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WO2011053765A1 - Apparatus and method for controlling odors and odor-causing microorganisms in building materials and preventing corrosion of primary and composite metals - Google Patents

Apparatus and method for controlling odors and odor-causing microorganisms in building materials and preventing corrosion of primary and composite metals Download PDF

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Publication number
WO2011053765A1
WO2011053765A1 PCT/US2010/054665 US2010054665W WO2011053765A1 WO 2011053765 A1 WO2011053765 A1 WO 2011053765A1 US 2010054665 W US2010054665 W US 2010054665W WO 2011053765 A1 WO2011053765 A1 WO 2011053765A1
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WIPO (PCT)
Prior art keywords
gas
odor
building materials
contents
molecules
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PCT/US2010/054665
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French (fr)
Inventor
Thomas W. O'connell
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PureLine Treatment Systems LLC
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PureLine Treatment Systems LLC
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Classifications

    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61LMETHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L2/00Methods or apparatus for disinfecting or sterilising materials or objects other than foodstuffs or contact lenses; Accessories therefor
    • A61L2/16Methods or apparatus for disinfecting or sterilising materials or objects other than foodstuffs or contact lenses; Accessories therefor using chemical substances
    • A61L2/20Gaseous substances, e.g. vapours
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61LMETHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L9/00Disinfection, sterilisation or deodorisation of air
    • A61L9/015Disinfection, sterilisation or deodorisation of air using gaseous or vaporous substances, e.g. ozone
    • CCHEMISTRY; METALLURGY
    • C23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23FNON-MECHANICAL REMOVAL OF METALLIC MATERIAL FROM SURFACE; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL; MULTI-STEP PROCESSES FOR SURFACE TREATMENT OF METALLIC MATERIAL INVOLVING AT LEAST ONE PROCESS PROVIDED FOR IN CLASS C23 AND AT LEAST ONE PROCESS COVERED BY SUBCLASS C21D OR C22F OR CLASS C25
    • C23F11/00Inhibiting corrosion of metallic material by applying inhibitors to the surface in danger of corrosion or adding them to the corrosive agent
    • C23F11/02Inhibiting corrosion of metallic material by applying inhibitors to the surface in danger of corrosion or adding them to the corrosive agent in air or gases by adding vapour phase inhibitors
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61LMETHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L2202/00Aspects relating to methods or apparatus for disinfecting or sterilising materials or objects
    • A61L2202/10Apparatus features
    • A61L2202/11Apparatus for generating biocidal substances, e.g. vaporisers, UV lamps
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61LMETHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L2202/00Aspects relating to methods or apparatus for disinfecting or sterilising materials or objects
    • A61L2202/10Apparatus features
    • A61L2202/12Apparatus for isolating biocidal substances from the environment
    • A61L2202/121Sealings, e.g. doors, covers, valves, sluices
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61LMETHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L2202/00Aspects relating to methods or apparatus for disinfecting or sterilising materials or objects
    • A61L2202/20Targets to be treated
    • A61L2202/25Rooms in buildings, passenger compartments
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61LMETHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L2209/00Aspects relating to disinfection, sterilisation or deodorisation of air
    • A61L2209/20Method-related aspects
    • A61L2209/21Use of chemical compounds for treating air or the like

Definitions

  • the technical field involves controlling odors and odor-causing microorganisms in building materials and preventing corrosion of primary and composite metals.
  • it is a method and apparatus for reducing the concentration of odor- causing bacteria and/or molecules (such as sulfur or hydrogen sulfide) in drywall, sheetrock, furnishings and/or other building materials using chlorine dioxide gas. This has the benefit of neutralizing the odors and simultaneously preventing corrosion of primary and composite metals used in the building.
  • Drywall is a common building material. It is made by pressing layers of gypsum-based plaster between two thick sheets of paper and kiln drying the resulting material.
  • Gypsum is a soft mineral composed of calcium sulfate dihydrate (CaS0 4 -2H 2 0). Gypsum is typically obtained by excavating it from naturally occurring mines. In recent years because of increased U.S. demand, gypsum or drywall has been obtained from overseas. It is believed that the defective drywall originated overseas. The defective drywall is generically called Chinese drywall.
  • the current method and apparatus provide an alternative to the full destruction and removal of wall and building material afflicted by the ailments associated with the defective drywall discussed above.
  • a method that does not require complete destruction and removal reduces costs of dealing with the problem by over 80%.
  • the current method further allows for treatment of home furnishings and contents while treating the affected building material.
  • the current method further prevents corrosion of primary and composite metals in the building.
  • One embodiment of the current method of reducing odor-causing microorganism concentration in building materials, home furnishings and/or contents comprises the steps of (a) producing C10 2 gas; and (b) exposing the building materials, home furnishings and/or contents to the C10 2 gas wherein the C10 2 gas kills substantially all odor- causing microorganisms in the building materials, home furnishings and/or contents to neutralizes odor.
  • the steps can be performed sequentially.
  • the C10 2 gas can be generated in a number of different ways.
  • CIO 2 gas can be generated by reacting chlorine gas with water and then adding sodium chlorite, by reacting sodium hypochlorite with an acid and then adding sodium chlorite, by reacting sodium chlorite and hydrochloric acid, using an electrochemical cell and sodium chlorite, using an electrochemical cell and sodium chlorate, using an equipment-based sodium chlorate and hydrogen peroxide method, reacting sodium chlorate and hydrogen peroxide, or by dry mix chlorine dioxide packets having a chlorite precursor packet and an acid activator packet.
