DE102023117588A1 - METHOD OF PRODUCING ENVIRONMENTALLY FRIENDLY AND ULTRA HIGH PERFORMANCE CONCRETE. - Google Patents

Abstract

The present invention discloses a method for producing ultra-high performance green concrete. This involves the preparation of coarse and fine raw materials from technical sand and stone aggregates in the mechanical sand and stone aggregate production line and the transportation of high-entropy cementitious powder produced in the powder production line to the construction site. The process uses quantitative packaging or precise measurement on a modular intelligent mixing production line to dose the ingredients, which are then automatically routed to the intelligent mixing equipment for the production of ultra-high performance concrete or mortar. The concrete is quickly transported to the concrete storage area and immediately poured into the desired shape using seamless pumping, belt conveying or bucket lifting methods. This invention effectively improves the processing, transportation, dosing and measuring processes of raw materials and enables integrated on-site dosing and production of concrete.

Description

Technical area

The present invention relates to the field of concrete production and more particularly to a production line for producing green and ultra-high performance concrete.

State of the art

Concrete is the most widely used building material and structural engineering material in various construction projects. However, conventional concrete often suffers from problems such as poor durability, significant structural cracks and insufficient strength.

Currently, there is a widespread problem of “massive beams, strong columns and thick pillars” in the construction of concrete structures, resulting in significant waste of resources. In addition, concrete structures in buildings often suffer from serious cracks, so it is often said that “no house, bridge or dam is free from cracks”, which poses a serious threat to the quality and safety of structures. In addition, the current practice of pumping ready-mixed concrete to overcome the workability problems in the first two hours leads to excessive use of various additives. This approach, which is intended to ensure short-term workability, brings with it hidden defects and risks for the long-term stability and quality of the buildings and thus significantly hinders the sustainable development of concrete.

In summary, current concrete production and pumping methods do not meet the requirements for concrete durability, high-quality development and green, low-carbon principles of the construction industry. They fall far short of the national goal of achieving “century-long projects and millennium-long plans” in terms of design requirements. There is an urgent need for technological innovation to develop advanced and environmentally friendly concrete manufacturing and construction processes that provide higher strength and longer lifespan. This will drive the fifth technological revolution in the concrete industry and contribute to the overall goal of sustainable and high-quality development.

