GB2454169A - Methods of producing article using particulate waste products - Google Patents
Methods of producing article using particulate waste products Download PDFInfo
- Publication number
- GB2454169A GB2454169A GB0720958A GB0720958A GB2454169A GB 2454169 A GB2454169 A GB 2454169A GB 0720958 A GB0720958 A GB 0720958A GB 0720958 A GB0720958 A GB 0720958A GB 2454169 A GB2454169 A GB 2454169A
- Authority
- GB
- United Kingdom
- Prior art keywords
- waste product
- waste
- coated
- mould
- 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.)
- Withdrawn
Links
- 239000002699 waste material Substances 0.000 title claims abstract description 154
- 238000001035 drying Methods 0.000 claims abstract description 28
- 239000011230 binding agent Substances 0.000 claims abstract description 27
- 239000000463 material Substances 0.000 claims abstract description 26
- 238000003825 pressing Methods 0.000 claims abstract description 23
- 239000002245 particle Substances 0.000 claims abstract description 21
- 239000011248 coating agent Substances 0.000 claims abstract description 16
- 238000000576 coating method Methods 0.000 claims abstract description 16
- 230000003014 reinforcing Effects 0.000 claims abstract description 13
- 239000002131 composite material Substances 0.000 claims abstract description 10
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 7
- 238000009826 distribution Methods 0.000 claims abstract description 6
- 239000011521 glass Substances 0.000 claims abstract description 6
- 229920000058 polyacrylate Polymers 0.000 claims abstract description 6
- 229910052500 inorganic mineral Inorganic materials 0.000 claims abstract description 5
- 239000011707 mineral Substances 0.000 claims abstract description 5
- 239000004568 cement Substances 0.000 claims abstract description 4
- 229920000642 polymer Polymers 0.000 claims abstract description 3
- 239000000047 product Substances 0.000 claims description 101
- 239000003795 chemical substances by application Substances 0.000 claims description 10
- 238000002156 mixing Methods 0.000 claims description 9
- 238000000034 method Methods 0.000 claims description 7
- 229910052751 metal Inorganic materials 0.000 claims description 5
- 239000010438 granite Substances 0.000 claims description 3
- 238000009499 grossing Methods 0.000 claims description 3
- 239000004579 marble Substances 0.000 claims description 3
- 239000002184 metal Substances 0.000 claims description 3
- 239000010445 mica Substances 0.000 claims description 3
- 229910052618 mica group Inorganic materials 0.000 claims description 3
- 239000000203 mixture Substances 0.000 claims description 3
- 239000004033 plastic Substances 0.000 claims description 3
- 239000010454 slate Substances 0.000 claims description 3
- 229920002994 synthetic fiber Polymers 0.000 claims description 3
- 239000007900 aqueous suspension Substances 0.000 claims description 2
- 239000006227 byproduct Substances 0.000 claims description 2
- 239000010805 inorganic waste Substances 0.000 claims description 2
- 239000010815 organic waste Substances 0.000 claims description 2
- -1 sands Substances 0.000 claims description 2
- 238000003801 milling Methods 0.000 claims 1
- 238000004513 sizing Methods 0.000 claims 1
- 239000000835 fiber Substances 0.000 abstract 1
- 238000004519 manufacturing process Methods 0.000 description 5
- 230000000694 effects Effects 0.000 description 4
- 239000004566 building material Substances 0.000 description 3
- 238000010276 construction Methods 0.000 description 3
- 238000011049 filling Methods 0.000 description 3
- 239000000126 substance Substances 0.000 description 3
- 241000609240 Ambelania acida Species 0.000 description 2
- 238000005299 abrasion Methods 0.000 description 2
- 239000010905 bagasse Substances 0.000 description 2
- 239000000945 filler Substances 0.000 description 2
- ODGAOXROABLFNM-UHFFFAOYSA-N Polynoxylin Chemical compound O=C.NC(N)=O ODGAOXROABLFNM-UHFFFAOYSA-N 0.000 description 1
- 229920001807 Urea-formaldehyde Polymers 0.000 description 1
- 238000010521 absorption reaction Methods 0.000 description 1
- 239000011449 brick Substances 0.000 description 1
- 239000003086 colorant Substances 0.000 description 1
- 230000002939 deleterious Effects 0.000 description 1
- 230000001419 dependent Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 239000000428 dust Substances 0.000 description 1
- 230000005611 electricity Effects 0.000 description 1
- 238000010304 firing Methods 0.000 description 1
- 238000009408 flooring Methods 0.000 description 1
- 239000008187 granular material Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 238000007654 immersion Methods 0.000 description 1
- 238000005470 impregnation Methods 0.000 description 1