  • the microorganisms can be bacteria.
  • the microorganisms can also use starch and sulfur to produce at least one sulfurous gas such as carbon disulfide, carbonyl sulfide, or hydrogen sulfide.
  • the building material can be drywall.
  • the C10 2 gas can penetrate the building materials, home furnishings and/or contents.
  • Another embodiment of the method of reducing odor-causing molecule concentration in a building materials, home furnishings and/or contents comprises the steps of (a) producing CIO 2 gas; and (b) exposing the building materials, home furnishings and/or contents to the CIO 2 gas wherein the CIO 2 gas reacts with the molecules to neutralize odor.
  • the steps can be performed sequentially.
  • the CIO 2 gas can be generated in a number of different ways.
  • CIO 2 gas can be generated by reacting chlorine gas with water and then adding sodium chlorite, by reacting sodium hypochlorite with an acid and then adding sodium chlorite, by reacting sodium chlorite and hydrochloric acid, using an electrochemical cell and sodium chlorite, using an electrochemical cell and sodium chlorate, using an equipment-based sodium chlorate and hydrogen peroxide method, reacting sodium chlorate and hydrogen peroxide, or by dry mix chlorine dioxide packets having a chlorite precursor packet and an acid activator packet.
  • the molecules can contain sulfur, such as carbon disulfide, carbonyl sulfide, and hydrogen sulfide.
  • the molecules can be produced by bacteria.
  • the building material can be drywall.
  • the CIO 2 gas can penetrate the building materials, home furnishings and/or contents.
  • Another method of reducing odor in building materials, home furnishings and/or contents comprises the steps of (a) producing CIO 2 gas; and (b) exposing the building materials, home furnishings and/or contents to the C10 2 gas wherein the C10 2 gas kills odor- causing microorganisms and reacts with odor-causing molecules to obtain improved odor neutralization.
  • the microorganisms can be bacteria.
  • the molecules can be selected from the group comprising carbon disulfide, carbonyl sulfide, and hydrogen sulfide.
  • the building material can be drywall.
  • the C10 2 gas can penetrate the building materials, home furnishings and/or contents.
  • a method of preventing corrosion of primary and composite metals in a building comprises the steps of (a) producing C10 2 gas; and (b) exposing the primary and composite metal to the C10 2 gas wherein said C10 2 gas reacts with corrosive molecules to convert the corrosive molecules into benign molecules.
  • the corrosive molecules can be in the form of a gas.
  • the corrosive molecules can be carbon disulfide, carbonyl sulfide, and/or hydrogen sulfide.
  • An apparatus for reducing odor in building materials, home furnishings and/or contents comprises a sealing area for sealing an infected building materials, home furnishings and/or contents and a C10 2 generator comprising an inlet for introducing at least one chlorine-containing feed chemical and an outlet for exhausting a C10 2 gas stream from the generator into the sealing area wherein introducing the C10 2 gas kills odor-causing microorganisms and reacts with odor-causing molecules to obtain improved odor neutralization.
  • the C10 2 generator can be mobile.
  • FIG. 1 is an illustration of an embodiment of the present method of reducing odors and/or odor-causing microorganisms in a building material using chlorine dioxide gas.
  • FIG. 2 is a graph showing results of the Acidithiobacillus assay testing on paper, paint and gypsum portions of sheetrock not treated using the present method of reducing odors and/or odor-causing microorganisms in a building material using chlorine dioxide gas
  • FIG. 3 is a graph showing results of the Acidithiobacillus assay testing on paper, paint and gypsum portions of sheetrock treated using the present method of reducing odors and/or odor-causing microorganisms in a building material using chlorine dioxide gas
  • the current disclosure relates to a method for reducing the concentration of bacteria and other odor-causing microorganisms in building materials. Specifically, it is a method of reducing the concentration of odor-causing bacteria and/or molecules in drywall, sheetrock, furnishings, household contents and/or other building materials using chlorine dioxide gas.
  • Chlorine dioxide has many industrial and municipal uses. When produced and handled properly, C10 2 is an effective and powerful biocide, disinfectant and oxidizer. C10 2 has been used as a disinfectant in the food and beverage industries, wastewater treatment, industrial water treatment, cleaning and disinfections of medical wastes, textile bleaching, odor control for the rendering industry, circuit board cleansing in the electronics industry, and uses in the oil and gas industry. It is an effective biocide at low concentrations and over a wide pH range. C10 2 is desirable because when it reacts with an organism, it reduces to chlorite ion and then to chloride, which studies to date have shown does not pose a significant adverse risk to human health. The use of chlorine, on the other hand, can result in the creation of chlorinated organic compounds when treating water. Chlorinated compounds are suspected to increase cancer risk.
  • the current method and apparatus involve deploying a C10 2 gas into a sealed area affected by odors and/or odor-causing microorganisms, such as bacteria.
  • the current method is effective against bacteria of the Acidithiobacillus genus.
  • the current method is not limited to this genus and will be effective against other odor causing bacteria as well.
  • the C10 2 gas fills the sealed, affected area.
  • the C10 2 gas will then penetrate the affected building material, for example a wall.
  • the C10 2 gas is able to destroy the cause of odors on the surface, in the center and on the backside of the building material.
  • the cause of the odor could be bacteria or a chemical, such as sulfur.
  • Fig. 1 illustrates the penetration of the building material by the C10 2 gas of the current method.
  • the C10 2 gas remedies odors using a two-fold solution.
