CA2236486A1 - Production of commercially useful materials from waste gypsum boards - Google Patents
Production of commercially useful materials from waste gypsum boards Download PDFInfo
- Publication number
- CA2236486A1 CA2236486A1 CA 2236486 CA2236486A CA2236486A1 CA 2236486 A1 CA2236486 A1 CA 2236486A1 CA 2236486 CA2236486 CA 2236486 CA 2236486 A CA2236486 A CA 2236486A CA 2236486 A1 CA2236486 A1 CA 2236486A1
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- Canada
- Prior art keywords
- product obtained
- waste
- gyproc
- boards
- additive
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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- 239000000463 material Substances 0.000 title claims abstract description 29
- 239000002699 waste material Substances 0.000 title claims abstract description 25
- 238000004519 manufacturing process Methods 0.000 title description 2
- 229910052602 gypsum Inorganic materials 0.000 title 1
- 239000010440 gypsum Substances 0.000 title 1
- 239000002245 particle Substances 0.000 claims abstract description 32
- 238000000034 method Methods 0.000 claims abstract description 30
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 27
- 239000002250 absorbent Substances 0.000 claims abstract description 14
- 230000002745 absorbent Effects 0.000 claims abstract description 14
- 238000010521 absorption reaction Methods 0.000 claims abstract description 9
- 239000000945 filler Substances 0.000 claims abstract description 8
- ZOMBKNNSYQHRCA-UHFFFAOYSA-J calcium sulfate hemihydrate Chemical compound O.[Ca+2].[Ca+2].[O-]S([O-])(=O)=O.[O-]S([O-])(=O)=O ZOMBKNNSYQHRCA-UHFFFAOYSA-J 0.000 claims abstract description 6
- 238000001035 drying Methods 0.000 claims abstract description 6
- 238000010438 heat treatment Methods 0.000 claims abstract description 6
- 239000011248 coating agent Substances 0.000 claims abstract description 4
- 238000000576 coating method Methods 0.000 claims abstract description 4
- 238000000227 grinding Methods 0.000 claims abstract description 3
- OSGAYBCDTDRGGQ-UHFFFAOYSA-L calcium sulfate Chemical compound [Ca+2].[O-]S([O-])(=O)=O OSGAYBCDTDRGGQ-UHFFFAOYSA-L 0.000 claims description 26
- 239000002893 slag Substances 0.000 claims description 22
- 239000011507 gypsum plaster Substances 0.000 claims description 16
- 239000000654 additive Substances 0.000 claims description 11
- 239000000835 fiber Substances 0.000 claims description 8
- 229920003043 Cellulose fiber Polymers 0.000 claims description 3
- 239000002023 wood Substances 0.000 claims description 3
- 229920001131 Pulp (paper) Polymers 0.000 claims description 2
- 239000002154 agricultural waste Substances 0.000 claims description 2
- 239000003610 charcoal Substances 0.000 claims description 2
- 239000003086 colorant Substances 0.000 claims description 2
- 239000000417 fungicide Substances 0.000 claims description 2
- 229910052500 inorganic mineral Inorganic materials 0.000 claims description 2
- 239000011707 mineral Substances 0.000 claims description 2
- 239000003415 peat Substances 0.000 claims description 2
- 239000004753 textile Substances 0.000 claims description 2
- 230000000996 additive effect Effects 0.000 claims 10
- 238000007580 dry-mixing Methods 0.000 claims 6
- 239000004033 plastic Substances 0.000 claims 1
- 241001465754 Metazoa Species 0.000 abstract description 12
- 239000000853 adhesive Substances 0.000 abstract description 4
- 239000000126 substance Substances 0.000 abstract description 4
- PASHVRUKOFIRIK-UHFFFAOYSA-L calcium sulfate dihydrate Chemical compound O.O.[Ca+2].[O-]S([O-])(=O)=O PASHVRUKOFIRIK-UHFFFAOYSA-L 0.000 abstract description 3
- 239000004593 Epoxy Substances 0.000 abstract description 2
- 241000282326 Felis catus Species 0.000 abstract description 2
- 239000011398 Portland cement Substances 0.000 abstract description 2
- 230000001070 adhesive effect Effects 0.000 abstract description 2
- 239000000969 carrier Substances 0.000 abstract description 2
- 239000004519 grease Substances 0.000 abstract description 2
- 239000004009 herbicide Substances 0.000 abstract description 2
- 239000003921 oil Substances 0.000 abstract description 2
- 239000000575 pesticide Substances 0.000 abstract description 2
- 229920000728 polyester Polymers 0.000 abstract description 2
- 239000000047 product Substances 0.000 description 11
- 229940095672 calcium sulfate Drugs 0.000 description 10
- 239000008187 granular material Substances 0.000 description 9
- 239000012467 final product Substances 0.000 description 6
- 230000015556 catabolic process Effects 0.000 description 3
- 238000006731 degradation reaction Methods 0.000 description 3
- 239000000203 mixture Substances 0.000 description 3
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 238000007493 shaping process Methods 0.000 description 2
- 235000017060 Arachis glabrata Nutrition 0.000 description 1
- 244000105624 Arachis hypogaea Species 0.000 description 1
- 235000010777 Arachis hypogaea Nutrition 0.000 description 1
- 235000018262 Arachis monticola Nutrition 0.000 description 1
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 1
- 240000008042 Zea mays Species 0.000 description 1
- 235000005824 Zea mays ssp. parviglumis Nutrition 0.000 description 1
- 235000002017 Zea mays subsp mays Nutrition 0.000 description 1
- 239000011358 absorbing material Substances 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- 229940095564 anhydrous calcium sulfate Drugs 0.000 description 1
- 239000011805 ball Substances 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
- ODINCKMPIJJUCX-UHFFFAOYSA-N calcium oxide Inorganic materials [Ca]=O ODINCKMPIJJUCX-UHFFFAOYSA-N 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 235000005822 corn Nutrition 0.000 description 1