• 1) Die Bauweise des Fertigbetonpumpens
  • Beeinflusst von Umweltpolitik und der gestiegenen Nachfrage nach Betonleistung und -menge wurde der traditionelle Ansatz des einfachen Vor-Ort-Mischens durch die fortschrittliche Technologie des Fertigbetonpumpens ersetzt. Fertigbetonmischanlagen haben die mit dem traditionellen Vor-Ort-Mischen verbundenen Umwelt- und Messgenauigkeitsprobleme effektiv gelöst und sind heute die vorherrschende Bauweise für Beton. Allerdings werden Fertigbetonmischanlagen in der Regel in abgelegenen Außenbezirken errichtet, während sich städtische Bauwerke in Stadtzentren befinden. Folglich wird der Beton nach der Produktion in den Vorortmischwerken innerhalb eines Zeitraums von 2 Stunden mithilfe von Betonmischfahrzeugen zu den Baustellen transportiert und dann mit Betonpumpen zu Hochhausstrukturen befördert. Gerade aufgrund dieser zweistündigen Transportdistanz sieht sich die moderne Betonqualität neuen Herausforderungen gegenüber:
    • (1) Verringerte Haltbarkeit von Beton. Um sicherzustellen, dass der Beton innerhalb von 2 Stunden zur Baustelle transportiert wird und gleichzeitig seine Verarbeitbarkeit erhalten bleibt, verlassen sich Betonhersteller stark auf die Zugabe von Zusatzmitteln, um die Abbindezeit des Betons zu verlängern. Diese Praxis führt jedoch zu verdeckten Mängeln und Gefahren, die die langfristige Qualitätssicherheit der Gebäude beeinträchtigen und die Lebensdauer des Betons selbst opfern, was die Produktionskosten für Beton erhöht.
    • (2) Erhöhte Transportkosten für Beton. Die Hin- und Rücktransportkosten von Betonmischfahrzeugen sind erheblich. Jedes Mal, wenn ein Fahrzeug Beton transportiert, muss es gründlich gereinigt werden, was zu einem enormen Verbrauch von Wasserressourcen führt. Darüber hinaus bleibt beim Entleerungsprozess nahezu 5 % des Betons unentleert, was zu erheblicher Verschwendung auf Großbaustellen führt. Darüber hinaus trägt dieser Prozess zu zusätzlichem Energieverbrauch und Umweltverschmutzung bei.
• 2) Nicht einheitliche Betonmischung beeinflusst Festigkeit und Lebensdauer
  • Beton, bestehend hauptsächlich aus Zuschlagstoffen (Sand und Kies), verschiedenen Pulvern, Wasser und verschiedenen Zusatzmitteln, wird gemischt, um die gewünschte Festigkeit oder Güteklasse zu erreichen. Traditionelle Methoden setzen auf eine Verlängerung der Mischzeit, um die Homogenität der Betonkomponenten zu verbessern. Mechanisches Mischen, das hauptsächlich in herkömmlichen Mischgeräten verwendet wird, nutzt die langsame Rotation mechanischer Klingen, um Konvektion, Wirbelbildung und Scherkräfte zwischen den Materialien zu erzeugen und so eine gründliche Durchmischung sicherzustellen. Bei der Zugabe von feinen Pulvern, einschließlich ultrafeiner Partikel im Nanobereich, stoßen mechanische Mischgeräte jedoch auf eine Größenunterschied zwischen der Maschinerie und den Zuschlagstoffen und Pulvern. Folglich können sie die grundlegende Herausforderung der Pulverhomogenisierung nicht bewältigen. Auf mikroskopischer Ebene behalten Pulver lokalisierte individuelle Komponenten bei, was vollständige chemische Reaktionen behindert und zu verborgenen Rissen im Beton führt. Dadurch bleibt das Festigungspotenzial des Betons untergenutzt. Zudem führt die Nicht-Uniformität in der Zusammensetzung zu einer ungleichmäßigen Festigkeitsverteilung in Betonelementen, was eine Erhöhung des Betonfestigkeitskoeffizienten zur Gewährleistung erforderlich macht. Dieses Phänomen führt zur Entstehung von „massiven Balken, kräftigen Säulen und dicken Pfeilern“, was zu einer Verschwendung erheblicher nicht erneuerbarer Ressourcen führt.
• 3) Instabilität bei der Korngrößenverteilung von Sand- und Kieszuschlägen
  • Mechanisch zerkleinerte Sand- und Kieszuschläge stellen die Hauptbestandteile von Beton dar und machen über 75-85 % seiner Zusammensetzung aus. Die Qualität dieser Zuschläge spielt eine entscheidende Rolle für die Gesamtqualität des Betons. Diese Zuschläge weisen signifikante Variationen in der Partikelgröße auf, die von Millimetern bis Mikrometern reichen. Während der Lagerung und des Transports von Sand- und Kieszuschlägen treten unvermeidliche Phänomene der Segregation auf. Die Segregation führt dazu, dass sich feinere Partikel im zentralen Bereich ansammeln, während grobere Zuschläge sich zum äußeren Bereich hin absetzen. Bei der Materialentnahme ist es üblich, Materialien von den äußeren Regionen in Richtung der inneren Regionen zu entnehmen. Folglich nutzen die ersten Chargen des Mischens grobere Zuschläge, während nachfolgende Chargen feinere Zuschläge verwenden. Diese gravierende Inkonsistenz beeinträchtigt die Qualität des Betons erheblich. Jede Charge mechanisch zerkleinerter Sand- und Kieszuschläge besitzt eine einzigartige Korngrößenverteilung, sodass eine präzise Kontrolle über die Rohstoffe in der Betonproduktion unmöglich ist und somit die genauen Messkapazitäten der Mischungsanlage beeinträchtigt werden.
• 4) Fehlende Verbindung zwischen der Produktion von Sand- und Kieszuschlägen und der Materialflusssteuerung in der Betonproduktion
  • Es besteht ein Mangel an Synchronisation zwischen der Produktion von Sand- und Kieszuschlägen und der Materialflusssteuerung in der Betonproduktion, was die Qualität der Betonrohstoffe in gewisser Weise beeinträchtigt. Unternehmen, die auf die Produktion von Sand- und Kieszuschlägen spezialisiert sind, legen den Fokus auf die Kontrolle der Produktionsqualität dieser Zuschläge, während Betonmischanlagen eine präzise Messgenauigkeit priorisieren. Leider fehlen den Zwischenschritten der Lagerung, des Transports und der Handhabung die notwendigen Qualitätskontrollmaßnahmen. Diese unzusammenhängende Vorgehensweise trägt zur Verschlechterung der Betonqualität bei und ist einer der Gründe für die mindere Leistungsfähigkeit des Betons.

An analysis of the reasons for the current problems with concrete is as follows:

