project zeothane

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PROJECT ZEOTHANEAERATED CATALYTIC COMPOUNDS.

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Zeothane is an advanced aerospace material having homogenously suspended natural zeolite particles within an aerated binder such as synthetic polyurethane polymers for applications of noxious gas and or particles adsorption and filtration, Zeothane can also be formulated to have zeolite particles suspended within a low temperature curing aerated refractory ceramic material.

Natural Zeolite is a mineral mined in many parts of the world, an inorganic micro-porous crystalline solid having a well-defined symmetrical structure that contain aluminium, silicon, and oxygen molecules in their regular lattice type framework whereby cations and water are located in the pores. The silicon and aluminium atoms are tetrahedrally coordinated with each other through shared oxygen atoms which define a highly regular interstitial structure of pores and chambers that allows some molecules to permeate through, and causes others to be either excluded, or broken down.

Natural Zeolite is mainly utilised by sewerage treatment plants for cultivating amoeba (good bacteria) to help break down excrement contaminated water and also to dry out sewerage sludge contained in holding ponds at various treatment plants world wide, other current uses of crushed natural zeolite packaged in cloth bags are, domestic or industrial odour adsorption. Industry has duplicated some of the natural zeolites, and synthesised many new ones targeted towards very specific purposes. Many of these expensive synthetic zeolites are used in the petrochemical industry to "crack" or break down various raw materials to form specific chemicals like petroleum.

Low density Zeothane comprises typically of natural zeolite, activated carbon and an aerated synthetic polymer or geo-cementitious binder which economically allows greater versatility for end use commercial products, due to the material being able to be easily moulded to any shape or form by injection moulding or casting processes, natural zeolite is typically supplied only as a rubble, rock or dust and conventional supply and packaging of zeolite has limited the scope of applications for utilising natural zeolite commercially to its full potential for domestic and general markets.

Zeothane catalyses many types of chemical reactions whereby such reactions take place within the internal cavities of the zeolite particles, activated carbon particles and optionally metallic particles suspended within the aerated polymer matrix or aerated ceramic matrix.

Such chemical reactions are that of catalysis by hydrogen-exchanged zeolite particles, having a molecular framework of bound protons which give rise to very high acidity.

Zeothane compounds can be formulated for organic reactions such as isomerisation and fuel synthesis and can also be formulated for usage as an oxidation or reduction catalyst by the addition of Platinum, Rhodium, Rhenium, Copper, and or Titanium particles suspended within an aerated polymer or cementitious matrix and or the metallic particles can be electro-plated to the Zeothane interstitial compound for further enhancement of catalysis.

ZEOTHANE CATALYTIC COMPOUNDS.

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Zeothane metallised substrate is most suited for nitrous oxide decomposition and molecular sieving for the separation of oxygen, argon, nitrogen, and other components of air.

Zeothane metallised substrate is formulated to effect multi molecular shape-selective properties for use in molecular adsorption whereby to preferentially adsorb certain molecules, while exclude other molecules, Zeothane has opened up a wide range of molecular sieving applications whereby the size and shape of pores controlling access of molecules into the Zeothane can be moderated or tuned for a variety of molecular separation processes, whereby molecules to be separated are differentiated on the basis of their electrostatic interactions with the metal ions that are electroplated and or mixed within the aerated binding matrix which suspends the zeolite particles.

Zeothane can selectively separate molecules based on differences of size, shape and polarity whereby different types of molecules can enter the Zeothane interstitial substrate, and diffuse through the channels more quickly, whereby other molecules are confined to be entrapped within the microscopic pores.

Such properties of the Zeothane catalytic compounds can remove atmospheric pollutants, such as engine exhaust gases and ozone-depleting CFCs, separate harmful organics and remove heavy metal ions from water, including those produced by nuclear fission.

Zeothane removes odours by being positively charged at an atomic level and thereby attracts transient negatively charged particles. It is to be realised the billions of microscopic pores of the Zeothane structure are eventually saturated with the adsorbed matter, whereby it shall be necessary to reactivate the zeolite particles for further adsorption by method of applying low energy infra red radiation or or wash the saturated substrate in 90 degree C water and dry the Zeothane substrate by ambient air or microwave energy.

