CA2174185C - Organomineral paste and method of use as construction material - Google Patents
Organomineral paste and method of use as construction material Download PDFInfo
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- CA2174185C CA2174185C CA 2174185 CA2174185A CA2174185C CA 2174185 C CA2174185 C CA 2174185C CA 2174185 CA2174185 CA 2174185 CA 2174185 A CA2174185 A CA 2174185A CA 2174185 C CA2174185 C CA 2174185C
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- 239000004035 construction material Substances 0.000 title description 20
- 238000000034 method Methods 0.000 title description 8
- 239000000203 mixture Substances 0.000 claims abstract description 33
- MHAJPDPJQMAIIY-UHFFFAOYSA-N Hydrogen peroxide Chemical compound OO MHAJPDPJQMAIIY-UHFFFAOYSA-N 0.000 claims abstract description 28
- 239000011230 binding agent Substances 0.000 claims abstract description 18
- 235000008733 Citrus aurantifolia Nutrition 0.000 claims abstract description 14
- 235000011941 Tilia x europaea Nutrition 0.000 claims abstract description 14
- 239000004571 lime Substances 0.000 claims abstract description 14
- 239000000725 suspension Substances 0.000 claims abstract description 14
- 229920002678 cellulose Polymers 0.000 claims abstract description 11
- 239000001913 cellulose Substances 0.000 claims abstract description 11
- 239000007864 aqueous solution Substances 0.000 claims abstract description 9
- QAOWNCQODCNURD-UHFFFAOYSA-L Sulfate Chemical compound [O-]S([O-])(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-L 0.000 claims abstract description 4
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 20
- 229910000358 iron sulfate Inorganic materials 0.000 claims description 16
- BAUYGSIQEAFULO-UHFFFAOYSA-L iron(2+) sulfate (anhydrous) Chemical compound [Fe+2].[O-]S([O-])(=O)=O BAUYGSIQEAFULO-UHFFFAOYSA-L 0.000 claims description 14
- 239000002699 waste material Substances 0.000 claims description 14
- 239000010802 sludge Substances 0.000 claims description 10
- 229920003043 Cellulose fiber Polymers 0.000 claims description 9
- 239000004568 cement Substances 0.000 claims description 8
- 239000000463 material Substances 0.000 claims description 8
- OSGAYBCDTDRGGQ-UHFFFAOYSA-L calcium sulfate Chemical compound [Ca+2].[O-]S([O-])(=O)=O OSGAYBCDTDRGGQ-UHFFFAOYSA-L 0.000 claims description 6
- 239000010893 paper waste Substances 0.000 claims description 6
- PMZURENOXWZQFD-UHFFFAOYSA-L Sodium Sulfate Chemical compound [Na+].[Na+].[O-]S([O-])(=O)=O PMZURENOXWZQFD-UHFFFAOYSA-L 0.000 claims description 2
- DIZPMCHEQGEION-UHFFFAOYSA-H aluminium sulfate (anhydrous) Chemical compound [Al+3].[Al+3].[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O DIZPMCHEQGEION-UHFFFAOYSA-H 0.000 claims description 2
- BFNBIHQBYMNNAN-UHFFFAOYSA-N ammonium sulfate Chemical compound N.N.OS(O)(=O)=O BFNBIHQBYMNNAN-UHFFFAOYSA-N 0.000 claims description 2
- 229910052921 ammonium sulfate Inorganic materials 0.000 claims description 2
- 235000011130 ammonium sulphate Nutrition 0.000 claims description 2
- 235000011132 calcium sulphate Nutrition 0.000 claims description 2
- OTYBMLCTZGSZBG-UHFFFAOYSA-L potassium sulfate Chemical compound [K+].[K+].[O-]S([O-])(=O)=O OTYBMLCTZGSZBG-UHFFFAOYSA-L 0.000 claims description 2
- 229910052939 potassium sulfate Inorganic materials 0.000 claims description 2
- 235000011151 potassium sulphates Nutrition 0.000 claims description 2
- 229910052938 sodium sulfate Inorganic materials 0.000 claims description 2
- 235000011152 sodium sulphate Nutrition 0.000 claims description 2
- 238000010276 construction Methods 0.000 abstract 1
- 239000002956 ash Substances 0.000 description 18
- 239000000243 solution Substances 0.000 description 8
- 238000004519 manufacturing process Methods 0.000 description 7
- 239000011449 brick Substances 0.000 description 6
- 238000001035 drying Methods 0.000 description 5
- 238000000576 coating method Methods 0.000 description 3
- 239000004567 concrete Substances 0.000 description 3
- 238000010438 heat treatment Methods 0.000 description 3
- 238000009413 insulation Methods 0.000 description 3
- CWYNVVGOOAEACU-UHFFFAOYSA-N Fe2+ Chemical compound [Fe+2] CWYNVVGOOAEACU-UHFFFAOYSA-N 0.000 description 2
