ES2424829B1 - Treatment procedure for recycling ceramic glazes as ceramic muds, for use as artificial pozzolans and reuse for all kinds of cements and asphalt mixtures - Google Patents

Abstract

Treatment procedure for recycling ceramic glazes as ceramic muds, for use as artificial pozzolans and reuse for all kinds of cements and asphalt mixes. # The objective of this patent is to use a new addition for cements and asphalt mixes. that solves an environmental problem produced by the leftovers of manufacturing processes in the ceramic industry. More specifically, the leftover recovery procedure includes: biological treatment; separation of liquid and solid parts; adjustments and potential of the pH, conductivity, salinity and TDS (total dissolved salts) of the liquid portion; weather drying of the solid portion in impermeable soil with conduits to collect leachates; crushed in jaw cylinders, mechanical dust collection; drying; continuous mill grinding and recovery with electrostatic precipitation of impalpable particles; and storage.

Description

Treatment procedure for recycling ceramic glazes as ceramic muds, for use as artificial pozzolans and reuse for all kinds of cements and asphalt mixtures.

Technique sector

The invention falls within the technical sector of construction, more specifically in relation to cements and asphalt mixtures. It also affects the ceramic sector as it is based on the reuse of its alumina silicates left over from the production process (ceramic mud).

Object of the invention

In the Spanish technical instruction for structural concrete and in its chapter 29 section 2 regarding additions, it indicates what inorganic, pozzolanic or latent hydraulicity materials that can be finely divided can be added to the concrete to improve some of its technical characteristics. As well as that in the article

29.2.1 of the same EHE technical instruction, some prescriptions are given that the pozzolans have to comply with. After the chained series of physical treatments, including thermal treatments, this alumina-silicate is fully complied with.

Properly treated ceramic enamels as alumina-silicates left over from the production process enjoy these properties. It is also possible to add a certain amount of this pozzolanic product to all kinds of asphalt mixes.

Thus, the object of this invention is, on the one hand, to recycle a surplus from the ceramic industry and, on the other hand, to obtain a product for the construction sector, with the same or better properties than the standard, with the consequent economic and environmental savings due to the use of this leftover.

Hence the protection in this patent "Treatment procedure for recycling ceramic glazes as ceramic muds, for use as artificial pozzolans and reuse for all kinds of cements and asphalt mixtures."

State of the art

Large amounts of waste and leftovers are generated in the European ceramic sector, but the one that quantitatively occupies the first place is ceramic enamels as alumina-silicates from the production process, of which a capable method is still not available today. for the total reuse of the same.

Although there are some ceramic processes to absorb a portion of these residues and surpluses, an important part of them still remains to be reused. Possible sectors for reuse are cements and asphalt mixes.

It can be shown that the alumina-silicates from the production process are mainly formed by remains of enamels. These alumina-silicates have a chemical and mineralogical composition similar to that of a ceramic enamel, a part with a glassy phase and another composed of minerals such as quartz, zircon, feldspars, carbonates, alumina and clay mineral (kaolin) as crystalline phases, in addition to a small proportion of ceramic dyes.

These alumina-silicates presented in the form of mud from the frits and ceramic glazes used and specifically in their glassy phase, have great internal activity. Presenting, by their nature, true electrolytic phenomena, due to the presence of divalent cations both high and low ionic radio. Note that glasses are highly viscous liquids at room temperature, so they resemble solid bodies.

Detailed description of the invention

The ceramic enamels as alumino-silicates from the production process in the way they are generated, have little pozzolanic activity, which means that they have to undergo treatment in order for it to appear. Said treatment comprises the following steps:

•

Collection of the ceramic excess generated in the cleaning of mills, tanks and pipes. Also at the points of application of ceramic enamels on the enamel lines.

•

Transfer of these surpluses to the treatment plant, which will necessarily be carried out by an authorized intermediate manager. According to Spanish regulations.

•

From here on, all operations must be carried out by an authorized manager, also in accordance with Spanish regulations.

•

Previous, primary and secondary biological treatment in E.D.A.R.

•

Liquid-solid separation.

5 • Treatment of the liquid portion, until reaching the appropriate parameters for its reuse in the preparation of ceramic slips.

• The solid portion at a density of 1,700 gr / 1 is pumped to a splicer where compact cylinders are obtained, with a humidity that is eliminated when passing them to a horizontal dryer. Endowing

1O alumino-silicates from a first heat treatment.

•

The solid portion can also be sent to vertical drying towers, by countercurrent hot air at 500-600 ° C (high heat treatment).

•

Crushing at particle size less than 45 microns, electrostatic precipitation

of the impalpable fraction. High heat treatment, thus increasing the pozzolanic activity of the alumino-silicates by 55.66%.

• Storage in silos for subsequent loading and transportation, carried out by an authorized carrier.

The reuse of ceramic enamels as ceramic mud has the

The main advantage is to valorize some leftovers, transforming one into a product with pozzolanic activity (solid), and the other into water (liquid) for reuse in ceramic slips.

The pozzolanic product obtained is useful for use together with cements, water and

25 aggregates as well as asphalt mixes. On the one hand, very significant energy savings are achieved by replacing part of the cement and asphalt mix with the pozzolanic product. On the other hand, it achieves that the final products obtained have a superior quality.

30 Method of implementation and application The product is born to deal with the milling processes in suitable mills and the cleaning of the deposits (cocios) that contain them, as well as the cleaning of the pipes that transport them and also of spills and cleaning of the application points in the enameling lines.

