SORBENT PADS AND A METHOD OF MANUFACTURING THE SAME

CROSS-REFERENCE TO RELATED APPLICATIONS [0001] The present application claims the priority of the Indian Provisional Patent

Application (PPA) with serial number 202041020656 filed on May 15, 2020, and subsequently post-dated by one month to June 15, 2020 with the title, “HIGH GRAVIMETRIC SORPTION CAPACITY OIL/CHEMICAL/DYE SORBENT PADS AND A METHOD OF MANUFACTURING THE SAME” The contents of above mentioned PPA are included entirely as reference herein.

BACKGROUND Technical Field

[0002] The embodiments of the present invention are generally related to a field ofoil spills and recovery of oils. The embodiments of the present invention are particularly related to a recovery using oil/chemical/dye sorbent pads in response to oil spills. The embodiments of the present invention are more particularly related to oil/chemical/dye sorbent pads having high gravimetric sorption capacity and a method of manufacturing the same.

Description of the Related Art [0003] Oil/Chemical/Dye spill accidents are hazardous whether the oil spill is in any water bodies like lakes, rivers, marinas, coastal areas of seas and oceans or on the shop floor of an industrial environment. The consequences of oil/chemical/dye spillage in water bodies affects the entire ecosystem, and specifically, the marine life which in turn affects the food supply chain and even pose a higher risk for commercial businesses. The oil/chemical/dye spillage on the shop floor of the work environment increases slippage and fall accidents of workmen, increases potential risks of fire hazards, and also result in human intake of contaminant material.

[0004] Conventional sorbent pads are of three types viz., organic or inorganic and synthetic. Organic sorbent pads include natural bark, peat, straws etc., that are naturally available, but they are difficult to function or operated on harsh environment of water. Major inorganic sorbent pads are vermiculite and pumice, but they are difficult to retrieve, whereas the synthetic sorbent pads made of poly propylene and polystyrene are viscous specific, less effective, non-reusable and costly. [0005] According to International Tanker Owners Pollution Federation Limited

(ITOPF) statistics, there are approximately 9351 Accidental spills from 1970 to 2019. The primary disadvantage of conventional sorbent pads available in the market is of high volume, more weight and low sorption capacity. Further, the conventional sorbent pads leave significant amount of oil/chemical/dye on the surface of the water and the recovery of the oil/chemical/dye from the conventional sorbent pads is not up to a considerable extent.

[0006] The absorbance test conducted on organic sorbent pads yielded the results of lOgrams of oil/chemical/dye absorbed per lgram of organic sorbent material. The absorbance test conducted on inorganic sorbent pads yielded the results of 2grams of oil/chemical/dye absorbed per lgram of inorganic sorbent material. The absorbance test conducted on synthetic sorbent pads yielded the results of 20grams of oil/chemical/dye absorbed per lgram of synthetic sorbent material. Moreover, the synthetic sorbent pads are not recyclable and causes secondary contamination to the environment. [0007] Hence, there is a need to provide oil/chemical/dye sorbent pads which are reusable, recyclable and have high gravimetric sorption capacity to weight ratio. Further there is a need for manufacturing the oil/chemical/dye sorbent pads which are reusable, recyclable and have high gravimetric sorption capacity to weight ratio. [0008] The above-mentioned shortcomings, disadvantages and problems are addressed herein, which will be understood by studying the following specifications.

OBJECTIVES OF THE EMBODIMENTS HEREIN

[0009] The primary objective of the embodiments of the present invention is to provide an oil/chemical/dye sorbent pad with a porous sorbent material of predetermined quantity sealed in between the layers of polymer membrane of predefined thickness.

[0010] Another objective of the embodiments of the present invention is to provide an oil/chemical/dye sorbent pad with gravimetric sorption capacity to weight ratio of more than 30.

[0011] Yet another objective of the embodiments of the present invention is to provide an oil/chemical/dye sorbent pad that is reusable for more than five cycles with efficiency drop of less than 75% over the five cycles.

[0012] Yet another objective of the embodiments of the present invention is to provide an oil/chemical/dye sorbent pad that does not allow any oil/chemical/dye leaching in saturated state unless subjected to threshold pressure. [0013] Yet another objective of the embodiments of the present invention is to provide an oil/chemical/dye sorbent pad wherein the absorbed oil/chemical/dye is easily extractable and useable for further applications. [0014] Yet another objective of the embodiments of the present invention is to provide an oil/chemical/dye sorbent pad with the porous sorbent material evenly distributed between the layers of polymer membrane via compartmentalization into small packets. [0015] Yet another objective of the embodiments of the present invention is to provide small packets of the oil/chemical/dye sorbent pad which acts as zones for effective holding of oils/chemicals/dyes and prevents agglomeration.

[0016] Yet another objective of the embodiments of the present invention is to provide an oil/chemical/dye sorbent pad where compartmentalization into small packets is done through stitching, heat press, UV curing, ultrasound sealing or combination thereof.

[0017] Yet another objective of the embodiments of the present invention is to provide an oil/chemical/dye sorbent pad wherein the layer of polymer membrane, which comes into contact with surface of water at a first stage has lesser thickness, and wherein the layer of polymer membrane which comes into contact with water at a later stage has greater thickness.