- 235000002918 Fraxinus excelsior Nutrition 0.000 description 2
- 239000000654 additive Substances 0.000 description 2
- -1 building blocks Substances 0.000 description 2
- ODINCKMPIJJUCX-UHFFFAOYSA-N calcium oxide Inorganic materials [Ca]=O ODINCKMPIJJUCX-UHFFFAOYSA-N 0.000 description 2
- 239000003795 chemical substances by application Substances 0.000 description 2
- 238000010411 cooking Methods 0.000 description 2
- 238000001704 evaporation Methods 0.000 description 2
- 230000008020 evaporation Effects 0.000 description 2
- HQKMJHAJHXVSDF-UHFFFAOYSA-L magnesium stearate Chemical compound [Mg+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O HQKMJHAJHXVSDF-UHFFFAOYSA-L 0.000 description 2
- 238000000465 moulding Methods 0.000 description 2
- 239000004014 plasticizer Substances 0.000 description 2
- 238000004537 pulping Methods 0.000 description 2
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 1
- 229920002134 Carboxymethyl cellulose Polymers 0.000 description 1
- VTLYFUHAOXGGBS-UHFFFAOYSA-N Fe3+ Chemical compound [Fe+3] VTLYFUHAOXGGBS-UHFFFAOYSA-N 0.000 description 1
- 229920000663 Hydroxyethyl cellulose Polymers 0.000 description 1
- 239000004354 Hydroxyethyl cellulose Substances 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 229910052791 calcium Inorganic materials 0.000 description 1
- AXCZMVOFGPJBDE-UHFFFAOYSA-L calcium dihydroxide Chemical compound [OH-].[OH-].[Ca+2] AXCZMVOFGPJBDE-UHFFFAOYSA-L 0.000 description 1
- BRPQOXSCLDDYGP-UHFFFAOYSA-N calcium oxide Chemical compound [O-2].[Ca+2] BRPQOXSCLDDYGP-UHFFFAOYSA-N 0.000 description 1
- 239000000292 calcium oxide Substances 0.000 description 1
- 235000013539 calcium stearate Nutrition 0.000 description 1
- 239000008116 calcium stearate Substances 0.000 description 1
- 239000001768 carboxy methyl cellulose Substances 0.000 description 1
- 235000010948 carboxy methyl cellulose Nutrition 0.000 description 1
- 239000008112 carboxymethyl-cellulose Substances 0.000 description 1
- 239000004927 clay Substances 0.000 description 1
- 239000003245 coal Substances 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 239000003086 colorant Substances 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000010440 gypsum Substances 0.000 description 1
- 229910052602 gypsum Inorganic materials 0.000 description 1
- 235000019447 hydroxyethyl cellulose Nutrition 0.000 description 1
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 description 1
- 235000019359 magnesium stearate Nutrition 0.000 description 1
- 229920000609 methyl cellulose Polymers 0.000 description 1
- 239000001923 methylcellulose Substances 0.000 description 1
- 235000010981 methylcellulose Nutrition 0.000 description 1
- 239000004570 mortar (masonry) Substances 0.000 description 1
- 239000000025 natural resin Substances 0.000 description 1
- 229920001296 polysiloxane Polymers 0.000 description 1
- 238000004064 recycling Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 150000003467 sulfuric acid derivatives Chemical class 0.000 description 1
- 229920003002 synthetic resin Polymers 0.000 description 1
- 239000000057 synthetic resin Substances 0.000 description 1
- 238000004078 waterproofing Methods 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B18/00—Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
- C04B18/04—Waste materials; Refuse
- C04B18/18—Waste materials; Refuse organic
- C04B18/24—Vegetable refuse, e.g. rice husks, maize-ear refuse; Cellulosic materials, e.g. paper, cork
- C04B18/241—Paper, e.g. waste paper; Paper pulp
- C04B18/243—Waste from paper processing or recycling paper, e.g. de-inking sludge
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
- C04B28/10—Lime cements or magnesium oxide cements
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
- C04B2111/00482—Coating or impregnation materials
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/20—Resistance against chemical, physical or biological attack
- C04B2111/28—Fire resistance, i.e. materials resistant to accidental fires or high temperatures
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
- Y02W30/00—Technologies for solid waste management
- Y02W30/50—Reuse, recycling or recovery technologies
