Synthetic resins or natural rubbers -- part of the class 520 ser – Synthetic resins – Processes of preparing a desired or intentional composition...
Reexamination Certificate
2001-10-09
2004-08-17
Yoon, Tae H. (Department: 1714)
Synthetic resins or natural rubbers -- part of the class 520 ser
Synthetic resins
Processes of preparing a desired or intentional composition...
C524S211000, C528S052000, C071S012000, C071S013000
Reexamination Certificate
active
06777469
ABSTRACT:
FIELD
This invention concerns urea and urea condensate reacted with sewer sludge for use as fertilizer, to produce resins, as odor controlling and as fire retardant agent. The invention also concerns the preparation and use of nitrogen containing compound produced by reacting urea or urea condensates with the compounds in sewer sludge. The nitrogen containing compounds produced by reacting urea or urea condensates with sewer sludge and/or its composition is useful in the reduction of odor in the process of dehydrating sewer sludge for use as a fertilizer, also useful in production of resins such as formaldehyde-urea condensate-sewer sludge resins, as a flame retardant to stop house fires, grass and forest fires, to produce flame retarded water based plastic, flame retarded plastics, flame retardant polyurethane foam, etc, and fire retardant flammable organic materials by incorporating in or by spraying on the outside of materials.
BACKGROUND
Urea in the form of a solid compound has been used as a flame retardant agent in polyurethane foams as outline in U.S. Pat. No. 4,385,131 (Fracalossi, et al.). Many patents use solid urea condensates, urea phosphates, urea borates and urea derivative as the flame retardant agent. Dried sewer sludge is used as a fertilizer but has a very low nitrogen content. The reaction of urea with sewer sludge, the use of urea to react with the sulfur containing compounds in sewer sludge and the use of aqueous or powdered nitrogen containing compound of urea condensates to reacted with sewer sludge as odor suppressant, as fertilizer with a high nitrogen content, for adjusting the pH of the sewer sludge and as the fire retardant compound are novel. When solid urea is used in sufficient amounts, as the flame retardant compound in the production of flame retardant organic products, such as polyurethane products it leaves a slummy or soapy feel to the outer surface of the urethane products, which is very undesirable. The urea migrates out and the product becomes less fire retardant. When the powdered or aqueous nitrogen containing compound urea and urea condensate reacted with sewer sludge are utilized, it reacts with the polyisocyanate and becomes a part of the product. There is no slimy or soapy feel to this foam Aqueous or solid urea condensate reaction products of sewer sludge when used as a fertilizer is very environmentally safe product, also safe to use to put out grass and forest fire and to flame retard organic materials. The aqueous or solid urea condensate reaction products of sewer sludge has both a rapid acting and a long acting nitrogen component. The ammonium salts and urea are rapid acting and the urea condensate and it's salts are long acting fertilizer with a slow release of nitrogen. When used for fire fighting the aqueous urea condensate reaction produced with sewer sludge may contain coloring agents such as iron oxide, thickening agents, gelling agents, corrosive inhibitors, bactericide agents, surfactant and wetting agents. The urea reacted with sewer sludge increases the nitrogen content in the sewer sludge fertilizer. The sewer sludge reacted with urea will react with aldehydes to produce aldehyde-urea-urea condensate sewer sludge resins.
What is lacking and what is needed are useful, safe and inexpensive products produced by reacting urea with sewer sludge. What is additionally lacking are compositions having aqueous or powdered nitrogen containing compound, such as urea or urea condensate reacted with sewer sludge, employed therein. What is additionally lacking is a method to reduce the odor from heating wet sewer sludge. What is additionally lacking is a method to produce resins utilizing sewer sludge.
SUMMARY
The wet sewer sludge cake contains many compounds both organic and inorganic. The urea and/or urea condensate will react with many of the compounds that are found in the sewer sludge such as sulfur oxyacids, urea, amino compounds, carbohydrates, hemicellulose, fatty acids, glycerine, amides, etc. Much of the sewer sludge is non-reacted fillers.
In one aspect, the invention comprises the aqueous or powdered nitrogen containing compound, urea-urea condensate-sewer sludge compositions products produced by reacting urea or urea condensates with sewer sludge. Another aspect of the invention is a process to prepare the aqueous or solid nitrogen containing compounds produced by reacting urea or urea condensate with sewer sludge and/or a composition.
Another aspect of this invention is the process to prepare an aqueous or solid nitrogen containing compounds, urea-urea condensate-sewer sludge compositions produced by reacting urea and/or urea condensate with sewer sludge and/or a composition by reacting and/or mixing:
(A) urea and/or urea condensate, in the amount of 10 to 200 parts by weight;
(B) sewer sludge, in the amount of 100 to 200 parts by dry weight;
(C) carbonization auxiliaries, in the amount of 0 to 300 parts by weight;
(D) metal containing compound that will accelerate the carbonization process, in the amount of 0 to 30 parts by weight;
(E) filler, in the amount of 0 to 300 parts by weight;
(F) water, in the amount of 0 to 500 parts by weight.
Another aspect of this invention is to apply the flame retardant compound of this invention in or on a more flammable organic material (Component H). The flame retardant compounds, aqueous or sold nitrogen containing compound, urea and urea condensate reacted with sewer sludge and/or it's composition, may be used.
Another aspect of this invention is to utilize the aqueous nitrogen containing compounds, urea and urea condensate reacted with sewer sludge and/or the aqueous nitrogen containing compounds, urea and urea condensate reaction products with sewer sludge composition to fight fires such as grass fires, forest fires, house fires, furniture fires, etc. In fighting grass fires a solution of aqueous urea-urea condensate-sewer sludge and/or aqueous nitrogen containing compound of urea, urea condensate reacted with sewer sludge composition, with or without, surfactant, to produce bubbles, may be sprayed directly on the flames or may be sprayed in front of the flames thereby wetting the organic materials in front of the fire. The aqueous urea and urea condensate reacted with sewer sludge and/or it's composition, even after drying, and for several day afterwards, will prevent the coated organic materials such as grass, leaves and bushes from catching on fire when exposed to flames.
Another aspect of this invention is to utilized urea or urea condensate to react with the sulfur compounds in the sewer sludge to reduced the odor produced by heating the sewer sludge. The urea and urea condensate also reacts with other compounds in the sewer sludge to produce fertilizer with an increase in the nitrogen content of the bio-fertilizer. The non-reacted urea may be used as a fertilizer.
Another aspect of this invention is to utilized the urea-urea condensate-sewer sludge composition to produce resins. This composition will react with aldehydes, polycarboxyl acids and/or anhydrides and polyepoxy compounds to produce resins.
COMPONENT A
Urea in any suitable form such as granules, beads, powder or an aqueous solution may be used in this invention. The urea may be first heated to form a urea condensate then used in this invention. The urea and/or urea condensate is used in the amount of 10 to 100parts by weight.
COMPONENT B
Any suitable sewer sludge may be used in this invention. It is preferred that the sewer sludge be in the form of a wet compressed solid mass. The sewer outflow is treated with coagulating compounds and the solids are coagulated, then the excess water is filtered off. The remaining solids are compressed into a wet solid mass known as a cake. The compressed sewer sludge contains many different compounds such as cellulose, carbohydrates, nitrogen containing compounds such as urea, proteins, amides, amino compounds and others, minerals, organic and inorganic salts, sulfur compounds and other compounds. The sewer sludge, based on it's dry weight, is used in the
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