- 150000002500 ions Chemical class 0.000 description 1
- 150000002513 isocyanates Chemical class 0.000 description 1
- 239000010893 paper waste Substances 0.000 description 1
- 239000000049 pigment Substances 0.000 description 1
- 239000002491 polymer binding agent Substances 0.000 description 1
- 235000013824 polyphenols Nutrition 0.000 description 1
- 230000005180 public health Effects 0.000 description 1
- 238000005086 pumping Methods 0.000 description 1
- 238000004064 recycling Methods 0.000 description 1
- 230000000284 resting Effects 0.000 description 1
- 238000005245 sintering Methods 0.000 description 1
- 239000002893 slag Substances 0.000 description 1
- 239000010802 sludge Substances 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000007858 starting material Substances 0.000 description 1
- 230000003068 static Effects 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 230000000007 visual effect Effects 0.000 description 1
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
- C04B20/00—Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups C04B14/00 - C04B18/00 and characterised by shape or grain distribution; Treatment of materials according to more than one of the groups C04B14/00 - C04B18/00 specially adapted to enhance their filling properties in mortars, concrete or artificial stone; Expanding or defibrillating materials
- C04B20/10—Coating or impregnating
- C04B20/1018—Coating or impregnating with organic materials
- C04B20/1029—Macromolecular compounds
- C04B20/1033—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
-
- B09B3/0041—
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B09—DISPOSAL OF SOLID WASTE; RECLAMATION OF CONTAMINATED SOIL
- B09B—DISPOSAL OF SOLID WASTE
- B09B3/00—Destroying solid waste or transforming solid waste into something useful or harmless
- B09B3/20—Agglomeration, binding or encapsulation of solid waste
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B09—DISPOSAL OF SOLID WASTE; RECLAMATION OF CONTAMINATED SOIL
- B09B—DISPOSAL OF SOLID WASTE
- B09B3/00—Destroying solid waste or transforming solid waste into something useful or harmless
- B09B3/20—Agglomeration, binding or encapsulation of solid waste
- B09B3/21—Agglomeration, binding or encapsulation of solid waste using organic binders or matrix
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B09—DISPOSAL OF SOLID WASTE; RECLAMATION OF CONTAMINATED SOIL
- B09B—DISPOSAL OF SOLID WASTE
- B09B3/00—Destroying solid waste or transforming solid waste into something useful or harmless
- B09B3/20—Agglomeration, binding or encapsulation of solid waste
- B09B3/25—Agglomeration, binding or encapsulation of solid waste using mineral binders or matrix
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C69/00—Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore
-
- 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
- C04B26/04—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
- C04B26/06—Acrylates
-
- 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
Abstract
A method of producing a composite article comprises the steps of obtaining material in fibre or particulate form from a waste product, coating fibres or particles of the material with a binder (in a mixer 24), drying the coated product (on a belt dryer 28) and pressing at least a portion of the material in a mould 32 to form an article. In another aspect, the method comprises obtaining first and second waste products in particulate form, separately coating the particles of the first and second waste products, layering the particles of the first and second waste products in a mould 32 and pressing the layered first and second waste products to form a composite article. Reinforcing materials 42 may be introduced to the mould 32 atop the first layer (40) (figure 3 - not shown). The waste product may be selected from a group comprising mineral, cement block, paper, sterilised municipal waste, glass. The particles of waste product may have a size distribution of between 20um and 200um. The binder may comprise a water based polymer, such as an acrylic polymer.
Description
METHOD OF MANUFACTURING AN ARTICLE
Increasing demand on natural resources and a growing desire to make the best use of all available materials contribute to a need to devise methods of forming durable, useful and aesthetically attractive products from recycled materials.
The construction industry has come under pressure to play a significant part in the recycling of building materials, the reduction in waste, conservation of natural resources and the overall conservation of energy. There is a clear need for construction products that are produced in an energy efficient manner and have a minimal or even negative impact on natural resources and/or the environment.
