EP4017838A1 - Brique rouge et son procédé de préparation - Google Patents

Brique rouge et son procédé de préparation

Info

Publication number
EP4017838A1
EP4017838A1 EP19942372.4A EP19942372A EP4017838A1 EP 4017838 A1 EP4017838 A1 EP 4017838A1 EP 19942372 A EP19942372 A EP 19942372A EP 4017838 A1 EP4017838 A1 EP 4017838A1
Authority
EP
European Patent Office
Prior art keywords
red
brick
mixture
red brick
bricks
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.)
Pending
Application number
EP19942372.4A
Other languages
German (de)
English (en)
Other versions
EP4017838A4 (fr
Inventor
Satish Narain JAJOO
Rajesh Kumar Saini
Anil Kumar Pandey
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Hindalco Industries Ltd
Original Assignee
Hindalco Industries Ltd
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Hindalco Industries Ltd filed Critical Hindalco Industries Ltd
Publication of EP4017838A1 publication Critical patent/EP4017838A1/fr
Publication of EP4017838A4 publication Critical patent/EP4017838A4/fr
Pending legal-status Critical Current

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • C04B28/04—Portland cements

Definitions

  • the present disclosure relates to red bricks made up of waste material generated in power plant and alumina refinery.
  • the present disclosure also related to a process of preparation of red bricks using the waste material generated in power plant and alumina refinery.
  • Bricks are the most used building materials in construction industry. It is being used to construct walls, foundations and many other parts of buildings and other masonry structures. Bricks are laid in courses and other many patterns termed as bond, it may be laid with various kinds of mortar to hold the bricks together and make a durable structure. The structures may be load bearing or just partition walls.
  • clay bricks There are many types of bricks available based on their use, size, forming methods, quality and material used for construction. Most common are clay bricks and chemically set bricks. Generally, clay bricks are baked in kiln after moulding and drying. Chemically set bricks are mixed with chemical or cement moulded and dried in open air and curing with watering or without watering. It gains strength with chemical reaction within it and therefore, there is no need of baking in kiln.
  • Red mud is an industrial waste from an alumina-producing industry.
  • the red mud is composed mainly of iron oxide, and hence is red in colour.
  • the quantity of red mud produced per ton of alumina produced, is generally about 1-2.5 tons.
  • the red mud is generally disposed of, posing environmental problems.
  • Chinese Patent Application Number CN101468905 discloses red mud unburned brick which mainly consists of 5-30 parts of red mud, 20-30 parts of fly ash, 20-50 parts of quartz sand or gravel powder, 5-15 parts of lime, 2-8 portions of gypsum and 0-3 parts of cement.
  • Chinese Patent Application Number CN1079452 discloses a red mud composite brick comprising red mud, fly ash, lime, gypsum and sand.
  • Another Chinese Patent Application Number CN101215142 relates to Bayer red mud composite brick, prepared by mixing raw materials of 20-35 parts of Bayer red mud, 15-34 parts of fly ash, 5-15 parts of carbide slag, 30-40 parts of slag, 5-12 parts of cement and 0-5 parts of gypsum.
  • Chinese Patent Application Number CN 101020603 discloses light red mud brick and its making process. The red brick in this publication is composed of 15-50 parts of red mud, 35-70 parts of fly ash, 8-12 parts of lime and 4-6 parts of silica sand.
  • carbide lime mostly used and it is by product of gas making plants and does not meet consistency in quality. Purity of such lime varies from 40 to 70%. Due to such non-consistency of lime quality, brick quality also gets affected and varies in compressive strength. Therefore, there is a need for an alternative to compositions using lime.
  • the primary object of the present disclosure is to provide a red brick comprising red mud; bottom ash; natural sand; fly ash; and Portland cement.
  • Another objective of the present disclosure is to provide a red brick having compressive strength of not less than 75 kg/cm 2 .
  • Yet another objective of the present disclosure is to provide a process for preparing a red brick.
  • an objective of the present disclosure is to provide a red brick made up of waste material generated in power plant and alumina refinery.
  • the present disclosure relates to a red brick comprising: 20-50 wt% of red mud; 10-20 wt% of bottom ash; 10-30 wt% of natural sand; 15-30 wt% of fly ash; and 4-15 wt% of Portland cement.
  • the present disclosure also relates to a process for preparing a red brick comprising: mixing 20-50 wt% of red mud, 10-20 wt% of bottom ash, 10-30 wt% of natural sand to form a first mixture; adding 15-30 wt% of fly ash and 4-15 wt% of Portland cement to the first mixture to form a second mixture; rolling the second mixture in a pan mixer having roller and scraper to produce a final mixture; moulding the final mixture in a brick press to provide a pressed red brick; and stacking the pressed red brick in yards to form a red brick.
  • the present disclosure provides a red brick comprising: 20-50 wt% of red mud; 10-20 wt% of bottom ash; 10-30 wt% of natural sand; 15-30 wt% of fly ash; and 4-15 wt% of Portland cement.
  • the red brick of the present disclosure has compressive strength of not less than 75 kg/cm 2 .
  • the red mud is a bi-product of Alumina refinery in aluminum manufacturing plant. It is generated in the process of extracting alumina from Bauxite ore. It is approx. 50 to 60 % of Bauxite used for alumina extraction. After drying and sieving the red mud (collected from pond), it is ready to use for red brick manufacturing.
  • the fly ash used in the present application has a particle size in the range of 90 Micron to 600 Micron.
  • the fly ash is very fine material generated in thermal power plant in process of burning coal in boilers to produce thermal energy.
  • the total ash generation is normally 40% of coal fed in boilers.
  • the fly ash generation is approx. 80% of total ash generation. Normally it is collected through electrostatic precipitators. Fly ash has a higher reactivity, and it acts as binding materials in reaction with cement.