- 238000002425 crystallisation Methods 0.000 description 1
- 230000008025 crystallization Effects 0.000 description 1
- 230000008020 evaporation Effects 0.000 description 1
- 238000001704 evaporation Methods 0.000 description 1
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N iron oxide Inorganic materials [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 1
- 239000000395 magnesium oxide Substances 0.000 description 1
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 1
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 description 1
- 229910044991 metal oxide Inorganic materials 0.000 description 1
- 150000004706 metal oxides Chemical class 0.000 description 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
- NDLPOXTZKUMGOV-UHFFFAOYSA-N oxo(oxoferriooxy)iron hydrate Chemical compound O.O=[Fe]O[Fe]=O NDLPOXTZKUMGOV-UHFFFAOYSA-N 0.000 description 1
- 235000020232 peanut Nutrition 0.000 description 1
- 239000008188 pellet Substances 0.000 description 1
- 230000005855 radiation Effects 0.000 description 1
- 238000004064 recycling Methods 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 235000012239 silicon dioxide Nutrition 0.000 description 1
- 238000002791 soaking Methods 0.000 description 1
- 239000011734 sodium Substances 0.000 description 1
- 229910052708 sodium Inorganic materials 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
- B01J20/02—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising inorganic material
- B01J20/04—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising inorganic material comprising compounds of alkali metals, alkaline earth metals or magnesium
- B01J20/045—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising inorganic material comprising compounds of alkali metals, alkaline earth metals or magnesium containing sulfur, e.g. sulfates, thiosulfates, gypsum
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
- B01J20/30—Processes for preparing, regenerating, or reactivating
- B01J20/3021—Milling, crushing or grinding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
- B01J20/30—Processes for preparing, regenerating, or reactivating
- B01J20/3078—Thermal treatment, e.g. calcining or pyrolizing
-
- 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
- C04B11/00—Calcium sulfate cements
- C04B11/26—Calcium sulfate cements strating from chemical gypsum; starting from phosphogypsum or from waste, e.g. purification products of smoke
- C04B11/262—Calcium sulfate cements strating from chemical gypsum; starting from phosphogypsum or from waste, e.g. purification products of smoke waste gypsum other than phosphogypsum
-
- 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
- C04B28/14—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 calcium sulfate cements
- C04B28/142—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 calcium sulfate cements containing synthetic or waste calcium sulfate cements
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2220/00—Aspects relating to sorbent materials
- B01J2220/40—Aspects relating to the composition of sorbent or filter aid materials
- B01J2220/42—Materials comprising a mixture of inorganic materials
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2220/00—Aspects relating to sorbent materials
- B01J2220/40—Aspects relating to the composition of sorbent or filter aid materials
- B01J2220/46—Materials comprising a mixture of inorganic and organic materials
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2220/00—Aspects relating to sorbent materials
- B01J2220/40—Aspects relating to the composition of sorbent or filter aid materials
- B01J2220/48—Sorbents characterised by the starting material used for their preparation
- B01J2220/4812—Sorbents characterised by the starting material used for their preparation the starting material being of organic character
- B01J2220/4825—Polysaccharides or cellulose materials, e.g. starch, chitin, sawdust, wood, straw, cotton
- B01J2220/4831—Polysaccharides or cellulose materials, e.g. starch, chitin, sawdust, wood, straw, cotton having been subjected to further processing, e.g. paper, cellulose pulp
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2220/00—Aspects relating to sorbent materials
- B01J2220/40—Aspects relating to the composition of sorbent or filter aid materials
- B01J2220/48—Sorbents characterised by the starting material used for their preparation
- B01J2220/4875—Sorbents characterised by the starting material used for their preparation the starting material being a waste, residue or of undefined composition
-
- 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)
- Organic Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Analytical Chemistry (AREA)
- Inorganic Chemistry (AREA)
- Materials Engineering (AREA)
- Structural Engineering (AREA)
- Physics & Mathematics (AREA)
- Thermal Sciences (AREA)
- Processing Of Solid Wastes (AREA)
Abstract
A commercially useful material is produced from waste gyproc boards containing calcium sulfate dihydrate, by a method comprising the steps of (a) grinding the waste gyproc boards to obtain particles having a substantially uniform size; (b) drying the particles obtained in step (a) to obtain moisture-free particles; (c) heating the moisture-free particles obtained in step (b) at a temperature of 128 to 162°C to convert the calcium sulfate dihydrate to calcium sulfate hemihydrate; (d) adding water to the product obtained in step (c) to form a paste;
(e) forming the paste obtained in step (d) into a shaped product of a predetermined size; and (f) drying the shaped product obtained in step (e) at a temperature of 105 to 120°C to obtain a commercially useful material. The materials produced by the method of the invention can be used for a variety of industrial and household purposes.