- Y02W30/91—Use of waste materials as fillers for mortars or concrete
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Structural Engineering (AREA)
- Materials Engineering (AREA)
- Organic Chemistry (AREA)
- Inorganic Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Life Sciences & Earth Sciences (AREA)
- Sustainable Development (AREA)
- Environmental & Geological Engineering (AREA)
- Civil Engineering (AREA)
- Adhesives Or Adhesive Processes (AREA)
- Compositions Of Macromolecular Compounds (AREA)
- Curing Cements, Concrete, And Artificial Stone (AREA)
Abstract
An organomineral construction paste comprises a mixture of a suspension of cellulose, lime and an aqueous solution of a sulfate and hydrogen peroxide. Airborne ash and hydraulic binders may also be added to impart additional moldable properties to the paste.
Description
_1_ 2174185 ORGANOMINERAL PASTE AND METHOD OF USE
AS CONSTRUCTION MATERIAL
TECHNICAL FIELD
The invention relates to organomineral pastes as well as to methods of use of pastes as construction materials.
BACKGROUND OF THE INVENTION
There are numerous known construction materials based on hydraulic binders and more particularly cement, such as building blocks, concrete products, outside coatings, fire protection materials, and ground surface coverings.
However, all of these materials experience extensive shrinkage, which leads to the presence of cracks. This shrinkage is due to the evaporation of the water in the finished products.
Clay bricks, which are obtained by molding, are also known construction materials. Brick manufacture, however, entails a cooking step.
There is also a known process for recycling airborne ash which is also known as fluidized bed ashes from blast furnaces and heating stations, wherein the airborne ash is mixed with other construction materials in order to make road coverings, for example. However, compositions presently containing airborne ash cannot be used as 'construction material because they do not have the necessary mechanical properties such as strength.
Accordingly, a need remains for a construction material which utilizes recycled materials, does not show immediate signs of evaporation and which does not require cooking steps in manufacturing to produce.
DETAILED DESCRIPTION OF THE INVENTION
The invention is based on the use of waste, in particular waste coming from the manufacture of paper, for the manufacture of construction materials as diverse as bricks, building blocks, concrete products, outside coatings, fire protection materials and ground surface coverings.
The invention aims to overcome the previously described disadvantages by providing an organomineral paste that is characterized by the fact that it is obtained by mixing a suspension of cellulose fibers and/or cellulose waste and/or primary sludge from papermaking and/or wastepaper with a suspension of lime, to which mixture an aqueous solution of sulfate and hydrogen peroxide is added.
More precisely, the mixture includes approximately or about 1 part by weight of the cellulose fibers and/or cellulose waste and/or primary sludge from papermaking and/or wastepaper and between approximately 0.7 and 0.8 parts by weight of lime and between approximately 10 and 12 parts by weight of water. The aqueous solution is obtained by mixing approximately 1 part by weight of iron sulfate with between approximately 2.5 and 3 parts by weight of water and between approximately 0.6 and 0.7 parts by weight 130- volume [ ~ 33 wt%] hydrogen peroxide. Herein lime is intended to include both calcium oxide (Ca0), as well as Calcium Hydroxide ( Ca ( OH ) 2 ) .
According to one characteristic of the paste of the invention, the mixture is obtained by mixing 1 part by weight of primary sludge from papermaking with 0.75 parts A
AS CONSTRUCTION MATERIAL
TECHNICAL FIELD
The invention relates to organomineral pastes as well as to methods of use of pastes as construction materials.
BACKGROUND OF THE INVENTION
There are numerous known construction materials based on hydraulic binders and more particularly cement, such as building blocks, concrete products, outside coatings, fire protection materials, and ground surface coverings.