[0018] Yet another objective of the embodiments of the present invention is to provide an oil/chemical/dye sorbent pad having the layers of polymer membrane with a predefined thickness of in the range of 8 microns-80 microns depending on the robustness and absorption capacity required for the application.

[0019] Yet another objective of the embodiments of the present invention is to provide an oil/chemical/dye sorbent comprising layers of polymer membrane which are fabricated from polypropylene, polyester LDPE and HDPE or the blend thereof. [0020] Yet another objective of the embodiments of the present invention is to provide an oil/chemical/dye sorbent pad comprising layers of polymer membrane having a plurality of uniformly dispersed micro size pores of predefined diameter, depending on the viscosity of oils/chemicals/dyes for better capillary action. [0021] Yet another objective of the embodiments of the present invention is to provide an oil/chemical/dye sorbent with polymer membrane comprising predefined diameter of uniformly dispersed micro size pores within a range of 1-100 pm.

[0022] Yet another objective of the embodiments of the present invention is to provide oil/chemical/dye sorbent pad made of the porous sorbent material selected from a group consisting of graphene nanoplatelets, graphene sponge, graphene aerogel, graphene balls, graphene foam, high surface area carbon, bark, peat, saw dust, wool, vermiculate, pumice, polypropylene, polyester or a combination thereof in different weight proportions.

[0023] Yet another objective of the embodiments of the present invention is to provide an oil/chemical/dye sorbent comprising the porous sorbent material with a density of less than 0.8 g/cm3 for better buoyant characteristics.

[0024] Yet another objective of the embodiments of the present invention is to provide an oil/chemical/dye sorbent comprising the porous sorbent material with a gravimetric sorption capacity to weight ratio of more than 50. [0025] Yet another objective of the embodiments of the present invention is to provide an oil/chemical/dye sorbent pad comprising the porous sorbent material with a meso, micro or macro porous structures. [0026] Yet another objective of the embodiments of the present invention is to provide an oil/chemical/dye sorbent pad comprising the porous sorbent material which is highly oleophilic and hydrophobic.

[0027] Yet another objective of the embodiments of the present invention is to provide an oil/chemical/dye sorbent pad comprising the porous sorbent material which is added with neutralizing agents like calcium carbonate, calcium oxide, magnesium hydroxide, sodium carbonate etc., for neutralization of chemicals.

[0028] Yet another objective of the embodiments of the present invention is to provide an oil/chemical/dye sorbent pad with an overall calorific value higher than 40000 KJ/KG.

[0029] These and other objects and advantages of the present invention will become readily apparent from the following detailed description taken in conjunction with the accompanying drawings.

SUMMARY [0030] This summary is provided to introduce a brief introduction of concepts related to the embodiments of the present invention. The concepts are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. [0031] The various embodiments of the invention provide an oil/chemical/dye sorbent pad for maximum recovery of oils/chemicals/dyes from spillage. The oil/chemical/dye sorbent pad comprises a porous sorbent material of predetermined quantity distributed uniformly and sealed in between the layers of polymer membrane via compartmentalization into small packets. These small packets of oil/chemical/dye sorbent pad acts as zones for effective holding of oils/chemicals/dyes and prevents agglomeration. The porous sorbent material is selected from a group consisting of graphene nanoplatelets, graphene sponge, graphene aerogel, graphene balls, graphene foam, high surface area carbon, bark, peat, saw dust, wool, vermiculate, pumice, polypropylene, polyester or a combination thereof in different weight proportions. The layers of polymer membrane are made from polypropylene, polyester LDPE and HDPE or the blend thereof.

[0032] According to one embodiment of the present invention, a method of fabricating of the oil/chemical/dye sorbent pad comprises the following steps. Layers of polymer membranes are held and joined on all the three sides to obtain a sac like structure. The polymer membranes are joined by a predetermined method. A mixture of neutralizing agents and porous sorbent material are filled in a predetermined quantity at the bottom of the joined layers of polymer membranes adjoining all three sides with a sac like structure. The mixture of neutralizing agents and porous sorbent material is distributed uniformly to achieve predefined height of the layers of polymer membranes adjoining all three sides with a sac like structure to form a first row. The first row is sealed by a predetermined method. The mixture of neutralizing agents and porous sorbent material of a predetermined quantity are filled next to the sealed first row of the joined layers of polymer membrane adjoining its three sides. The mixture of neutralizing agents and porous sorbent material is uniformly distributed to achieve predefined thickness between the layers of polymer membrane joined together to form a second row. The second row is sealed by a predetermined method. The steps of distributing the mixture of neutralizing agents and porous sorbent material uniformly to achieve predefined thickness between the layers of polymer membrane joined together are repeated to form five rows of oil/chemical/dye sorbent pad. The rows are sealed by a predetermined method. The layers of polymer membrane filled with the porous sorbent material are sealed and joined together in four columns to compartmentalize the oil/chemical/dye sorbent pad into a plurality of small packets therein. According to an embodiment, the plurality of packets is 20 or more. The columns are formed by sealing/joining oil/chemical/dye sorbent pad by a predetermined method. The oil/chemical/dye sorbent pad comprises five rows and four columns. The compartmentalization of the oil/chemical/dye sorbent pad into small packets act as plurality of zones for effective holding of oils/chemicals/dyes for preventing agglomeration. The fabricated oil/chemical/dye sorbent pad is analyzed for gravimetric sorption capacity, efficiency, reusability and calorific value.