Typical uses include the absorption of oil, grease and chemicals on floors and elsewhere, in animal toilet applications as a cat box absorbent, as carriers for chemicals, such as pesticides and herbicides, in various agricultural and horticultural applications. They can also be used as fillers for agricultural and horticultural applications. When admixed with an adhesive agent such as Portland cement, epoxy or polyester adhesives, they can be applied onto walls and/or floors to provide a decorative coating.
(e) forming the paste obtained in step (d) into a shaped product of a predetermined size; and (f) drying the shaped product obtained in step (e) at a temperature of 105 to 120°C to obtain a commercially useful material. The materials produced by the method of the invention can be used for a variety of industrial and household purposes.
Typical uses include the absorption of oil, grease and chemicals on floors and elsewhere, in animal toilet applications as a cat box absorbent, as carriers for chemicals, such as pesticides and herbicides, in various agricultural and horticultural applications. They can also be used as fillers for agricultural and horticultural applications. When admixed with an adhesive agent such as Portland cement, epoxy or polyester adhesives, they can be applied onto walls and/or floors to provide a decorative coating.
Description
"Production of Commercially Useful Materials from Waste Gyproc Boards"
The present invention pertains to improvements in the field of waste recycling. More particularly, the invention is directed to a method of producing commercially useful materials from waste gyproc boards.
Waste gyproc boards coming from demolition and :LO gyproc board factories represent a serious threat to t=he environment as they accumulate by thousands to hundred thousands of tons in many dumping sites. They retain humidity and thus promote the formation of undesirable mildew. Degradation of the calcium sulfate contained in :L5 the waste gyproc boards under the influence of infra-red and ultraviolet radiations causes the generation of H2S
and S02 which contaminate the environment.
Gyproc boards contain calcium sulfate dihydrat:e, :?0 silicon dioxide, cellulosic fibers as well as various metal oxides such as aluminum oxide, calcium oxide, ferric oxide and magnesium oxide. Calcium sulfate dehydrate is known to have liquid absorbing properties, as disclosed for example in U.S. Patent Nos. 4,163,674 and 4,264,543.
a?5 However, waste gyproc boards are not suitable for use as absorbents or any other useful products such as fillers for agricultural and horticultural applications.
It is therefore an object of the present ~s0 invention to overcome the above drawbacks and to provide a method of producing a commercially useful material fx-om waste gyproc boards.
According to one aspect of the invention, there .5 is thus provided a method of producing a commercially useful material from waste gyproc boards containing calcium sulfate dehydrate. The method of the invention comprises the steps oi=:
a) grinding the waste gyproc boards to obtain particles having a substantially uniform size;
b) drying the particles obtained in step (a) to obtain moisture-free particles;
c) heating the moisture-free particles obtained in step (b) at a temperature of 128 to 162°C to convert the calcium sulfate dehydrate to calcium sulfate T_0 hemihydrate;
d) adding water to the product obtained in step (c) to form a paste;
e) forming the paste obtained in step (d) into a shaped product of a predetermined size; and J_5 f) drying the shaped product obtained in step (e) at a temperature of 105 to 120°C to obtain a commercially useful material.
The present invention also provides, in another ~'.0 aspect thereof, a commercially useful material derived from waste gyproc boards and produced by the above method.
