CN112041285A - Method for producing building aggregates from fly ash and aggregates obtained by this method - Google Patents
Method for producing building aggregates from fly ash and aggregates obtained by this method Download PDFInfo
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- CN112041285A CN112041285A CN201980023158.1A CN201980023158A CN112041285A CN 112041285 A CN112041285 A CN 112041285A CN 201980023158 A CN201980023158 A CN 201980023158A CN 112041285 A CN112041285 A CN 112041285A
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- Prior art keywords
- fly ash
- alkaline activator
- aggregate
- alkaline
- curing
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- 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
- C04B18/02—Agglomerated materials, e.g. artificial aggregates
- C04B18/021—Agglomerated materials, e.g. artificial aggregates agglomerated by a mineral binder, e.g. cement
Abstract
The invention relates to a method for producing building aggregates, comprising the following steps: (i) preparing a material comprising (in weight percent): fly ash (80% to 99.75%); alkaline activators (0.25% to 20%); water (6% to 30% of the total weight of fly ash and alkaline activator); (ii) mixing the alkaline activator with all of the above water to produce an alkaline activator solution, and then mixing the alkaline activator solution with fly ash to produce a geopolymer mortar; (iii) molding the geopolymer mortar having a desired size at a compression force of 2MPa or more, wherein the molding is performed by hydraulic pressing, extrusion, rolling or flat plate lamination; (iv) curing; (v) optionally, crushing the building aggregate obtained above to a predetermined size. Furthermore, the present invention relates to a construction aggregate produced from fly ash obtained by the above method.
Description
Technical Field
The present invention relates to a method for producing building aggregates, such as artificial sand, stone, from fly ash; and artificial sand and stone obtained by the method. The product obtained by this method almost does not contain carbon dioxide (CO)2) Discharge to the air
Background
Currently, fly ash waste is usually disposed of by dumping, causing severe environmental pollution and scattering dust into the air, and dumping takes up land space.
On the other hand, building materials such as sand and stone are increasingly scarce because they are natural resources that are not renewable. At the same time, as the population grows, the demand for buildings and the production of building materials also increases.
The use of fly ash in construction is still limited due to its ultra-smoothness and mildness.
Methods for producing fly ash beads and surface treating them using spray drying to produce fly ash beads having fine powdery characteristics are well known and can be used as a substitute for construction sand. This manufactured sand made from fly ash has a low modulus and hardness and is only suitable for use as construction sand in some cases. Such artificial sand cannot be used as a material in common use.
Therefore, there is a need to replace natural sand with existing fly ash sources, which can meet the technical requirements for high quality construction sand.
Disclosure of Invention
The basic object of the invention is to propose a method for producing aggregates from fly ash, artificial sands, stones thus obtained with this method.
The inventors have discovered, by chance, that mixing fly ash with an alkaline activator helps to improve the density and size of the fly ash, making it suitable for use as a building material. It has also been found that the initial hardness can be obtained by accelerating the polymerization process by increasing the compressive force and simultaneously increasing the temperature of the polymerization process, which is sufficient to produce a product having a hardness suitable for transport and storage during manufacture. The present invention has been completed based on the above findings.
Specifically, the present invention proposes:
[1] a method for producing construction aggregate from fly ash, comprising the steps of:
(i) preparing a material comprising (in weight percent): fly ash (80% to 99.75%); alkaline activators (0.25% to 20%); water (6% to 30% of the total weight of fly ash and alkaline activator);
(ii) mixing the alkaline activator with all of the above water to produce an alkaline activator solution, and then mixing the alkaline activator solution with fly ash to produce a geopolymer mortar;
(iii) molding a geopolymer mortar having a desired size with a compression force of 2MPa or more, wherein the molding is performed using hydraulic pressing, extrusion, rolling or flat plate lamination;
(iv) curing by:
-optionally steam curing to 100 ℃ or autoclaving;
-drying at a temperature of 60 ℃ to 250 ℃; to obtain building aggregate from the fly ash; and
(v) optionally, crushing the building aggregate obtained above to a predetermined size.
[2] The method for producing building aggregate from ash according to paragraph [1], wherein the alkaline activator is selected from the group comprising: sodium hydroxide, potassium silicate, sodium silicate, molten glass, calcium hydroxide, or mixtures thereof.
[3] The method for producing construction aggregate from fly ash according to paragraph [1] or [2], wherein the curing in step (iv) is performed by:
-steam curing to 100 ℃; and
-drying at a temperature of 60 ℃ to 250 ℃.
[4] The method for producing building aggregate from fly ash according to any one of paragraphs [1] to [3], wherein the drying is performed by an infrared curing oven, a resistance oven or a microwave oven.