[0033] According to one embodiment of the present invention, the porous sorbent material is selected from a group consisting of graphene nanoplatelets, graphene sponge, graphene aerogel, graphene balls, graphene foam, high surface area carbon, polypropylene, and polyester.

[0034] According to one embodiment of the present invention, the neutralizing agents are selected from the group consisting of calcium carbonate, calcium oxide, magnesium hydroxide, sodium carbonate, and wherein the neutralizing agents neutralizes chemical reaction.

[0035] According to one embodiment of the present invention, the method of sealing/joining rows, columns, and compartmentalization of oil/chemical/dye sorbent pad into small packets is selected from a group consisting of stitching, heat press, UV curing, ultrasound sealing or a combination thereof. [0036] According to one embodiment of the present invention, the porous sorbent materials have a density of less than 0.8 g/cm3 for better buoyant characteristics. The porous sorbent material with a gravimetric sorption capacity to weight ratio is 50 or greater than 50. The porous sorbent material has a meso, micro or macro porous structures.

[0037] According to one embodiment of the present invention, the layers of polymer membrane are made from polypropylene, polyester LDPE and HDPE.

[0038] According to one embodiment of the present invention, the layers of polymer membrane with a predefined thickness of in the range of 8 microns-80 microns depending on the robustness and absorption capacity required for the application.

[0039] According to one embodiment of the present invention, the oil/chemical/dye sorbent with polymer membrane comprises uniformly dispersed micro size pores with a predefined diameter range. The diameter range of micro size pores is 1- 100 pm. [0040] According to one embodiment of the present invention, the gravimetric sorption capacity of the oil/chemical/dye sorbent pad with respect to weight ratio is 30 or greater than 30.

[0041] According to one embodiment of the present invention, the reusability of the oil/chemical/dye sorbent pad is more than five cycles. The oil/chemical/dye sorbent pad illustrates an efficiency drop of less than 75% after five cycles.

[0042] According to one embodiment of the present invention, the calorific value of the oil/chemical/dye sorbent pad is 40000 KJ/KG. [0043] According to one embodiment of the present invention, the oil/chemical/dye sorbent pad has a gravimetric sorption capacity to weight ratio of more than 30.

[0044] According to one embodiment of the present invention, the oil/chemical/dye sorbent pad is reusable for about more than five cycles.

[0045] According to one embodiment of the present invention, the oil/chemical/dye sorbent pad does not allow any oil/chemical/dye dripping in saturated state unless subjected to threshold pressure.

[0046] According to one embodiment of the present invention, the layers of polymer membrane comprise a plurality of uniformly dispersed micro size pores of predefined diameter for better capillary action.

[0047] According to one embodiment of the present invention, the absorbent pad comprises a plurality of polymer membrane layers, and wherein the layer of polymer membrane which comes into contact with water at first stage has a lower thickness and wherein the layer of polymer membrane which comes into contact with water at a later stage has a higher thickness.

[0048] According to one embodiment of the present invention, an oil/chemical/dye sorbent pad having high gravimetric sorption capacity to weight ratio of more than 30, is provided. The oil/chemical/dye sorbent pad includes a porous sorbent material of predetermined quantity uniformly distributed and sealed in between the layer of polymer membrane via compartmentalization into small packets. The compartmentalization into small packets acts as zone for effective holding of oils/chemicals/dyes and prevents agglomeration. The porous sorbent material is selected from one of graphene nanoplatelets, graphene sponge, graphene aerogel, graphene balls, graphene foam, high surface area carbon, bark, peat, saw dust, wool, vermiculate, pumice, polypropylene, polyester or a combination thereof in different weight proportions. The layers of polymer membrane are spun bound and made from polypropylene, polyester LDPE and HDPE or the blend thereof.

[0049] According to one embodiment of the present invention, a method of fabricating of the oil/chemical/dye sorbent pad, is provided. The method comprises the following steps. The layers of polymer membrane are held against each other and joined on all the three sides through either stitching, heat press, UV curing, ultrasound sealing or a combination thereof. A porous sorbent material of predetermined quantity is filled at the bottom of the joined layers of polymer membrane adjoining its three sides. The porous sorbent material is distributed uniformly to achieve predefined height of the layers of polymer membrane that are joined together to form a first row. Again, the porous sorbent material of the same quantity is filled at the bottom of the first row of the joined layers of polymer membrane adjoining its three sides. The porous sorbent material is distributed uniformly to achieve predefined thickness between the layers of polymer membrane joined together to form a second row. All the above-mentioned steps are repeated for a plurality of times to form the oil/chemical/dye sorbent pad of a plurality of rows. Finally, the layers of polymer membrane filled with the porous sorbent material are joined together in three columns to compartmentalize the oil/chemical/dye sorbent pad into a plurality of small packets therein. The compartmentalization of the oil/chemical/dye sorbent pad into small packets acts as zone for effective holding of oils/chemicals/dyes, and also prevents agglomeration. [0050] According to one embodiment of the present invention a method of deployment of oil/chemical/dye sorbent pads over a spillage area of oils/chemicals/dyes across the water body and their collection mechanism on saturation, is provided. The method of deployment of oil/chemical/dye sorbent pads over water bodies and their collection on saturation comprises the following steps. It is very difficult to drop the oil/chemical/dye sorbent pads at exact locations covering wide portions of oil/chemical/dye spillage. Hence, drones are used to drop oil/chemical/dye sorbent pads covering wide-spread area of oil/chemical/dye spillage. The oil/chemical/dye sorbent pads saturated with oil/chemical/dye are collected by ships for recovery of the oil/chemical/dye from the sorbent pads for secondary applications.