Applicant has found quite unexpectedly that commercially useful products, particularly liquid 25 absorbing materials, filler materials for agricultural and horticultural applications and decorative coating materials for walls and floors, can be produced at a low cost from waste gyproc boards by converting the calcium sulfate dehydrate contained in the waste gyproc boards to ~:0 calcium sulfate hemihydrate having binding properties and serving to bind the other components of gyproc boards. The waste gyproc boards must first be ground to obtain particles having a substantially uniform size, which are then dried to obtain moisture-free particles, for example, a5 by heating the partic:Les at a temperature of 105 to 120°C
in a circulating air oven for a period of time sufficient to evaporate all traces of water. The moisture-free particles are heated at a temperature of 128 to 162"C, preferably about 145°C, to partially dehydrate the calcium sulfate dihydrate and to thereby convert same to calcium sulfate hemihydrate. Care should be taken to avoid heating the moisture-free particles at a temperature above 162 "C, since at a temperature of 163°C calcium sulfate hemihydrate loses all its water of crystallization and is converted to anhydrous calcium sulfate. Water is added to the resulting product to form a paste. The paste is formed 7_0 into a shaped product of a predetermined size, for example, granules, pellets or balls, and the shaped product is then dried at a temperature of 105 to 120°C to obtain the desired absorbent or filler material. If t:he shaped product is dried at a temperature less than 105°C, 7_5 the evaporation of water is insufficient so that t:he absorption characteristics of the final product are adversely affected. At a temperature above 120°C, on t:he other hand, there is a partial conversion of the hydrated calcium sulfate to calcium sulfate to calcium sulfate ~'.0 hemihydrate, which weakens the final product and leads to the formation of cracker therein.
Various additives can be dry-mixed with t:he product obtained in step (c) with a view to increasing t:he ~~5 absorption characteristics, density, hardness and/or water-resistance of t:he material obtained in step (f);
fungicidal agents and/or coloring agents can also be added. For example, when it is desired to increase t:he absorption characteristics of the final product, wood DSO cellulose fibers, textile fibers, paper pulp, peat fines, mineral fines, charcoal, agricultural waste materials such as corn stalks and peanut shells, or porous plast=ic materials can be added. Use is preferably made of cellulosic fibers in an amount of 0.5 to 30 wt.$. When it ~S5 is desired to increase the density of the final produces, powdered slag can be added it is preferably used in an amount of 5 to 80 wt. g. Since powdered slag exhibits binding properties, it can also be used to increase the hardness of the final product. In such a case, the powdered slag is preferably added in an amount of 1 to 80 wt.~. When using powdered slag, acidified water is preferably added in step (d) to reduce the pH so that t:he final product has a pH of about 7. On the other hand, when it is desired to increase the water-resistance of the final product, gypsum plaster which is also called "Plaster of Paris" can be added. The gypsum plaster is 7.0 preferably used in an amount of 10 to 80 wt.~. A clumping agent such as sodium ~>icarbonate can also be added.
A particularly preferred absorbent material produced in accordance with the invention is derived from 7.5 about 50 wt.~ waste gyproc boards and contains about 25 wt.$ powdered slag, about 20 wt.$ gypsum plaster and about 5 wt.~ cellulosi.c fibers. Such an absorbent material not only exhibits increased hardness and absorption characteristics but is also highly resistant to ~!0 degradation by water.
A particularly preferred filler material produced by the methcrd of the invention is derived from about 50 wt.~ waste gyproc contains about boards and a!5 25 wt.~ gypsum plaster and about 25 wt.~ powdered slag.
Such a filler material. exhibits not only increased density and :hardness but is alsoresistant to degradation by water.
.0 The materials produced in accordance with the invention can be used for a variety of industrial and household purposes. Typical uses include the absorption of oil, grease and chemicals on floors and elsewhere, in animal toilet applications as a cat box absorbent, as a5 carriers for chemical~~, such as pesticides and herbicides, in various agricultural and horticultural applications.
They can also be used as fillers for agricultural and horticultural applications . When admixed with an adhesive agent such as Portland cement, epoxy or polyester adhesives, they can be applied onto walls and/or floors to provide a decorative coating.
The following non-limiting examples illustrate the invention.
EXAMPLE 1:
7.0 120 kg of the waste humid gyproc boards were broken down into small particles and dried at 115°C in an air dryer until the particles became moisture-free. The temperature of the dryer was gradually increased to heat the moisture-free part=icles at a temperature of 150°C for J.5 a duration of 20 minutes. The particles thus obtained which contained hemihydrated calcium sulfate are hereinafter referred t:o "H.H.C.S. particles".
kg of the H.H.C.S. particles were mixed with ~!0 a suitable amount of water to form a paste suitable for shaping into granules. The granules were dried at 115°C
then broken down into different mesh sizes from mesh 5 to 40. '.Che broken granules were then redried in the same dryer at 115°C.
a! 5 EXAMPLE 2:
The present invention pertains to improvements in the field of waste recycling. More particularly, the invention is directed to a method of producing commercially useful materials from waste gyproc boards.
Waste gyproc boards coming from demolition and :LO gyproc board factories represent a serious threat to t=he environment as they accumulate by thousands to hundred thousands of tons in many dumping sites. They retain humidity and thus promote the formation of undesirable mildew. Degradation of the calcium sulfate contained in :L5 the waste gyproc boards under the influence of infra-red and ultraviolet radiations causes the generation of H2S
and S02 which contaminate the environment.
Gyproc boards contain calcium sulfate dihydrat:e, :?0 silicon dioxide, cellulosic fibers as well as various metal oxides such as aluminum oxide, calcium oxide, ferric oxide and magnesium oxide. Calcium sulfate dehydrate is known to have liquid absorbing properties, as disclosed for example in U.S. Patent Nos. 4,163,674 and 4,264,543.
a?5 However, waste gyproc boards are not suitable for use as absorbents or any other useful products such as fillers for agricultural and horticultural applications.
