to 5% wt of water, preferably from 0.01% to 2% wt, more preferably from 0.01% to 1% wt and even more preferably from 0.05% to 0.5% wt of water.

[0024] Hydrocarbon fluid by means of the invention refers to a hydrocarbon cut from the distillation of crude oil, preferably from atmospheric distillation and/or vacuum distillation of crude oil, preferably from atmospheric distillation followed by vacuum distillation. The hydrocarbon fluid of the invention is also preferably subjected to hydrotreatment, catalytic cracking or hydrocracking. The hydrocarbon fluid of the invention is also preferably subjected to the steps of dearomatization and desulfurization optionally. The hydrocarbon fluid of the invention can also preferably be subjected to a hydrodewaxing step.

[0025] Preferably, the hydrocarbon cut obtained after the distillation of crude oil is a diesel fuel. This diesel fuel is subjected to hydrocracking or catalytic cracking, hydrodewaxing, hydrotreatment steps, optionally followed by dearomatization and desulfurization steps. The hydrocarbon fluid may be a mixture of hydrocarbon fluids subjected to the steps described above.

[0026] The hydrocarbon fluid according to the invention can also refer to a cut originated from biological origin or in other words from biomass. By hydrocarbon fluid from biological origin the applicant means a hydrocarbon fluid produced from biological raw materials from the group consisting of vegetable oils, animal fats, fish oils, and mixtures thereof. Suitable biological raw materials include rapeseed oil, canola oil, colza oil, tall oil, sunflower oil, soybean oil, hemp oil, olive oil, linenseed oil, mustard oil, palm oil, arachis oil, castor oil, coconut oil, animal fats such as suet, tallow, blubber, recycled alimentary fats, starting materials produced by genetic engineering, and biological starting materials produced by microbes such as algae and bacteria. Condensation products, esters, or other derivatives obtained from biological raw materials may also be used as starting materials.

[0027] The hydrocarbon fluid from biological origin is then produced by using for instance a process first comprising a hydrodeoxygenation (HDO) step for decomposing the structure of the biological ester or triglyceride constituent, and for removing oxygen, phosphorus and sulfur compounds, concurrently hydrogenating the olefinic bonds, followed by isomerization of the product thus obtained, thus branching the hydrocarbon chain and improving the low temperature properties of the paraffin. The product may for instance be fractionated to give the desired fractions. The desired fractions are then subjected to hydrotreatement and distillation to obtain the desired hydrocarbon fluid specifications according to the invention.

[0028] The hydrocarbon fluid may be a mixture of hydrocarbon fluids originated from crude oil and/or from biomass. Preferably the hydrocarbon fluid is a dearomatised and/or desulfurized hydrocarbon fluid. Preferably the hydrocarbon fluid is selected from the group consisting of hydrotreated hydrockracked hydrocarbon fluid and hydrotreated hydrodewaxed hydrocarbon fluid, alone or in combination. Preferably the anti-dust additive composition comprises at least one hydrotreated hydrodewaxed hydrocarbon fluid.

[0029] The hydrocarbon fluid as described above has preferably a distillation range comprised between 230° C. and 410° C., preferably between 250° C. and 400° C. and more preferably between 280° C. and 400° C. according to ASTM D86. The hydrocarbon fluid may comprise one or more fractions of distillation ranges included in the said fraction. The hydrocarbon fraction according to the invention has preferably a carbon range comprised between C12 and C29 atoms of carbon and preferably between C13 and C27 atoms of carbon according to ASTM D2887.

[0030] The hydrocarbon fluid of the invention comprises advantageously more than 60% wt of paraffinic compounds, preferably more than 65% wt, even more preferably more than 70% wt determined by GCxGC analyses. The hydrocarbon fluid according to the invention consists advantageously of a majority of isoparaffin and a minority of normal paraffin. Preferably the hydrocarbon fraction contains more than 50% wt of isoparaffin and less than 20% wt of normal paraffin determined by GC-MS analyses. The hydrocarbon fraction of the invention comprises preferably less than 50% wt of naphthenic compounds, preferably less than 40% wt, even more preferably less than 30% wt determined by GCxGC analyses. The hydrocarbon fluid of the invention comprises preferably less than 20% wt of polynaphthenic compounds, preferably less than 10% wt, even more preferably less than 5% wt determined by GCxGC analyses.