[5] The method for producing construction aggregate from fly ash according to any one of paragraphs [1] to [4], wherein the alkaline activator is mixed with sodium hydroxide and molten glass, wherein the mass fraction (dry weight basis) of the sodium hydroxide and the molten glass ranges from 10/1 to 1/10.
[6] A building aggregate made from fly ash obtained by the method of any one of the preceding paragraphs
Detailed Description
The key components in geopolymerization are fly ash, which acts as volcanic ash, and alkaline activators.
The fly ash in the present invention is fly ash from a thermal power plant or an incineration plant, which may be type F or type C, mainly contains silica, calcium oxide, alumina, iron oxide and carbon, and may be considered as a kind of volcanic ash. In the role of pozzolans, a certain amount of fly ash can be replaced by other sources of pozzolans, such as scoria, bottom ash, but as a less preferred embodiment.
The alkaline activators of the present invention include those well known in the geopolymer art. In particular, the alkaline activator is selected from the group comprising: sodium hydroxide, potassium silicate, sodium silicate, molten glass, calcium hydroxide, or mixtures thereof. The molten glass is Na20.nSi02Or K20.mSiO2Or mixtures thereof, wherein n and m are commercially available siliconAn acid salt module which can be used as a stand alone base activator or mixed with other bases in any proportion. Generally, the basic activators are used in solid form, after which they are dissolved in a predetermined amount of water to become a solution, which is then mixed with the other ingredients. However, the alkaline activator may be mixed with other powders such as fly ash and then mixed with a predetermined amount of water to keep the production in process. Due to the high cost of NaOH and KOH, and the lower cost of molten glass, it is preferred that the alkaline activator be a mixture of NaOH or KOH with molten glass where the mass fraction (dry weight basis) of NaOH or KOH with molten glass ranges from 10/1 to 1/10.
In a preferred embodiment of the invention, the invention proposes a method for producing building aggregate from geopolymeric material, comprising the following steps:
(i) preparing a material comprising (in weight percent): fly ash (80% to 99.75%); alkaline activators (0.25% to 20%); water (6% to 30% of the total weight of fly ash and alkaline activator);
(ii) mixing the alkaline activator with all of the above water to produce an alkaline activator solution, which will then be mixed with fly ash to produce a geopolymer mortar;
(iii) molding a geopolymer mortar having a desired size with a compression force of 2MPa or more, wherein the molding is performed using hydraulic pressing, extrusion, rolling or flat plate lamination;
(iv) curing by:
-optionally steam curing to 100 ℃ or autoclaving;
-drying at a temperature of 60 ℃ to 250 ℃; to obtain building aggregate from the fly ash; and
(v) optionally, crushing the building aggregate obtained above to a predetermined size.
In steps (i) and (ii), if the alkaline activator is in the form of a solid, it may be mixed with a predetermined amount of water prepared in step (i) to make a solution, and then the solution is mixed with fly ash into a semi-dry or concentrated solution. Alternatively, the alkaline activator is dry blended with the fly ash and then mixed with water. If the alkaline activator is in the form of an aqueous solution, the amount of water in the solution must be such as to take into account a predetermined amount of water, so that the total amount of water remains unchanged, and so that the fly ash mass is not too fluid to be pressed or extruded. Methods and mixing devices for facilitating the mixing of fly ash with alkaline activators are well known in the art.
The total amount of water is from 6% to 30%, preferably from 8% to 15%, or even better 10% of the total weight of the alkaline activator and the fly ash. An amount of water in excess of 30% of the total weight is not preferred as it would make the fly ash cake too viscous to be extruded after mixing. Less than the recommended amount of water may not be sufficient to penetrate all of the fly ash beads, resulting in uneven mixing.
The amount of alkaline activator must be sufficient to carry out the geopolymerization process, i.e. at least equal to 0.25% of the total weight of fly ash and alkaline activator. The use of an excess of the basic activator may lead to waste due to the high price of the substance. Thus, the amount of alkaline activator should not exceed 20% of the total weight, better still be from 1% to 8% of the total weight, or even better still be from 4% to 6% of the total weight.
In the molding method for forming the original product block, the mold and the anti-sticking surface treatment of the inside of the mold are performed in a conventional manner. The shape of the shaped product piece preferably has a simple cross-section, such as circular, square or rectangular. Preferably, a double action pressing method is used, i.e. pressing from top to bottom and from bottom to top. The minimum compression force is 2MPa to accelerate the joining of the mixture, so that the product pieces can be released from the mould without waiting for an adhesive process after the pressing process. Higher compression forces are preferred, such as 5Mpa or 10Mpa or 15Mpa, up to 30Mpa or even higher compression forces may be used throughout. A compressive force of less than 2MPa is not preferred because under this force the product is not tightly packed, leading to the possibility of cracking after release from the mould. At compressive forces greater than 2MPa, after the desired compressive force is reached, the die can be released to perform the next press cycle, thereby reducing production cycles and improving productivity. Compression forces in excess of 20MPa or 30MPa are generally not preferred as there is a high risk of damaging the mould, reducing the expected life of the product, leading to other risks and costs.