Current methods of producing building materials, such as roof and flooring tiles, require energy intensive activities such as quarrying and firing at temperatures of up to 110000.
Moreover, it is common that these methods create waste disposal problems, thus leaving legacies of land spoil tips.
Meanwhile, current methods of producing materials from recycled aggregates require the use of substances such as phenolics, isocyanates and urea formaldehyde. Use of such substances is clearly undesirable from both public health and environmental perspective, particularly as these substances are understood to produce leachate. Furthermore, recycled materials are typically used as fillers, so the methods still use significant quantities of natural resources.
The present invention seeks to address these problems by providing an energy efficient method ror manufacturing building materials from reclaimed aggregates and waste products.
In a first aspect, the invention relates to a method of producing a composite article comprising the steps of obtaining waste product in particulate form, coating particles of the waste product with a binder, and pressing at least a portion of the waste product in a mould to form an article.
Preferably, the waste product comprises any material selected from organic or inorganic wastes or by-products of other processes. Preferably, the waste product comprises material selected from the group comprising: mineral, cement block, bagasse, paper, sterilised io municipal waste, glass. More preferably, the waste product comprises a mineral material such as slate, mica, granite, sands, marble or andulucite Preferably the particles of waste material have a size distribution between 201.im and 2000pm.
In some embodiments, the waste product comprises, at least in part, material reclaimed from the waste material of the method of the present invention. In other embodiments, the waste product comprises, at least in part, material milled from articles formed according to the method of the present invention.
Preferably, the waste material has a moisture content of 2% or lower. If the waste material has a moisture content of above 2%, it is subjected to an auxiliary drying step, therein reducing the moisture content to 2% or lower.
Preferably, the binder comprises a water based polymer. More preferably, the binder comprises an acrylic polymer. Most preferably, the binder comprises a blend of acrylic polymers held in a water suspension.
Preferably the coating step comprises mixing the waste product with the binder in a mixer.
The mixer may comprise a Continuous mixer or a batch mixer. The waste product and binder are preferably mixed for less than 20 minutes. More preferably, the waste product and binder are mixed for less than 10 minutes. If the waste product and binder are mixed continuously, they are mixed so as to have a Froude number less than 1.
Preferably the coating step comprises mixing the waste material and the binder in a waste:binder ratio of 65-95:35-5. More preferably, the coating step comprises mixing the waste material and the binder in a wastebinder ratio of 90:10.
Preferably the method Comprises a drying step following the coating step to dry coated waste product before pressing. The drying step preferably comprises drying the coated waste product in a Continuous dryer to produce dried coated waste product. Alternatively, the drying step comprises drying the coated waste product in a batch dryer.
Preferably, the drying step comprises exposing the coated waste product to a current of air at elevated temperature In some embodiments the current of air is at a temperature of between about 100°C and about 200°C.
Preferably the drying step has a duration of less than 20 minutes More preferably, the drying step has a duration of less than 10 minutes.
Preferably an aliquot of dried coated waste material is introduced to the coated waste material prior to the drying step.
Preferably, the drying step reduces the moisture content of the coated waste product to 5% or lower. More preferably, the drying step reduces the moisture content of the coated waste product to 3% or lower. Most preferably, the drying step reduces the moisture content of the coated waste product to 2% or lower Preferably, the step of pressing the waste product comprises introducing a first aliquot of the coated waste product to a mould. Preferably, the first aliquol of coated waste material is smoothed within the mould to create a first layer of coated waste material.
Preferably, reinforcing agents are introduced to the mould. Preferably, the reinforcing agents comprise materials selected from the group metal or plastic rods; glass, natural or synthetic fibres; meshes and/or lattices. Preferably, the reinforcing agents are introduced to the mould atop the first layer of coated waste material.
Preferably, a second aliquot of the coated waste material is introduced to the mould.
Preferably, the second aliquot is introduced to the mould atop the first layer of coated waste material or atop the reinforcing agents. The second aliquot of coated waste material is preferably smoothed within the mould to create a second layer of coated waste material.
Preferably the step of pressing the waste product comprises applying a pressure of between 1 OOkgcm2 and 200kgcm2 to the waste product.
Preferably the step of pressing the waste product is performed at elevated temperature.
More preferably the step of pressing the waste product is performed at between 90°C and 250°C. Most preferably, the step of pressing the waste product is performed at between 180°C and 220°C.