  • the C10 2 gas reacts with the chemicals that are the source of the odor.
  • affected drywall was found to emit sulfurous gases, namely (1) carbon disulfide, (2) carbonyl sulfide, and (3) hydrogen sulfide.
  • C10 2 gas reacts with these chemicals to form benign compositions. This is one method of remedying the sulfuric "rotten egg" smell.
  • the C10 2 gas also kills microorganisms, such as bacteria, that produce the sulfuric odor-causing chemicals.
  • microorganisms such as bacteria
  • bacteria that produce the sulfuric odor-causing chemicals.
  • the predominant view in the industry was that it was a chemical phenomenon, rather than a biological one.
  • Applicants obtained affected drywall and tested it for the presence of bacteria.
  • Applicants found such bacteria. Reducing the concentration of odor-causing bacteria further helps to neutralize the sulfuric "rotten egg” smell.
  • the two-fold approach can provide better neutralization of the "rotten egg” smell and can also neutralize primary and composite metal corroding gases.
  • the pieces of drywall were sent to a lab for examination.
  • the drywall was tested using a real time PCR based assay to quantify and detect levels of DNA from the Acidithiobacillus genus.
  • the assay is designed to specifically detect Acidithiobacillus ferrooxidans and Acidithiobacillus thiooxidans, two hydrogen sulfide producing bacteria.
  • the assay will also detect two other bacteria reported to produce hydrogen sulfide, Acidithiobacillus albertenis and Acidithiobacillus caldus.
  • a positive result from the real time PCR assay provides strong evidence for the presence of the aforementioned organisms.
  • the assay reports positive samples in Ct values - the cycle where the DNA signal crosses a defined threshold. If DNA from the target organism is present, the instrument will display a curved line that crosses this threshold, if no DNA is present, this line will remain flat and not report a Ct value for the sample. This number is based on the exponential amplification of the target DNA if present. There is an inverse relationship between the amount of DNA present and the Ct value obtained; thus, the smaller the Ct number, the larger the amount of DNA present in the analyzed sample.
  • Drywall or sheetrock was separated into paint (the front side of the drywall), paper (the back side of the drywall) and gypsum (the interior gypsum powder portion of the drywall) samples.
  • the paint and paper samples were cut into approximately 5 mm x 5 mm sections using an isopropyl alcohol/flame sterilized razor blade. As much of the gypsum layer was removed from these samples as possible.
  • the gypsum samples were cut in approximately 5 mm x 5mm x 5 mm cubes. The cut samples were transferred to a sterile, 1.5 ml non-stick eppendorf tube containing 100 ml of pTE and crushed/rendered with an isopropyl alcohol / flame sterilized steel rod.
  • the tubes were then centrifuged at 14.5 kRPM for 2 minutes to pellet debris and the supernatants harvested.
  • the harvested supernatants were then treated with a WizardTM Genomic DNA vacuum extraction kit - protocol modified for gram-negative bacteria.
  • the extractions were harvested in 200 ⁇ extraction buffer and 2 ⁇ of the extracted DNA was then analyzed.
  • FIG. 2 shows the presence of Acidithiobacillus genus DNA in the paper, paint, and gypsum portions of the untreated sheetrock (orange, grey, and blue lines). The gypsum portion of the sheetrock (blue line) shows a very weak signal. The positive result of the assay indicates that a species of the Acidithiobacillus genus was present in the supplied sheetrock sample.
  • the sample of treated drywall provided as a post treatment sample shows no positive detection of the Acidithiobacillus genus in the paper of the sheetrock but potentially a very low signal in the gypsum portion. These samples also no longer emitted odors.
  • FIG. 3 provides some evidence that the chlorine dioxide gas treatment may have reduced the level of Acidithiobacillus below the sensitivity limit of the assay at least in the paper. Longer treatment time with the chlorine dioxide gas can better permeate the gypsum of the sheetrock and eliminate any signal from the gypsum.
  • Producing C10 2 gas for use in treatment processes is desirable because there is greater assurance of C10 2 purity when in the gas phase.
  • Pure or substantially pure C10 2 is desirable because it allows the user to precisely maintain the amount of C10 2 added to the building material. (The single term "pure” will be used hereinafter to mean either pure or substantially pure.) If too little C10 2 is added the dosage will not be effective in killing odor- causing microorganisms. Addition of pure C10 2 allows the user to carefully monitor and adjust the amount of C10 2 added to the building materials. This enables the user to add adequate C10 2 to kill the odor-causing microorganisms.
  • Gaseous C10 2 is also desirable for the current method because of its easy application to large areas of affected building material. Gaseous C10 2 can be easily applied to a large area by sealing the room and generating the gas. This allows for treatment of furnishing and household contents, such as clothing, while treating the affected building material. Applicants also found that chlorine dioxide gas is able to penetrate the building materials. This allows for treatment of the surface, center and backside of the affected building material, such as a wall. Gaseous C10 2 also avoids leaving messy solid or liquid material to be cleaned up after treatment. Gaseous C10 2 is also desirable because it will not cause corrosion or destruction of primary and composite metals.
  • C10 2 is, however, unstable in the gas phase and will readily undergo decomposition into chlorine gas (Cl 2 ), oxygen gas (0 2 ), and heat.
  • the high reactivity of C10 2 generally requires that it be produced and used at the same location.
