GB2058736A - Structural material - Google Patents

Structural material Download PDF

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Publication number
GB2058736A
GB2058736A GB8030501A GB8030501A GB2058736A GB 2058736 A GB2058736 A GB 2058736A GB 8030501 A GB8030501 A GB 8030501A GB 8030501 A GB8030501 A GB 8030501A GB 2058736 A GB2058736 A GB 2058736A
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GB
United Kingdom
Prior art keywords
fly ash
structural material
weight
moisture content
binder
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.)
Granted
Application number
GB8030501A
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GB2058736B (en
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.)
MACMILLAN DEV Ltd
Original Assignee
MACMILLAN DEV 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 MACMILLAN DEV Ltd filed Critical MACMILLAN DEV Ltd
Priority to GB8030501A priority Critical patent/GB2058736B/en
Publication of GB2058736A publication Critical patent/GB2058736A/en
Application granted granted Critical
Publication of GB2058736B publication Critical patent/GB2058736B/en
Expired legal-status Critical Current

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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
    • C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
    • C04B26/02—Macromolecular compounds
    • C04B26/28—Polysaccharides or derivatives thereof
    • C04B26/285—Cellulose or derivatives thereof
    • 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
    • C04B18/04—Waste materials; Refuse
    • C04B18/06—Combustion residues, e.g. purification products of smoke, fumes or exhaust gases
    • C04B18/08—Flue dust, i.e. fly ash
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/91—Use of waste materials as fillers for mortars or concrete

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Environmental & Geological Engineering (AREA)
  • Combustion & Propulsion (AREA)
  • Civil Engineering (AREA)
  • Processing Of Solid Wastes (AREA)
  • Compositions Of Oxide Ceramics (AREA)

Abstract

A lightweight structural material is produced from pulverised fly ash having a bulk density before pressing of not more than 1.3.gm/cm<3> together with 0.5-2.0% by weight an organic binder, the composition being pressed at a pressure of not less than 1.5 tons/in<2> to form a coherent body which is subsequently fired at a temperature in the region of 1000-1200 DEG C.

