AU2017101329A4

AU2017101329A4 - Frx – environmentally sustainable value-added manufactured sand from carbonate rich desert sand for construction and other applications

Info

Publication number: AU2017101329A4
Application number: AU2017101329A
Authority: AU
Inventors: Peter Anil Rodricks
Original assignee: Rodricks Peter
Current assignee: Rodricks Peter
Priority date: 2017-10-01
Filing date: 2017-10-01
Publication date: 2017-11-09
Anticipated expiration: 2025-10-01

Abstract

A method for the production of value added fine aggregate composed principally of Silica and high purity Lime (CaO) from carbonate rich coastal desert sand through calcination process in rotary kiln; key applications of resulting product named FRX Sand, an environmentally advantageous alternative for sand-dependent construction activities including bricks and blocks production in conjunction with fly ash with C02 recovery and sequestration, low-cement construction plaster and raw material alternative to natural sands and quarry sourced silica and lime for the cement industry.

Description

FRX - ENVIRONMENTALLY SUSTAINABLE VALUE-ADDED MANUFACTURED SAND FROM CARBONATE RICH DESERT SAND FOR CONSTRUCTION AND OTHER APPLICATIONS BACKGROUND OF INVENTION: [0001] There is an acute global shortage of sand for construction purposes leading to widespread environmental degradation and illegal exploitation of natural river and marine sands. Directly related is the large volumes of fresh water used to process these sands prior to their use in construction to cleanse them of silt and salts. The continued widespread use of fired clay bricks and construction forms also results in the loss of topsoil and increased C02 emissions. This invention aims to mitigate these problems through the use of alternative and waste materials.

[0002] Consistent with the geology of coastal deserts, sands can contain high concentrations of Calcium Carbonate in the form of sedimentary sandstone. These carbonate rich sands are both abundant and logistically accessible without the extensive infrastructure associated with mining and quarrying and can be processed through existing technology widely used in the cement industry. This geological phenomenon is therefore a key basis for this invention.

[0003] Fly Ash from thermal power plants continues to be produced globally as a waste product in enormous quantities, about half of which are not recycled. International Energy Agency forecasts indicate that thermal power will remain a significant source of electricity by 2030 - thus the need for fly ash recycling will continue well into the future.

[0004] This invention will enable governments and the construction industry develop a sustainable alternative to river and marine sands with significant environmental benefits. Possible applications include aggregate, cement, bricks & blocks, plaster and liquid C02 commercialisation. Much of the research has centered on the Middle-East where carbonate rich desert sand, key production inputs and commercial potential are optimal for production projects. DESCRIPTION: FRX SAND: [0005] This invention relates to the manufacturing method employed to convert carbonate rich coastal desert sands into a value-added material named FRX Sand for the construction industry, fly-ash brick and block industry thereby mitigating waste fly ash from thermal power plants, Cement manufacture, production of construction plaster and C02 recovery and sequestration. FRX is composed of Silica, high purity Lime (CaO) and minor trace elements.

[0006] Cement manufacture: Partial replacement of river and marine Silica sand and quarried Lime in production process [0007] Plaster: Production of construction plaster by mixture of a high percentage of FRX Sand with Portland cement at a 5:1 ratio. The high purity of finely divided Lime in FRX Sand enables the production of low cement plasters in a simple and efficient process.

[0008] Fly Ash Bricks & Blocks: FRX Sand utilization as value added fine aggregate with high purity Lime to reduce use of natural sands, crushed quarry rock and quarried Lime.

These alternatives reduce the use of fired clay and concrete products.

[0009] Zero Emission Integrated FRX and Fly Ash Bricks & Blocks Manufacture Process: Harness the synergies of FRX Sand production and Fly Ash Bricks & Blocks production to recover heat for the Autoclave curing process and produce liquid C02 from LNG/LPG combustion in kiln and from calcination process for commercial purposes - in particular, for Enhanced Oil Recovery (EOR) and thereby, C02 sequestration. FRX MANUFACTURE METHOD: [0010] FRX Sand is produced by the calibrated calcination of carbonate-rich desert sand in a Rotary kiln to achieve -99.9% calcination of Calcium Carbonate (CaC03) to Lime (CaO). Said production method leaves the produced material without sintering or agglomeration effects. FRX Sand retains the original finely divided state of raw desert sand, eliminating additional crushing processes enabling immediate on-site utilization or transportation. It is also possible to customise the proportion of Lime and Calcium Carbonate in resulting FRX product by variations of temperature and residence times in the rotary kiln.

[0011] Detailed Process: Thermogravimetric analysis (TGA) of desert sand to determine physical conditions of calcination followed by calcination in rotary kiln set at 4-5 RPM. Complete conversion of the calcium carbonate content of the sand is achieved at 900 °C in a one (1) hour residence time.

Claims

1. Method of manufacture of FRX Sand composed principally of Silica and high purity Lime (CaO) from carbonate rich desert sand through described calcination process. Said process includes variations in calcination temperature ranges and resident times to achieve different formulations of Silica, Calcium Carbonate and Calcium Oxide.

2. The method according to Claim 1 and Fig 4 integrating the production of FRX Sand and Fly Ash Bricks and Blocks while recovering waste heat and C02 from the FRX calcination process to generate steam for the Autoclave curing process and production of liquid C02 through an integrated liquid C02 plant utilizing the waste C02 from combustion of LPG/LNG and the calcination process, said Integration method delivering Zero C02 Emission production.

3. According to Claim 1, milled or processed variations of FRX as a raw material and/or supplement in the manufacture of Cement as an alternative to Silica and quarry sourced Lime CaO

4. According to Claim 1, the method of production of FRX construction plaster combining the major proportion of FRX sand with Portland cement and/or other cementitious materials to create a single combined plaster product