However, all of these materials experience extensive shrinkage, which leads to the presence of cracks. This shrinkage is due to the evaporation of the water in the finished products.
Clay bricks, which are obtained by molding, are also known construction materials. Brick manufacture, however, entails a cooking step.
There is also a known process for recycling airborne ash which is also known as fluidized bed ashes from blast furnaces and heating stations, wherein the airborne ash is mixed with other construction materials in order to make road coverings, for example. However, compositions presently containing airborne ash cannot be used as 'construction material because they do not have the necessary mechanical properties such as strength.
Accordingly, a need remains for a construction material which utilizes recycled materials, does not show immediate signs of evaporation and which does not require cooking steps in manufacturing to produce.
DETAILED DESCRIPTION OF THE INVENTION
The invention is based on the use of waste, in particular waste coming from the manufacture of paper, for the manufacture of construction materials as diverse as bricks, building blocks, concrete products, outside coatings, fire protection materials and ground surface coverings.
The invention aims to overcome the previously described disadvantages by providing an organomineral paste that is characterized by the fact that it is obtained by mixing a suspension of cellulose fibers and/or cellulose waste and/or primary sludge from papermaking and/or wastepaper with a suspension of lime, to which mixture an aqueous solution of sulfate and hydrogen peroxide is added.
More precisely, the mixture includes approximately or about 1 part by weight of the cellulose fibers and/or cellulose waste and/or primary sludge from papermaking and/or wastepaper and between approximately 0.7 and 0.8 parts by weight of lime and between approximately 10 and 12 parts by weight of water. The aqueous solution is obtained by mixing approximately 1 part by weight of iron sulfate with between approximately 2.5 and 3 parts by weight of water and between approximately 0.6 and 0.7 parts by weight 130- volume [ ~ 33 wt%] hydrogen peroxide. Herein lime is intended to include both calcium oxide (Ca0), as well as Calcium Hydroxide ( Ca ( OH ) 2 ) .
According to one characteristic of the paste of the invention, the mixture is obtained by mixing 1 part by weight of primary sludge from papermaking with 0.75 parts A
by weight of lime and 11 parts by weight of water. The aqueous solution is obtained by the mixing of 1 part by weight of iron sulfate with 2.7 parts by weight of water and 0.65 parts by weight of 130-volume hydrogen peroxide.
According to another characteristic of the paste of the invention, the weight ratio of the mixture to the solution is between 7:1 and 8:1. More precisely, the weight ratio of the mixture to the solution is 7.65:1.
The paste of the invention can also contain airborne ash and a hydraulic binder. In this case it is comprised of a mixture of approximately 1 part by weight of actual paste with between approximately 0.9 and 1.3 parts airborne ash and between approximately 0.01 and 0.02 parts by weight hydraulic binder.
A preferred paste contains 1 part by weight of actual paste, 1.1 parts by weight of airborne ash, and 0.01 parts by weight hydraulic binder. The preferred hydraulic binder of the invention is cement.
The use of the paste in the manufacturing of a construction material is also an object of the invention.
In effect, it has been found that a suspension of cellulose fibers, cellulose waste and waste from the primary sludge of the papermaking process or wastepaper disposal process, in water, to which a suspension of lime and a solution of iron sulfate and hydrogen peroxide are added, allows one to obtain a homogeneous organomineral paste that can be used in the manufacture of a construction material with thermal insulation, sound insulation, and fire resistance properties.
The organomineral paste of the invention is obtained by a process which includes two steps:
1. pulping of the waste by mixing of approximately 1 part by weight cellulose fibers and/or cellulose waste and/or primary sludge from papermaking and/or wastepaper with between approximately 0.7 and 0.8 parts by weight of ~.: Zo4~a5 lime and between approximately 10 and 11 parts by weight of water, and 2. mixing of the pulped waste obtained in the preceding step with a solution obtained by mixing of approximately 1 part by weight of iron sulfate with between approximately 2.5 and 3 parts by weight of water and between approximately 0.6 and 0.7 parts by weight of 130-volume hydrogen peroxide.
Preferably, in the first step 1 part by weight of the suspension of cellulose fibers and/or cellulose waste and/or primary sludge from papermaking and/or wastepaper is mixed with 0.75 parts by weight of lime and 11 parts by weight of water. The solution used in the second step is obtained by mixing approximately 1 part by weight of iron sulfate with approximately 2.7 parts by weight of water and approximately 0.65 parts by weight of 130-volume hydrogen peroxide.
