NL2002282C2 - Pozzolanic binder composition. - Google Patents
Pozzolanic binder composition. Download PDFInfo
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- NL2002282C2 NL2002282C2 NL2002282A NL2002282A NL2002282C2 NL 2002282 C2 NL2002282 C2 NL 2002282C2 NL 2002282 A NL2002282 A NL 2002282A NL 2002282 A NL2002282 A NL 2002282A NL 2002282 C2 NL2002282 C2 NL 2002282C2
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- NL
- Netherlands
- Prior art keywords
- composition
- metakaolin
- pozzolane
- binder composition
- composition according
- Prior art date
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- 239000000203 mixture Substances 0.000 title claims description 108
- 239000011230 binding agent Substances 0.000 title claims description 53
- ODINCKMPIJJUCX-UHFFFAOYSA-N Calcium oxide Chemical compound [Ca]=O ODINCKMPIJJUCX-UHFFFAOYSA-N 0.000 claims description 62
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 claims description 57
- 239000000463 material Substances 0.000 claims description 43
- 239000000292 calcium oxide Substances 0.000 claims description 34
- 235000012255 calcium oxide Nutrition 0.000 claims description 34
- 239000004568 cement Substances 0.000 claims description 26
- 239000010881 fly ash Substances 0.000 claims description 25
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 claims description 16
- 239000002920 hazardous waste Substances 0.000 claims description 12
- 239000010802 sludge Substances 0.000 claims description 10
- 239000002689 soil Substances 0.000 claims description 9
- 230000006641 stabilisation Effects 0.000 claims description 9
- 239000002699 waste material Substances 0.000 claims description 9
- 229910000019 calcium carbonate Inorganic materials 0.000 claims description 8
- 239000002440 industrial waste Substances 0.000 claims description 5
- 238000009434 installation Methods 0.000 claims description 4
- 239000008247 solid mixture Substances 0.000 claims description 4
- 238000007711 solidification Methods 0.000 claims description 4
- 230000008023 solidification Effects 0.000 claims description 4
- XFWJKVMFIVXPKK-UHFFFAOYSA-N calcium;oxido(oxo)alumane Chemical compound [Ca+2].[O-][Al]=O.[O-][Al]=O XFWJKVMFIVXPKK-UHFFFAOYSA-N 0.000 claims description 3
- 239000010893 paper waste Substances 0.000 claims 2
- 238000011105 stabilization Methods 0.000 claims 2
- 239000012530 fluid Substances 0.000 claims 1
- -1 residual Substances 0.000 claims 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 11
- 239000005995 Aluminium silicate Substances 0.000 description 9
- 235000012211 aluminium silicate Nutrition 0.000 description 9
- 239000004567 concrete Substances 0.000 description 9
- 238000004519 manufacturing process Methods 0.000 description 8
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 6
- BRPQOXSCLDDYGP-UHFFFAOYSA-N calcium oxide Chemical compound [O-2].[Ca+2] BRPQOXSCLDDYGP-UHFFFAOYSA-N 0.000 description 6
- 239000000047 product Substances 0.000 description 6
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 5
- 239000006227 byproduct Substances 0.000 description 5
- 229910052791 calcium Inorganic materials 0.000 description 5
- 239000011575 calcium Substances 0.000 description 5
- AXCZMVOFGPJBDE-UHFFFAOYSA-L calcium dihydroxide Chemical compound [OH-].[OH-].[Ca+2] AXCZMVOFGPJBDE-UHFFFAOYSA-L 0.000 description 5
- 239000000920 calcium hydroxide Substances 0.000 description 5
- 229910001861 calcium hydroxide Inorganic materials 0.000 description 5
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 3
- 239000002956 ash Substances 0.000 description 3
- 239000004566 building material Substances 0.000 description 3
- 239000003245 coal Substances 0.000 description 3
- 238000009826 distribution Methods 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 239000003546 flue gas Substances 0.000 description 3
- 231100001261 hazardous Toxicity 0.000 description 3
- 229910052500 inorganic mineral Inorganic materials 0.000 description 3
- 235000010755 mineral Nutrition 0.000 description 3
- 239000011707 mineral Substances 0.000 description 3
- 239000002245 particle Substances 0.000 description 3
- 239000000377 silicon dioxide Substances 0.000 description 3