  • the fly ash is directly mixed in red brick manufacturing.
  • the bottom ash has a particle size in the range of 0.15 mm to 4.75 mm.
  • the bottom ash is also a bi-product of coal burning in boilers of thermal plant. It is coarser in nature. Bottom ash generation is approx. 20% of total as generation in thermal power plant. Bottom ash has a reactivity value of 5-7% which helps to increase the strength of the brick. Due to less reactivity, bottom ash also acts as filler material like natural sand. After getting desired particle size, it is ready to use in red brick manufacturing.
  • the natural sand has a particle size in the range of 0.3 mm to 4.75 mm. Natural sand is found in river bed. The dried sand is cleaned to remove any foreign materials and it is ready to use in red brick manufacturing. Natural sand acts as a filler material.
  • Bottom ash has lesser number of coarse particles in comparison to natural sand.
  • a combination of sand and bottom ash meets the desired particle size distribution of the composition of the composition for better workability of mix during the manufacturing of red bricks.
  • Portland cement is a standard product available in market. It is a binding material commonly used in building construction industries. It reacts with filler materials and develops strength. It is directly added in red brick manufacturing.
  • the Portland cement contains gypsum. Gypsum is available as a bi-product of chemical and fertilizer industries. Gypsum also influences the setting process of brick and gaining early strength.
  • the present disclosure also provides a process for preparing a red brick comprising: mixing 20-50 wt% of red mud, 10-20 wt% of bottom ash, 10-30 wt% of natural sand to form a first mixture, adding 15-30 wt% of fly ash and 4-15 wt% of Portland cement to the first mixture to form a second mixture, rolling the second mixture in a pan mixer having roller and scraper to produce a final mixture, moulding the final mixture in a brick press to provide a pressed red brick, and stacking the pressed red brick in yards to form a red brick.
  • the rolling of second mixture in the pan mixer is carried out for 3 minutes, at 28-35 °C.
  • the molding of final mixture is carried out for 30 Sec, at 28-35 °C.
  • the stacking of pressed red brick is carried out for 3 days inside shed and 12 days in open yard, at atmospheric temperature and pressure. Further, the natural sand is dried and cleaned to remove foreign materials before mixing with red mud and bottom ash to obtain
  • the developed red bricks are made using 70% waste material generated in power plant and alumina refinery. These bricks are not required to burn in kiln and no air pollution is caused due to burning of huge coal in normal lay bricks production.
  • the parameters such as Compressive Strength, Size, Weight, Water Absorption and Efflorescence, of the red bricks of the present application are comparative to normal clay bricks which are commercially available.
  • red bricks gain required strength in 15 days in open area and ready to use. As it is machine produced so there is no any dimensional variation, it is little higher in weight but very little water absorbent.
  • the advantages of the present disclosure include utilization of waste generated in power plant and alumina refineries, up-cycling of waste to useful product, low costs as machine production is involved. As no precious earth/clay is being used, and no coal is burnt as it is a cold setting material, it also saves environment. There is no deformation in shape and size, and the red bricks are comparable to normal clay bricks in shape, size, appearance and strength.
  • EXAMPLE 1 Preparation of Red Brick 13 wt% of Bottom ash in the particle size range of 0.15 mm to 4.75 mm, 20 wt% of natural sand in the particle size range of 0.3 mm to 4.75 mm and 31 wt% of red mud were mixed to form a first mixture. To this first mixture, 25 wt % of fly ash in the particle size range of 45 pm to 600 pm, and 11 wt % of Portland cement were added and mixed to form a second mixture. The second mixture thus formed was then rolled for 3 minutes in a pan mixer having roller and scraper at 30 °C to produce final mixture. This final mixture was moulded for 30 seconds in a brick press at 30 °C to provide a pressed red brick. The pressed red brick was stacked for 3 days inside shed and 12 days in open area in yards at atmospheric temperature and pressure to form a red brick.
  • the red brick thus formed has a composition as set out in the table below -
  • the red brick thus formed has a composition as set out in the table below -
  • the red brick thus formed has a composition as set out in the table below -
  • the red brick thus formed has a composition as set out in the table below -
  • 15 wt% of Bottom ash in the particle size range of 0.15 mm to 4.75 mm, 15 wt% of natural sand in the particle size range of 0.3 mm to 4.75 mm and 45 wt% of red mud were mixed to form a first mixture.
  • 17 wt % of fly ash in the particle size range of 45 pm to 600 pm, and 8 wt % of Portland cement were added and mixed to form a second mixture.
  • the second mixture thus formed was then rolled for 3 minutes in a pan mixer having roller and scraper at 35 °C to produce final mixture.
  • This final mixture was moulded for 30 seconds in a brick press at 35 °C to provide a pressed red brick.
  • the pressed red brick was stacked for 3 days inside shed and 12 days in open area in yards at atmospheric temperature and pressure to form a red brick.
  • the red brick thus formed has a composition as set out in the table below - Table 5.
  • Composition of the Red Brick 5 EXAMPLE 6: Testing of compressive strength of red bricks
  • red bricks of the present disclosure were tested for compressive strength in comparison with the commercially available clay bricks, such as MEERA, DLX, SAMAJ, TRISHOOL, KAMAL and JAMUNA. Comparison of the compressive strengths are shown in the table below -
  • the red bricks of the present disclosure exhibit superior compressive strength than the red bricks with lime but without bottom ash.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Processing Of Solid Wastes (AREA)
  • Press-Shaping Or Shaping Using Conveyers (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)
  • Preparation Of Clay, And Manufacture Of Mixtures Containing Clay Or Cement (AREA)