In the second step approximately 7 and 8 parts by weight of the mixture obtained in the first step is mixed with approximately 1 part by weight of the solution of iron sulfate described in the second step. Preferably, 7.66 parts by weight of the mixture obtained in the first step is mixed with 1 part by weight of the solution of iron sulfate described in the secornl step.
In a preferred embodiment of the invention, primary sludge is used from the papermaking process rather than cellulose fibers and/or cellulose waste because, in this case, the use of large pulpers for pulping this waste can be avoided, and it is sufficient to use a conventional mixer. However, the paste obtained cannot be used as construction material because it is difficult to mold, for example, in the form of bricks or building blocks, and because it contains a large quantity of water and must therefore be dried with heat. Furthermore, when dried, the paste of the invention requires excessive shrinkage for it to be usable.
In order to avoid the problem of shrinkage, and still obtain a construction material that can be sprayed or floated, with good mechanical properties, the organomineral paste according to the invention is used in a mixture with a hydraulic binder such as cement.
In order to obtain a product which can be molded in the form of bricks, building blocks, or curbstones or any moldable concrete product, waste which one generally wishes to recycle, such as airborne ash, is added to the paste according to the invention with the hydraulic binder. Such ash may come from blast furnaces and/or from heating stations. The airborne ash acts as a liquefier and plasticizer and gives the composition of the invention, properties of molding ability which are due to the airborne ash. Due to the low density of the paste of the invention, resulting from its inclusion of modified cellulose fibers, the product obtained has excellent sound and heat insulation and fire resistance properties.
Surprisingly, it has been discovered that a very small quantity of hydraulic binder, on the order of approximately 5% by weight of the total composition, is sufficient to give the final construction material obtained from the paste of the invention suffici2-nt mechanical properties so that it can be used as it is. Obviously, greater quantities of hydraulic binder may be used as desired.
Furthermore, with 5% by weight hydraulic binder, the shrinkage after 7 days of drying is less than 200 ~m per meter. This result compares with a shrinkage of greater than 1,000 ~m per meter in the case of mortars, and up to 4,000 ~Cm per meter in the case of a microconcrete after 7 days of drying.
Tests of mechanical strength performed on construction materials obtained by simple drying of the paste of the invention in open air show that there is a noncleavage fracture which allows the construction material to be used in seismic risk zones.
The construction material obtained from the composition according to the invention retains all of its properties when the composition is obtained by mixing of approximately 1 part by weight of the cellulose paste with between approximately 0.9 and 1.3 parts by weight of airborne ash and between approximately 0.02 and 0.01 parts by weight of cement. A preferred composition is, however, obtained by mixing 1 part by weight of the cellulose paste with 1.1 parts by weight of airborne ash and 0.01 parts by weight of cement.
The airborne ash can be replaced by pozzolana or any other equivalent material. However, a preferred composition includes airborne ash from coal heating stations known as "fluidized bed ashes."
Additionally, other sulfates may be used instead of iron sulfate, including aluminum sulfate, potassium sulfate, sodium sulfate, calcium sulfate, and ammonium sulfate .
Various additives known in the field of construction materials can be added to the composition of the invention such as coloring agents . White cement can be used as a hydraulic binder in order to give the desired color to the final material.
The invention will now be described by means of a preferred example of the composition according to the invention, which is given only for the sake of illustration and not for limiting the invention.
Example.
300 kg primary sludge from papermaking is mixed with 225 kg lime and 3,300 kg water. The mixture is stirred to keep the cellulose fibers from settling; mixed with a solution composed of 115 kg ferrous iron sulfate, 310 kg _7_ water, and 75 kg 130-volume hydrogen peroxide. The hydrogen peroxide transforms the ferrous iron sulfate into ferric iron sulfate.
The resultant organomineral paste is homogenous and contains a high water weight. The presence of this high water weight provides the advantage of not requiring the addition of more water during the manufacture of the actual construction material, i.e. the addition of the hydraulic binder and of the airborne ash.
In order to obtain a construction material according to the invention, one mixes the cellulose paste obtained above with 2,162 kg fluidized bed ash and 217 kg cement.