[0051] It is to be understood that the aspects and embodiments of the present invention may be used in any combination with each other. Several of the aspects and embodiments may be combined to form further additional embodiments of the present invention. [0052] The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.

[0053] These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating preferred embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.

BRIEF DESCRIPTION OF THE DRAWINGS

[0054] The other objects, features and advantages will occur to those skilled in the art from the following description of the preferred embodiment and the accompanying drawings in which:

[0055] FIG.1A illustrates a top side perspective view of an oil/chemical/dye sorbent pad, according to one embodiment of the present invention.

[0056] FIG. IB illustrates a front side perspective view of an oil/chemical/dye sorbent pad, according to one embodiment of the present invention.

[0057] FIG.1C illustrates a side view of an oil/chemical/dye sorbent pad, along a width direction, according to one embodiment of the present invention.

[0058] FIG. ID illustrates a side view of the oil/chemical/dye sorbent pad, along a length direction, according to one embodiment of the present invention. [0059] FIG. IE illustrates a cross sectional view of the oil/chemical/dye sorbent pad, according to one embodiment of the present invention.

[0060] FIG.2 illustrates a flow chart explaining the process of steps involved in a method of fabricating of the oil/chemical/dye sorbent pad, according to one embodiment of the present invention. [0061] FIG.3 illustrates a schematic representation of deployment of oil/chemical/dye sorbent pads over a spillage area of oils/chemicals/dyes across the water body and their collection mechanism on saturation, according to one embodiment of the present invention.

[0062] Although the specific features of the present invention are shown in some drawings and not in others. This is done for convenience only as each feature may be combined with any or all of the other features in accordance with the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0063] The detailed description of various exemplary embodiments of the present invention is described herein with reference to the accompanying drawings. It should be noted that the embodiments are described herein in such details as to clearly communicate the present invention. However, the amount of details provided herein is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present invention as defined by the appended claims.

[0064] It is also to be understood that various arrangements may be devised that, although not explicitly described or shown herein, embody the principles of the present invention. Moreover, all statements herein reciting principles, aspects, and embodiments of the present invention, as well as specific examples, are intended to encompass equivalents thereof.

[0065] While the embodiments of this susceptible to various modifications and alternative forms, specific embodiment thereof has been shown by way of example in the drawings and will be described in detail below. It should be understood, however that it is not intended to limit the present invention to the forms disclosed, but on the contrary, the present invention is to cover all modifications, equivalents, and alternatives falling within the scope of the present invention.

[0066] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises”, “comprising”, “includes” and/or “including,” when used herein, specify the presence of stated features, integers, steps, operations, elements and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components and/or groups thereof.

[0067] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which example embodiments belong. It will be further understood that terms, e.g., those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

[0068] In the following detailed description, reference is made to the accompanying drawings that form a part hereof, and in which the specific embodiments that may be practiced is shown by way of illustration. These embodiments are described in sufficient detail to enable those skilled in the art to practice the embodiments and it is to be understood that the logical, mechanical and other changes may be made without departing from the scope of the embodiments. The following detailed description is therefore not to be taken in a limiting sense. [0069] The various embodiments of the invention provide an oil/chemical/dye sorbent pad which performs maximum recovery of oils/chemicals/dyes from spillage. The oil/chemical/dye sorbent pad comprises a porous sorbent material of predetermined quantity distributed uniformly and sealed in between the layers of polymer membrane via compartmentalization into small packets. These small packets of oil/chemical/dye sorbent pad acts as zones for effective holding of oils/chemicals/dyes and prevents agglomeration. The porous sorbent material is selected from one of graphene nanoplatelets, graphene sponge, graphene aerogel, graphene balls, graphene foam, high surface area carbon, bark, peat, saw dust, wool, vermiculate, pumice, polypropylene, polyester or a combination thereof in different weight proportions. The layers of polymer membrane are made from polypropylene, polyester LDPE and HDPE or the blend thereof.