• 1) The design of ready-mixed concrete pumping
  • Influenced by environmental policies and the increased demand for concrete performance and quantity, the traditional approach of simple on-site mixing has been replaced by the advanced technology of ready-mix concrete pumping. Ready-mix concrete batching plants have effectively solved the environmental and measurement accuracy problems associated with traditional on-site mixing and are now the predominant construction method for concrete. However, precast concrete batching plants are usually built in remote outskirts, while urban structures are located in city centers. Consequently, after production at the on-site batching plants, the concrete is transported to the construction sites using concrete mixer trucks within a period of 2 hours and then conveyed to high-rise structures using concrete pumps. It is precisely because of this two-hour transport distance that modern concrete quality faces new challenges:
    • (1) Reduced durability of concrete. To ensure that concrete is transported to the construction site within 2 hours while maintaining its workability, concrete manufacturers rely heavily on the addition of admixtures to extend the setting time of the concrete. However, this practice leads to hidden defects and hazards that affect the long-term quality safety of the buildings and sacrifice the life of the concrete itself, increasing the production cost of concrete.
    • (2) Increased transportation costs for concrete. The round-trip transportation costs of concrete mixer trucks are significant. Every time a vehicle transports concrete, it needs to be thoroughly cleaned, which results in huge consumption of water resources. In addition, nearly 5% of the concrete remains undrained during the emptying process, resulting in significant waste on large construction sites. In addition, this process contributes to additional energy consumption and environmental pollution.
• 2) Non-uniform concrete mix affects strength and service life
  • Concrete, consisting primarily of aggregates (sand and gravel), various powders, water and various admixtures, is mixed to achieve the desired strength or grade. Traditional methods rely on extending the mixing time to improve the homogeneity of the concrete components. Mechanical mixing, primarily used in traditional mixing equipment, uses the slow rotation of mechanical blades to create convection, vortexing, and shear forces between materials to ensure thorough mixing. However, when adding fine powders, including nanoscale ultrafine particles, mechanical mixing equipment encounters a size mismatch between the machinery and the aggregates and powders. Consequently, they cannot meet the fundamental challenge of powder homogenization. At a microscopic level, powders retain localized individual components, hindering complete chemical reactions and leading to hidden cracks in concrete. As a result, the concrete's strengthening potential remains underutilized. In addition, the non-uniformity in composition leads to uneven strength distribution in concrete elements, which requires an increase in the concrete strength coefficient to ensure. This phenomenon leads to the creation of “massive beams, stout columns and thick pillars,” resulting in the waste of significant non-renewable resources.
• 3) Instability in the grain size distribution of sand and gravel aggregates
  • Mechanically crushed sand and gravel aggregates are the main components of concrete and make up over 75-85% of its composition. The quality of these aggregates plays a crucial role in the overall quality of the concrete. These aggregates have significant variations in particle size, ranging from millimeters to micrometers. During the storage and transportation of sand and gravel aggregates, inevitable segregation phenomena occur. Segregation causes finer particles to accumulate in the central area, while coarser aggregates settle towards the outer area. When extracting materials, it is common to extract materials from the outer regions towards the inner regions. Consequently, the first batches of mixing use coarser aggregates, while subsequent batches use finer aggregates. This serious inconsistency significantly affects the quality of the concrete. Each batch of mechanically crushed sand and gravel aggregates has a unique particle size distribution, making precise control over the raw materials in concrete production impossible, thereby compromising the accurate measurement capabilities of the mixing plant.
• 4) Lack of connection between the production of sand and gravel aggregates and material flow control in concrete production
  • There is a lack of synchronization between the production of sand and gravel aggregates and the material flow control in concrete production, which affects the quality of concrete raw materials to some extent. Companies specializing in the production of sand and gravel aggregates focus on controlling the production quality of these aggregates, while concrete batching plants prioritize precise measurement accuracy. Unfortunately, the intermediate steps of storage, transport and handling lack the necessary quality control measures. This disjointed approach contributes to the deterioration of concrete quality and is one of the reasons for poor concrete performance.

With the advancement of society, the demand for high-quality concrete in the market is continuously increasing. Therefore, developing a production line for environmentally friendly high-performance concrete that includes both on-site mixing and construction is an urgent technological challenge that needs to be addressed.

Content of this application

Given these circumstances, the aim of this invention is to provide a production line for producing green, ultra-high performance concrete. The production line combines on-site mixing and construction, thus overcoming the shortcomings of existing technologies.

• (1) die Vorbereitung von Rohstoffen für den Zuschlagstoff in einer Zuschlagstoffproduktionslinie;
• (2) die Vorbereitung von Pulvermaterialien aus hochentropischem Zementpulver in einer Pulverproduktionslinie;
• (3) die Bereitstellung einer modularen Mischproduktionslinie auf einer Baustelle, wobei die Zuschlagstoffrohstoffe und die Pulvermaterialien aus hochentropischem Zementpulver auf der Mischproduktionslinie quantitativ verpackt oder direkt gemessen und proportioniert werden. Anschließend werden die Zuschlagstoffrohstoffe und die Pulvermaterialien automatisch zu einer Mischausrüstung transportiert, um den ultrahochleistungsfähigen Beton oder Mörtel herzustellen;
• (4) der ultrahochleistungsfähige Beton wird mittels nahtloser Pumpleitung, Förderband oder Eimerhebemethoden in einen Betonlagerbereich transportiert, um ihn sofort zu gießen.

A method for producing environmentally friendly and ultra-high performance concrete is provided. The method includes:

• (1) the preparation of raw materials for the aggregate in an aggregate production line;
• (2) the preparation of powder materials from high entropic cement powder in a powder production line;
• (3) the provision of a modular mixing production line at a construction site, whereby the aggregate raw materials and the high entropic cement powder powder materials are quantitatively packaged or directly measured and proportioned on the mixing production line. Then, the aggregate raw materials and powder materials are automatically transported to mixing equipment to produce the ultra-high performance concrete or mortar;
• (4) The ultra-high performance concrete is transported to a concrete storage area by seamless pumping line, conveyor belt or bucket lifting methods for immediate pouring.

In some embodiments, the powdered binder is premixed to make the powder materials, and then the aggregate raw materials are mixed with the powder materials to make the ultra-high performance concrete.

In some embodiments, in the powder production line for the powdery binder, pretreatment of the powder binder is performed by uniform dry mixing; the pretreated powder binder is quantitatively packaged and transported to the construction site; Water is uniformly added to the pretreated powder binder and mixed to form a mixed slurry; then the aggregate raw materials and the mixed slurry are mixed to produce the ultra-high performance concrete or mortar.

In some embodiments, the powdered binders are precisely measured and proportioned in the mixing production line and transported to a high speed mix in the powder mixing device to obtain the mixing slurry. The mixed slurry is then mixed on-site with the precisely proportioned and measured aggregate raw materials to produce the ultra-high performance concrete or mortar.

In some embodiments, the aggregate raw materials from the aggregate production line are packaged into aggregate packages according to the requirements of the concrete formula and the dosing requirements of the dosing station. The powder materials from the powder production line are also packed into dry powder packages according to the requirements of the concrete formula and the dosing requirements of the dosing station. At least one packaging for mixing is required for each batch.

In some embodiments, the aggregate raw materials and the powder materials are packaged into mixed dry material packages according to the concrete formula requirements and the batching requirements of the batching station, with at least one package per batch used for mixing.

In some embodiments, the material conveying and metering system is installed in a modular and automated form to measure the aggregate raw materials and the powder materials on site.