Abstract

La présente invention concerne une brique rouge comprenant : 20 à 50 % en poids de boue rouge ; 10 à 20 % en poids de mâchefer ; 10 à 30 % en poids de sable naturel ; 15 à 30 % en poids de cendres volantes ; et 4 à 15 % en poids de ciment Portland. La présente invention concerne également un procédé de préparation d'une brique rouge consistant : à mélanger 20 à 50 % en poids de boue rouge, 10 à 20 % en poids de mâchefer, 10 à 30 % en poids de sable naturel afin de former un premier mélange, à ajouter 15 à 30 % en poids de cendres volantes et 4 à 15 % en poids de ciment Portland au premier mélange afin de former un second mélange, à laminer le second mélange dans un mélangeur à plateau ayant un rouleau et un racleur afin de produire un mélange final, à mouler le mélange final dans une presse à briques afin d'obtenir une brique rouge pressée, et à empiler la brique rouge pressée dans des chantiers afin de former une brique rouge.
EP19942372.4A 2019-08-22 2019-11-20 Brique rouge et son procédé de préparation Pending EP4017838A4 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IN201911033876 2019-08-22
PCT/IN2019/050858 WO2021033193A1 (fr) 2019-08-22 2019-11-20 Brique rouge et son procédé de préparation

Publications (2)

Publication Number Publication Date
EP4017838A1 true EP4017838A1 (fr) 2022-06-29
EP4017838A4 EP4017838A4 (fr) 2023-10-11

Family

ID=74660639

Family Applications (1)

Application Number Title Priority Date Filing Date
EP19942372.4A Pending EP4017838A4 (fr) 2019-08-22 2019-11-20 Brique rouge et son procédé de préparation

Country Status (5)

Country Link
EP (1) EP4017838A4 (fr)
CN (1) CN114787099A (fr)
AU (1) AU2019462547A1 (fr)
BR (1) BR112022003387A2 (fr)
WO (1) WO2021033193A1 (fr)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN113264715B (zh) * 2021-05-24 2022-07-29 燕山大学 基于生活垃圾焚烧飞灰的重金属固化性免烧砖及其制备方法

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN100471816C (zh) * 2006-09-07 2009-03-25 贵阳白云耀筑新型建筑材料厂 一种赤泥轻质砖及其制备方法
CN101456703A (zh) * 2007-12-12 2009-06-17 孙建树 赤泥免烧砖的生产工艺
CN101468905A (zh) * 2007-12-28 2009-07-01 刘贵堂 赤泥免烧砖及其制备方法
CN101215142A (zh) * 2008-01-04 2008-07-09 华中科技大学 一种拜耳法赤泥复合砖及其生产方法
WO2018037422A1 (fr) * 2016-08-22 2018-03-01 Hindalco Industries Limited Matériau de plâtre prêt à l'emploi préparé à l'aide de déchets industriels

Also Published As

Publication number Publication date
CN114787099A (zh) 2022-07-22
EP4017838A4 (fr) 2023-10-11
BR112022003387A2 (pt) 2022-05-17
WO2021033193A1 (fr) 2021-02-25
AU2019462547A1 (en) 2022-04-07

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