[0070] The various embodiments of the invention provide an oil/chemical/dye sorbent pad for maximum recovery of oils/chemicals/dyes from spillage. The oil/chemical/dye sorbent pad comprises a porous sorbent material of predetermined quantity distributed uniformly and sealed in between the layers of polymer membrane via compartmentalization into small packets. These small packets of oil/chemical/dye sorbent pad acts as zones for effective holding of oils/chemicals/dyes and prevents agglomeration. The porous sorbent material is selected from a group consisting of graphene nanoplatelets, graphene sponge, graphene aerogel, graphene balls, graphene foam, high surface area carbon, bark, peat, saw dust, wool, vermiculate, pumice, polypropylene, polyester or a combination thereof in different weight proportions. The layers of polymer membrane are made from polypropylene, polyester LDPE and HDPE or the blend thereof. [0071] According to one embodiment of the present invention, a method of fabricating of the oil/chemical/dye sorbent pad comprises the following steps. Layers of polymer membranes are held and joined on all the three sides to obtain a sac like structure. The polymer membranes are joined by a predetermined method. A mixture of neutralizing agents and porous sorbent material are filled in a predetermined quantity at the bottom of the joined layers of polymer membranes adjoining all three sides with a sac like structure. The mixture of neutralizing agents and porous sorbent material is distributed uniformly to achieve predefined height of the layers of polymer membranes adjoining all three sides with a sac like structure to form a first row. The first row is sealed by a predetermined method. The mixture of neutralizing agents and porous sorbent material of a predetermined quantity are filled next to the sealed first row of the joined layers of polymer membrane adjoining its three sides. The mixture of neutralizing agents and porous sorbent material is uniformly distributed to achieve predefined thickness between the layers of polymer membrane joined together to form a second row. The second row is sealed by a predetermined method. The steps of distributing the mixture of neutralizing agents and porous sorbent material uniformly to achieve predefined thickness between the layers of polymer membrane joined together are repeated to form five rows of oil/chemical/dye sorbent pad. The rows are sealed by a predetermined method. The layers of polymer membrane filled with the porous sorbent material are sealed and joined together in four columns to compartmentalize the oil/chemical/dye sorbent pad into a plurality of small packets therein. According to an embodiment herein, the plurality of small packets is 20 or more. The columns are formed by sealing/joining oil/chemical/dye sorbent pad by a predetermined method. The oil/chemical/dye sorbent pad comprises five rows and four columns. The compartmentalization of the oil/chemical/dye sorbent pad into small packets act as plurality of zones for effective holding of oils/chemicals/dyes for prevents agglomeration, small packets of the oil/chemical/dye sorbent pad which acts as zones for effective holding of oils/chemicals/dyes and prevents agglomeration. The fabricated oil/chemical/dye sorbent pad is analyzed for gravimetric sorption capacity, efficiency, reusability, and calorific value.

[0072] According to one embodiment of the present invention, the porous sorbent material is selected from a group consisting of graphene nanoplatelets, graphene sponge, graphene aerogel, graphene balls, graphene foam, high surface area carbon, polypropylene and polyester.

[0073] According to one embodiment of the present invention, the neutralizing agents are selected from the group consisting of calcium carbonate, calcium oxide, magnesium hydroxide, sodium carbonate, and wherein the neutralizing agents neutralizes chemical reaction. [0074] According to one embodiment of the present invention, the method of sealing/joining rows, columns, and compartmentalization of oil/chemical/dye sorbent pad into small packets is selected from a group consisting of stitching, heat press, UV curing, ultrasound sealing or a combination thereof.

[0075] According to one embodiment of the present invention, the porous sorbent materials have a density of less than 0.8 g/cm3 for better buoyant characteristics. The porous sorbent material with a gravimetric sorption capacity to weight ratio is 50 or greater than 50. The porous sorbent material has a meso, micro or macro porous structures. [0076] According to one embodiment of the present invention, the layers of polymer membrane are made from polypropylene, polyester LDPE and HDPE.

[0077] According to one embodiment of the present invention, the layers of polymer membrane with a predefined thickness of in the range of 8microns-80 microns depending on the robustness and absorption capacity required for the application.

[0078] According to one embodiment of the present invention, the oil/chemical/dye sorbent with polymer membrane comprises uniformly dispersed micro size pores with a predefined diameter range. The diameter range of micro size pores is 1- 100 pm. [0079] According to one embodiment of the present invention, the gravimetric sorption capacity of the oil/chemical/dye sorbent pad with respect to weight ratio is 30 or greater than 30.

[0080] According to one embodiment of the present invention, the reusability of the oil/chemical/dye sorbent pad is five cycles. The oil/chemical/dye sorbent pad illustrates an efficiency drop of less than 75% after five cycles.

[0081] According to one embodiment of the present invention, the calorific value of the oil/chemical/dye sorbent pad is 40000 KJ/KG.

[0082] According to one embodiment of the present invention, the oil/chemical/dye sorbent pad has a gravimetric sorption capacity to weight ratio of more than 30.

[0083] According to one embodiment of the present invention, the oil/chemical/dye sorbent pad is reusable for about more than five cycles. [0084] According to one embodiment of the present invention, the oil/chemical/dye sorbent pad does not allow any oil/chemical/dye dripping in saturated state unless subjected to threshold pressure.

[0085] According to one embodiment of the present invention, the layers of polymer membrane comprise a plurality of uniformly dispersed micro size pores of predefined diameter for better capillary action.

[0086] According to one embodiment of the present invention, the absorbent pad comprises a plurality of polymer membrane layers, and wherein the layer of polymer membrane, which comes into contact with water at first stage, has a lower thickness and wherein the layer of polymer membrane which comes into contact with water at a later stage has a higher thickness.