It is therefore an object of the present ~s0 invention to overcome the above drawbacks and to provide a method of producing a commercially useful material fx-om waste gyproc boards.
According to one aspect of the invention, there .5 is thus provided a method of producing a commercially useful material from waste gyproc boards containing calcium sulfate dehydrate. The method of the invention comprises the steps oi=:
a) grinding the waste gyproc boards to obtain particles having a substantially uniform size;
b) drying the particles obtained in step (a) to obtain moisture-free particles;
c) heating the moisture-free particles obtained in step (b) at a temperature of 128 to 162°C to convert the calcium sulfate dehydrate to calcium sulfate T_0 hemihydrate;
d) adding water to the product obtained in step (c) to form a paste;
e) forming the paste obtained in step (d) into a shaped product of a predetermined size; and J_5 f) drying the shaped product obtained in step (e) at a temperature of 105 to 120°C to obtain a commercially useful material.
The present invention also provides, in another ~'.0 aspect thereof, a commercially useful material derived from waste gyproc boards and produced by the above method.
Applicant has found quite unexpectedly that commercially useful products, particularly liquid 25 absorbing materials, filler materials for agricultural and horticultural applications and decorative coating materials for walls and floors, can be produced at a low cost from waste gyproc boards by converting the calcium sulfate dehydrate contained in the waste gyproc boards to ~:0 calcium sulfate hemihydrate having binding properties and serving to bind the other components of gyproc boards. The waste gyproc boards must first be ground to obtain particles having a substantially uniform size, which are then dried to obtain moisture-free particles, for example, a5 by heating the partic:Les at a temperature of 105 to 120°C
in a circulating air oven for a period of time sufficient to evaporate all traces of water. The moisture-free particles are heated at a temperature of 128 to 162"C, preferably about 145°C, to partially dehydrate the calcium sulfate dihydrate and to thereby convert same to calcium sulfate hemihydrate. Care should be taken to avoid heating the moisture-free particles at a temperature above 162 "C, since at a temperature of 163°C calcium sulfate hemihydrate loses all its water of crystallization and is converted to anhydrous calcium sulfate. Water is added to the resulting product to form a paste. The paste is formed 7_0 into a shaped product of a predetermined size, for example, granules, pellets or balls, and the shaped product is then dried at a temperature of 105 to 120°C to obtain the desired absorbent or filler material. If t:he shaped product is dried at a temperature less than 105°C, 7_5 the evaporation of water is insufficient so that t:he absorption characteristics of the final product are adversely affected. At a temperature above 120°C, on t:he other hand, there is a partial conversion of the hydrated calcium sulfate to calcium sulfate to calcium sulfate ~'.0 hemihydrate, which weakens the final product and leads to the formation of cracker therein.
Various additives can be dry-mixed with t:he product obtained in step (c) with a view to increasing t:he ~~5 absorption characteristics, density, hardness and/or water-resistance of t:he material obtained in step (f);
fungicidal agents and/or coloring agents can also be added. For example, when it is desired to increase t:he absorption characteristics of the final product, wood DSO cellulose fibers, textile fibers, paper pulp, peat fines, mineral fines, charcoal, agricultural waste materials such as corn stalks and peanut shells, or porous plast=ic materials can be added. Use is preferably made of cellulosic fibers in an amount of 0.5 to 30 wt.$. When it ~S5 is desired to increase the density of the final produces, powdered slag can be added it is preferably used in an amount of 5 to 80 wt. g. Since powdered slag exhibits binding properties, it can also be used to increase the hardness of the final product. In such a case, the powdered slag is preferably added in an amount of 1 to 80 wt.~. When using powdered slag, acidified water is preferably added in step (d) to reduce the pH so that t:he final product has a pH of about 7. On the other hand, when it is desired to increase the water-resistance of the final product, gypsum plaster which is also called "Plaster of Paris" can be added. The gypsum plaster is 7.0 preferably used in an amount of 10 to 80 wt.~. A clumping agent such as sodium ~>icarbonate can also be added.
A particularly preferred absorbent material produced in accordance with the invention is derived from 7.5 about 50 wt.~ waste gyproc boards and contains about 25 wt.$ powdered slag, about 20 wt.$ gypsum plaster and about 5 wt.~ cellulosi.c fibers. Such an absorbent material not only exhibits increased hardness and absorption characteristics but is also highly resistant to ~!0 degradation by water.
A particularly preferred filler material produced by the methcrd of the invention is derived from about 50 wt.~ waste gyproc contains about boards and a!5 25 wt.~ gypsum plaster and about 25 wt.~ powdered slag.
Such a filler material. exhibits not only increased density and :hardness but is alsoresistant to degradation by water.