  • C10 2 gas there are a number of methods of producing C10 2 gas which are known to persons familiar with the technology involved here. One or more of these methods can be used. Here are some exemplary methods of producing C10 2 gas. C10 2 gas can be produced using electrochemical cells and a sodium chlorite (C10 2 ⁇ ) or chlorate (CIO 3 ) solution. An equipment based sodium chlorate/hydrogen peroxide method also exists. Alternatively, non- equipment based binary, multiple precursor dry or liquid precursor technologies can be used. Examples of non-equipment based methods of C10 2 generation include dry mix chlorine dioxide packets that include both a chlorite precursor packet and an acid activator packet.
  • C10 2 ⁇ sodium chlorite
  • CIO 3 chlorate
  • An equipment based sodium chlorate/hydrogen peroxide method also exists.
  • non- equipment based binary, multiple precursor dry or liquid precursor technologies can be used. Examples of non-equipment based methods of C10 2 generation include dry mix chlorine dioxide packets that include both a chlorite precursor
  • hypochlorous acid reacts with water to form hypochlorous acid and hydrochloric acid. These acids then react with sodium chlorite to form chlorine dioxide, water and sodium chloride.
  • sodium hypochlorite is combined with hydrochloric or other acid to form hypochlorous acid. Sodium chlorite is then added to this reaction mixture to produce chlorine dioxide.
  • the third method combines sodium chlorite and sufficient hydrochloric acid.
  • the current apparatus comprises a sealing area and a C10 2 generator.
  • the C10 2 generator should also have an outlet for exhausting a C10 2 gas stream from the generator into the sealing area.
  • the C10 2 generator has an input for electricity. There is also an inlet for at least one chlorine containing chemical.
  • the C10 2 generator is an electrochemical generator.
  • the electrochemical generator comprises an anolyte loop and a catholyte loop.
  • the purpose of the anolyte loop is to produce a chlorine dioxide (C10 2 ) gas by oxidation of chlorite or chlorate, and the process can be referred to as a C10 2 gas generator loop.
  • the C10 2 gas generator loop is essentially a C10 2 gas source.
  • Various sources of C10 2 are available and known in the water treatment field.
  • the catholyte loop of the C10 2 gas generator loop produces sodium hydroxide and hydrogen gas by reduction of water.
  • the process can be operated through a program logic control (PLC) system that can include displays.
  • PLC program logic control

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Abstract

A method of reducing odor in building materials, home furnishings and/or contents and of preventing corrosion of primary and composite metals in a building, comprises producing ClO2 gas and exposing the building materials, home furnishings, contents and/or primary and composite metals to the ClO2 gas wherein the ClO2 gas kills odor-causing microorganisms and/or reacts with odor-causing, corrosive molecules to obtain improved odor neutralization and non-corrosive benign molecules. An apparatus for reducing odor in building materials, home furnishings and/or contents comprises a sealing area for sealing an infected building material and a ClO2 generator comprising an inlet for introducing at least one chlorine-containing feed chemical and an outlet for exhausting a ClO2 gas stream from the generator into the sealing area wherein introducing the ClO2 gas kills odor-causing microorganisms and/or reacts with odor-causing molecules to obtain improved odor neutralization.

Description

TITLE
APPARATUS AND METHOD FOR CONTROLLING ODORS AND ODOR- CAUSING MICROORGANISMS IN BUILDING MATERIALS AND PREVENTING CORROSION OF PRIMARY AND COMPOSITE METALS
FIELD OF THE INVENTION
[0001] Generally, the technical field involves controlling odors and odor-causing microorganisms in building materials and preventing corrosion of primary and composite metals. Specifically, it is a method and apparatus for reducing the concentration of odor- causing bacteria and/or molecules (such as sulfur or hydrogen sulfide) in drywall, sheetrock, furnishings and/or other building materials using chlorine dioxide gas. This has the benefit of neutralizing the odors and simultaneously preventing corrosion of primary and composite metals used in the building.
BACKGROUND OF THE INVENTION
[0002] Recently, concerns over defective drywall have arisen among building occupants in the United States. A number of building occupants noticed a foul odor emitting from the walls of their buildings. This was particularly noted in regions with high temperature and humidity. Building occupants also reported respiratory tract infections, sinus problems and nosebleeds. Building occupants also noted that primary and composite metal surfaces such as copper pipes, copper wiring, and copper air conditioner coils corrode, turning black and powdery. Building occupants also noticed that home furnishings and contents, such as clothing, absorbed the odors.
[0003] Samples of drywall from the affected buildings were obtained and tested. Laboratory tests of the samples identified emissions of at least three sulfurous gases, namely (1) carbon disulfide, (2) carbonyl sulfide, and (3) hydrogen sulfide. These gases have an odor of "rotten eggs", which explains the foul odor. Hydrogen sulfide also reacts with copper to form a black, powdery substance, which explains the problems with copper surfaces.
[0004] Drywall is a common building material. It is made by pressing layers of gypsum-based plaster between two thick sheets of paper and kiln drying the resulting material. Gypsum is a soft mineral composed of calcium sulfate dihydrate (CaS04-2H20). Gypsum is typically obtained by excavating it from naturally occurring mines. In recent years because of increased U.S. demand, gypsum or drywall has been obtained from overseas. It is believed that the defective drywall originated overseas. The defective drywall is generically called Chinese drywall.
[0005] There has not previously been a satisfactory method for remedying a building affected by the defective drywall discussed above. Prior approaches have included ozone, hepa-vacuums, electromagnetic charges and coatings. None of these approaches remedied the problem. This may be due in part to the fact that the underlying cause of the problem was not understood. Air fresheners have been used to cover the foul odor. However, they also fail to address the underlying cause of the problem.