Preferably, the waste product is at elevated temperature during the pressing step. More preferably, the waste product is at between 90°C and 250°C during the pressing step. Most preferably, the waste product is at between 180°C and 220°C during the pressing step.
Preferably the waste product is pressed for less than 10 minutes. More preferably the waste product is pressed for between 30 seconds and 5 minutes.
s Preferably, the article so-formed has a density between 200 kg/rn3 and 4000 kg/rn3.
In a second aspect of the invention, there is provided a method of producing a composite article comprising obtaining first and second waste products in particulate form, separately coating particles of the first waste product and the second waste product, layering particles of the first waste product and the second waste product within a mould, and pressing the layered first and second waste products to form an article.
In order that the invention may be more fully understood, reference is made to the accompanying drawings, in which: Figure 1 displays a schematic process diagram of a process including the method of the invention.
Figure 2 displays a first aliquot of waste material in a mould.
Figure 3 displays a first layer of waste material in a mould Figure 4 displays a reinforcing agent resting atop a first layer of waste material in a mould.
Figure 5 displays a second aliquot of waste material in a mould.
Figure 6 displays a second layer of waste material in a mould ready for pressing.
Figure 7 displays waste material being pressed within a mould.
Figure 8 displays a bi-layered article made according a process including a method of the invention.
In a preferred embodiment, the invention relates to a method of making tiles, in particular roof tiles, from waste materials It is envisaged, for example that the method be used to manufacture high quality tiles from waste aggregate materials such as dust, slag or granules of such materials as slate, mica, granite, marble, andulucite, sands, cement block waste, sterilised municipal waste, bagasse, waste paper and sludge.
In a first step, waste material is provided and transferred via a material transfer unit 14 to a pre-sieve hopper 16. From the pre-sieve hopper 16, the waste material is introduced to sieve 18 to be sized, such that a particle size distribution of between 2Opm and 2000pm is io collected in a collection hopper 20. Particles of waste material found to be too large for the preferred particle size distribution may be transferred to a mill (not shown) to be milled and reintroduced to pre-sieve hopper 16, thereby maximising the use of available material.
It is preferred that the particles of waste material do not comprise more than about 2% moisture at this stage of the process. If the moisture content is found to be too high, then the waste material is dried by an auxiliary belt drier 21.
The sized waste material is transferred from the collection hopper 20 to a storage hopper 22, which gravimetrically feeds the sized waste material into a continuous mixer 24. An accurate pumping system 26 provides a water based, acrylic polymer binder to the mixer 24, such that the ratio of waste material to binder is 90:10 by weight.
The mixer 24 is operated to effect a thorough coating of the waste product particles. This is achieved by ensuring that the mixing has a Froude number less than 1. The mixer 24 effects mixing for a period of between 4 minutes and 10 minutes, during which time the particles of waste material are evenly coated with the binder.
Once coated, the particles of waste material are introduced to a belt dryer 28, where they are exposed to a current of air, preferably at a temperature between 150°C and 200°C for between 1 and 10 minutes. The drying step may be optimised by the introduction of a quantity of fully dried coated waste material to the wet coated waste material before the step commences. After the drying step, the coated waste material is has a moisture content of around 2% to 3%.
Once dry, the dryer transfers the dried coated waste product to a mould filling hopper 30, from where aliquots of the product are introduced to moulds 32 by a mould filling device 34.
This is preferably achieved by adding a first aliquot 38 of dried coated waste material to a mould 32, as shown in Figure 2, then smoothing the first aliquot 38 of waste material to create a first layer 40, as shown in Figure 3. Optional reinforcing materials 42, such as metal or plastic rods, or glass, natural or synthetic fibres, or meshes or lattices, may be introduced to the mould 32 atop the first layer, as is shown in Figure 4. Such reinforcing materials significantly increase the strength of the finished article. A second aliquot 44 of the dried coated waste product is then introduced to the mould 32, as shown in Figure 5 and smoothed over the first layer 40 to create a second layer 46, as is shown in Figure 6.
Press 36 is then actuated to exert a pressure of around lookgcm° to 200kgcm2 onto the waste product within the moulds 32, as shown in Figure 7, for around 2 minutes at a temperature of around 200°C. The pressing step effects a sintering of the coated waste product particles, such that a solid article is formed.