A composition is obtained which can be molded in any form, such as bricks, curbstones, etc., with a very low degree of shrinkage with drying. Drying can advantageously be natural, done in the air at ambient temperature and pressure. The resultant material exhibits good thermal conductivity, good compressive, tensile strength, and has a low density. This composition can also be used as a coating, which can be sprayed or floated. It can contain a water-retaining substance such as methylcellulose, hydroxyethylcellulose, and carboxymethylcellulose, a waterproofing agent such as silicone, a calcium or magnesium stearate, or any other additive for the purpose of giving other particular properties to the composition of the invention, as are known in the field, such as gypsum, calcium sulfate, a ~ natural or synthetic resin, a plasticizer, or an air entraining agent.
According to another characteristic of the paste of the invention, the weight ratio of the mixture to the solution is between 7:1 and 8:1. More precisely, the weight ratio of the mixture to the solution is 7.65:1.
The paste of the invention can also contain airborne ash and a hydraulic binder. In this case it is comprised of a mixture of approximately 1 part by weight of actual paste with between approximately 0.9 and 1.3 parts airborne ash and between approximately 0.01 and 0.02 parts by weight hydraulic binder.
A preferred paste contains 1 part by weight of actual paste, 1.1 parts by weight of airborne ash, and 0.01 parts by weight hydraulic binder. The preferred hydraulic binder of the invention is cement.
The use of the paste in the manufacturing of a construction material is also an object of the invention.
In effect, it has been found that a suspension of cellulose fibers, cellulose waste and waste from the primary sludge of the papermaking process or wastepaper disposal process, in water, to which a suspension of lime and a solution of iron sulfate and hydrogen peroxide are added, allows one to obtain a homogeneous organomineral paste that can be used in the manufacture of a construction material with thermal insulation, sound insulation, and fire resistance properties.
The organomineral paste of the invention is obtained by a process which includes two steps:
1. pulping of the waste by mixing of approximately 1 part by weight cellulose fibers and/or cellulose waste and/or primary sludge from papermaking and/or wastepaper with between approximately 0.7 and 0.8 parts by weight of ~.: Zo4~a5 lime and between approximately 10 and 11 parts by weight of water, and 2. mixing of the pulped waste obtained in the preceding step with a solution obtained by mixing of approximately 1 part by weight of iron sulfate with between approximately 2.5 and 3 parts by weight of water and between approximately 0.6 and 0.7 parts by weight of 130-volume hydrogen peroxide.
Preferably, in the first step 1 part by weight of the suspension of cellulose fibers and/or cellulose waste and/or primary sludge from papermaking and/or wastepaper is mixed with 0.75 parts by weight of lime and 11 parts by weight of water. The solution used in the second step is obtained by mixing approximately 1 part by weight of iron sulfate with approximately 2.7 parts by weight of water and approximately 0.65 parts by weight of 130-volume hydrogen peroxide.
In the second step approximately 7 and 8 parts by weight of the mixture obtained in the first step is mixed with approximately 1 part by weight of the solution of iron sulfate described in the second step. Preferably, 7.66 parts by weight of the mixture obtained in the first step is mixed with 1 part by weight of the solution of iron sulfate described in the secornl step.
In a preferred embodiment of the invention, primary sludge is used from the papermaking process rather than cellulose fibers and/or cellulose waste because, in this case, the use of large pulpers for pulping this waste can be avoided, and it is sufficient to use a conventional mixer. However, the paste obtained cannot be used as construction material because it is difficult to mold, for example, in the form of bricks or building blocks, and because it contains a large quantity of water and must therefore be dried with heat. Furthermore, when dried, the paste of the invention requires excessive shrinkage for it to be usable.
In order to avoid the problem of shrinkage, and still obtain a construction material that can be sprayed or floated, with good mechanical properties, the organomineral paste according to the invention is used in a mixture with a hydraulic binder such as cement.
In order to obtain a product which can be molded in the form of bricks, building blocks, or curbstones or any moldable concrete product, waste which one generally wishes to recycle, such as airborne ash, is added to the paste according to the invention with the hydraulic binder. Such ash may come from blast furnaces and/or from heating stations. The airborne ash acts as a liquefier and plasticizer and gives the composition of the invention, properties of molding ability which are due to the airborne ash. Due to the low density of the paste of the invention, resulting from its inclusion of modified cellulose fibers, the product obtained has excellent sound and heat insulation and fire resistance properties.