In some embodiments, the aggregate raw materials from the aggregate production line and the powder materials from the powder production line are transported and proportioned directly by the material conveying and metering system.

The material conveying and dosing system includes an aggregate conveying and dosing system for measuring and conveying the aggregate raw materials and a powder conveying and dosing system for measuring and conveying the powder materials. The aggregate conveying and dosing system and the powder conveying and dosing system are mounted in a tower or flat configuration depending on the pouring location.

In some embodiments, a wastewater treatment system is mounted at the bottom of the mixing equipment to treat the cleaning water of the mixing equipment. The treated water can be reused to make the concrete.

In some embodiments, the material flow uses 5G signal transmission technology, and the entire material transportation process is equipped with digitalized information monitoring and real-time digital testing and verification of concrete quality.

Compared to existing technology, the present invention discloses an integrated process for on-site batching and construction of environmentally friendly (ultra) high performance concrete. This includes the preparation of coarse and fine raw materials such as technical sand and stone aggregates in the mechanism sand and stone aggregate production line, as well as the transportation of the prepared high-entropy cement powder in the powder production line to a modular, intelligent th mixed production line set up at the construction site. The process uses quantitative packaging or precise measurement of the ingredients or raw materials on the modular intelligent mixing production line, which are then automatically transported to the intelligent mixing equipment to produce the (ultra) high performance concrete or mortar. The (ultra) high performance concrete or mortar is quickly transported to the concrete storage area and immediately poured using seamless pump line, conveyor belt or bucket lifting methods.

It is noteworthy that during the preparation of the high entropic cement powder, a dry mixing method is used in the powder production line to ensure the homogeneity of the cement powder. This guarantees thorough and even mixing during the subsequent concrete production and thus enables (ultra) high-performance concrete. In addition, the use of a modular, intelligent mixing production line on the construction site allows the precise measurement of ingredients and enables direct and rapid transport of concrete or mortar to the concrete storage area for immediate pouring. This effectively solves problems associated with the existing precast process, such as high costs due to the need for mixing trucks, bagging, performance degradation and high energy consumption.

• (1) Präzise Vorverarbeitung des Pulvers: Durch die Vorverarbeitung des Pulvers wird eine gründliche und gleichmäßige Vermischung sichergestellt, was die Homogenität des Betons gewährleistet. Dadurch werden Mängel vermieden, die durch eine ungleichmäßige Vermischung des Pulvers verursacht werden, wie z. B. eine einzelne chemische Zusammensetzung und unzureichende Reaktion, was die Festigkeit des Betons erheblich verbessert.
• (2) Vor-Ort präzise Proportionierung und Dosierung: Während des Vor-Ort-Mischprozesses ermöglichen der Einsatz von präziser Proportionierung und Dosierung oder quantitativen Verpackungstechniken eine genaue Proportionierung und Dosierung. Dies verbessert die Stabilität des Betons und ermöglicht die Herstellung von umweltfreundlichem (ultra) hochleistungsfähigem Beton, wodurch die Probleme mit hohem Kohlenstoffgehalt, geringer Qualität und kurzer Lebensdauer im Zusammenhang mit traditionellen Betonherstellungs- und Bauprozessen gelöst werden. Es bietet auch eine praktikable Lösung für die Kohlenstoff-, Personal- und Höhenbeschränkungen in der Betonindustrie.
• (3) Modulare, abgedichtete Konfiguration: Im Prozess der Vor-Ort präzisen Proportionierung und Dosierung oder quantitativen Verpackung wird eine modulare, abgedichtete Konfiguration verwendet, um das Risiko von Lecks zu minimieren und Staubemissionen zu reduzieren. Dies führt zu geringeren Kosten für die Staubabscheidung und trägt zu einer umweltfreundlichen Vorgehensweise bei.
• (4) Optimierung der Betonzusammensetzung: Die vorliegende Erfindung optimiert die Zusammensetzung von Beton und reduziert effektiv Umweltverschmutzung und Energieverbrauch in der Betonindustrie. Erstens reduziert sie unter Beibehaltung der Betonleistung signifikant den Zementverbrauch. Im Vergleich zu traditionellen Verfahren kann der Zementverbrauch um 50% reduziert werden, wodurch die Kohlenstoffemissionen verringert werden. Zweitens verringert sie die Kosten für den Betrieb von Mischerfahrzeugen. Der produzierte Mischboden kann sofort transportiert und gegossen werden, wodurch die Notwendigkeit für verschiedene Zusatzstoffe zur Aufrechterhaltung der Verarbeitbarkeit über einen Zeitraum von 2 Stunden entfällt. Dadurch bleibt der Beton ohne Absacken intakt, wodurch der Bedarf an übermäßigen Zusatzstoffen zur Aufrechterhaltung der Fließfähigkeit reduziert wird. Darüber hinaus spart es Arbeitskräfte und Ressourcen, die für die Reinigung von Mischerfahrzeugen erforderlich sind, und reduziert so den Wasserverbrauch in der Betonindustrie.
• (5) Verbesserung der Betonstabilität: Durch die Beseitigung verschiedener unkontrollierbarer Faktoren, die die Betonqualität in traditionellen Herstellungsprozessen beeinträchtigen, gewährleistet die vorliegende Erfindung eine verbesserte Stabilität des Betons.