- UXVMQQNJUSDDNG-UHFFFAOYSA-L Calcium chloride Chemical compound [Cl-].[Cl-].[Ca+2] UXVMQQNJUSDDNG-UHFFFAOYSA-L 0.000 description 2
- QAOWNCQODCNURD-UHFFFAOYSA-L Sulfate Chemical compound [O-]S([O-])(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-L 0.000 description 2
- 239000000654 additive Substances 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 2
- 239000010882 bottom ash Substances 0.000 description 2
- 238000001354 calcination Methods 0.000 description 2
- 239000001110 calcium chloride Substances 0.000 description 2
- 229910001628 calcium chloride Inorganic materials 0.000 description 2
- 159000000007 calcium salts Chemical class 0.000 description 2
- 230000000052 comparative effect Effects 0.000 description 2
- YGANSGVIUGARFR-UHFFFAOYSA-N dipotassium dioxosilane oxo(oxoalumanyloxy)alumane oxygen(2-) Chemical compound [O--].[K+].[K+].O=[Si]=O.O=[Al]O[Al]=O YGANSGVIUGARFR-UHFFFAOYSA-N 0.000 description 2
- 239000010459 dolomite Substances 0.000 description 2
- 229910000514 dolomite Inorganic materials 0.000 description 2
- 230000007613 environmental effect Effects 0.000 description 2
- 239000000945 filler Substances 0.000 description 2
- 239000010440 gypsum Substances 0.000 description 2
- 229910052602 gypsum Inorganic materials 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 150000002739 metals Chemical class 0.000 description 2
- 239000004570 mortar (masonry) Substances 0.000 description 2
- 229910052627 muscovite Inorganic materials 0.000 description 2
- 150000003839 salts Chemical class 0.000 description 2
- 239000002893 slag Substances 0.000 description 2
- 230000003019 stabilising effect Effects 0.000 description 2
- 238000003860 storage Methods 0.000 description 2
- 239000000454 talc Substances 0.000 description 2
- 229910052623 talc Inorganic materials 0.000 description 2
- 238000007669 thermal treatment Methods 0.000 description 2
- CPELXLSAUQHCOX-UHFFFAOYSA-M Bromide Chemical compound [Br-] CPELXLSAUQHCOX-UHFFFAOYSA-M 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- BVKZGUZCCUSVTD-UHFFFAOYSA-L Carbonate Chemical compound [O-]C([O-])=O BVKZGUZCCUSVTD-UHFFFAOYSA-L 0.000 description 1
- VEXZGXHMUGYJMC-UHFFFAOYSA-M Chloride anion Chemical compound [Cl-] VEXZGXHMUGYJMC-UHFFFAOYSA-M 0.000 description 1
- 235000008733 Citrus aurantifolia Nutrition 0.000 description 1
- MYMOFIZGZYHOMD-UHFFFAOYSA-N Dioxygen Chemical compound O=O MYMOFIZGZYHOMD-UHFFFAOYSA-N 0.000 description 1
- 235000019738 Limestone Nutrition 0.000 description 1
- 239000011398 Portland cement Substances 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- 235000011941 Tilia x europaea Nutrition 0.000 description 1
- 230000003213 activating effect Effects 0.000 description 1
- 230000004913 activation Effects 0.000 description 1
- 239000012190 activator Substances 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- 230000033228 biological regulation Effects 0.000 description 1
- 229910001622 calcium bromide Inorganic materials 0.000 description 1
- 229940043430 calcium compound Drugs 0.000 description 1
- 150000001674 calcium compounds Chemical class 0.000 description 1
- OSGAYBCDTDRGGQ-UHFFFAOYSA-L calcium sulfate Inorganic materials [Ca+2].[O-]S([O-])(=O)=O OSGAYBCDTDRGGQ-UHFFFAOYSA-L 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 150000001805 chlorine compounds Chemical class 0.000 description 1
- 238000002485 combustion reaction Methods 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 239000004035 construction material Substances 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- LPTQBQUNGHOZHM-UHFFFAOYSA-N dicalcium;silicate;hydrate Chemical compound O.[Ca+2].[Ca+2].[O-][Si]([O-])([O-])[O-] LPTQBQUNGHOZHM-UHFFFAOYSA-N 0.000 description 1
- 229910001882 dioxygen Inorganic materials 0.000 description 1
- 229910001653 ettringite Inorganic materials 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 239000011440 grout Substances 0.000 description 1
- XLYOFNOQVPJJNP-ZSJDYOACSA-N heavy water Substances [2H]O[2H] XLYOFNOQVPJJNP-ZSJDYOACSA-N 0.000 description 1
- 230000036571 hydration Effects 0.000 description 1
- 238000006703 hydration reaction Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-M hydroxide Chemical compound [OH-] XLYOFNOQVPJJNP-UHFFFAOYSA-M 0.000 description 1