[0031] The hydrocarbon fluid according to the invention contains very low aromatics content. By very low the applicant means a hydrocarbon fluid comprising less than 0.1% wt of aromatics, preferably less than 800 ppm, even more preferably less than 600 ppm measured by UV spectrometry. The hydrocarbon fluid according to the invention is preferably free of benzenic compounds. By free the applicant means a hydrocarbon fluid comprising less than 10 ppm of benzenic compounds and more preferably less than 1 ppm according to ASTM D6229.

[0032] Preferably the hydrocarbon fluid according to the invention has a sulfur content below 10 ppm and more preferably less than 2 ppm according to ASTM D5453. The hydrocarbon fluid according to the invention has preferably a kinematic viscosity at 40° C. comprised between 2 and 22 mm.sup.2/s, preferably between 2 and 15 mm.sup.2/s and more preferably between 3 and 14 mm.sup.2/s according to ASTM D445. The hydrocarbon fluid of the invention has a pour point according to ASTM D97 between −50 and +10° C., preferably between −45 and 0° C. The hydrocarbon fluid according to the invention also has the advantage of being readily available on the market and to be relatively economical in the product chain of oil distillation. The amount of hydrocarbon fluid in the anti-dust additive composition according to the invention is preferably comprised between 95 to 99% wt.

[0033] The anti-dust additive composition according to the invention comprises also at least one surfactant. Surfactants are compounds that lower the surface tension (or interfacial tension) between two liquids or between a liquid and a solid. Preferably the surfactant according to the invention is biodegradable. The surfactant used in the anti-dust additive composition is preferably a nonionic surfactant. Preferably the surfactant is selected from the group consisting of sorbitan oleate, triblock copolymers derived from ethylene oxide and propylene oxide, fatty alcohol and ethylene oxide condensate on fatty acids, alone or in combination. The amount of surfactant in the anti-dust additive composition according to the invention is preferably comprised between 0.1% to 10% wt of one or more surfactants, more preferably between 0.5% to 5% wt.

[0034] The anti-dust additive composition according to the invention also comprises water. The presence of water in the additive according to the invention preserves a clear and transparent product. The amount of water in the additive is essential to lead to a stable formulation. Without water an unclear composition is formed with a precipitation of the additives which leads to the separation in two phases of the anti-dust additive composition. The amount of water in the additive according to the invention is preferably comprised between 0.01% to 5% wt, preferably between 0.01% to 2% wt, more preferably between 0.01% to 1% wt and even more preferably between 0.05% to 0.5% wt.

[0035] The anti-dust additive composition according to the invention is free of volatile organic compounds (VOC). According to one preferred embodiment, the emissions of VOC of a tile adhesive formulated with the anti-dust additive composition according to the invention complies with the requirements of Blue Angel RAL-UZ113 and GEV EMICODE (level EC1+). In particular, the anti-dust additive composition fully respects the Blue Angel certification for products and services that have environmentally friendly aspects. The anti-dust additive composition according to the invention complies with the Blue Angel RAL-UZ 113 “Basic Criteria for Award of the Environmental Label —Low-Emission Floor Covering Adhesives and other Installation Materials”: it respects all the requirements about exclusion of substances and preparations.

[0036] Preparations of construction material are well known. In particular, material powdery binders as construction materials are prepared according to all known processes. According to one preferred embodiment of the invention, the process of preparation of construction material comprises the step of adding an anti-dust additive composition to a material powdery binder. Preferably the anti-dust additive composition according to the process of the invention and to one preferred embodiment is added by blending with a material powdery binder or by vaporisation on a material powdery binder. Preferably the construction material prepared according to the process of the invention comprises between 0.01% and 10% wt of the anti-dust additive composition, preferably between 0.05% and 5% wt, more preferably between 0.1% and 2% wt, even more preferably between 0.2% and 1% wt.