[0087] According to one embodiment of the present invention, an oil/chemical/dye sorbent pad having high gravimetric sorption capacity to weight ratio of more than 30, is provided. The oil/chemical/dye sorbent pad includes a porous sorbent material of predetermined quantity uniformly distributed and sealed in between the layer of polymer membrane via compartmentalization into small packets. The compartmentalization into small packets acts as zone for effective holding of oils/chemicals/dyes and prevents agglomeration. The porous sorbent material is selected from one of graphene nanoplatelets, graphene sponge, graphene aerogel, graphene balls, graphene foam, high surface area carbon, bark, peat, saw dust, wool, vermiculate, pumice, polypropylene, polyester, or a combination thereof in different weight proportions. The layers of polymer membrane are spun bound and made from polypropylene, polyester LDPE and HDPE or the blend thereof. [0088] According to one embodiment of the present invention, a method of fabricating of the oil/chemical/dye sorbent pad, is provided. The method comprises the following steps. The layers of polymer membrane are held against each other and joined on all the three sides through either stitching, heat press, UV curing, ultrasound sealing or a combination thereof. A porous sorbent material of predetermined quantity is filled at the bottom of the joined layers of polymer membrane adjoining its three sides. The porous sorbent material is distributed uniformly to achieve predefined height of the layers of polymer membrane that are joined together to form a first row. Again, the porous sorbent material of the same quantity is filled at the bottom of the first row of the joined layers of polymer membrane adjoining its three sides. The porous sorbent material is distributed uniformly to achieve predefined thickness between the layers of polymer membrane joined together to form a second row. All the above-mentioned steps are repeated for a plurality of times to form the oil/chemical/dye sorbent pad of a plurality of rows. Finally, the layers of polymer membrane filled with the porous sorbent material are joined together in three columns to compartmentalize the oil/chemical/dye sorbent pad into a plurality of small packets therein. The compartmentalization of the oil/chemical/dye sorbent pad into small packets acts as zone for effective holding of oils/chemicals/dyes, and also prevents agglomeration.

[0089] According to one embodiment of the present invention, a method of deployment of oil/chemical/dye sorbent pads over a spillage area of oils/chemicals/dyes across the water body and their collection mechanism on saturation, is provided. The method of deployment of oil/chemical/dye sorbent pads over water bodies and their collection on saturation comprises the following steps. It is very difficult to drop the oil/chemical/dye sorbent pads at exact locations covering wide portions of oil/chemical/dye spillage. Hence, drones are used to drop oil/chemical/dye sorbent pads covering wide-spread area of oil/chemical/dye spillage. The oil/chemical/dye sorbent pads saturated with oil/chemical/dye are collected by ships for recovery of the oil/chemical/dye from the sorbent pads for secondary applications. [0090] FIG.1A illustrates a top side perspective view of an oil/chemical/dye sorbent pad, according to one embodiment of the present invention. FIG. IB illustrates a front side perspective view of an oil/chemical/dye sorbent pad, according to one embodiment of the present invention. FIG.1C illustrates a side view of an oil/chemical/dye sorbent pad, along a width direction, according to one embodiment of the present invention. FIG. ID illustrates a side view of the oil/chemical/dye sorbent pad, along a length direction, according to one embodiment of the present invention.FIG.lE illustrates a cross sectional view of the oil/chemical/dye sorbent pad, according to one embodiment of the present invention.

[0091] With respect to FIG.1A-FIG.1E, an oil/chemical/dye sorbent pad 100 of standard dimension is provided. The standard dimension of oil/chemical/dye sorbent pad is of 40 x 50 cm and is indicated by reference numerals X and Y respectively. The standard dimension is finalized by considering parameters of optimum absorption capacity and economical price. As illustrated in FIG.1A, IB, 1C, ID and IE the layers of polymer membrane 102 and 104 are held against each other and joined on all the three sides through either stitching, heat press, UV curing, ultrasound sealing or a combination thereof. A porous sorbent material 106 of predetermined quantity is filled at the bottom of the joined layers of polymer membrane 102 and 104 adjoining its three sides. The layers of polymer membrane filled with the porous sorbent material are joined together in a plurality of columns and rows are compartmentalized into a plurality of small packets 108 therein. The compartmentalization of the oil/chemical/dye sorbent pad into small packets acts as zone for effective holding of oils/chemicals/dyes, and also prevents agglomeration.

[0092] According to one embodiment of the present invention, an oil/chemical/dye sorbent pad (100) having high gravimetric sorption capacity of about more than 30. The oil/chemical/dye sorbent pad (100) includes a porous sorbent material (106) of predetermined quantity uniformly distributed and sealed in between the layer of polymer membrane (102 and 104) via compartmentalization into small packets (108). The compartmentalization into small packets (108) acts as zone for effective holding of oils/chemicals/dyes and prevents agglomeration. The porous sorbent material (106) is selected from one of graphene nanoplatelets, graphene sponge, graphene aerogel, graphene balls, graphene foam, high surface area carbon, bark, peat, saw dust, wool, vermiculate, pumice, polypropylene, polyester, or a combination thereof in different weight proportions. The layers of polymer membrane (102 and 104) are spun bound and made from polypropylene, polyester LDPE and HDPE or the blend thereof.