[0006] Since none of the previously used approaches satisfactorily remedied the problem, affected walls are typically completely destroyed and the defective drywall is removed. This is an expensive and inconvenient solution. It commonly displaces building occupants for long periods of time. It forces the building occupant to spend large amounts of money replacing the destroyed walls. It fails to address the odor absorbed by home furnishings and other household contents, such as clothing. It also fails to address the problem of corrosion of primary and composite metals in the building.
SUMMARY OF THE INVENTION
[0007] The current method and apparatus provide an alternative to the full destruction and removal of wall and building material afflicted by the ailments associated with the defective drywall discussed above. A method that does not require complete destruction and removal reduces costs of dealing with the problem by over 80%. The current method further allows for treatment of home furnishings and contents while treating the affected building material. The current method further prevents corrosion of primary and composite metals in the building.
[0008] One embodiment of the current method of reducing odor-causing microorganism concentration in building materials, home furnishings and/or contents comprises the steps of (a) producing C102 gas; and (b) exposing the building materials, home furnishings and/or contents to the C102 gas wherein the C102 gas kills substantially all odor- causing microorganisms in the building materials, home furnishings and/or contents to neutralizes odor. The steps can be performed sequentially. [0009] The C102 gas can be generated in a number of different ways. For example, CIO2 gas can be generated by reacting chlorine gas with water and then adding sodium chlorite, by reacting sodium hypochlorite with an acid and then adding sodium chlorite, by reacting sodium chlorite and hydrochloric acid, using an electrochemical cell and sodium chlorite, using an electrochemical cell and sodium chlorate, using an equipment-based sodium chlorate and hydrogen peroxide method, reacting sodium chlorate and hydrogen peroxide, or by dry mix chlorine dioxide packets having a chlorite precursor packet and an acid activator packet.
[0010] The microorganisms can be bacteria. The microorganisms can also use starch and sulfur to produce at least one sulfurous gas such as carbon disulfide, carbonyl sulfide, or hydrogen sulfide. The building material can be drywall. The C102 gas can penetrate the building materials, home furnishings and/or contents.
[0011] Another embodiment of the method of reducing odor-causing molecule concentration in a building materials, home furnishings and/or contents comprises the steps of (a) producing CIO2 gas; and (b) exposing the building materials, home furnishings and/or contents to the CIO2 gas wherein the CIO2 gas reacts with the molecules to neutralize odor. The steps can be performed sequentially.
[0012] The CIO2 gas can be generated in a number of different ways. For example, CIO2 gas can be generated by reacting chlorine gas with water and then adding sodium chlorite, by reacting sodium hypochlorite with an acid and then adding sodium chlorite, by reacting sodium chlorite and hydrochloric acid, using an electrochemical cell and sodium chlorite, using an electrochemical cell and sodium chlorate, using an equipment-based sodium chlorate and hydrogen peroxide method, reacting sodium chlorate and hydrogen peroxide, or by dry mix chlorine dioxide packets having a chlorite precursor packet and an acid activator packet.
[0013] The molecules can contain sulfur, such as carbon disulfide, carbonyl sulfide, and hydrogen sulfide. The molecules can be produced by bacteria. The building material can be drywall. The CIO2 gas can penetrate the building materials, home furnishings and/or contents.
[0014] Another method of reducing odor in building materials, home furnishings and/or contents comprises the steps of (a) producing CIO2 gas; and (b) exposing the building materials, home furnishings and/or contents to the C102 gas wherein the C102 gas kills odor- causing microorganisms and reacts with odor-causing molecules to obtain improved odor neutralization.
[0015] The microorganisms can be bacteria. The molecules can be selected from the group comprising carbon disulfide, carbonyl sulfide, and hydrogen sulfide. The building material can be drywall. The C102 gas can penetrate the building materials, home furnishings and/or contents.
[0016] A method of preventing corrosion of primary and composite metals in a building, the method comprises the steps of (a) producing C102 gas; and (b) exposing the primary and composite metal to the C102 gas wherein said C102 gas reacts with corrosive molecules to convert the corrosive molecules into benign molecules.
[0017] The corrosive molecules can be in the form of a gas. The corrosive molecules can be carbon disulfide, carbonyl sulfide, and/or hydrogen sulfide.
[0018] An apparatus for reducing odor in building materials, home furnishings and/or contents comprises a sealing area for sealing an infected building materials, home furnishings and/or contents and a C102 generator comprising an inlet for introducing at least one chlorine-containing feed chemical and an outlet for exhausting a C102 gas stream from the generator into the sealing area wherein introducing the C102 gas kills odor-causing microorganisms and reacts with odor-causing molecules to obtain improved odor neutralization. The C102 generator can be mobile.
[0019] These and other features of the present method and apparatus are discussed or apparent in the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is an illustration of an embodiment of the present method of reducing odors and/or odor-causing microorganisms in a building material using chlorine dioxide gas.
[0021] FIG. 2 is a graph showing results of the Acidithiobacillus assay testing on paper, paint and gypsum portions of sheetrock not treated using the present method of reducing odors and/or odor-causing microorganisms in a building material using chlorine dioxide gas [0022] FIG. 3 is a graph showing results of the Acidithiobacillus assay testing on paper, paint and gypsum portions of sheetrock treated using the present method of reducing odors and/or odor-causing microorganisms in a building material using chlorine dioxide gas
DETAILED DESCRIPTION OF PREFERRED EMBODIMENT(S)
[0023] The current disclosure relates to a method for reducing the concentration of bacteria and other odor-causing microorganisms in building materials. Specifically, it is a method of reducing the concentration of odor-causing bacteria and/or molecules in drywall, sheetrock, furnishings, household contents and/or other building materials using chlorine dioxide gas.