The finished tile is removed from the mould and allowed to cool.
Those skilled in the art will recognise that some of the steps and apparatus described above may be changed without departing from the scope of the invention. For example, the dryer is preferably a belt dryer, or some other such dryer that allows for continuous drying, but in other embodiments the dryer may be a drum dryer, or some other dryer suitable for batch drying In some preferred embodiments, the mixing step and drying step are performed within the same apparatus, in a substantially simultaneous manner. Furthermore, in some alternative embodiments, the quantity of sized waste material and binder introduced to the mixer is measured volumetrically.
In some embodiments, a bi-layered composite article 48, as shown in Figure 8, is formed A second waste product is coated and dried in a separate process line, by a method substantially as described above, eventually being collected in a second mould filling hopper 30.
Once the first layer of dried coated waste product and the optional reinforcing agents have been introduced to the mould 32, as described above, an aliquot of the second dried coated waste product is introduced atop the first layer and smoothed to make a second layer. The first and second waste products are then pressed together, as described above, to make a bi-Iayered article The bi-layered article created has two major surfaces, each having a characteristic appearance, dependent largely on the visual and textural qualities of the two waste materials used. Such a bi-layered article affords an additional level of choice to the end- user For example, if the product is a tile, then the user may lay an array of tiles in a chequered pattern, without exhausting his or her supply of tiles of one of the colours A bi-layered article, as described above, could also be manufactured by using two aliquots of a single waste product, coated and dried substantially as described above, with one or both of the two layers having a pigment or dye introduced in the coating or drying step.
Additionally, or alternatively, each of the major surfaces of the bi-layered product may have a different finish applied to it in a final step of manufacture.
In further embodiments, certain inclusions may be made in the mixture such that the finished article exhibits secondary functionality. For example, metallic elements may be included to enable a tile to discharge static electricity, so enabling it to be used in electrically sensitive locations. Such metallic elements could also be heated to provide a source of heating for the area of use.
The composite material made by the method described above exhibits exceptional qualities of, for example, dimensional stability throughout exposure to the water and extremes of temperature. The composite material is thus suitable for many applications beyond tiles, including bricks, lintels and decorative or bespoke construction mouldings Furthermore, the composite material exhibits excellent wear characteristics when tested for deep abrasion properties.
Example 1
A tile was manufactured according to the method described above. The tile was then tested according to the appropriate ISO standards, unexpectedly yielding excellent results. The results of these tests are shown below.
Water absorption % by mass: 0.1% to 0.6% ISO 10545-3 Dimensional stability: Length & Width +1-1% ISO 10545-2 Thickness �1-2% ISO 10545-2 Straightness of sides -i-I-0.1% ISO 10545-2 Rectangularity �1-0. 1% ISO 10545-2) Surface Flatness -i-I-1% (ISO 10545-2) Frost resistance: Minimum of 100 cycles (ISO 10545-12) Water impregnation by full immersion method.
s Strength Modulus of rupture: iON/mm2 -70 N/mm2 ISO (10545-4) Breaking strength Not less than 750N (ISO 10545-4) Deep abrasion resistance: Not more than 124mm3 (ISO 10545-6)
Example 2
End of life tiles made according to the present invention were milled to a suitable particle size and used as at least part of a starting material for use in the method. No deleterious properties of the so- formed article were identified.
Tiles at the end of their useful life can also be used as a filler for other uses.
