Rock dusting compositions and methods of use thereof

1. A composition consisting essentially of rock dust, water, a pumping aid, and a polymer; wherein the composition has a water content and a polymer content sufficient to allow the polymer (i) to disperse water molecules within the composition and, upon drying of the composition, (ii) to dissipate forming void spaces in the dried composition; wherein the dried composition comprises agglomerated particles, said agglomerated particles comprising polymer chains having rock dust particles attached thereto; wherein the water content is from about 15 to about 40 percent by weight of the composition, and the polymer content is from about 0.001 to about 0.1 percent by weight of the composition; and wherein the pumping aid consists essentially of a surfactant or a gas incorporated into the composition; wherein the surfactant is present in an amount sufficient to make the composition pumpable and to disperse the polymer.

2. The composition of claim 1 wherein the void spaces comprise from about 3 to about 50 percent by volume of the composition.

3. The composition of claim 1 wherein the polymer is selected from the group consisting of acrylamide homopolymers, acrylamide copolymers, a combination of acrylamide homopolymers and acrylamide copolymers, and polymers that are starch ethers.

4. The composition of claim 1 wherein the rock dust is selected from the group consisting of ground limestone, Class F fly ash, Class C fly ash, silica fume, gypsum, anhydrite, expansive clays, non-expansive clays, fine ground mine tailings, and mixtures thereof.

5. The composition of claim 1 wherein the surfactant is selected from the group consisting of laurel ether sulfates, sulfates of fatty alcohol ethoxylates, sulfate esters of fatty alcohols, sulfates of fatty acids, sulfonates of fatty acids, ethoxylates of fatty acids, carboxylates of fatty acids, alkanolamides, alkanolamines, alkylaryl sulfonates, polyethylene oxide-polypropylene oxide block copolymers, alkylphenol ethoxylates, fluorocarbon containing surfactants, olefin sulfonates, olefin sulfates, hydrolyzed proteins, and mixtures thereof.

6. A foamed or aerated composition consisting essentially of rock dust, water, a pumping aid, and a polymer; wherein the water content is from about 15 to about 40 percent by weight of the composition, and the polymer content is from about 0.001 to about 0.1 percent by weight of the composition; and wherein the pumping aid consists essentially of a surfactant or a gas incorporated into the composition; wherein the surfactant is present in an amount sufficient to make the composition pumpable and to disperse the polymer.

7. A process for preparing a composition, said process comprising:

a) providing the composition according to claim 1 ; and

b) flocculating the composition under flocculation conditions sufficient to form agglomerated particles, said agglomerated particles comprising polymer chains having rock dust particles attached thereto.

8. A process for preparing the composition according to claim 1 , said process comprising:

a) mixing the rock dust and the water to give a first mixture;

b) mixing the pumping aid and the polymer to give a second mixture;

c) adding the second mixture to the first mixture to give said composition; and

d) optionally mixing with agitation the composition to give a foamed or aerated composition.

9. A process for forming the composition according to claim 1 on a surface, said process comprising:

a) mixing the rock dust and the water to give a first mixture;

b) mixing the pumping aid and the polymer to give a second mixture;

c) adding the second mixture to the first mixture to give said composition;

d) optionally mixing with agitation the composition to give a foamed or aerated composition;

d) applying the composition or foamed or aerated composition to the surface; and

e) allowing the composition or foamed or aerated composition to dry on the surface.

10. The process of claim 9 wherein the composition or foamed or aerated composition allowed to dry on the surface comprises agglomerated particles, said agglomerated particles comprising polymer chains having rock dust particles attached thereto.

11. A method of dusting coal mine surfaces, said method comprising:

a) providing the composition according to claim 1 ;

b) optionally mixing with agitation the composition to give a foamed or aerated composition;

c) applying the composition or foamed or aerated composition to a coal mine surface; and

d) allowing the composition or foamed or aerated composition to dry on the coal mine surface.

12. The method of claim 11 wherein the composition dried on the coal mine surface comprises agglomerated particles, said agglomerated particles comprising polymer chains having rock dust particles attached thereto.

13. The method of claim 11 wherein the composition or foamed or aerated composition dried on the coal mine surface has sufficient adherence to the coal mine surface that, upon ignition of coal dust and/or gas within a coal mine, a concussion from an explosion and/or fire causes at least a portion of the rock dust particles to detach from the polymer chains to produce a rock dust-air suspension.

14. The method of claim 13 wherein the rock dust-air suspension suppresses propagation of a flame and/or fire caused by ignition of coal dust and/or gas within the coal mine.

15. A method for suppressing propagation of a flame and/or fire caused by ignition of coal dust and/or gas within a coal mine, said method comprising:

a) providing the composition according to claim 1 ;

d) optionally mixing with agitation the composition to give a foamed or aerated composition;

b) applying the composition or foamed or aerated composition to a coal mine surface; and

c) allowing the composition or foamed or aerated composition to dry on the coal mine surface;

wherein said composition or foamed or aerated composition dried on the coal mine surface has sufficient adherence to the coal mine surface that, upon ignition of coal dust and/or gas within the coal mine, a concussion from an explosion and/or fire causes at least a portion of the rock dust to detach from the coal mine surface to produce a rock dust-air suspension that suppresses propagation of a flame and/or fire in the coal mine.

16. The method of claim 15 wherein the composition dried on the coal mine surface comprises agglomerated particles, said agglomerated particles comprising polymer chains having rock dust particles attached thereto.