[0024] Chlorine dioxide (C102) has many industrial and municipal uses. When produced and handled properly, C102 is an effective and powerful biocide, disinfectant and oxidizer. C102 has been used as a disinfectant in the food and beverage industries, wastewater treatment, industrial water treatment, cleaning and disinfections of medical wastes, textile bleaching, odor control for the rendering industry, circuit board cleansing in the electronics industry, and uses in the oil and gas industry. It is an effective biocide at low concentrations and over a wide pH range. C102 is desirable because when it reacts with an organism, it reduces to chlorite ion and then to chloride, which studies to date have shown does not pose a significant adverse risk to human health. The use of chlorine, on the other hand, can result in the creation of chlorinated organic compounds when treating water. Chlorinated compounds are suspected to increase cancer risk.
[0025] The current method and apparatus involve deploying a C102 gas into a sealed area affected by odors and/or odor-causing microorganisms, such as bacteria. As an example, the current method is effective against bacteria of the Acidithiobacillus genus. However, the current method is not limited to this genus and will be effective against other odor causing bacteria as well.
[0026] The C102 gas fills the sealed, affected area. The C102 gas will then penetrate the affected building material, for example a wall. By penetrating the building material, the C102 gas is able to destroy the cause of odors on the surface, in the center and on the backside of the building material. The cause of the odor could be bacteria or a chemical, such as sulfur. Fig. 1 illustrates the penetration of the building material by the C102 gas of the current method.
[0027] The C102 gas remedies odors using a two-fold solution. First, the C102 gas reacts with the chemicals that are the source of the odor. As discussed above, affected drywall was found to emit sulfurous gases, namely (1) carbon disulfide, (2) carbonyl sulfide, and (3) hydrogen sulfide. C102 gas reacts with these chemicals to form benign compositions. This is one method of remedying the sulfuric "rotten egg" smell.
[0028] The C102 gas also kills microorganisms, such as bacteria, that produce the sulfuric odor-causing chemicals. Previously, the source of the sulfuric odor-causing chemical emissions was not known. The predominant view in the industry was that it was a chemical phenomenon, rather than a biological one. Applicants obtained affected drywall and tested it for the presence of bacteria. Applicants found such bacteria. Reducing the concentration of odor-causing bacteria further helps to neutralize the sulfuric "rotten egg" smell. The two-fold approach can provide better neutralization of the "rotten egg" smell and can also neutralize primary and composite metal corroding gases.
[0029] Specifically, applicants conducted a study of a home with defective drywall that was creating sulfur odors. A four inch by four inch sample of drywall was taken before C102 gas was deployed into the house. The house was sealed off. C102 gas was deployed into the home for four hours. Two days after the gas was deployed a second four inch by four inch sample of drywall was taken.
[0030] The pieces of drywall were sent to a lab for examination. At the lab, the drywall was tested using a real time PCR based assay to quantify and detect levels of DNA from the Acidithiobacillus genus. The assay is designed to specifically detect Acidithiobacillus ferrooxidans and Acidithiobacillus thiooxidans, two hydrogen sulfide producing bacteria. The assay will also detect two other bacteria reported to produce hydrogen sulfide, Acidithiobacillus albertenis and Acidithiobacillus caldus.
[0031] A positive result from the real time PCR assay provides strong evidence for the presence of the aforementioned organisms. The assay reports positive samples in Ct values - the cycle where the DNA signal crosses a defined threshold. If DNA from the target organism is present, the instrument will display a curved line that crosses this threshold, if no DNA is present, this line will remain flat and not report a Ct value for the sample. This number is based on the exponential amplification of the target DNA if present. There is an inverse relationship between the amount of DNA present and the Ct value obtained; thus, the smaller the Ct number, the larger the amount of DNA present in the analyzed sample.
[0032] Drywall or sheetrock was separated into paint (the front side of the drywall), paper (the back side of the drywall) and gypsum (the interior gypsum powder portion of the drywall) samples. The paint and paper samples were cut into approximately 5 mm x 5 mm sections using an isopropyl alcohol/flame sterilized razor blade. As much of the gypsum layer was removed from these samples as possible. The gypsum samples were cut in approximately 5 mm x 5mm x 5 mm cubes. The cut samples were transferred to a sterile, 1.5 ml non-stick eppendorf tube containing 100 ml of pTE and crushed/rendered with an isopropyl alcohol / flame sterilized steel rod. The tubes were then centrifuged at 14.5 kRPM for 2 minutes to pellet debris and the supernatants harvested. The harvested supernatants were then treated with a Wizard™ Genomic DNA vacuum extraction kit - protocol modified for gram-negative bacteria. The extractions were harvested in 200 μΐ extraction buffer and 2 μΐ of the extracted DNA was then analyzed.
[0033] DNA testing confirmed the existence of bacteria in the pre-treated drywall sample. Bacteria were detected on both surfaces and inside the drywall itself. The untreated sample also continued to emit odors. FIG. 2 shows the presence of Acidithiobacillus genus DNA in the paper, paint, and gypsum portions of the untreated sheetrock (orange, grey, and blue lines). The gypsum portion of the sheetrock (blue line) shows a very weak signal. The positive result of the assay indicates that a species of the Acidithiobacillus genus was present in the supplied sheetrock sample.