.0 The materials produced in accordance with the invention can be used for a variety of industrial and household purposes. Typical uses include the absorption of oil, grease and chemicals on floors and elsewhere, in animal toilet applications as a cat box absorbent, as a5 carriers for chemical~~, such as pesticides and herbicides, in various agricultural and horticultural applications.
They can also be used as fillers for agricultural and horticultural applications . When admixed with an adhesive agent such as Portland cement, epoxy or polyester adhesives, they can be applied onto walls and/or floors to provide a decorative coating.
The following non-limiting examples illustrate the invention.
EXAMPLE 1:
7.0 120 kg of the waste humid gyproc boards were broken down into small particles and dried at 115°C in an air dryer until the particles became moisture-free. The temperature of the dryer was gradually increased to heat the moisture-free part=icles at a temperature of 150°C for J.5 a duration of 20 minutes. The particles thus obtained which contained hemihydrated calcium sulfate are hereinafter referred t:o "H.H.C.S. particles".
kg of the H.H.C.S. particles were mixed with ~!0 a suitable amount of water to form a paste suitable for shaping into granules. The granules were dried at 115°C
then broken down into different mesh sizes from mesh 5 to 40. '.Che broken granules were then redried in the same dryer at 115°C.
a! 5 EXAMPLE 2:
5 kg of the H.H.C.S. particles obtained in Example 1 were well mixed with 2 kg of gypsum plaster.
Water was added to th.e resulting mixture to form a paste a0 suitable for shaping into granules. The granules were dried at 115°C and then broken down into different mesh sizes from mesh 5 to 40. The broken granules were then redried in the same dryer at 115°C.
.C 5 EXAMPLE 3 Example 2 was repeated, except that the H.H.C.S.
particles were mixed with 3 kg of gypsum plaster.
EXAMPLE 4:
Example 2 was repeated, except that the H.H.C.S.
particles were mixed with 4 kg of gypsum plaster.
EXAMF?LE 5:
Example 2 w.as repeated, except that the H.H.C.S.
part_Lcles were mixed 'with 5 kg of gypsum plaster.
EXAMI?LE 6:
Example 4 was repeated, except that 0.5 kg of defibrated waste hygienic paper was added to the mixture containing the H.H.C.S. particles and gypsum plaster, prior to adding the water.
EXAMPLE 7:
Example 2 was repeated, except that the H.H.C..S.
particles were mixed with 1 kg of powdered slag.
EXAMPLE 8:
Example 2 was repeated, except that the H.H.C.S.
particles were mixed with 2 kg of powdered slag.
EXAMPLE 9:
Example 2 was repeated, except that the H.H.C.S.
particles were mixed with 3 kg of powdered slag.
EXAMPLE 10:
Example 2 was repeated, except that the H.H.C.S.
particles were mixed with 4 kg of powdered slag.
EXANfPLE 11:
Example 2 was repeated, except that the H.H.C.S.
particles were mixed with 5 kg of powdered slag.
Water was added to th.e resulting mixture to form a paste a0 suitable for shaping into granules. The granules were dried at 115°C and then broken down into different mesh sizes from mesh 5 to 40. The broken granules were then redried in the same dryer at 115°C.
.C 5 EXAMPLE 3 Example 2 was repeated, except that the H.H.C.S.
particles were mixed with 3 kg of gypsum plaster.
EXAMPLE 4:
Example 2 was repeated, except that the H.H.C.S.
particles were mixed with 4 kg of gypsum plaster.
EXAMF?LE 5:
Example 2 w.as repeated, except that the H.H.C.S.
part_Lcles were mixed 'with 5 kg of gypsum plaster.
EXAMI?LE 6:
Example 4 was repeated, except that 0.5 kg of defibrated waste hygienic paper was added to the mixture containing the H.H.C.S. particles and gypsum plaster, prior to adding the water.
EXAMPLE 7:
Example 2 was repeated, except that the H.H.C..S.
particles were mixed with 1 kg of powdered slag.
EXAMPLE 8:
Example 2 was repeated, except that the H.H.C.S.
particles were mixed with 2 kg of powdered slag.
EXAMPLE 9:
Example 2 was repeated, except that the H.H.C.S.
particles were mixed with 3 kg of powdered slag.
EXAMPLE 10:
Example 2 was repeated, except that the H.H.C.S.
particles were mixed with 4 kg of powdered slag.
EXANfPLE 11:
Example 2 was repeated, except that the H.H.C.S.
particles were mixed with 5 kg of powdered slag.
EXAMPLE 12:
Example 8 was repeated, except that 1 kg of gypsum plaster was added to the mixture containing the H.H.C.S. particles and powdered slag, prior to adding the water.
EXAMPLE 13:
Example 12 was repeated, except that the amount of pc>wdered slag added was 2 kg.
EXAMPLE 14:
Example 12 was repeated, except that the amount of powdered slag added was 3 kg.
EXAM~?LE 15:
Example 12 was repeated, except that the amount of powdered slag added was 4 kg.