Description

SPECIFICATION Structural material The invention relates to structural materials.
Power stations produce substantial quantities of waste material in the form of fly ash. Generally this material has not been commercially usable and is dumped in a pulverised powdered form.
Various attempts have been made to use the material either alone or combined with clay to produce compositions from which bricks or other building products can be manufactured, but hitherto it has not been possible to produce a commercially viable product of this kind.
We have now found that it is possible to produce a lightweight structural material having very attractive thermal and sound insulating properties using as a starting material a particular selected grade or type of pulverised fly ash.
Thus the invention provides a structural material consisting of a lightweight rigid body formed from pressed and fired pulverised fly ash having a bulk density before pressing of not more than 1.3 gm/cm3, together with 0.52.0% by weight of an organic binder.
The invention also provides a method of producing a lightweight structural material from pulverised fly ash comprising forming a mouldable composition by admixing with fly ash having a bulk density of not more than 1.3 gm/cm3, 0.52.0% by weight of an organic binder, and appropriate moisture content pressing the composition at a pressure of not less than 1.5 tons/in2 to form a coherent body, and firing the body at a temperature in the region of 1000-1 2000 C.
The organic binder is preferably present in an amount of approximately 1% by weight, a suitable binder being carboxy methyl cellulose such as that sold by British Celanese Limited under the Trade Mark Cellacol.
Adjustment of the moisture content of the fly ash is important to facilitate pressing and the achievement of an acceptable finished product.
The moisture content is preferably in the region of 1 0-25% by weight of the fly ash. Best results are achieved with a moisture content of 1 5-20% by weight.
The pressing pressure may be varied dependent on the precise composition of the fly ash and the intended properties of the final product. In tests best results have been obtained using pressing pressures of the order of 2 tones per square inch and pressures of around 2-3 tons per square inch are preferred, the higher pressures producing a denser and stronger product.
The firing temperature may also be varied within the range 1000-1 2000 C, but temperatures of around 1050-11 000C are preferred. The firing temperature may require to be varied dependent on the nature and quality of the pulverised fly ash utilised, on the moisture content and pressure applied, and on the desired properties of the final material.
In one particular embodiment, given by way of example only, pulverised fly ash having an initial bulk density of 1.1 gm/cm3 had its moisture content adjusted to 15% and 0.5% by weight of Cellocol binder added. The resultant composition was pressed at pressure of 2 tons per square inch to form a consolidated body which was then fired at a temperature of 1 000C to produce a lightweight rigid title having a density of 1 gm/cm3. This is substantially less than the density of products in the nature of bricks or the like hitherto produced from pulverised fly ash, with or without the addition of other materials. In addition, the lightweight materials according to the invention have good thermal and acoustic insulation properties and may be used for a variety of purposes.It is envisaged that such materials may be used, for example, in the production of insulation panels, bricks, blocks or tiles which could be glazed on one face if required.
Various modifications may be made without departing from the invention. For example, the moisture content, pressure and temperature referred to may be varied dependent on individual requirements and other organic binders may be incorporated. The material may also be used for a variety of purposes other than those referred to. If crushed to form particles or granules, the material could be used as a substitute for presently available particulate insulating materials.
1. A structural material consisting of a lightweight rigid body formed from pressed and fired pulverised fly ash having a bulk density before pressing of not more than 1.3 gm/cm3, together with 0.52.0% by weight of an organic binder.
2. A structural material according to claim 1 including 1% by weight of binder.
3. A structural material according to claim 1 or 2 wherein said binder is a carboxy methyl cellulose.
4. A structural material according to claim 3 wherein said binder is Cellacol.
5. A structural material according to any preceding claim having a density after firing of approximately 1 gm/cm3.
6. A structural material substantially as hereinbefore described.
7. A method of producing a lightweight structural material from pulverised fly ash comprising forming a mouldable composition by admixing with fly ash having a bulk density of not more than 1.3 gm/cm3, 0.52.0% by weight of an organic binder, and appropriate moisture content, pressing the composition at a pressure of not less than 1.5 tons/in2 to form a coherent body, and firing the body at a temperature in the region of 1000-12000C.
8. A method according to claim 7 wherein the composition includes 1% /O of binder.
9. A method according to claim 7 or 8, wherein the binder is a carboxy methyl cellulose.
10. A method according to any of claims 7 to 9 wherein pressing is effected at a pressure of
**WARNING** end of DESC field may overlap start of CLMS **.

Claims (16)