Metallised Zeothane substrates can also be regenerated for continual reuse by electrolysis or by application of low energy heating.

Zeothane is comprised mainly of inorganic oxides having microporous uniform pore dimensions, ion exchange properties, ability to develop internal acidity, high thermal stability, and very large internal surface area for maximum catalysis of reactions. Zeothane can be made in densities ranging from 80 Kg m3 to 2200 Kg m3 and can be supplied in plate form, sheet form and pipe form and is easily cut and or machined. Alternatively Zeothane can be cast or injection moulded with conventional tooling.

MARKET APPLICATIONS FOR ZEOTHANE AERATED POLYMERDENSITY 277 kg m3

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Partitions or screens. self supporting panels which can be moved about an open space workshop,hospital,office and school for purpose of reducing air pollution and airborne particulates, which have a deleterious affect on health and stamina. Removable panels or boards with print or picture affixed and suspended on a wall with an air space minima behind substrate, of 12mm, for purpose of allowing a reactive interface unless print or picture has a sufficient pore size to allow the diameter of a carbon dioxide molecule to permeate through the printed paper or plastic material to the zeolite substrate underside. For purpose of atmospheric conditioning of children's rooms and nursury, asthmatic and bronchial sufferers, elderly citizens living within industrial areas or areas of high road traffic air pollution. Air breathing apparatus filter cartridges for filtering dust and noxious vapours. Injection moulded disposable dust masks. ( same profile as existing paper masks but made 5 mm thick of substrate 277kg m3 ) for work place safety and or medical environments. Removable panels or boards or small plates for enclosures within submarines, aircraft, military ships,trucks and automobiles for purpose of atmospheric conditioning and odours adsorption. Injection moulded disposable safety nose plugs (substrate 277 Kg m3 ) for dust filtration or noxious gas emissions filtrations from eg weld fumes, paint fumes,. (profile of nose plugs shall be similar to a babies dummy but smaller, and inserted directly within nostrils.) Injection moulded Zeothane punnets or packaging cartons for export of perishables such as vegetable or plant matter, the advantage being that the substrate shall adsorb noxious gases and water vapour from entering into and out of the packaged goods in which ordinarily humidity is the major accelerant for ripening and or decay of plant matter within an enclosure or packaging. Zeothane chips or beads for loose fill packaging within boxes or cartons for protection of goods against moisture,impact and heat.

Zeothane linings for smoking cubicles or smoking rooms for restaurants,Public houses, entertainment venues, offices, shopping centres and airportsfor adsorbing and filtering passive smoke emissions.Note- Zeothane polymer substrates can contain a fire retardant.


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Zeothane chips or beads for admixture of potting soils for controlling soils alkalinity. Zeothane Hydroponic medium. Zeothane injection moulded carburettor air intake filters. Zeothane Acoustic insulation. Removable odour adsorption Zeothane panel, panels or small plates for public or domestic latrines. Disposable odour adsorption panel in which affixes by double sided adhesive tape to underside of garbage bins lids or wheely bin lids. ( sized to suit.) Oil or Petrol filter cartridges for adsorption of water contamination. (density substrate 620kgm3). Retro fit disposable exhaust tail pipe plug filters for reducing noxious gas emissions generated by petroleum fueled lawn mowers or small capacity combustion engines. The substrate used is Zeothane Aerated Ceramic Lattice density 500 kg m3 with rhodium and platinum particles. When the exhaust catalytic filters become saturated and clogged with hydro-carbon residues, the plug filters are expelled under pressure, and to prevent the filters from littering by pressure ejection, their is provision on the filters to be secured from falling from the tail pipe but still allowing the exhaust to escape until the filter can be regenerated or exchanged. The aforesaid filter can incorporate a whistling tell tale device to alert the operator that the Zeothane catalytic exhaust filter requires exchanging. Retro-fit Zeothane Aerated Ceramic Lattice with rhodium and platinum particles catalytic filters for chimneys or industrial smoke stacks or flues for air emissions control. Disposable Zeothane polymer substrate 277 kg m3 chips or beads to be mixed progressively with refuse within rubbish bins so as to adsorb noxious odours. Disposable or Re-generative Zeothane water softening filter cartridges, suitable for domestic potable water and or bore water. Sludge desiccator / aerators made from Regenerative Zeothane plates inserted within holding ponds and or tanks for dewatering sludge or sewerage and gas adsorption . Effluent vent filters for odour emissions control and gas adsorption.