Claims (1)
- Claims 1. A method of producing a composite article comprising obtaining waste product in particulate form, coating particles of the waste product with a binder, drying the coated waste product and pressing at least a portion of the dried coated waste product in a mould to form an article.2. A method according to Claim 1, wherein the waste product comprises a material selected from organic or inorganic wastes or by-products of other processes 3 A method according to Claim 1 or 2, wherein the waste product comprises material selected from the group comprising mineral, cement block, paper, sterilised Q municipal waste, glass.4 A method according to Claim 3, wherein the waste product comprises a mineral material selected from the group slate, mica, granite, sands, marble or andulucite.5. A method according to any preceding Claim comprising the step of milling and/or sizing the waste product before coating, to provide a controlled size distribution 6 A method according to any preceding Claim, wherein the particles of waste product have a size distribution between 2Oim and 20001jm 7 A method according to any preceding Claim, wherein the waste product comprises, at least in part, material reclaimed from the waste product of the method according to any preceding Claim.8. A method according to any preceding Claim, wherein the waste product has a moisture content of 2% or lower.9. A method according to any preceding Claim, wherein the binder comprises a water based polymer, such as an acrylic polymer A method according to Claim 9, wherein the binder comprises a blend of acrylic polymers held in a water suspension 11. A method according to any preceding Claim, wherein the coating step comprises mixing the waste product with the binder in a mixer.CC 12 A method according to Claim 11, wherein the mixer comprises a batch mixer.13 A method according to Claim 11 or 12, wherein the waste product and binder are mixed for less than 20 minutes 14 A method according to Claim 13, wherein the waste product and binder are mixed for less than 10 minutes A method according to Claim 11, wherein the mixer comprises a continuous mixer.16 A method according to Claim 15, wherein, the waste product and binder are mixed so as to have a Froude number less than 1.17 A method according to any of Claims 11 to 16, wherein the coating step comprises mixing the waste product and the binder in a waste binder ratio of 65-95 35-5 18 A method according to Claim 17, wherein the coating step comprises mixing the waste product and the binder in a waste binder ratio of 90:10 19 A method according to Claim 18, wherein the drying step comprises drying the coated waste product in a continuous or batch dryer to produce dried coated waste product A method according to Claim 18 or 19, wherein the drying step comprises exposing the coated waste product to a current of air at elevated temperature 21 A method according to Claim 20, wherein the current of air is at a temperature of between about 100°C and about 200°CCQ 22 A method according to any of Claims 18 to 21, wherein the drying step has a duration of less than 20 minutes t'j 15 23 A method according to Claim 22, wherein the drying step has a duration of less than minutes 24 A method according to any of Claims 18 to 23, wherein an aliquot of dried coated waste product is introduced to the coated waste product prior to the drying step A method according to any of Claims 18 to 24, wherein the drying step reduces the moisture content of the coated waste product to 5% or lower 26. A method according to any preceding Claim, wherein the step of pressing the waste product comprises introducing a first aliquot of the coated waste product to a mould.27 A method according to Claim 26, further comprising the step of smoothing the first aliquot of coated waste product within the mould to create a first layer of coated waste product.28 A method according to Claim 26 or 27, further comprising the step of introducing reinforcing agents to the mould.29 A method according to Claim 28, wherein the reinforcing agents comprise materials selected from the group. metal or plastic rods; glass, natural or synthetic fibres; io meshes and/or lattices. CoQ 30 A method according to Claim 28 or 29, wherein the reinforcing agents are introduced Q to the mould atop the first layer of coated waste product.31 A method according to any of Claims 26 to 30, wherein a second aliquot of the coated waste product is introduced to the mould.32. A method according to Claim 31, wherein the second aliquot is introduced to the mould atop the first layer of coated waste product 33 A method according to Claim 31, wherein the second aliquot is introduced to the mould atop the reinforcing agents 34 A method according to any of Claims 31 to 33, further comprising the step of smoothing the second aliquot of coated waste product within the mould to create a second layer of coated waste product 35. A method according to any preceding Claim, wherein the step of pressing the waste product comprises applying a pressure of between lOOkgcm2 and 200kgcm2 to the waste product 36 A method according to any preceding Claim, wherein the step of pressing the waste product is performed at elevated temperature.37 A method according to Claim 36, wherein the step of