**WARNING** start of CLMS field may overlap end of DESC **. SPECIFICATION Structural material The invention relates to structural materials. Power stations produce substantial quantities of waste material in the form of fly ash. Generally this material has not been commercially usable and is dumped in a pulverised powdered form. Various attempts have been made to use the material either alone or combined with clay to produce compositions from which bricks or other building products can be manufactured, but hitherto it has not been possible to produce a commercially viable product of this kind. We have now found that it is possible to produce a lightweight structural material having very attractive thermal and sound insulating properties using as a starting material a particular selected grade or type of pulverised fly ash. Thus the invention provides a structural material consisting of a lightweight rigid body formed from pressed and fired pulverised fly ash having a bulk density before pressing of not more than 1.3 gm/cm3, together with 0.52.0% by weight of an organic binder. The invention also provides a method of producing a lightweight structural material from pulverised fly ash comprising forming a mouldable composition by admixing with fly ash having a bulk density of not more than 1.3 gm/cm3, 0.52.0% by weight of an organic binder, and appropriate moisture content pressing the composition at a pressure of not less than 1.5 tons/in2 to form a coherent body, and firing the body at a temperature in the region of 1000-1 2000 C. The organic binder is preferably present in an amount of approximately 1% by weight, a suitable binder being carboxy methyl cellulose such as that sold by British Celanese Limited under the Trade Mark Cellacol. Adjustment of the moisture content of the fly ash is important to facilitate pressing and the achievement of an acceptable finished product. The moisture content is preferably in the region of 1 0-25% by weight of the fly ash. Best results are achieved with a moisture content of 1 5-20% by weight. The pressing pressure may be varied dependent on the precise composition of the fly ash and the intended properties of the final product. In tests best results have been obtained using pressing pressures of the order of 2 tones per square inch and pressures of around 2-3 tons per square inch are preferred, the higher pressures producing a denser and stronger product. The firing temperature may also be varied within the range 1000-1 2000 C, but temperatures of around 1050-11 000C are preferred. The firing temperature may require to be varied dependent on the nature and quality of the pulverised fly ash utilised, on the moisture content and pressure applied, and on the desired properties of the final material. In one particular embodiment, given by way of example only, pulverised fly ash having an initial bulk density of 1.1 gm/cm3 had its moisture content adjusted to 15% and 0.5% by weight of Cellocol binder added. The resultant composition was pressed at pressure of 2 tons per square inch to form a consolidated body which was then fired at a temperature of 1 000C to produce a lightweight rigid title having a density of 1 gm/cm3. This is substantially less than the density of products in the nature of bricks or the like hitherto produced from pulverised fly ash, with or without the addition of other materials. In addition, the lightweight materials according to the invention have good thermal and acoustic insulation properties and may be used for a variety of purposes.It is envisaged that such materials may be used, for example, in the production of insulation panels, bricks, blocks or tiles which could be glazed on one face if required. Various modifications may be made without departing from the invention. For example, the moisture content, pressure and temperature referred to may be varied dependent on individual requirements and other organic binders may be incorporated. The material may also be used for a variety of purposes other than those referred to. If crushed to form particles or granules, the material could be used as a substitute for presently available particulate insulating materials. CLAIMS
1. A structural material consisting of a lightweight rigid body formed from pressed and fired pulverised fly ash having a bulk density before pressing of not more than 1.3 gm/cm3, together with 0.52.0% by weight of an organic binder.
2. A structural material according to claim 1 including 1% by weight of binder.
3. A structural material according to claim 1 or 2 wherein said binder is a carboxy methyl cellulose.
4. A structural material according to claim 3 wherein said binder is Cellacol.
5. A structural material according to any preceding claim having a density after firing of approximately 1 gm/cm3.
6. A structural material substantially as hereinbefore described.
7. A method of producing a lightweight structural material from pulverised fly ash comprising forming a mouldable composition by admixing with fly ash having a bulk density of not more than 1.3 gm/cm3, 0.52.0% by weight of an organic binder, and appropriate moisture content, pressing the composition at a pressure of not less than 1.5 tons/in2 to form a coherent body, and firing the body at a temperature in the region of 1000-12000C.
8. A method according to claim 7 wherein the composition includes 1% /O of binder.
9. A method according to claim 7 or 8, wherein the binder is a carboxy methyl cellulose.
10. A method according to any of claims 7 to 9 wherein pressing is effected at a pressure of 1.5-3 tons/in2.
11. A method according to any of claims 7 to 9 wherein the moisture content of the composition is adjusted to 10-25% by weight before pressing.
12. A method according to claim 11 wherein the moisture content is adjusted to 15-20% by weight before pressing.
13. A method according to any of claims 7 to 12 wherein firing is effected at a temperature of 1050-1 1000C.
14. A method producing a lightweight structural material from pulverised fly ash substantially as hereinbefore described.
15. A lightweight structural material produced by the method according to any of claims 7 to 14.
16. Any novel subject matter or combination including novel, subject matter herein disclosed, whether or not within the scope of or relating to the same invention as any of the preceding claims.
GB8030501A 1979-09-22 1980-09-22 Structural material Expired GB2058736B (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB8030501A GB2058736B (en) 1979-09-22 1980-09-22 Structural material

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB7933406 1979-09-22
GB8030501A GB2058736B (en) 1979-09-22 1980-09-22 Structural material

Publications (2)

Publication Number Publication Date
GB2058736A true GB2058736A (en) 1981-04-15
GB2058736B GB2058736B (en) 1983-04-07

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4701222A (en) * 1985-01-14 1987-10-20 Ube Industries, Ltd. Process for producing an artificial light-weight aggregate
US4784894A (en) * 1984-03-23 1988-11-15 Kearney & Trecker Corporation Molded polymer composite

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4784894A (en) * 1984-03-23 1988-11-15 Kearney & Trecker Corporation Molded polymer composite
US4701222A (en) * 1985-01-14 1987-10-20 Ube Industries, Ltd. Process for producing an artificial light-weight aggregate

Also Published As

Publication number Publication date
GB2058736B (en) 1983-04-07

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PCNP Patent ceased through non-payment of renewal fee