The present invention effectively improves the processing, transportation, proportioning and metering of raw materials, thus enabling the integration of on-site mixing and concrete construction. The specific positive effects are as follows:

• (1) Precise pre-processing of powder: Pre-processing of powder ensures thorough and uniform mixing, which ensures the homogeneity of concrete. This avoids defects caused by uneven mixing of the powder, such as: B. single chemical composition and insufficient reaction, which greatly improves the strength of concrete.
• (2) On-site precise proportioning and dosing: During the on-site mixing process, the use of precise proportioning and dosing or quantitative packaging techniques enable accurate proportioning and dosing. This improves the stability of the concrete and enables the production of environmentally friendly (ultra) high performance concrete, solving the problems of high carbon, low quality and short lifespan associated with traditional concrete manufacturing and construction processes. It also provides a viable solution to the carbon, labor and height constraints in the concrete industry.
• (3) Modular sealed configuration: In the process of on-site precise proportioning and dosing or quantitative packaging, a modular sealed configuration is used to minimize the risk of leaks and reduce dust emissions. This results in lower dust collection costs and contributes to an environmentally friendly approach.
• (4) Optimization of concrete composition: The present invention optimizes the composition of concrete and effectively reduces environmental pollution and energy consumption in the concrete industry. Firstly, it significantly reduces cement consumption while maintaining concrete performance. Compared to traditional methods, cement consumption can be reduced by 50%, reducing carbon emissions. Secondly, it reduces the costs of operating mixer vehicles. The mixed soil produced can be transported and poured immediately, eliminating the need for various additives to maintain workability over a period of 2 hours. This keeps the concrete intact without sagging, reducing the need for excessive additives to maintain flowability. In addition, it saves labor and resources required for cleaning mixer vehicles, thereby reducing water consumption in the concrete industry.
• (5) Improving Concrete Stability: By eliminating various uncontrollable factors that affect concrete quality in traditional manufacturing processes, the present invention ensures improved stability of concrete.

The additional advantages, objects and features of the present invention are explained to some extent in the following section. Furthermore, upon careful study and research of the following context, it will be apparent to those skilled in the art or through the practice of the invention that the objects and other advantages of the present invention can be achieved and achieved through the following specification.

Short description of the drawing

• 1 ist ein erster schematischer Flussdiagramm eines Verfahrens zur Herstellung von umweltfreundlichem und hochleistungsfähigem Beton gemäß der vorliegenden Erfindung.
• 2 ist ein zweites schematisches Flussdiagramm des Verfahrens zur Herstellung von umweltfreundlichem und hochleistungsfähigem Beton gemäß der vorliegenden Erfindung.
• 3 ist ein drittes schematisches Flussdiagramm des Verfahrens zur Herstellung von umweltfreundlichem und hochleistungsfähigem Beton gemäß der vorliegenden Erfindung.
• 4 ist ein viertes schematisches Flussdiagramm des Verfahrens zur Herstellung von umweltfreundlichem und hochleistungsfähigem Beton gemäß der vorliegenden Erfindung.
• 5 ist ein fünftes schematisches Flussdiagramm des Verfahrens zur Herstellung von umweltfreundlichem und hochleistungsfähigem Beton gemäß der vorliegenden Erfindung.
• 6 ist ein sechstes schematisches Flussdiagramm des Verfahrens zur Herstellung von umweltfreundlichem und hochleistungsfähigem Beton gemäß der vorliegenden Erfindung.
• 7 ist ein siebtes schematisches Flussdiagramm des Verfahrens zur Herstellung von umweltfreundlichem und hochleistungsfähigem Beton gemäß der vorliegenden Erfindung.
• 8 ist ein achtes schematisches Flussdiagramm des Verfahrens zur Herstellung von umweltfreundlichem und hochleistungsfähigem Beton gemäß der vorliegenden Erfindung.

In order to more clearly explain the objects, technical solutions and advantages of the present invention, a detailed description is given below in conjunction with the accompanying drawings.

• 1 is a first schematic flow diagram of a process for producing environmentally friendly and high performance concrete according to the present invention.
• 2 is a second schematic flow diagram of the process for producing environmentally friendly and high performance concrete according to the present invention.
• 3 is a third schematic flow diagram of the process for producing environmentally friendly and high performance concrete according to the present invention.
• 4 is a fourth schematic flow diagram of the process for producing environmentally friendly and high performance concrete according to the present invention.
• 5 is a fifth schematic flow diagram of the process for producing environmentally friendly and high performance concrete according to the present invention.
• 6 is a sixth schematic flow diagram of the process for producing environmentally friendly and high performance concrete according to the present invention.
• 7 is a seventh schematic flow diagram of the process for producing environmentally friendly and high performance concrete according to the present invention.
• 8th is an eighth schematic flow diagram of the process for producing environmentally friendly and high performance concrete according to the present invention.

Detailed description of the embodiments

The following detailed description refers to the accompanying drawings and presents the preferred embodiments of the present invention. It should be understood that these embodiments are provided for illustrative purposes only and do not limit the scope of the invention.

• (1) Vorbereiten von groben Zuschlagstoffen in einer Zuschlagstoffproduktionslinie.
• (2) Vorbereiten eines Pulvermaterials aus hochentropischem Zementpulver in einer Pulverproduktionslinie.
• (3) Bereitstellen einer modularen Mischproduktionslinie auf einer Baustelle, wobei die groben Zuschlagstoffe und das Pulvermaterial aus hochentropischem Zementpulver auf der Mischproduktionslinie quantitativ verpackt oder direkt gemessen und proportioniert werden. Die groben Zuschlagstoffe und das Pulvermaterial werden anschließend automatisch zu einer Mischvorrichtung transportiert, um den hochleistungsfähigen Beton oder Mörtel herzustellen.
• (4) Übertragen des hochleistungsfähigen Betons in einen Betonlagerbereich zur sofortigen Verwendung durch nahtloses Pumpen, Förderbandtransport oder Eimerhebemethoden.