Surprisingly, it has been discovered that a very small quantity of hydraulic binder, on the order of approximately 5% by weight of the total composition, is sufficient to give the final construction material obtained from the paste of the invention suffici2-nt mechanical properties so that it can be used as it is. Obviously, greater quantities of hydraulic binder may be used as desired.
Furthermore, with 5% by weight hydraulic binder, the shrinkage after 7 days of drying is less than 200 ~m per meter. This result compares with a shrinkage of greater than 1,000 ~m per meter in the case of mortars, and up to 4,000 ~Cm per meter in the case of a microconcrete after 7 days of drying.
Tests of mechanical strength performed on construction materials obtained by simple drying of the paste of the invention in open air show that there is a noncleavage fracture which allows the construction material to be used in seismic risk zones.
The construction material obtained from the composition according to the invention retains all of its properties when the composition is obtained by mixing of approximately 1 part by weight of the cellulose paste with between approximately 0.9 and 1.3 parts by weight of airborne ash and between approximately 0.02 and 0.01 parts by weight of cement. A preferred composition is, however, obtained by mixing 1 part by weight of the cellulose paste with 1.1 parts by weight of airborne ash and 0.01 parts by weight of cement.
The airborne ash can be replaced by pozzolana or any other equivalent material. However, a preferred composition includes airborne ash from coal heating stations known as "fluidized bed ashes."
Additionally, other sulfates may be used instead of iron sulfate, including aluminum sulfate, potassium sulfate, sodium sulfate, calcium sulfate, and ammonium sulfate .
Various additives known in the field of construction materials can be added to the composition of the invention such as coloring agents . White cement can be used as a hydraulic binder in order to give the desired color to the final material.
The invention will now be described by means of a preferred example of the composition according to the invention, which is given only for the sake of illustration and not for limiting the invention.
Example.
300 kg primary sludge from papermaking is mixed with 225 kg lime and 3,300 kg water. The mixture is stirred to keep the cellulose fibers from settling; mixed with a solution composed of 115 kg ferrous iron sulfate, 310 kg _7_ water, and 75 kg 130-volume hydrogen peroxide. The hydrogen peroxide transforms the ferrous iron sulfate into ferric iron sulfate.
The resultant organomineral paste is homogenous and contains a high water weight. The presence of this high water weight provides the advantage of not requiring the addition of more water during the manufacture of the actual construction material, i.e. the addition of the hydraulic binder and of the airborne ash.
In order to obtain a construction material according to the invention, one mixes the cellulose paste obtained above with 2,162 kg fluidized bed ash and 217 kg cement.
A composition is obtained which can be molded in any form, such as bricks, curbstones, etc., with a very low degree of shrinkage with drying. Drying can advantageously be natural, done in the air at ambient temperature and pressure. The resultant material exhibits good thermal conductivity, good compressive, tensile strength, and has a low density. This composition can also be used as a coating, which can be sprayed or floated. It can contain a water-retaining substance such as methylcellulose, hydroxyethylcellulose, and carboxymethylcellulose, a waterproofing agent such as silicone, a calcium or magnesium stearate, or any other additive for the purpose of giving other particular properties to the composition of the invention, as are known in the field, such as gypsum, calcium sulfate, a ~ natural or synthetic resin, a plasticizer, or an air entraining agent.
Claims (11)
1. An organomineral paste comprising a mixture of a first suspension of materials selected from the group consisting of cellulose fibers, cellulose waste, primary sludge from papermaking and wastepaper, a second suspension of lime, an aqueous solution of a sulfate selected from the group consisting of iron sulfate, aluminum sulfate, calcium sulfate, sodium sulfate, potassium sulfate and ammonium sulfate and hydrogen peroxide.
2. The paste as claimed in claim 1, wherein said sulfate is iron sulfate.
3. The paste as claimed in claim 2, wherein said hydrogen peroxide is 130-volume hydrogen peroxide.
4. The paste as claimed in claim 3, wherein said first suspension is present in about 1 part by weight, said suspension of lime includes between about 0.7 and 0.8 parts by weight of lime and between about 10 and 12 parts by weight of water, said aqueous solution of iron sulfate includes about 1 part by weight of iron sulfate and between about 2.5 and 3 parts by weight of water and said 130-volume hydrogen peroxide is present between about 0.6 and 0.7 parts by weight.