- 239000003295 industrial effluent Substances 0.000 description 1
- 229910052622 kaolinite Inorganic materials 0.000 description 1
- 239000004571 lime Substances 0.000 description 1
- 239000006028 limestone Substances 0.000 description 1
- 229910044991 metal oxide Inorganic materials 0.000 description 1
- 238000000034 method Methods 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 239000010813 municipal solid waste Substances 0.000 description 1
- 230000001737 promoting effect Effects 0.000 description 1
- 230000009257 reactivity Effects 0.000 description 1
- 150000003467 sulfuric acid derivatives Chemical class 0.000 description 1
- 229910021653 sulphate ion Inorganic materials 0.000 description 1
- 238000010998 test method Methods 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
- 238000004056 waste incineration Methods 0.000 description 1
- 238000004065 wastewater treatment Methods 0.000 description 1
Classifications
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- 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
- C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
- C04B14/02—Granular materials, e.g. microballoons
- C04B14/04—Silica-rich materials; Silicates
- C04B14/10—Clay
- C04B14/106—Kaolin
-
- 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
-
- 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
- C04B28/18—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 mixtures of the silica-lime type
-
- 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
- C04B7/00—Hydraulic cements
- C04B7/24—Cements from oil shales, residues or waste other than slag
- C04B7/28—Cements from oil shales, residues or waste other than slag from combustion residues, e.g. ashes or slags from waste incineration
-
- 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
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P40/00—Technologies relating to the processing of minerals
- Y02P40/10—Production of cement, e.g. improving or optimising the production methods; Cement grinding
-
- 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
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Materials Engineering (AREA)
- Organic Chemistry (AREA)
- Structural Engineering (AREA)
- Environmental & Geological Engineering (AREA)
- Civil Engineering (AREA)
- Combustion & Propulsion (AREA)
- Dispersion Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Inorganic Chemistry (AREA)
- Curing Cements, Concrete, And Artificial Stone (AREA)
Description
f ΐ
POZZOLANIC BINDER COMPOSITION
FIELD OF THE INVENTION
The invention pertains to pozzolanic binder compositions for use in concrete and/or 5 cement, and in stabilisation and solidification of (hazardous) waste, building materials, waste and by-products, soil and sludge. The invention also pertains to the use of residue or waste materials in pozzolanic binder compositions. Pozzolanic behaviour refers to the material’s ability to irreversibly harden upon contact with water.
10 BACKGROUND OF THE INVENTION
It is known to thermally convert kaolin-containing material to a material having pozzolanic and hydraulic properties. According to US 5,868,829, a pozzolanic material can be obtained by incinerating kaolin-containing paper residue, thus obtaining a metakaolin-containing composition and converting calcium carbonate partially into 15 quicklime and calcium hydroxide. Considered to have twice the reactivity of most other pozzolans, metakaolin is a valuable admixture for concrete/cement applications. In the art - confirmed in US 5,868,829 and US 2005/0223950 -, calcium oxide is believed to have adverse effects on the strength of concrete and hardened cement manufactured with the pozzolane.
20 US 5,868,829 discloses a composition comprising 40 % metakaolinite, 50 % calcium hydroxide, calcium carbonate, calcium oxide, metals, chlorides and sulphates, wherein calcium oxide is present in such small amounts that it has a negligible effect on the compression strength of cement in which it is contained. Commercially available metakaolin-containing compositions disclosed in US 5,868,829 show small grain sizes, 25 typically 90 % is smaller than 64 microns. Such small grain size distributions may give rise to storage and transport problems.