Among extrusion methods for producing virgin products, the screw extrusion method is used together with conventional techniques to produce a constant length product having a cross section similar to that of an extrusion die, the size of which depends on the extruder capacity, simple cross sections (such as circular, square or rectangular) being preferred; the number of molding holes depends on the extruder throughput. A non-preferred method is based on intermittent extrusion with a piston, pressing of the material through an extrusion die, or a combination of extrusion and pressing based on conventional principles.
In a less preferred embodiment of the invention, the geopolymer mortar does not require forming and can be cured directly into hard blocks and then crushed to produce man-made sand and stone.
The purpose of the curing is to thoroughly and completely enhance the geopolymerization process, so that the cured product can obtain the necessary hardness, thereby shortening the production cycle. Curing is carried out by: optionally, steam curing to 100 ℃ or autoclaving; drying at a temperature of 60 ℃ to 250 ℃. As mentioned above, the drying process helps the product to obtain an initial hardness that meets the input material requirements of the crusher, e.g. an initial hardness of 2MPa to 60MPa or higher.
In a preferred embodiment of the invention, the drying process is carried out by means of an electric resistance ring which supplies heat to the cylinder and to the extrusion head at a conditioning temperature of up to 250 ℃, depending on the size of the product block. In this embodiment, the steam curing process is skipped.
In another preferred embodiment of the present invention, the drying process is performed by an infrared curing oven, a resistance oven, a solar oven or a microwave oven. It is preferable to use a microwave oven to shorten the drying time, improve the drying efficiency and transfer heat. With a microwave oven, the drying process takes only a few minutes to less than 30 minutes, depending on the size of the product pieces.
The drying time depends on the product size as long as the core of the product reaches a predetermined temperature. The calculation of drying time, drying capacity, oven size is common knowledge that can be easily proposed by a person skilled in the art and need not be described anew.
In another preferred embodiment of the invention, the product is optionally subjected to steam curing or autoclaving at a temperature of 100 ℃ for half an hour to several hours, depending on the product size, before drying to cure the product, in order to achieve the following: the alkaline activator and the additive are uniformly absorbed into the fly ash or the aggregate, thereby increasing the hardness of the product.
The solidified product pieces will be placed in a conventional sand or stone crusher to be crushed to the desired size and put into use.
In another preferred embodiment of the invention, the feed mixture may contain other ingredients that are mixed with the fly ash prior to the shaping process. The mixture components include those known in the art of building material production, but are not limited to the following: inorganic binders such as cement, calcium hydroxide, zeolite, bentonite, gypsum, CaO, MgO; an organic binder; additives such as plasticizers, water-proofing compounds, colorants, strength-enhancing additives, and the like.
Depending on the size of the product made using the above method, it can be considered as building stone or strain hardened aggregate. If they are crushed, they are crushed to the desired size to replace the sand used in construction.
The aggregate obtained by the method of the invention has high hardness, compressive strength of 2MPa and higher, and modulus similar to that of common building sandstone. Therefore, they are suitable for replacing sandstone for buildings. The proportion of fly ash and alkaline activator in the aggregate and other feed mixtures depends on the intended use of the man-made sand and stone material; to obtain the desired strength and to meet other technical requirements.
Examples of the invention
Example 1: production of artificial sand
The materials are as follows:
fly ash collected from Vinh Tan 2 thermal power plant: 990kg
NaOH solid flakes: 10kg of
-water: 100kg of
(iii) carrying out the steps (i) to (ii) of the above method to produce a geopolymer mortar. Specifically, NaOH is mixed with water to produce an alkaline solution, which is then mixed with fly ash. Finally, 1100kg of geopolymer mortar containing fly ash and NaOH were obtained.
Cylindrical beads having a diameter of 5mm and a length of 5mm were produced using an extruder having a compression force of 2MPa, and then dried for 3 minutes with a microwave oven until the temperature at the center of the beads reached 200 ℃. The product is released and placed in a crusher until the beads can pass through a 2.5mm hole to be used as artificial sand, the same quality as the original grit for high performance concrete.
This method can produce 1000kg of artificial sand.
Example 2: production of synthetic sand using mixed alkaline activators
The materials are as follows:
fly ash collected from Vinh Tan 2 thermal power plant: 905kg
NaOH solid flakes: 60kg of
45% of molten glass: 78kg (equal to 35kg solid)
-water: 57kg of
The procedure was performed as described in example 1, which produced 1000kg of synthetic sand.