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Small plates of Zeothane substrate 277 kg m3 placed within refrigerator or cool rooms for adsorption of odours which affect food freshness and hygiene. Cool room linings for insulation and adsorption of noxious vapours. Disposable or regenerative Zeothane panels for paint fume adsorption within domestic enclosures. (hardware market or industrial market). Disposable lining 5mm thick to be placed at bottom of kitty litter trays with either conventional adsorbents placed on top or alternatively with natural zeolite, for purpose of odour adsorption. Floor cavity thermal insulation panels and moisture adsorption for control of dampness and associated musty odours under floor boards. Reusable scented Zeothane substrate 277 or 375 kg m3 for odour adsorption whilst simultaneously producing scented emissions for domestic air freshening of latrines, bathrooms, bedrooms, closets, wardrobes and draws. Marketed with water soluble scent additive for re scenting and regenerating the substrate. Just add scented crystals to hot water and soak ZEOFRESH air pure diskette for 10 minutes and allow to dry and replace back into diskette holder. (disk=Dia 80 X 20 mm) Scented Zeothane substrate 277Kg m3 ( diameter 50mm X 10mm thick ) proprietary perfumed diskettes for placement within pockets of shirt, blouse, coats, dresses, trousers, handbags, suitcases, whereby the discreet placement of diskette shall emit pleasant odour of name brand perfumes and when placed within pockets of garments upon being worn shall emit vapours of scent proportional to temperature rise activation due to body heat and adsorb body odour emissions. Market scope, body odour control and or novel medium for the application of scents relevant to personal grooming.

Zeothane thermal insulation for commercial and domestic dwellings. Zeothane is essentially non-toxic via oral, dermal, ocular, routes of exposure however standard safety precautions are required for minimising respiratory ingestion via handling, machine cutting or heating Zeothane Aerated Polymer substrates. However Zeothane Aerated Refractory Ceramic Foam substrates do not combust and can be formulated to withstand 1388 degrees C and possess a minimum density of 440 Kg m3.


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Zeothane refrigerant and or ice generation panels provide for cooling based on the principle of evaporation. Zeothane panels are placed and lined within an air tight thermally insulated enclosure essentially a fridge box or esky having a small reservoir of water.The fridge, esky or ice thermos also has a low voltage powered or manually operated vacuum pump whereby the cooling system is based on the phenomenon of the evaporation temperature of a fluid whereby water vapourisation is dependant on the surrounding pressure. At 20 deg. C water starts boiling at a pressure below 20 milli Bar. Water evaporation requires heat, the evaporation heat during this process is taken from the liquid water, which results in a loss of temperature.

The Zeothane panels adsorb water vapour from the wet air within the enclosure and there after evacuating the system of with the vacuum pump, the water starts to boil and the rest of the water cools down until the Zeothane is able to adsorb all the evaporated water, the water will then evaporate from the Zeothane panels and therefore effect further the cooling process of the panels lining the enclosure.

Water moistened Zeothane cooling panels for the evaporative cooling of interior or exterior walls of domestic and or commercial buildings. The cooling of the panels is effected by ambient heat evaporating the water vapour contained therein the billions of microscopic pores, during the evaporation process the Zeothane panels lining the walls cool and provide for a heat sink due to a greater temperature gradient and thereby absorb heat contained in thermal massive construction elements such as masonry and steel cladding and thereto minimise blackbody radiation emissions to occupants .

Water moistened Zeothane evaporative cooling head bands or wrist bands for cooling of body during physical exertion and strenuous activities.

Water moistened Zeothane evaporative cooling insulative jackets for cooling canned or bottled beverages.

Zeothane plant pots for moisture retention and slow release fertiliser for soil conditioning.

Zeothane aquaculture filters for water purification and adsorption pf ammonia.

Zeothane water filters for water softening by exchanging the sodium in zeolite for the calcium and magnesium present in the water.

Regenerative Zeothane floats with small weights cast within the injection moulded floatprofile to stop the light weight substrates from blowing away off the sewerage holding ponds water surface, for purpose of odour adsorption.