[0034] Conversely, the sample of treated drywall provided as a post treatment sample shows no positive detection of the Acidithiobacillus genus in the paper of the sheetrock but potentially a very low signal in the gypsum portion. These samples also no longer emitted odors. FIG. 3 provides some evidence that the chlorine dioxide gas treatment may have reduced the level of Acidithiobacillus below the sensitivity limit of the assay at least in the paper. Longer treatment time with the chlorine dioxide gas can better permeate the gypsum of the sheetrock and eliminate any signal from the gypsum.
[0035] Producing C102 gas for use in treatment processes is desirable because there is greater assurance of C102 purity when in the gas phase. Pure or substantially pure C102 is desirable because it allows the user to precisely maintain the amount of C102 added to the building material. (The single term "pure" will be used hereinafter to mean either pure or substantially pure.) If too little C102 is added the dosage will not be effective in killing odor- causing microorganisms. Addition of pure C102 allows the user to carefully monitor and adjust the amount of C102 added to the building materials. This enables the user to add adequate C102 to kill the odor-causing microorganisms.
[0036] Gaseous C102 is also desirable for the current method because of its easy application to large areas of affected building material. Gaseous C102 can be easily applied to a large area by sealing the room and generating the gas. This allows for treatment of furnishing and household contents, such as clothing, while treating the affected building material. Applicants also found that chlorine dioxide gas is able to penetrate the building materials. This allows for treatment of the surface, center and backside of the affected building material, such as a wall. Gaseous C102 also avoids leaving messy solid or liquid material to be cleaned up after treatment. Gaseous C102 is also desirable because it will not cause corrosion or destruction of primary and composite metals.
[0037] C102 is, however, unstable in the gas phase and will readily undergo decomposition into chlorine gas (Cl2), oxygen gas (02), and heat. The high reactivity of C102 generally requires that it be produced and used at the same location.
[0038] There are a number of methods of producing C102 gas which are known to persons familiar with the technology involved here. One or more of these methods can be used. Here are some exemplary methods of producing C102 gas. C102 gas can be produced using electrochemical cells and a sodium chlorite (C102 ~) or chlorate (CIO3 ) solution. An equipment based sodium chlorate/hydrogen peroxide method also exists. Alternatively, non- equipment based binary, multiple precursor dry or liquid precursor technologies can be used. Examples of non-equipment based methods of C102 generation include dry mix chlorine dioxide packets that include both a chlorite precursor packet and an acid activator packet. Other such processes include, but are not limited to, acidification of sodium chlorite, oxidation of chlorite by chlorine, oxidation of chlorite by persulfate, use of acetic anhydride on chlorite, use of sodium hypochlorite and sodium chlorite, use of dry chlorine/chlorite, reduction of chlorates by acidification in the presence of oxalic acid, reduction of chlorates by sulfur dioxide, and the ERCO R-2®, R-3®, R-5®, R-8®, R-10® and R-l l® processes, from which C102 is generated from NaC103 in the presence of NaCl and H2SO4 (R-2 and R-3 processes), from NaC103 in the presence of HCl (R-5 process), from NaC103 in the presence of H2SO4 and CH3OH (R-8 and R-10 processes), and from NaC103 in the presence of H202 and H2SC"4 (R-l 1 process).
[0039] Here, three methods will illustrate some possibilities. In the first method, chlorine reacts with water to form hypochlorous acid and hydrochloric acid. These acids then react with sodium chlorite to form chlorine dioxide, water and sodium chloride. In a second method, sodium hypochlorite is combined with hydrochloric or other acid to form hypochlorous acid. Sodium chlorite is then added to this reaction mixture to produce chlorine dioxide. The third method combines sodium chlorite and sufficient hydrochloric acid.
[0040] The current apparatus comprises a sealing area and a C102 generator. The C102 generator should also have an outlet for exhausting a C102 gas stream from the generator into the sealing area.
[0041] In one embodiment, the C102 generator has an input for electricity. There is also an inlet for at least one chlorine containing chemical. There are three different types of chemical feed systems: a vacuum system, a pressure system and a combination system. Many types of feed systems can be employed to deliver chemicals in a fluid state. Chlorine gas, for example, can be added by a vacuum or combination feed system.
[0042] In one embodiment the C102 generator is an electrochemical generator. The electrochemical generator comprises an anolyte loop and a catholyte loop. The purpose of the anolyte loop is to produce a chlorine dioxide (C102) gas by oxidation of chlorite or chlorate, and the process can be referred to as a C102 gas generator loop. The C102 gas generator loop is essentially a C102 gas source. Various sources of C102 are available and known in the water treatment field. The catholyte loop of the C102 gas generator loop produces sodium hydroxide and hydrogen gas by reduction of water. The process can be operated through a program logic control (PLC) system that can include displays.
[0043] Mobile equipment is ideal. This allows the equipment to be manufactured off site, shipped to the desired location, utilized and then removed. This provides ease in transportation, faster erection and commissioning. The C102 generator can be made in a mobile fashion. [0044] While particular elements, embodiments and applications of the present invention have been shown and described, it will be understood, of course, that the invention is not limited thereto since modifications can be made by those skilled in the art without departing from the scope of the present disclosure, particularly in light of the foregoing teachings.