[0037] The anti-dust additive composition according to the invention is used for decreasing the dust emission during the fabrication of construction material with material powdery binder and/or during the use of said construction material. Preferably, the anti-dust additive composition according to the invention is used for decreasing the dust emission during fabrication of industrial mortars, dry coatings, cements and tile adhesives. Especially, the invention allows reducing the dust emission during the step of mixing the material powdery binder with the other constituents of a tile adhesive, such as water.

Examples

[0038] In the following description, the examples illustrate the invention without limiting it. Different formulations of dust binder containing hydrocarbon fluids, surfactants and water in emulsion have been evaluated.

[0039] The following examples describe the anti-dust additive compositions comprising: [0040] the hydrocarbon fluid HYDROSEAL G340H commercialised by the society TOTAL FLUIDS (hydrotreated hydrodewaxed hydrocarbon fluid) and/or, [0041] the hydrocarbon fluid HYDROSEAL G400H commercialised by the society TOTAL FLUIDS (hydrotreated hydrocracked hydrocarbon fluid) and/or, [0042] the hydrocarbon fluid NEXBASE 3030 (catalytically hydroisomerized and dewaxed base oil) and, [0043] a combination of Polioxol 5106, Span 80, Clariant Emulsogen MTP 070 or Croda Synperonic PE/31 surfactants (nonionic surfactants), [0044] and water.

[0045] The Table 1 indicates the mains characteristics of each hydrocarbon fluid according to the example.

TABLE-US-00001 TABLE1 75% Hydroseal G340H/25% Hydroseal Hydroseal Hydroseal Nexbase Parameters G340H G400H G400H 3030 Initial boiling point, 330 304 314 302 (° C.) [ASTM D86] Final boiling point, 380 347 373 368 (° C.) [ASTM D86] Kinematic viscosity at 10.3 6 8.7 12 40° C., (mm.sup.2/s) [ASTM D445] Pour point (° C.) −35 −2 −15 −30 [ASTM D97] Aromatic (ppm) 57 80 61 420 [UV spectrometry] Naphthenic (%) 24.7 24.0 24.3 27 [GC2D] Paraffinic (%) 74.3 76.0 74.7 73 [GC2D] N-paraffin (%) 0.1 16.0 4.1 — [GC2D] Isoparaffin (%) 74.2 60.0 70.6 — [GCMS] Sulphur (ppm) <2 <2 <2 <1 [ASTM D5453] Benzenes (ppm) <10 <10 <10 <10 [ASTM D6229]

[0046] The table 2 shows the different anti-dust additive compositions.

TABLE-US-00002 TABLE 2 Anti- Anti- Anti- Anti- Anti- dust 1 dust 2 dust 3 dust 4 dust 5 Raw material % % % % % HYDROSEAL G340H 96.90  72.68  — 72.68  100 HYDROSEAL G400H — 24.22  — 24.22  — NEXBASE 3030 — — 96.90  — — Polioxol 5106 2.55 2.55 2.55 — — Span 80 0.45 0.45 0.45 — — Clariant Emulsogen — — — 2.80 — MTP 070 Croda Synperonic PE/31 — — — 0.20 — Water 0.10 0.10 0.10 0.10 —

[0047] The table 3 shows the mortar composition used for the tile adhesive. The mortar is a REDI Fliesenkleber Extra-Flex dry mortar. It is a Class C2 TE dry mortar (according to EN 12004).

TABLE-US-00003 TABLE 3 Raw material % Silica Sand (0-0.3 mm) 32.1 Filler (Calcium Carbonate) 17.7 Portland cement CEM I 42.5 R 40.0 Dispersion Powder (Polyvinylacetate- 4.5 Copolymerisat) Celluloseether 0.5 Pulverized Fly ash 3.0 Microsilica (Amorphous silicon dioxide powder) 2.0 Thixotropic Agent (Layered silicate) 0.05 Bentonite 0.15

[0048] The table 4 indicates the different tile Adhesive formulations corresponding to tables 1, 2 and 3.