EXAMI?LE 16:
Example 12 was repeated, except that the amount of powdered slag added was 5 kg.
The bulk density, hardness, water absorption and resistance to water of the products obtained in Examples 1 through 16 were tested.
The bulk density was determined by filing a graduated cylinder without tamping. The hardness was determined according to the standard test ASTM # E728-91, and compared with i~he hardness of granules made from 100 wt.o gypsum plaster. The water absorption was determined according to the procedure described in US
Patent No. 4,183,763 (col. 11). The resistance to water was determined by soaking' the granules (2 g) in water for 2-4 hours and compressing with a spatula.
_ 7 _ The results are reported in the following Table:
Ex. Bulk Water Resistance Suitable No. density Hardness absorp- to water application pound / tion feet3 1 46 56$ 0.8 Week Animal litter 2 48 71$ 0.65 Moderate Animal litter 3 49 80$ 0.6 Moderate Animal litter 4 51 86$ 0.55 Moderate Animal litter 5 50.5 99.5$ 0.5 Good Animal litter 6 45.2 83~ 0.75 Moderate Animal litter 7 50 80$ 0.6 Good Animal litter 8 55 92~ 0.5 Good Animal litter 9 58 99$ 0.6 Good Animal litter 10 62 102 0.5 Very good Animal litter &
absorbent 11 69 106$ 0.4 Very good Absorbent 12 56 1259s 0.38 Very good Absorbent 13 58 142$ 0.3 Very good Absorbent 14 63 167$ 0.3 Very good Absorbent 15 68 189$ 0.31 Excellent Absorbent 16 72 207$ 0.29 Excellent Absorbent _ g
Example 8 was repeated, except that 1 kg of gypsum plaster was added to the mixture containing the H.H.C.S. particles and powdered slag, prior to adding the water.
EXAMPLE 13:
Example 12 was repeated, except that the amount of pc>wdered slag added was 2 kg.
EXAMPLE 14:
Example 12 was repeated, except that the amount of powdered slag added was 3 kg.
EXAM~?LE 15:
Example 12 was repeated, except that the amount of powdered slag added was 4 kg.
EXAMI?LE 16:
Example 12 was repeated, except that the amount of powdered slag added was 5 kg.
The bulk density, hardness, water absorption and resistance to water of the products obtained in Examples 1 through 16 were tested.
The bulk density was determined by filing a graduated cylinder without tamping. The hardness was determined according to the standard test ASTM # E728-91, and compared with i~he hardness of granules made from 100 wt.o gypsum plaster. The water absorption was determined according to the procedure described in US
Patent No. 4,183,763 (col. 11). The resistance to water was determined by soaking' the granules (2 g) in water for 2-4 hours and compressing with a spatula.
_ 7 _ The results are reported in the following Table:
Ex. Bulk Water Resistance Suitable No. density Hardness absorp- to water application pound / tion feet3 1 46 56$ 0.8 Week Animal litter 2 48 71$ 0.65 Moderate Animal litter 3 49 80$ 0.6 Moderate Animal litter 4 51 86$ 0.55 Moderate Animal litter 5 50.5 99.5$ 0.5 Good Animal litter 6 45.2 83~ 0.75 Moderate Animal litter 7 50 80$ 0.6 Good Animal litter 8 55 92~ 0.5 Good Animal litter 9 58 99$ 0.6 Good Animal litter 10 62 102 0.5 Very good Animal litter &
absorbent 11 69 106$ 0.4 Very good Absorbent 12 56 1259s 0.38 Very good Absorbent 13 58 142$ 0.3 Very good Absorbent 14 63 167$ 0.3 Very good Absorbent 15 68 189$ 0.31 Excellent Absorbent 16 72 207$ 0.29 Excellent Absorbent _ g
Claims (22)
1. A method of producing a commercially useful material from waste gyproc boards containing calcium sulfate dehydrate, comprising the steps of:
a) grinding the waste gyproc boards to obtain particles having a substantially uniform size;
b) drying the particles obtained in step (a) to obtain moisture-free particles;
c) heating the moisture-free particles obtained in step (b) at a temperature of 128 to 162°C to convert the calcium sulfate dehydrate to calcium sulfate hemihydrate;
d) adding water to the product obtained in step (c) to form a paste;
e) forming the paste obtained in step (d) into a shaped product of a predetermined size; and f) drying the shaped product obtained in step (e) at a temperature of 105 to 120°C to obtain a commercially useful material.
a) grinding the waste gyproc boards to obtain particles having a substantially uniform size;
b) drying the particles obtained in step (a) to obtain moisture-free particles;
c) heating the moisture-free particles obtained in step (b) at a temperature of 128 to 162°C to convert the calcium sulfate dehydrate to calcium sulfate hemihydrate;
d) adding water to the product obtained in step (c) to form a paste;
e) forming the paste obtained in step (d) into a shaped product of a predetermined size; and f) drying the shaped product obtained in step (e) at a temperature of 105 to 120°C to obtain a commercially useful material.