These leftovers are stored in this industry in rafts, from where they are extracted by suction by authorized intermediate managers (transport).

They are then deposited with authorized managers to either reuse them in the composition of ceramic slips or leave them in controlled landfills.

It is proposed in this patent of "Treatment procedure for recycling ceramic glazes as ceramic mud, for use as artificial pozzolans and reuse for all kinds of cements and asphalt mixtures ·, perform a treatment consisting of:

one.

Perform as in any E.D.A.R. with its usual procedural methods, a previous treatment, a primary treatment and a secondary treatment by the biological procedure. That is to say, to reproduce in a controlled installation, the treatment that nature performs to the waters.

2.

Also perform the liquid-solid separation as in any E.D.A.R.

3.

Adjust pH, pH potential, conductivity, salinity, and T.D.S. of the liquid portion, for reuse in the preparation of ceramic slips. Specifically, adjust the pH until its values are between 8 and 11; the conductivity in microsiemens / cm is between 900 and 11 00; the potential pH is between -90 and -120; TDS (total dissolved salts) in mg / 1 between 500 and 600 as well as salinity between 0.3 and 0.6.

Four.

The solid portion at a density of 1,700 gr / 1 is pumped to a coater where compact cylinders are obtained, with a humidity that is eliminated when passing them to a horizontal dryer. Giving the alumino-silicates a first heat treatment.

5.

The solid portion can also be sent to vertical drying towers, by countercurrent hot air at 500-600 ° C (high heat treatment).

6.

Grinding of the resulting product to a particle size of less than 45 microns, with recovery of the impalpable fraction by electrostatic precipitation, so that the emission of solid particles into the atmosphere is guaranteed to be less than allowed. High heat treatment, thus increasing the pozzolanic activity of the alumino-silicates by 55.66%.

7.

Storage and transportation.

The final product obtained with this treatment is a powder, with a particle size of less than 45 microns, mainly composed of AL20a, CaO, K20, MgO, Na20, Si02, ZnO, Zr02, Fe20 3 and B20 3 and practically free of Cr and so = 3 total, approximately 45% glassy phase and 55% crystalline phase, easily reactive with Ca (OH) 2 (portlandite) from the hydration of cement and also with those given in the compositions of asphalt mixes.

Specifically, the concentration of the oxides in the solid portion will be included, in

%, between the following values:

-AL20a 10 and 20

-CaO 4y 17

-K201y5

-MgO 0.5y3

-Na20 0.5y3

-Yes0240y65

-Zn02y8

-Zr023 and 9

-Fe20 3 0.5 and 3

-B20a1y3

Also being included the sum of the percentages Si02, AI20a, and Fe20a, between the values 60 and 80.

The artificial pozzolans obtained will be used as an addition for all types of cements, concretes and mortars, used for all types of construction and also their use for all types of asphalt mixes used in the construction of all types of buildings, roads, highways, motorways, roads and clamps on any type of soil.

Claims

one.

Procedure for treating ceramic enamels (alumino-silicates), in the form of ceramic muds, characterized in that it turns them into artificial pozzolans for use as an addition to all types of cements, concretes and mortars, used for all types of constructions and also their use for all types of asphalt mixes, comprising the following stages:

2.

The method of claim 1, wherein in step e) the values are adjusted

pH until it is in the following ranges: -pH 8 and 11 -Potential pH -90 and -120 -Conductivity in microsiemens / cm 900 and 1100 -TDS in mg / 1,500 and 600 -Salinity between 0.3 and 0.6

3.

The method of claim 1, wherein in step e) drying is carried out in continuous horizontal driers up to 0.5% of the H20 content. It includes a high heat treatment that increases the pozzolanic activity of the alumino-silicates.

to.

Sludge pretreatment, primary treatment and treatment

secondary by the biological procedure.

b.

Separation of the parts, liquid and solid.

c.

Adjust the pH, pH potential, conductivity, salinity and TDS of the

liquid portion, for

its reuse in the preparation of slips

ceramics.

d.

Pumping of the solid portion at a density of 1,700 gr / 1 at a

extruder to obtain compact cylinders, with a humidity that

it is eliminated by passing them through a horizontal dryer.

and.

Delivery of the solid portion to vertical drying towers, by air

heat in countercurrent at 500-600 ° C, which is a treatment

high thermal.

F.

Crushing of the resulting product, with recovery of the fraction

impalpable by electrostatic precipitation, so that it is guaranteed

that the emission of solid particles into the atmosphere is less than

allowed. Aggressive heat treatment because grinding is done

with

heat input, by countercurrent hot air, to a

temperature between 500 ° and 600 ° C.

The method of claim 1, wherein during phase f, the resulting product is ground to a particle size of less than 45 microns. Includes aggressive heat treatment. 5. Product obtained by the procedures defined in claims 1 to 4. The final product will have the following concentrations in% comprised between the values: -AL203 10 AND 20 -CaO 4 and 17 -K20 1 AND 5 -MgO 0.5 AND 3 - Na20 0.5 and 3 -Si0240 Y 65 -ZnO 2 and 8 -Zr023 and 9 -Fe203 0.5 and 3 -82031 Y 3 The sum of the percentages Si02, Ab03, and Fe203 also being included, between the values 60 and 80. 6. Use of the product obtained according to the procedure defined in claims 1 to 4, as an addition for all types of cements, concretes and mortars, used for all types of constructions and buildings. 20 25 7. Use of the product obtained according to the procedure defined in claims 1 to 4, as an addition for all types of asphalt mixtures used in the construction of highways, expressways, motorways, roads and cladding on any type of soil.