Referring to A process for producing environmentally friendly and high-performance concrete is provided. The procedure includes the following steps.

• (1) Preparing coarse aggregates in an aggregate production line.
• (2) Preparing a powder material of high entropic cement powder in a powder production line.
• (3) Providing a modular mixing production line at a construction site, where the coarse aggregates and high entropic cement powder powder material are quantitatively packed or directly measured and proportioned on the mixing production line. The coarse aggregates and powder material are then automatically transported to a mixing device to produce the high-performance concrete or mortar.
• (4) Transferring the high-performance concrete to a concrete storage area for immediate use by seamless pumping, conveyor belt transport, or bucket lifting methods.

In steps (1) and (2), the coarse aggregates produced by the aggregate production line can be transported to the construction site via bulk transportation, modular packaging transportation or quantitative packaging transportation. For materials transported in bulk or bulk packaging, they can be precisely measured on site and transported to intelligent mixing equipment. For materials in quantitative packaging, they can be added to the intelligent mixing equipment in at least one packaging unit per batch.

The powder materials produced by the powder production line can be transported to the construction site via bulk transportation, modular packaging transportation or quantitative packaging transportation. Modular packaging transportation or quantitative packaging transportation can be carried out by separate measurement packaging or mixed packaging after measurement. For materials transported in bulk or in large packaging, they can be precisely measured on site and added to the intelli Gent mixing equipment can be transported. For materials in quantitative packaging, they can be added to the intelligent mixing equipment in at least one packaging unit per batch.

In step (2), the powdered cement mixture is first subjected to a high-entropic homogeneous mixture to produce high-entropic powdered raw material. This is then mixed at low speed with the aggregates to produce the ultra-high strength concrete or mortar product.

The highly entropic cement powder is preferably produced by dry mixing and packaged uniformly in the production line. It is then transported to the construction site where water is added to achieve a high entropic homogeneous mixture and produce a blend. The mixture is then mixed with the aggregates (sand and gravel) to produce ultra-high-strength concrete or mortar products. The high entropy cement powder production line mentioned here refers to a powder production plant that produces, measures and performs high entropy mixing of concrete powder raw materials.

In addition, it is possible to use precise control and measuring methods for dosing the raw materials on site. In particular, the high-entropic cement powder, when supplied in loose form, is precisely measured and dosed in a modular intelligent mixing production line. The material is then automatically conveyed to the high speed mixing device to ensure thorough and homogeneous mixing, resulting in a blend. This mixture is then mixed with precisely measured on-site sand and gravel aggregates to produce (ultra) high-strength concrete or mortar products.

In a preferred embodiment, a modular assembly of an automated material conveying and metering system is installed at the construction site. This system enables precise on-site measurement of aggregates and powder materials. Specifically, the automated material conveying and dosing system is designed as a modular unit, facilitating easy transport and lifting. It can be quickly assembled on site using lifting equipment and ready for immediate use.

More preferably, the modular assembly of the automated material conveying and dosing system is used for the direct modular transport and dosing of the manufactured sand and gravel aggregates from the production line as well as the concrete powder materials from the powder production line. Specifically, the sand and gravel aggregates produced in the sand and gravel production line and the concrete powder materials produced in the powder production line are directly loaded into the automated material conveying and dispensing system. They are then transported modularly to the construction site, where they are subjected to precise on-site measurement and transported to the intelligent mixing equipment to produce (ultra) high-strength concrete or mortar products. This approach effectively solves the dust problems associated with transportation and on-site preparation, ensuring environmental friendliness and high production efficiency.

More preferably, the containerized automated material conveying and metering system includes an aggregate conveying and metering system for transporting and metering the produced sand and gravel aggregates and a powder conveying and metering system for transporting and metering the powder materials. These systems can be arranged in a vertical station or in a flat configuration depending on the requirements of the operating site. Specifically, the aggregate conveying and dosing system and the powder conveying and dosing system can be arranged depending on the size of the construction site. For larger construction sites, a flat configuration can be used, where the aggregate conveying and dosing system and the powder conveying and dosing system are placed separately on the construction site and connected to the intelligent mixing equipment. For narrower construction sites, vertical station assembly can be used, where the aggregate conveying and dosing system and the powder conveying and dosing system are stacked in a modular structure. The aggregate conveying and dosing system and the powder conveying and dosing system can be positioned on any finished building floor, either on the same floor or on different floors.

Alternatively, the modular quantitative packaging process can be used for direct material placement. Specifically, in the sand and gravel production line, the produced sand and gravel aggregates can be packed into aggregate bags according to the concrete formulation requirements and the dosage requirements of the mixing plant. In the powder production line, the concrete powder materials can be customized during the production process according to the concrete formulation requirements and Packed in dry powder bags according to the dosage requirements of the mixing system. Both the aggregate bags and the dry powder bags can be used for dosing in quantities of at least one bag per batch.

It is preferred to use an integrated sand and gravel production line and powder production line to pack the produced sand and gravel aggregates and powder materials into mixed dry packs according to the concrete formulation requirements and the dosage requirements of the mixing plant. The mixed dry packs are then used for dosing in quantities of at least one pack per batch. This integrated approach facilitates management and transportation, reduces transportation costs and improves production efficiency.