2. A method as claimed in claim 1, wherein step (b) is carried out by heating the particles obtained in step (a) at a temperature of 105 to 120°C.
3. A method as claimed in claim 1, wherein step (c) is carried out at a temperature of about 145°C.
4. A method as claimed in claim 1, further including the step of dry-mixing the product obtained in step (c), prior to adding water, with at least one additive for increasing absorption characteristics of the material obtained in step (f).
5. A method as claimed in claim 4, wherein said additive is selected from the group consisting of wood cellulose fibers, textile fibers, paper pulp, peat fines, mineral fines, charcoal, agricultural waste materials and porous plastic materials.
6. A method as claimed in claim 5, wherein said additive comprises wood cellulose fibers.
7. A method as claimed in claim 6, wherein the cellulosic fibers are added in an amount of 0.5 to 30 wt.%.
8. A method as claimed in claim 1, further including the step of dry-mixing the product obtained in step (c), prior to adding water, with an additive for increasing density of the product obtained in step (f).
9. A method as claimed in claim 8, wherein said additive comprises powdered slag.
10. A method as claimed in claim 9, wherein the powdered slag is added in an amount of 5 to 80 wt.%.
11. A method as claimed in claim 1, further including the step of dry-mixing the product obtained in step (c), prior to adding water, with an additive for increasing hardness of the product obtained in step (f).
12. A method as claimed in claim 10, wherein said additive is powdered slag.
13. A method as claimed in claim 11, wherein the powdered slag is added in an amount of 1 to 80 wt.%.
14. A method as claimed in claim 1, further including the step of dry-mixing the product obtained in step (c), prior to adding water, with an additive for increasing water-resistance of the product obtained in step (f).
15. A method as claimed in claim 14, wherein said additive comprises gypsum plaster.
16. A method as claimed in claim 14, wherein the gypsum plaster is added in an amount of 10 to 80 wt.%.
17. A method as claimed in claim 1, further including the step of dry-mixing the product obtained in step (c), prior to adding water, with an additive selected from the group consisting of fungicidal agents and coloring agents.
18. A method as claimed in claim 1, further including the step of dry-mixing the product obtained in step (c), prior to adding water, with powdered slag, gypsum plaster and cellulosic fibers.
19. A method as claimed in claim 18, wherein the powdered slag, gypsum plaster and cellulosic fibers are added in amounts of about 25 wt.%, 20 wt.% and 5 wt.%, respectively.
20. An absorbent material derived from waste gyproc boards and produced by a method as defined in any of claims 1, 4, 5, 6, 11, 12, 14, 15, 18 and 19.
21. A filler material derived from waste gyproc boards and produced by a method as defined in claim 1, 8 or 9.
22. A decorative coating material derived from waste gyproc boards and produced by a method as defined in any of claims 1, 11, 12, 14, 15 and 17.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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CA 2236486 CA2236486A1 (en) | 1998-05-01 | 1998-05-01 | Production of commercially useful materials from waste gypsum boards |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CA 2236486 CA2236486A1 (en) | 1998-05-01 | 1998-05-01 | Production of commercially useful materials from waste gypsum boards |
Publications (1)
Publication Number | Publication Date |
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CA2236486A1 true CA2236486A1 (en) | 1999-11-01 |
Family
ID=29275634
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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CA 2236486 Abandoned CA2236486A1 (en) | 1998-05-01 | 1998-05-01 | Production of commercially useful materials from waste gypsum boards |
Country Status (1)
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CA (1) | CA2236486A1 (en) |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN105251468A (en) * | 2015-10-22 | 2016-01-20 | 丁玉琴 | Preparation method of environment-friendly indoor poisonous gas adsorbent |
CN109701488A (en) * | 2018-12-20 | 2019-05-03 | 宝钢湛江钢铁有限公司 | A method of heavy metal absorbent is prepared using industrial waste |
EP3517514A1 (en) * | 2018-01-30 | 2019-07-31 | Holcim Technology Ltd. | Method of processing plasterboards |
-
1998
- 1998-05-01 CA CA 2236486 patent/CA2236486A1/en not_active Abandoned
Cited By (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN105251468A (en) * | 2015-10-22 | 2016-01-20 | 丁玉琴 | Preparation method of environment-friendly indoor poisonous gas adsorbent |
EP3517514A1 (en) * | 2018-01-30 | 2019-07-31 | Holcim Technology Ltd. | Method of processing plasterboards |
WO2019150251A1 (en) * | 2018-01-30 | 2019-08-08 | Holcim Technology Ltd | Method of processing plasterboards |
CN111630016A (en) * | 2018-01-30 | 2020-09-04 | 霍尔辛姆科技有限公司 | Method for treating gypsum boards |
CN109701488A (en) * | 2018-12-20 | 2019-05-03 | 宝钢湛江钢铁有限公司 | A method of heavy metal absorbent is prepared using industrial waste |
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