[0093] According to one embodiment of the present invention, the oil/chemical/dye sorbent pad 100 comprises a dimension of 40 x 50 cm, weighs 22 grams and absorbs oils/chemicals/dyes up to 1.7 liters.

[0094] According to one embodiment of the present invention, the predefined height of the layers of polymer membrane 102 and 104 filled with the porous sorbent material 106 is in a range of 4000-8000 microns.

[0095] According to one embodiment of the present invention, all the small packets 108 include the porous sorbent material 106 of the same quantity to ensure uniform absorption of oil/chemical/dye across the sorbent pad 100 and thereby ensuring better buoyancy characteristics.

[0096] According to one embodiment of the present invention, preferably 12 grams of the porous sorbent material 106 is filled in the oil/chemical/dye sorbent pad of 40 x 50 cm dimension with each of the small packets 108 containing 0.6 grams of the porous sorbent material 106. The oil/chemical/dye sorbent pad 100 is fabricated in a plurality of different dimensions depending on the required absorption capacity and industrial applications. At the same time, the amount of the porous sorbent material 106 filled into the oil/chemical/dye sorbent pad 100 also varies depending on its dimension. [0097] According to one embodiment of the present invention, the oil/chemical/dye sorbent pad 100 has gravimetric sorption capacity to weight ration of more than 30 and is reusable for more than five cycles with efficiency drop of less than 75% over the five cycles.

[0098] According to one embodiment of the present invention, the oil/chemical/dye sorbent pad 100 does not allow any oil/chemical/dye dripping in saturated state unless subjected to threshold pressure.

[0099] According to one embodiment of the present invention, the oil/chemical/dye sorbent pad 100 facilitates in easily extraction of the absorbed oil/chemical/dye for further applications. [0100] According to one embodiment of the present invention, the layers of polymer membrane (102 and 104) are of same thickness or of different thickness. The layers of polymer membrane (102 and 104) with greater thickness provides robustness to the oil/chemical/dye sorbent pad 100 and the layers of polymer membrane (102 and 104) with lower thickness gives high absorption rate to the oil/chemical/dye sorbent pad

100.

[0101] According to one embodiment of the present invention, the oil/chemical/dye sorbent pad 100 is dropped into the spillage area in such a way that the layer of polymer membrane (102 or 104) with a lower thickness, comes into contact with the spill at first and the layer of polymer membrane (102 or 104) with greater thickness comes into contact with the spill at a later stage.

[0102] According to one embodiment of the present invention, the thickness of the layers of polymer membrane (102 and 104) is within a range of about 8 to 80 microns. [0103] According to one embodiment of the present invention, the layers of polymer membrane (102 and 104) are fabricated from polypropylene, polyester LDPE and HDPE or the blend thereof and are capable of withstanding abrasion from rocks, minerals, salts and action of waves of water bodies without any tear-off. The layers of polymer membrane include a plurality of uniformly dispersed micro size pores of diameter in the range of 1-100 pm depending on the viscosity of oils/chemicals/dyes for better capillary action.

[0104] According to one embodiment of the present invention, the porous sorbent material 106 of the oil/chemical/dye sorbent pad 100 is selected from a group consisting of graphene nanoplatelets, graphene sponge, graphene aerogel, graphene balls, graphene foam, high surface area carbon, bark, peat, saw dust, wool, vermiculate, pumice, polypropylene, polyester or a combination thereof in different weight proportions.

[0105] According to one embodiment of the present invention, the porous sorbent material 106 is highly oleophilic, hydrophobic, and is capable of absorbing a variety of oils/chemicals/dyes as the contact angle of water is greater than the porous sorbent material 106. The porous sorbent material 106 has gravimetric sorption capacity of about greater than 50 and density of about less than 0.8 gm/cm3. The porous sorbent material 106 has meso, micro or macro porous structure thereby providing high surface area for trapping oil/chemical/dye molecules within the cavities with minimal dripping off factor.

[0106] According to one embodiment of the present invention, the oil/chemical/dye sorbent pad 100 is recyclable with an overall calorific value of about higher than 40000 KJ/KG and does not cause any secondary pollution.

[0107] According to one embodiment of the present invention, the porous sorbent material 106 is added with neutralizing agents like calcium carbonate, calcium oxide, magnesium hydroxide, sodium carbonate etc., for neutralization of chemicals.

[0108] FIG.2 illustrates a flow chart explaining the process steps involved in the method of fabricating of the oil/chemical/dye sorbent pad, according to one embodiment of the present invention, is provided. The layers of polymer membranes 102 and 104 are held against each other and joined on all the three sides through either stitching, heat press, UV curing, ultrasound sealing or a combination thereof (201). A porous sorbent material of predetermined quantity is filled at the bottom of the joined layers of polymer membrane adjoining its three sides (202). The porous sorbent material is distributed uniformly to achieve predefined height of the layers of polymer membrane 102 and 104 joined together to form a first row (203). Again, the porous sorbent material of the same quantity is filled at the bottom of the first row of the joined layers of polymer membrane adjoining its three sides (204). The porous sorbent material is distributed uniformly to achieve predefined thickness between the layers of polymer membrane joined together to form a second row (205). All the above-mentioned steps are repeated for more than three times to form the oil/chemical/dye sorbent pad of five rows (206). Finally, the layers of polymer membrane filled with the porous sorbent material are joined together in three columns to compartmentalize the oil/chemical/dye sorbent pad into 20 small packets therein (207). The compartmentalization of the oil/chemical/dye sorbent pad into small packets acts as zone for effective holding of oils/chemicals/dyes, and also prevents agglomeration.