FORMULATION FOR ZEOTHANE CATALYTIC COMPOUNDS.

Molecular adsorption metallised refractive catalytic aerated ceramic.

An inorganic ceramic foam compound having suspended therein the ceramic lattice,Natural Zeolite and activated carbon particles for application of high temperature gaseous / fluidic molecular adsorption of pollutants such as noxious gases and or heavymetals and filtration of particulates in fluid streams.

Typical proportions for the formulation are –

31 grams Ortho phosphoric acid.

30 grams Aluminium Hydroxide.

1.0 gram Bentonite.

6.5 grams Aluminium meta-phosphate.

0.15 gram Metal powder Zinc,Magnesium or Aluminium 150 to 325 mesh.

1.20 gram of Activated Carbon having particle size of 300 to 400 mesh.

30.15 grams of Natural Zeolite having particle size of 300 to 400 mesh.

The dry ingredients are mixed and blended slowly with the acid. Vigorous agitationproduces a chemical reaction that causes water of hydration converting the mixture Into a slurry.

The slurry is then poured or injected into a suitable profiled or shapedmould having applied a silicon fluid surface release agent.

The compound is fully aerated at 30 minutes and is cured at 85 degrees C for 7 hours or to accelerate the curing apply 150 degree C after 2 hours at 85 degree C.

The density of aeration can be varied by the amount of slurry poured into a coveredmould thereby constraining the aeration to produce a smaller cellular structure.By varying the size of the metal powder, large particles cause larger bubbles to formthereby lowering the density of the refractory compound however the cellular structure Is irregular.By varying the quantity of metal powder the porosity of the ceramic lattice can be 5 percent or varied to 80 percent and the density range 2200 Kg m3 to 440 kg m3.

The inventive step pertaining the current invention is to provide for a greater surface area for catalysis interaction with gases or fluids for adsorption and particulates filtrationdue to spreading and binding molecules of zeolite over a larger space within an aeratedplastic or aerated ceramic medium as opposed to the same quantity of zeolite particlescontained within a porous bag, permeable vessel or container as is typically marketed. The cited formulations are of the most practicable density due to having sufficient porosityfor catalytic interaction, filtration whilst possessing structural integrity.

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Molecular adsorption metallised refractive catalytic aerated ceramic.

An inorganic ceramic foam compound having suspended therein the ceramic lattice,Natural Zeolite and/or Synthetic Z.S.M.5 zeolite, activated carbon and/or, rhodium particles for application of high temperature gaseous / fluidic molecular adsorption and catalysis of pollutants such as noxious gases and or heavy metals andfiltration of particulates in fluid streams.

The cured molecular adsorption refractory ceramic compound can have applied an electro conductive film electro plated by electrolysis to the entire mass and surface area of the interstitial ceramic compound.

The aforesaid electroplated film can be either rhodium,chromium,platinum,coppermetals or zinc oxide all being catalytic elements.

The metallic film electroplated upon and within the cited interstitial compound can have applied an electrical charge imparted to the metallised zeolite/ceramic catalyticsubstrate thereby providing for electric control of the valence for electrostaticattraction of reactant particulates engaging the external and internal surface area of the ceramic / zeolite foam substrate.

Alternatively control of valence for electrostatic repulsion of particulates from theInternal and external surface areas of the cited ceramic/zeolite interstitial compoundIs provided for purpose of expelling adsorbed particulates.

The electrostatic regeneration of the metallised aerated zeolite/ceramic catalytic foamcan occur within an electrolyte solution at low voltage or alternatively a high voltagecharge of suitable polarity can be applied to the electro conductive metallisedzeolite/ceramic interstitial compound and thereto also a correspondingpotential difference applied to a conductive plate or plates separated by an atmosphereof inert gas or gases whereby the entrapped particulates adsorbed within the zeolite and catalysis metals contained therein and upon the aerated ceramic interstitial compoundare electro statically precipitated to condense there upon the charged plates.

The molecular adsorption refractory ceramic compound can be molded in plate,blocks or pipedic forms thereto be inserted or cast within a suitable encasement or conveyance tube whereby a fluid or gaseous flow is contained therein.