US 2005/0223950 refers to the pozzolanic material CDEM-ash 1 obtained by thermal treatment of paper sludge as described in PCT/NL95/0280 [of which the aforementioned US 5,868,829 is a continuation], and alleges to improve it by reducing 30 the content of calcium compounds.
According to its abstract, JP 2001/04861 lpertains to a low-cost cement additive that consists of incineration ash obtained by incinerating paper making sludge. The metakaolin content varies between 20 and 95 wt%, and calcium oxide and calcium 2002282-
< I
2 hydroxide amounts range between 0 and 50 wt%. According to the Tables the amounts of CaO are far less, below 10 wt%. In some embodiments, additional cement additives may be present, preferably in amounts of 0 - 30 wt%, but preferably in amounts of 1 -10 wt%.
5 DE 20 2004 016 270 suggests incineration ash-based binder compositions in waste water treatment.
Traditionally, pozzolanic binder compositions contain cement or cementitious materials (burned limestone). However, cement is relatively expensive to produce, and its production involves large CO2 emissions. Outside the field of binder compositions, 10 cement is often replaced by cheaper materials, such as furnace slag, fly ash or fillers. However, for binding purposes options are limited. Sometimes fly ash is added, a byproduct of energy production, industrial processes and/or waste treatment. Addition of fly ash to ordinary Portland cement causes retardation of development of the strength of the cement and increases its properties to withstand aggressive environments.
15 Hence, there is a need in the art to replace at least part of conventional pozzolane binder compositions with environmentally friendly components. These should preferably yield at least similar binding characteristics, and render a binder composition that can be applied in treatment/ stabilisation of contaminated materials, in particular when high in salt content and metals (Cl, Br and SO4). There is also the need to 20 develop pozzolane compositions which exhibit good flowability and grain size distribution, are easy to produce, also from an environmental perspective.
SUMMARY OF THE INVENTION
To this end, the inventors have found that a pozzolanic composition having excellent 25 properties can be obtained by admixing metakaolin-containing compositions, fly ash and quicklime (CaO), The metakaolin-containing composition is largely produced from by-products from paper residues incineration. The other components typically originate from energy production and industrial incineration plants.
In the art, quicklime is considered a delicate component when used in concrete 30 applications, since it causes concrete to expand (and crack) in time. Knowing the potential of quicklime to disintegrate concrete, the skilled person has always been reluctant to apply quicklime in pozzolanic materials. Hence, the role of the quicklime as a beneficial activator in the pozzolane binder composition according to the invention 3 ( i is unforeseen in the art. Although the inventors do not wish to be tied down to any hypotheses, it is believed that the quicklime reacts - upon activation with water - and with both the metakaolin and fly ash, thus amending the mineral structures (e.g. ettringite, Friedelsalt, CAH, CSH etc) and porosity and density of these materials.
5 Without the activating quicklime within the binder composition, pozzolanic behaviour is found to be suppressed.
As demonstrated in the accompanying examples, the pozzolane binder composition of the present invention exhibits improved durability and compressive strength over e.g. commercially available metakaolin-containing material, such as 10 described in US 5,868,829, US 2005/0223950 and JP 2001/048611, and can withstand aggressive salty environments that are particularly high in chloride and/or sulphate. The pozzolanic binder compositions according to the present invention also exhibit higher water retention and desirable flowability (rheological properties) in dry form compared to conventional compositions. The water retention properties are better than those 15 reported for metakaolin and cements, in itself already better than for mortar. Improved water retention properties may be beneficial when treating sludge-like materials.
Although the inventors do not wish to be tied down to any theory, the advantageous effects of the pozzolanic composition of the invention on the treatment of hazardous and aggressive environments is attributed to its high calcium, silicium and 20 alumina content. Upon hydration, the composition forms calcium-aluminate hydrate, which exhibits improved resistance to salts than for instance calcium-silicate hydrate, largely present in calcium-dominated cementitious materials.