[0109] FIG.3 illustrates a schematic representation of deployment of oil/chemical/dye sorbent pads over a spillage area of oils/chemicals/dyes across the water body and their collection mechanism on saturation, according to one embodiment of the present invention. With respect to FIG. 3, the method of deployment of oil/chemical/dye sorbent pads 100 over water bodies and their collection on saturation is as follows: It is very difficult to drop the oil/chemical/dye sorbent pads 100 at exact locations covering wide portions of oil/chemical/dye spillage 200. Hence, drones 300 are used to drop oil/chemical/dye sorbent pads 100 covering wide-spread area of oil/chemical/dye spillage 200. The oil/chemical/dye sorbent pads 100 saturated with oil/chemical/dye are collected by ships 400 for recovery of the oil/chemical/dye from the sorbent pads 100 for secondary applications.

[0110] According to one embodiment of the present invention, the oil/chemical/dye sorbent pads are tested and analyzed for the sorption capacity and number of cycles. The oil/chemical/dye sorbent pad is weighed. The oil/chemical/dye sorbent pad is placed in a container having oil with known density. The sorbent pad is kept in the container for a time period of 5-15 minutes for oil absorption. The sorbent pad comprising absorbed oil is removed and total weight is measured. The sorbent pad is squeezed to remove the absorbed oil. The recovered oil is measured using a measuring cylinder. Weight difference between the sorbent pad without oil and the amount of oil absorbed in liters is calculated using the density value of the oil. The same sorbent pad is again placed in the container comprising oil. Same process is repeated, and the amount oil absorbed and recovered is measured. The sorbent pad is reused for 5-6 cycles. [0111] According to one embodiment of the present invention, the absorbed oil in first cycle - up to 1700 ml. Recovered oil in first cycle - up to 1400 ml. Total oil absorbed after 5th cycle - up to 4600 ml. Total oil recovered after 5th cycle - up to 3700 ml.

[0112] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. [0113] It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope. [0114] Although the embodiments herein are described with various specific embodiments, it will be obvious for a person skilled in the art to practice the embodiments herein with modifications. Although the embodiments herein are described with various specific embodiments, it will be obvious for a person skilled in the art to practice the embodiments herein with modifications.

TECHICAL ADVANTAGES OF THE INVENTION

[0115] The embodiments of the present invention provide an oil/chemical/dye sorbent pad with a porous sorbent material of predetermined quantity uniformly distributed and sealed in between the layers of polymer membrane via compartmentalization into small packets.

[0116] The embodiments of the present invention provide an oil/chemical/dye sorbent pad with gravimetric sorption capacity of about more than 30 and can be reusable for more than five cycles.

[0117] The embodiments of the present invention provide an oil/chemical/dye sorbent pad that does not allow any oil/chemical/dye dripping in saturated state unless subjected to threshold pressure.

[0118] The embodiments of the present invention provide an oil/chemical/dye sorbent pad wherein the layer of polymer membrane which comes into contact with the spillage first has lesser thickness and the layer of polymer membrane which comes into contact with the spillage at a later stage has greater thickness.

[0119] The embodiments of the present invention provide an oil/chemical/dye sorbent pad where compartmentalization into small packets acts as zone for effective holding of oils/chemicals/dyes and prevent agglomeration.

[0120] The embodiments of the present invention provide an oil/chemical/dye sorbent pad where compartmentalization into small packets is done through stitching, heat press, UV sealing, ultrasound sealing or combination thereof. [0121] The embodiments of the present invention provide an oil/chemical/dye sorbent pad wherein the porous sorbent material is selected from one of graphene nanoplatelets, graphene sponge, graphene aerogel, graphene balls, graphene foam, high surface area carbon, bark, peat, saw dust, wool, vermiculate, pumice, polypropylene, polyester or a combination thereof in different weight proportions.

[0122] The embodiments of the present invention provide an oil/chemical/dye sorbent pad wherein the layers of polymer membrane are made from polypropylene, polyester LDPE and HDPE or the blend thereof.

[0123] The embodiments of the present invention provide an oil/chemical/dye sorbent pad wherein the layers of polymer membrane include a plurality of uniformly dispersed micro size pores of predefined diameter for better capillary action.

[0124] While the foregoing describes various embodiments of the present invention, other and further embodiments of the present invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The present invention is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the present invention when combined with information and knowledge available to the person having ordinary skill in the art.

[0125] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments.

[0126] It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope.

[0127] Although the embodiments herein are described with various specific embodiments, it will be obvious for a person skilled in the art to practice the embodiments herein with modifications. Although the embodiments herein are described with various specific embodiments, it will be obvious for a person skilled in the art to practice the embodiments herein with modifications.