Example 3: production of artificial sandstone by moulding
The materials are as follows:
fly ash collected from Vinh Tan 2 thermal power plant: 905kg
NaOH solid flakes: 60kg of
45% of molten glass: 78kg (equal to 35kg solid)
-water: 57kg of
Performing the steps (i) to (ii) of the above method to produce a geopolymer mortar. This mortar was loaded into a cubic mold having a size of 150 mm. The concrete block was steam-cured at 100 ℃ for 1 hour, then dried in a microwave oven for 5 minutes, and then subjected to a test, and a compressive strength of 55MPa was obtained. The product is released and placed in a crusher to produce an artificial stone of 10mm x 20mm to 30mm x 40mm size or an artificial sand of 1mm to 3mm size. This method can produce 1000kg of artificial sand or stone.
Example 4: production of artificial sandstone by extrusion method
The procedure was performed as described in example 3, but the amount of water until the geopolymer mortar was produced was 107 kg. This mortar was loaded into a screw extruder, then fibers having a diameter of 50mm were extruded, then placed on a conveyor belt through a microwave dryer having a temperature of up to 200 ℃, and then loaded into a crusher to produce artificial stones having a size of 10mm x 20mm to 30mm x 40mm, or artificial sands having a bead size of 1mm to 3 mm. This method can produce 1000kg of artificial sand or stone.
Benefits that can be realized
The present invention successfully proposes a method for producing a building aggregate that can be used to replace ordinary building sandstone. The method can be easily applied in production practice due to its short production cycle, and the aggregate obtained from the method of the present invention can be easily customized to meet the specific application requirements from ground filling to the production of common building materials and components.
Claims (6)
1. A method for producing construction aggregate from fly ash, comprising the steps of:
(i) preparing a material comprising (in weight percent): fly ash (80% to 99.75%); alkaline activators (0.25% to 20%); water (6% to 30% of the total weight of fly ash and alkaline activator);
(ii) mixing the alkaline activator with all of the above water to produce an alkaline activator solution, and then mixing the alkaline activator solution with fly ash to produce a geopolymer mortar;
(iii) molding a geopolymer mortar having a desired size with a compression force of 2MPa or more, wherein the molding is performed using hydraulic pressing, extrusion, rolling or flat plate lamination;
(iv) curing by:
-optionally steam curing to 100 ℃ or autoclaving;
-drying at a temperature of 60 ℃ to 250 ℃; to obtain building aggregate from the fly ash; and
(v) optionally, crushing the building aggregate obtained above to a predetermined size.
2. The method for producing building aggregate from fly ash according to claim 1, wherein the alkaline activator is selected from the group comprising: sodium hydroxide, potassium silicate, sodium silicate, molten glass, calcium hydroxide, or mixtures thereof.
3. A process for producing construction aggregate from fly ash according to claim 1 or 2, wherein the curing in step (iv) is carried out by:
-steam curing to 100 ℃; and
-drying at a temperature of 60 ℃ to 250 ℃.
4. The method for producing building aggregate from fly ash according to any one of claims 1-3, wherein the drying is performed by an infrared curing oven, a resistance oven or a microwave oven.
5. The method for producing building aggregate from fly ash according to any one of claims 1-4, wherein the alkaline activator is mixed from sodium hydroxide and molten glass, wherein the mass fraction (on a dry basis) of sodium hydroxide and molten glass ranges from 10/1 to 1/10.
6. A building aggregate made from fly ash, the building aggregate produced by the method of any one of claims 1-5.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| VN1-2018-01444 | 2018-04-05 | ||
| VN201801444 | 2018-04-05 | ||
| PCT/VN2019/000005 WO2019195862A1 (en) | 2018-04-05 | 2019-04-02 | Method for producing construction aggregate from fly ash and the aggregate obtained with this method |
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| Publication Number | Publication Date |
|---|---|
| CN112041285A true CN112041285A (en) | 2020-12-04 |
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| CN201980023158.1A Pending CN112041285A (en) | 2018-04-05 | 2019-04-02 | Method for producing building aggregates from fly ash and aggregates obtained by this method |
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| CN (1) | CN112041285A (en) |
| WO (1) | WO2019195862A1 (en) |
Cited By (1)
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| CN113563036A (en) * | 2021-08-27 | 2021-10-29 | 叶县鸿立实业有限公司 | Fly ash autoclaved brick containing fly ash of garbage power plant and preparation method thereof |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US11795104B2 (en) * | 2018-08-23 | 2023-10-24 | Em Resources Llc | Aggregate materials and methods of preparation thereof |
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| WO2019195862A1 (en) | 2019-10-10 |
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