TABLE-US-00004 TABLE 4 Tile adhesive A B C D E F Raw material % % % % % % Dry mortar 100 99.50 99.50 99.50 99.50 99.50 Anti-dust 1 0.50 Anti-dust 2 0.50 Anti-dust 3 0.50 Anti-dust 4 0.50 Anti-dust 5 0.50

[0049] The table 5 shows the mechanical properties tested for each of the tile adhesives of table 4.

TABLE-US-00005 TABLE 5 Tile Adhesive A B C D E F Particle size distribution (DIN EN 1015-1) <0.090 mm 63.4 62.5 60.4 60.0 61.3 60.9 >0.090 mm 36.5 37.3 39.4 39.9 38.5 38.9 and <0.500 mm >0.500 mm 0.1 0.2 0.2 0.1 0.2 0.2 >1.000 mm 0.0 0.0 0.0 0.0 0.0 0.0 Ashing (Weight loss [%]) 3 hours at 0.09 0.18 0.16 0.16 0.17 0.16 105° C. 3 hours at 3.35 3.88 4.04 3.76 3.91 3.81 450° C. Slipping Test 200 g Tile (DIN EN 1308) [mm] 0.0 0.0 0.0 0.0 0.0 0.0 Density of Green mortar (DIN EN 1015-6) [kg/dm.sup.3] 1.535 1.589 1.523 1.544 1.541 1.538 Tensile strength (DIN EN 1348) after 28 days [N/mm.sup.2] 1.87 1.82 1.87 1.97 1.93 1.60 Tensile strength with longer open time 30 min. (DIN EN 1348) after 28 days [N/mm.sup.2] 0.74 0.61 0.82 0.92 0.70 0.61 Tensile strength (DIN EN 1348) after 7 days dry storage and 21 days water immersion [N/mm.sup.2] unknown 0.91 0.99 0.97 0.94 0.59

[0050] The results of table 5 show that the anti-dust additive composition according to the invention has no negative impacts on the mechanical properties of the tile adhesives (tile adhesives B, C, D and E). In the contrary, the tile adhesive containing only hydrocarbons fluids (tile adhesive F) presents non acceptable mechanical properties, as shown in Table 5. This reference with a pure Hydrocarbon as anti-dust additive composition has a significant lower tensile strength according to DIN EN 1348 which leads to an unusable tile adhesive.

[0051] The tables 6 and 7 indicate the dust emission evaluation for the tile adhesives tested. The table 6 shows the anti-dust performance of the tile adhesives according to Dust Mon L Machine from Microtrac commonly used by producers. The table 7 shows the anti-dust efficiency according to the French standard NF P 94-103 modified.

[0052] Table 6: Dust Mon L Machine: The DustMon L consists of a dosing system which is detachable and easy to snap in and out of the instrument body, sample collector, LED light source and detector. It offers a wide measurement from high-dust level products to low-dust products. The sample is filled into the sample beaker. After starting the measurement the valve opens and the sample drops down through the tube into the sample box. The dust of the sample will rise into the measurement area between the light source and the detector. Depending on the concentration of dust the light intensity will decrease. This is a direct indication for the amount of dust in the sample. Already during the ongoing analyses the DustMon L software is showing the progress of the dust sedimentation. After 30 seconds the analysis is completed all data can be viewed such as: maximum dust concentration (0-100 of complete dust concentration), end value, dust index (maximum value after 30 seconds), particule size distribution of the dust fraction.

[0053] The column dust is an index for the spontaneity of the dust formation. A smaller value means a lower dust formation at the beginning. The dust area is a value for the total formation during the test duration of 30 seconds. A smaller value means less dust in total.

TABLE-US-00006 TABLE 6 Tile Adhesives Dust Dust Area A 69.4 756.1 B 26.9 201.6 C 17.9 133.9 D 22.5 157.1 E 23.4 175.5 F 17.8 146.3

[0054] Table 6 results show that dust is reduced from 3 to 4 times in the tile adhesives containing the anti-dust additive compositions (tile adhesives B to E) comparing to cement alone in formulation A. The NF 94-103 standard allows the determination of the dust emission rate of the evaluated tile adhesive composition. For this evaluation the standard has been slightly modified in order to better discriminate the dust emission of each tile adhesive. The tests have been performed under the operate mode of NF P 94-103 with the following modifications: depression of 2.76 hPA instead of 5.52 hPa (32+2 mn of liquid and d=0.88) and 3 minutes of aspiration instead of 4 minutes. This evaluation shows the percentage of volatile product for each tile adhesive tested (dust emission).