A wastewater treatment system is integrated at the bottom of the mixing equipment to treat the water used for mixing and cleaning the construction equipment. The treated water can be recycled and reused to make concrete or mortar. This recycling of wastewater promotes energy savings and environmental sustainability.

In the above integrated process, the material flow can be transmitted using 5G signal technology, and the whole process is digitally monitored and controlled, with online digital detection and verification of concrete quality. This enables automated and intelligent production.

The aggregate production line for producing manufactured sand and gravel aggregates includes mechanism fine aggregates with a grain size of 0-5mm, mechanism mica stones with a grain size of 5-10mm and mechanism crushing stones with a grain size of 10-20mm.

The powder production line prepares cement powder, ordinary stone powder, ultra-fine stone powder and mineral additives. The mineral additives may include two or more of the following ingredients: coal ash, mineral powder, silica, quartz powder and microspheres. The dry mix opening process is used to homogeneously mix and prepare the powder materials for high entropic cement powder.

Compared to traditional on-site mixing plants, the present invention effectively improves the handling, transportation, dosing and sizing of raw materials. Firstly, it ensures thorough and even mixing of the powder materials, ensuring the homogeneity of the concrete. This avoids defects that can arise from uneven mixing of the powder, such as: B. uneven chemical composition and incomplete reactions. This improves the strength of the concrete. Secondly, it enables precise dosage and dimensions, which increases the stability of the concrete. Finally, it promotes environmentally friendly practices by effectively preventing dust generation during the transportation of raw materials and concrete production.

Compared to conventional precast processes, the present invention allows the concrete or mortar to be transported and poured directly onto the concrete surface in a very short time. This effectively solves the problems associated with high cost, decrease in formability and performance degradation due to the need for intermediate transfers by mixer trucks in traditional precast methods. This also leads to a reduction in energy consumption.

The raw material information used in Examples 1-5 includes: Conch brand cement grade 425, Mingchuan grade II fly ash, Haotong S95 grade mineral powder, self-made polycarboxylate superplasticizer (solid content: 12%), medium Sand and 5-25mm of broken stone from the mechanism.

This baseline experiment used the traditional precast pumping process with a C30 mix. The settling value was 220±20mm, the settling time was 2 hours and the settling loss was less than 20mm. The propagation diameter was φ550±20mm. Example 1: Production of concrete using traditional formula and methods. raw materials cement Coal ash slag Manufactured sand Manufactured gravel Additives Water Consumption (kg/m ² ) 240 50 50 900 1000 6 165

Taking the production of 1 m3 of concrete as an example, according to the traditional concrete production process, the aggregates and powder are transferred from the storage tanks to the mixing plant. Using the material dosing and measuring system, the additives and powder are added separately to the mixing device in the correct proportions. After adding admixtures and water, the concrete is mixed and produced.

Example 2 uses the traditional formula and combines a precisely site-proportioned, measuring and powder premixing process to produce concrete.

The aggregates are stored in containers and the dry powder is packed proportionally according to the class. Let's take C30 concrete as an example. raw materials cement Coal ash slag Manufactured sand Manufactured gravel Additives Water Consumption (kg/m ² ) 240 50 50 900 1000 5 165

The aggregates and dry-mixed powder are transferred from the storage tanks to the mixing station. First, the dry powder is proportionally mixed with water using the material dosing and measuring system to obtain a slurry. The aggregates and slurry are then fed proportionally into the mixing device. After adding admixtures and water, the mixture is stirred to make concrete. In this experiment, the same formula as in Example 1 is used to verify the improvement in concrete performance using the method described in Example 2 under the same conditions and with the same raw materials.

Since this invention is suitable for on-site use, the requirement for the workability of traditional ready-mixed concrete with pumpability is not very high. Therefore, the required workability can be achieved with a reduced dosage of additives to achieve a workability with a slump value of 220 ± 20 mm, a setting time of 2 hours, a slump loss of < 20 mm and a spreading diameter of φ550 ± 20 mm to achieve.

In Example 3, the traditional formula is used in combination with the modular packaging process for raw materials and the dry powder premix process for concrete production.

The aggregates are packaged whole according to a certain ratio, and the dry powder, which has been dry-mixed according to the specifications, is packaged proportionally. Let's take C30 concrete as an example, the process is as follows. raw materials cement Coal ash slag Manufactured sand Manufactured gravel Additives Water Consumption (kg/m ² ) 240 50 50 900 1000 4.5 165

In Example 3, the aggregates are processed into aggregate packages at the aggregate production site, while the dry powder, which has already been dry-mixed, is processed into powder packages at the powder production site. These packets are then added to the mixer along with the additive and water using a mixing ratio of 1 packet per batch. After mixing, the resulting mixture is used to make concrete. In this experiment, the same formula as in Example 1 is used to demonstrate the improved performance of concrete To demonstrate the use of the method described in Example 3 under the same conditions and with equivalent raw materials.

Since the present invention is suitable for on-site use, the requirements for the workability of traditional ready-mixed concrete with pumpability are not very high. Therefore, the required workability can be achieved with a reduced dosage of additives to achieve a slump value of 220 ± 20 mm, a slump holding time of 2 hours, a slump loss of less than 20 mm and an expansion of φ550 ± 20 mm to reach.

Example 4 adopts the identical production method as Example 2, while changing the formula in Example 4 to achieve the results of Example 1. raw materials cement Coal ash slag Manufactured sand Manufactured gravel Additives Water Consumption (kg/m ² ) 190 60 60 880 1050 4.5 160

By using the same production process as in Example 2 and optimizing the formulation, we were able to achieve concrete products with mechanical performance results comparable to those found in Example 1. In addition, a cost savings analysis was carried out.