5. The paste as claimed in claim 4, wherein said first suspension includes about 1 part by weight primary sludge from papermaking, said suspension of lime includes about 0.75 parts by weight of lime and about 11 parts by weight of water, said aqueous solution of iron sulfate includes about 1 part by weight of iron sulfate and about 2.7 parts by weight of water and said hydrogen peroxide is present in about 0.65 parts by weight.
6. The paste as claimed in claim 1 wherein the weight ratio of said first suspension to said aqueous solution is in the range of about 7:1 and 8:1.
7. The paste as claimed in claim 6 wherein the weight ratio of said first suspension to said aqueous solution is about 7.65:1.
8. A paste mixture comprising a mixture of said paste as claimed in claim 1, airborne ash and a hydraulic binder.
9. The paste mixture as claimed in claim 8 wherein said paste, said airborne ash and said hydraulic binder are present in a mixture of about 1 part by weight of said paste in said paste mixture, about 1 and 1.3 parts by weight of airborne ash in said paste mixture and about 0.01 and 0.02 parts by weight of hydraulic binder in said paste mixture.
10. The paste mixture as claimed in claim 9 wherein said airborne ash is present in about 1.1 parts by weight and said hydraulic binder is present in about 0.01 parts by weight.
11. The paste mixture as claimed in claim 8, 9 or 10 wherein said hydraulic binder is cement.
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| FR9509584A FR2737719B1 (en) | 1995-08-07 | 1995-08-07 | ORGANO-MINERAL PASTE AND USE THEREOF AS A CONSTRUCTION MATERIAL |
| FR9509584 | 1995-08-07 | ||
| US08/574,035 | 1995-12-18 | ||
| US08/574,035 US5538553A (en) | 1995-12-18 | 1995-12-18 | Organomineral paste and method of use as construction material |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2174185A1 CA2174185A1 (en) | 1997-02-08 |
| CA2174185C true CA2174185C (en) | 2001-01-02 |
Family
ID=26232151
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2174185 Expired - Fee Related CA2174185C (en) | 1995-08-07 | 1996-04-15 | Organomineral paste and method of use as construction material |
Country Status (3)
| Country | Link |
|---|---|
| AU (1) | AU6506496A (en) |
| CA (1) | CA2174185C (en) |
| WO (1) | WO1997007301A2 (en) |
Families Citing this family (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN110744046B (en) * | 2019-09-26 | 2021-12-21 | 黄川南 | Metal grouting and grouting formed faucet liner and manufacturing method thereof |
| CN110963777A (en) * | 2019-12-28 | 2020-04-07 | 陕西凝远新材料科技股份有限公司 | Autoclaved aerated concrete block produced by dry soil silt and preparation method thereof |
Family Cites Families (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4406703A (en) * | 1980-02-04 | 1983-09-27 | Permawood International Corporation | Composite materials made from plant fibers bonded with portland cement and method of producing same |
| DE3608544C1 (en) * | 1986-03-14 | 1987-04-09 | Redco Nv | Lightweight insulation panels and methods of making the same |
| US5350451A (en) * | 1991-07-08 | 1994-09-27 | Patterson Eric W | Building material made from waste paper and method for producing the same |
| DE4141271C1 (en) * | 1991-12-14 | 1992-11-05 | Sicowa Verfahrenstech | |
| US5346549A (en) * | 1992-10-23 | 1994-09-13 | Johnson William B | Environmentally stabilized products formed from ash and papermill waste |
| US5500044A (en) * | 1993-10-15 | 1996-03-19 | Greengrove Corporation | Process for forming aggregate; and product |
-
1996
- 1996-04-15 CA CA 2174185 patent/CA2174185C/en not_active Expired - Fee Related
- 1996-07-23 WO PCT/US1996/012058 patent/WO1997007301A2/en not_active Ceased
- 1996-07-23 AU AU65064/96A patent/AU6506496A/en not_active Abandoned
Also Published As
| Publication number | Publication date |
|---|---|
| AU6506496A (en) | 1997-03-12 |
| WO1997007301A3 (en) | 1997-04-10 |
| CA2174185A1 (en) | 1997-02-08 |
| WO1997007301A2 (en) | 1997-02-27 |
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| EEER | Examination request | ||
| MKLA | Lapsed |