Claims

CLAIMS What is claimed is:
1. A method of reducing odor-causing microorganism concentration in building materials, home furnishings and/or contents, the method comprising the steps of:
(a) producing C102 gas; and
(b) exposing said building materials, home furnishings and/or contents to said C102 gas
wherein said C102 gas kills substantially all odor-causing microorganisms in said building materials, home furnishings and/or contents to neutralize odor.
2. The method of claim 1 wherein said steps are performed sequentially.
3. The method of claim 1 wherein said C102 gas is generated by reacting chlorine gas with water and then adding sodium chlorite.
4. The method of claim 1 wherein said C102 gas is generated by reacting sodium hypochlorite with an acid and then adding sodium chlorite.
5. The method of claim 1 wherein said C102 gas is generated by reacting sodium chlorite and hydrochloric acid.
6. The method of claim 1 wherein said C102 gas is generated using an electrochemical cell and sodium chlorite.
7. The method of claim 1 wherein said C102 gas is generated using an electrochemical cell and sodium chlorate.
8. The method of claim 1 wherein said C102 gas is generated using an equipment-based sodium chlorate, acid and hydrogen peroxide method.
9. The method of claim 1 wherein said C102 is produced by reacting sodium chlorate, acid and hydrogen peroxide.
10. The method of claim 1 wherein said C102 is produced by dry mix chlorine dioxide packets having a chlorite precursor packet and an acid activator packet.
11. The method of claim 1 wherein said microorganisms are bacteria.
12. The method of claim 1 wherein said microorganisms also use starch and sulfur to produce at least one sulfurous gas.
13. The method of claim 12 wherein said at least one sulfurous gas is selected from the group comprising carbon disulfide, carbonyl sulfide, and hydrogen sulfide.
14. The method of claim 1 wherein said building material is drywall.
15. The method of claim 1 wherein said C102 gas penetrates said building material.
16. A method of reducing odor-causing molecule concentration in building materials, home furnishings and/or contents, the method comprising the steps of:
(a) producing C102 gas; and
(b) exposing said building materials, home furnishings and/or contents to said C102 gas
wherein said C102 gas reacts with said molecules to neutralize odor.
17. The method of claim 16 wherein said steps are performed sequentially.
18. The method of claim 16 wherein said C102 gas is generated by reacting chlorine gas with water and then adding sodium chlorite.
19. The method of claim 16 wherein said C102 gas is generated by reacting sodium hypochlorite with an acid and then adding sodium chlorite.
20. The method of claim 16 wherein said C102 gas is generated by reacting sodium chlorite and hydrochloric acid.
21. The method of claim 16 wherein said C102 gas is generated using an electrochemical cell and sodium chlorite.
22. The method of claim 16 wherein said C102 gas is generated using an electrochemical cell and sodium chlorate.
23. The method of claim 16 wherein said C102 gas is generated using an equipment-based sodium chlorate, acid and hydrogen peroxide method.
24. The method of claim 16 wherein said C102 is produced by reacting sodium chlorate, acid and hydrogen peroxide.
25. The method of claim 16 wherein said C102 is produced by dry mix chlorine dioxide packets having a chlorite precursor packet and an acid activator packet.
26. The method of claim 16 wherein said molecules contain sulfur.
27. The method of claim 26 wherein said molecules are selected from the group comprising carbon disulfide, carbonyl sulfide, and hydrogen sulfide.
28. The method of claim 16 wherein said molecules are produced by bacteria.
29. The method of claim 16 wherein said building material is drywall.
30. The method of claim 16 wherein said C102 gas penetrates said building materials, home furnishings and/or contents.
31. A method of reducing odor in building materials, home furnishings and/or contents, the method comprising the steps of:
(a) producing C102 gas; and
(b) exposing said building materials, home furnishings and/or contents to said C102 gas
wherein said C102 gas kills odor-causing microorganisms and reacts with odor- causing molecules to obtain improved odor neutralization.
32. The method of claim 31 wherein said microorganisms are bacteria.
33. The method of claim 31 wherein said molecules are selected from the group comprising carbon disulfide, carbonyl sulfide, and hydrogen sulfide.
34. The method of claim 31 wherein said building material is drywall.
35. The method of claim 31 wherein said C102 gas penetrates said building materials, home furnishings and/or contents.
36. An apparatus for reducing odor in building materials, home furnishings and/or contents, the apparatus comprising:
(a) a sealing area for sealing infected building materials, home furnishings and/or contents; and
(b) a C102 generator comprising an inlet for introducing at least one chlorine- containing feed chemical and an outlet for exhausting a C102 gas stream from said generator into said sealing area;
wherein introducing said C102 gas kills odor-causing microorganisms and reacts with odor-causing molecules to obtain improved odor neutralization.
37. The apparatus of claim 21 wherein said C102 generator is mobile.
38. A method of preventing corrosion of primary and composite metals in a building, the method comprising the steps of:
(a) producing C102 gas; and
(b) exposing said primary and composite metal to said C102 gas
wherein said C102 gas reacts with corrosive molecules to convert said corrosive molecules into benign molecules.
39. The method of claim 38 wherein said corrosive molecules are a gas.
40. The method of claim 38 wherein said corrosive molecules are selected from the group comprising carbon disulfide, carbonyl sulfide, and hydrogen sulfide.
PCT/US2010/054665 2009-10-30 2010-10-29 Apparatus and method for controlling odors and odor-causing microorganisms in building materials and preventing corrosion of primary and composite metals Ceased WO2011053765A1 (en)

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Citations (6)

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