Example 5 adopts the identical production method as Example 3, while changing the formula in Example 5 to achieve the results of Example 1. raw materials cement Coal ash slag Manufactured sand Manufactured gravel Additives Water Consumption (kg/m ² ) 160 50 50 880 1050 4 150

By using the identical production methodology as in Example 3 and by optimizing the formulation, we have achieved a product that has mechanical performance comparable to the tested results of Example 1. In addition, we will analyze the cost saving ratio.

Experimental tests

1. The mechanical performance of the concrete was according to the standard GB/T50081-2019 “Standard Test Methods for Mechanical Properties of Concrete” tested.

2. The experimental test results on the mechanical performance of the concrete in Examples 1-5 and the cost saving analysis are presented in the table below. Detection element Examples 1 Examples 2 Examples 3 Examples 4 Examples5 Compressive strength (MPa) 33.1 38.9 41.2 34.1 33.5 Cement saving (%) / / / 20.80% 33.30% Increase in strength (%) / 17.52% 24.47% 3.02% 1.21% Water resistance index P6 P8 P10 P8 P8

From the experimental results in the table it can be seen:

The mechanical properties of the concrete prepared in Examples 2-5 still meet the requirements for use. In Examples 2-3, the mechanical performance of the concrete shows a significant improvement with a strength increase of more than 15%. In Examples 4-5, with comparable mechanical properties to Example 1, a cement saving of over 20% is achieved, which leads to a significant reduction in the economic costs of the concrete.

Waterproofing has been improved from the usual P6 level to P8 or higher.

Based on the above, the integrated process described in this invention offers several advantages. First, it improves the homogeneity of the concrete slurry components, resulting in a more uniform flowability and homogeneity of the concrete product. Secondly, the integrated on-site mixing and pouring process, combined with accurate on-site proportioning or quantitative packaging of raw materials, addresses the problems of measurement errors and quality deviations commonly encountered in traditional commercial concrete plants. As a result, the manufactured concrete products show significant improvements in various performance aspects while achieving significant energy cost savings.

The above description is merely the preferred embodiment of the present invention and should not be interpreted as limiting the invention in any way. Any simple modifications, equivalent variations or refinements based on the technical essence of the present invention are still within the scope of the invention.

QUOTES INCLUDED IN THE DESCRIPTION

This list of documents listed by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• GB 500812019 T [0057]

Claims (10)

Method for producing a green and ultra-high performance concrete, characterized by : (1) preparation of aggregate raw materials in an aggregate production line; (2) preparing a powder material of high entropy powdered cement in a powder production line; (3) Providing a modular mixing production line at a construction site, whereby the aggregate raw materials and the high entropy powdered cement powder materials are measured and dosed using quantitative packing or direct measurement on the mixing production line; wherein the aggregate raw materials and the powder materials are then automatically conveyed to a mixing plant to produce the ultra-high performance concrete or mortar; And (4) conveying the ultra-high performance concrete to a concrete storage area for immediate pouring using seamless pumping, belt conveying or bucket lifting methods. Procedure according to Claim 1 , characterized in that to produce the powder materials, the powdered cement is premixed and then the aggregate raw materials are mixed with the powder materials to produce the ultra-high-performance concrete. Procedure according to Claim 2 , characterized in that in the powder production line for the powdered cement, the pretreatment of the powder takes place in a uniform dry mixture; quantitative packaging and transportation of the pretreated cement powder to the construction site; Add and evenly mix water to the pretreated cement powder to form a mixed slurry; and mixing the aggregate raw materials and the mixed slurry to produce the ultra-high performance concrete or mortar. Procedure according to Claim 2 , characterized in that the powdered cements are accurately measured and dosed in the mixing production line and conveyed to the powder mixing plant for high-speed mixing to obtain the mixing slurry; To produce the ultra-high-performance concrete or mortar, the mixed slurry is precisely dosed and mixed with the aggregate raw materials on site. Procedure according to Claim 3 , characterized in that the aggregate raw materials from the aggregate production line are packaged into aggregate packages in accordance with the requirements of a specific recipe and the dosing requirements of the dosing station; The powder materials from the powder production line are packed into dry powder packages according to the requirements of the concrete recipe and the dosage requirements of the batching station, with both batches requiring at least one package per batch for mixing. Procedure according to Claim 2 , characterized in that the aggregate raw materials and the powder materials are packaged in mixed dry material packages according to the requirements of the concrete recipe and the dosage requirements of the dosage station; with at least one pack per batch used for mixing. Procedure according to Claim 2 , characterized in that the material conveying and dosing system is installed on site in a modular and automatic form for dosing the aggregate raw materials and the powder materials. Procedure according to Claim 6 , characterized in that the aggregate raw materials obtained from the aggregate production line and the powder materials obtained from the powder production line are directly conveyed and metered through the material conveying and metering system; wherein the material conveying and metering system includes an aggregate conveying and metering system for measuring and transporting the aggregate raw materials and a powder conveying and metering system for measuring and transporting the powder materials; The aggregate conveying and dosing system and the powder conveying and dosing system are mounted in a tower or flat configuration depending on the casting location. Procedure according to Claim 1 , characterized in that a wastewater treatment system for treating cleaning water of the mixing system is attached to the bottom of the mixing system; A recycled water can be reused to make the concrete. Procedure according to Claim 1 , characterized in that the material flow uses 5G signal transmission technology, and the entire material handling process is equipped with digitalized information monitoring and real-time digital detection and verification of concrete quality.

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