pressing the waste product is performed at between 90°C and 250°C, say, between 180°C and 220°C 38 A method according to any preceding Claim, wherein the waste product is at elevated Q temperature during the pressing stepC39 A method according to Claim 38, wherein the waste product is at between 90°C and 250°C during the pressing step, say, between 180°C and 220°C.40. A method according to any preceding Claim, wherein the waste product is pressed for less than 10 minutes, say, between 30 seconds and 5 minutes.41 A method according to any preceding Claim, wherein the article so-formed has a density between 200 kg/rn3 and 4000 kg/rn3.42 A method of producing a composite article comprising obtaining first and second waste products in particulate form, separately coating particles of the first waste product and the second waste product, layering particles of the first waste product and the second waste product within a mould, and pressing the layered first and second waste products to form an article.43 A method according to any preceding Claim, wherein the waste product comprises, at least in part, material mifled from articles formed according to a method according to any preceding Claim CoC c'J
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GB0720958A GB2454169A (en) | 2007-10-25 | 2007-10-25 | Methods of producing article using particulate waste products |
EP08842638A EP2225053A2 (en) | 2007-10-25 | 2008-10-24 | Method of manufacturing an article |
PCT/GB2008/003630 WO2009053720A2 (en) | 2007-10-25 | 2008-10-24 | Method of manufacturing an article |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GB0720958A GB2454169A (en) | 2007-10-25 | 2007-10-25 | Methods of producing article using particulate waste products |
Publications (2)
Publication Number | Publication Date |
---|---|
GB0720958D0 GB0720958D0 (en) | 2007-12-05 |
GB2454169A true GB2454169A (en) | 2009-05-06 |
Family
ID=38829935
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
GB0720958A Withdrawn GB2454169A (en) | 2007-10-25 | 2007-10-25 | Methods of producing article using particulate waste products |
Country Status (3)
Country | Link |
---|---|
EP (1) | EP2225053A2 (en) |
GB (1) | GB2454169A (en) |
WO (1) | WO2009053720A2 (en) |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE102010016687A1 (en) * | 2010-04-29 | 2011-11-03 | Aco Severin Ahlmann Gmbh & Co. Kg | Cover e.g. manhole cover, manufacturing method for covering opening in underground construction, involves applying material mix comprising plastic into mold, and compressing mix by pressing of pressing structure on membrane or plate |
CN104941774A (en) * | 2015-07-13 | 2015-09-30 | 黄顺昌 | Method for recovering and processing waste granite into ceramic tile raw material |
CN105500512A (en) * | 2014-09-22 | 2016-04-20 | 江西斯米克陶瓷有限公司 | Distributing technology simulating crystal granite by vitrified tiles |
Families Citing this family (3)
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CN102773912A (en) * | 2011-05-13 | 2012-11-14 | 江西斯米克陶瓷有限公司 | Tablet line flower fabric technology for vitrified tiles |
CN105498903B (en) * | 2016-01-25 | 2018-09-07 | 广州大学 | A kind of discarded concrete prepares the system and device and method of reclaimed sand |
CN114247729B (en) * | 2021-11-30 | 2022-11-15 | 绿源环保有限公司 | Method for quickly making bricks by using construction wastes |
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NL7301755A (en) * | 1973-02-08 | 1974-08-12 | Making articles from metal filings and waste - by coating with glue and press-moulding | |
NL9200882A (en) * | 1992-05-20 | 1993-12-16 | St I W L World Building Brick | Processing method and fabrication processing of pulp, waste sludge, and other waste materials |
US6007765A (en) * | 1995-04-21 | 1999-12-28 | Exori-Import-Export Gmbh & Co. Kg | Method of producing molded articles |
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EP1180763A2 (en) * | 2000-08-15 | 2002-02-20 | Mitsubishi Heavy Industries, Ltd. | Ceramic sound absorbing material and manufacturing method therefor |
US20040032047A1 (en) * | 2002-08-19 | 2004-02-19 | Yu-Chuan Hou | Raw material composition of environmental protection coffin and manufacturing method thereof |
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Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE102010016687A1 (en) * | 2010-04-29 | 2011-11-03 | Aco Severin Ahlmann Gmbh & Co. Kg | Cover e.g. manhole cover, manufacturing method for covering opening in underground construction, involves applying material mix comprising plastic into mold, and compressing mix by pressing of pressing structure on membrane or plate |
DE102010016687B4 (en) * | 2010-04-29 | 2012-07-19 | Aco Severin Ahlmann Gmbh & Co. Kg | A method of making a cover and a cover made by this method |
CN105500512A (en) * | 2014-09-22 | 2016-04-20 | 江西斯米克陶瓷有限公司 | Distributing technology simulating crystal granite by vitrified tiles |
CN104941774A (en) * | 2015-07-13 | 2015-09-30 | 黄顺昌 | Method for recovering and processing waste granite into ceramic tile raw material |
Also Published As
Publication number | Publication date |
---|---|
EP2225053A2 (en) | 2010-09-08 |
GB0720958D0 (en) | 2007-12-05 |
WO2009053720A2 (en) | 2009-04-30 |
WO2009053720A3 (en) | 2009-12-17 |
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