TABLE-US-00007 TABLE 7 Tile Adhesives Result (%) A 53.7 B 33.6 C 30.7 D 36.0 E 27.0 F 24.0

[0055] Table 7 confirms that the dust emissions are reduced by almost 2. Tile adhesive E with anti dust additive composition 4 composed of the hydrocarbon fluids mixed shows the best result in term of mechanicals properties and dust reduction. Tile adhesive F with hydrocarbon fluid alone (anti-dust additive composition 5) shows good dust reduction results but non-acceptable mechanical properties with a significant lower tensile strength.

[0056] Table 8 indicates the evaluation of the emissions of volatile organic compounds (VOC) according to ISO 16000-3, ISO 16000-6, ISO 16000-9 and ISO 16000-11 of the GEV EMICODE requirements for the tile adhesive E which shows the best results in terms of mechanical properties and dust reduction.

TABLE-US-00008 TABLE 8 Concen- EC1 tration EC2 EC1 Plus Parameter μg/m.sup.3 μg/m.sup.3 μg/m.sup.3 μg/m.sup.3 Total VOC after 3 days 170 ≦3000 ≦1000 ≦750 Total VOC after 28 days 26 ≦300 ≦100 ≦60 Total Semi VOC after 3 days <5 ≦100 ≦50 ≦40 Total VOC without LCI * 26 >40 ≦40 after 28 days R-value (dimensionless) 0.0073 >1 ≦1 after 28 days Formaldehyde after 3 days <3 ≦50 Acetaldehyde after 3 days 23 ≦50 Sum Formaldehyde + 0.013 ≦0.05 Acetaldehyde after 3 days (ppm) Total Carcinogens after <1 ≦10 3 days Total Carcinogens after <1 ≦1 28 days * LCI: lowest concentration of interest

[0057] The results in table 8 indicate that with the anti-dust additive of tile adhesive composition E composed with hydrocarbon fluids mixed according to the invention and to one preferred embodiment, the concentration of total volatile organic compounds (TVOC) after 3 days or 28 days are extremely low. With 26 μg/m.sup.3 of TVOC after 28 days the anti-dust additive composition has the best possible result corresponding to the EMICODE emission class EC1 Plus.

[0058] Table 9 indicates the evaluation of the emissions of volatile organic compounds (VOC) according to ISO 16000-3, ISO 16000-6, ISO 16000-9 and ISO 16000-11 of the Blue Angel RAL-UZ 113 certification requirements for the tile adhesive E which shows the best results in terms of mechanicals properties and dust reduction.

TABLE-US-00009 TABLE 9 Test after 3 days Test after 28 days Concen- Limit Concen- Limit tration value tration value Parameter μg/m.sup.3 μg/m.sup.3 μg/m.sup.3 μg/m.sup.3 Total VOC 200 ≦1000 33 ≦100 Total semi VOC <5 — <5 ≦50 R-value 0.054 — 0.0073 ≦1 (dimensionless) Total VOC without 7.1 — <5 ≦40 LCI * Total Carcinogens <1 ≦10  <1 ≦1 Sum Formaldehyde + <0.003 ppm 0.05 ppm — — Acetaldehyde * LCI: lowest concentration of interest

[0059] The results in table 9 indicate that with the anti-dust additive composition of tile adhesive E formulated with hydrocarbon fluids mixed according to the invention and to one preferred embodiment, the concentration of volatile organic compounds (TVOC) after 3 days or 28 days are extremely low. With 33 μg/m.sup.3 of TVOC after 28 days the anti-dust additive composition has the best possible result to comply with RAL UZ 113 for “Low-emission Floor Covering Adhesives and other Installation Materials”.