The aforesaid gas or fluid flow passes through the porous molecular adsorptionrefractive aerated ceramic to be exhausted via the micro pores whereby the catalysis material is defined typically as natural zeolite particles which will convert the reactant gas or fluid.

Maximum temperature of heat resistance of the Ceramic Aerated compound is1388 degrees C, after curing the Ceramic Aerated compound can be cemented, cut with a hacksaw, machine cut, or water jet profiled to shape.

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An organic polymeric foam compound preferably that of rigid polyurethane having suspended therein the interstitial compound , Natural Zeolite and activated carbon particles for application of low temperature gaseous / fluidic molecular adsorption of pollutants suchas noxious gases and or heavy metals and filtration of particulates in fluid streams .


60 parts of Natural Zeolite 300 to 400 mesh

17parts of polyurethane (inclusive of expanding foaming agent)

3 parts of aluminium hydroxide

10 parts activated carbon

The dry powders are first blended with the polyurethane resin and subsequently injected into a given mould or formwork whereby a suited foaming agent is simultaneously introduced to the given mixture contained therein the mould. Upon introduction of the foaming agent the polyurethane resin expands and produces an aerated polymeric structurewhich suspends the Natural Zeolite particles homogeneously within a cellular lattice.

The density of aeration of the given polymerized zeolite interstitial compound can be varied by the amount of polyurethane resin and foaming agent injected into a coveredmould thereby constraining the aeration to produce a smaller or larger cellular structure.

Thereto also further catalysis particles can be suspended within the aerated polymersubstrate by mixing within the polyurethane resin and natural zeolite either rhodium,chromium,platinum,copper metals particles or zinc.


60 parts of Natural Zeolite 300 to 400 mesh

17parts of polyurethane (inclusive of expanding foaming agent)

3 parts of aluminium hydroxide

10 parts of either rhodium,chromium,platinum,copper metals particles or zinc 400 mesh.

Molecular adsorption catalytic aerated polymer.

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An organic polymeric foam compound having suspended therein the polymer interstitial compound, Natural Zeolite and/or Synthetic Z.S.M.5 zeolite, activated carbon and/or,rhodium particles for application of low temperature gaseous / fluidic molecular adsorption and catalysis of pollutants such as noxious gases and or heavy metals andfiltration of particulates in fluid streams.

The cured molecular adsorption aerated polymerized zeolite compound can have applied an electro conductive film electro plated by electrolysis to the entire mass and surface area of the interstitial compound.

The aforesaid electroplated film can be either rhodium,chromium,platinum,coppermetals or zinc oxide all being catalytic elements.

The metallic film electroplated upon and within the cited interstitial compound can have applied an electrical charge imparted to the metallised zeolite/aerated polymercatalytic substrate thereby providing for electric control of the valence for electrostaticattraction of reactant particulates engaging the external and internal surface area of the zeolite/rigid foam substrate.

Alternatively control of valence for electrostatic repulsion of particulates from theinternal and external surface areas of the cited interstitial compound Is provided for purpose of expelling adsorbed particulates.

The electrostatic regeneration of the metallised aerated zeolite/polymer catalytic foamcan occur within an electrolyte solution at low voltage or alternatively a high voltagecharge of suitable polarity can be applied to the electro conductive metallisedinterstitial compound and thereto also a corresponding potential difference appliedto a conductive plate or plates in close proximity,separated by an atmosphere of inertgas or gases whereby the entrapped particulates adsorbed within the zeolite and catalysis metals contained therein and upon the aerated plastic interstitial compound are electro statically precipitated to condense there upon the charged plates.

The molecular adsorption aerated polymer which suspends the zeolite particlescan be moulded in plate,blocks or pipedic forms thereto be inserted or cast within a suitable encasement or pipedic conveyance tube whereby a fluid or gaseous flowis contained therein.

The aforesaid gas or fluid flow passes through the porous molecular adsorptionaerated polymer to be exhausted via the micro pores whereby the catalysis material is defined typically as natural zeolite particles which will convert the reactant gas or fluid.

Maximum temperature of heat resistance of the aerated polymer / natural zeolitecompound is 130 degrees C, the aerated polymer / natural zeolite catalytic compound can be glued, cut with a hacksaw, machine cut, or water jet profiled to a given shape.

Molecular adsorption metallised aerated catalytic polymer.

project zeothane

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