Moreover, the use of cementitious materials to obtain desirable pozzolanic behaviour is found superfluous, thus allowing for reduction of CO2 emission levels in 25 production. The inventors found that pozzolanic binder compositions could be produced “CO2 emission”-free, when compared to regular cement binder compositions. It is found that the pozzolanic binder composition of the invention can advantageously be applied in treating hazardous waste materials, for example APC residues, contaminated soils, industrial fly ashes, sludges and waste materials like^MSWI 30 (municipal solid waste incineration) bottom ash.
> » 4
DETAILED DESCRIPTION OF THE INVENTION
The invention pertains to a pozzolanic binder composition comprising (i) 40 - 80 % of a metakaolin-containing composition, (ii) 20 - 50 wt% fly ash, and (iii) 5-20 % quicklime, based on the total dry weight of the composition.
5 In a preferred embodiment, the metakaolin-containing composition comprising 5 - 20 % quicklime, 15 - 35 % metakaolin, and 30 - 50 % calcium carbonate, based on its dry weight.
In a preferred embodiment, the pozzolanic binder composition contains CaO in an amount 55 - 80 wt%.In a preferred embodiment, the metakaolin is obtained or 10 obtainable by incinerating kaolin-containing paper residue.
In a preferred embodiment, the pozzolanic binder composition contains substantially no cement.
The invention also pertains to the use of the pozzolanic binder composition in treatment of hazardous waste materials.
15 In one embodiment, the invention provides for the use of the pozzolanic binder composition for stabilisation and solidification of industrial waste products, soil and sludge stabilisation, and in cement mixtures.
In one embodiment, the invention pertains to a cementitious composition containing the pozzolanic binder composition, 20 In one embodiment, the invention pertains to a solid composition containing hydrated pozzolanic binder composition according to the invention, the composition containing calcium-aluminate hydrate. The solid composition may comprise industrial and/or hazardous waste, industrial fly ashes and/or soil or sludge.
25 The pozzolanic binder composition of the invention comprises metakaolin, and more than 50 wt% CaO (XRF analysis), preferably up to 80 wt%, more preferably up to 70 wt%, even more preferably up to 60 wt%, based on the total dry weight of the composition. The composition has a mineral structure. The composition preferably contains 10-30 wt%, more preferably 10-25 wt% metakaolin, more preferably up to 30 18 wt%, based on dry weight. The ‘CaO’ content as measured using XRF represents all calcium salts in the composition, such as calcium oxide, calcium carbonate, calcium hydroxide and calcium chloride, bromide and sulphate. It is typically described as CaO, given the fact that the composition is based on incineration materials and CaO is the I 1 5 predominant form, Alternatively, CaO could be described as “incinerated calcium”.
The sum of calcium oxide, calcium carbonate, calcium hydroxide, and calcium chloride, all recalculated in terms of CaO, is preferably in the range of 55 - 80 %.
The pozzolanic composition is preferably obtainable or obtained by blending 40 -5 80% of a metakaolin-containing composition obtained or obtainable by incinerating kaolin-containing paper residue, 20 - 50 % fly ash and 5 - 20 % (quick)lime, based on total dry weight. The metakaolin-containing composition is preferably obtained or obtainable by incinerating paper residue from paper industry; in a fluidised bed installation. Suitable conditions are described below.
10 Also, the pozzolanic binder composition of the invention is preferably low in cement or cementitious materials, more preferably containing less than 5 wt%, more preferably less than 1 wt%. Most preferably, the binder composition contains substantially no cementitious materials at all. With “cementitious materials” it is understood cement, concrete, mortar or grout or the like.
15 The composition is characterised by its “pozzolanic” behaviour, i.e. its ability to harden upon contact with water. Part of the quicklime reacts to calcium hydroxide and subsequently reacts with the fly ash and metakaolin. The composition itself is in dry, powdery form. Preferably, 50 - 70 % of the particles has a diameter of less than 50 pm, as measured using PSD analysis (particle size distribution). Preferably, between 80 and 20 95 % of the particles has a diameter of less than 250 pm.
Further, the term "binder" is defined as the ability of the composition to selectively bind a powdered construction material, such as cement, furnace slag, concrete, or natural materials such as industrial fly ashes, building materials, soil or sludge, hazardous waste materials, into a shaped (monolithic) object or granular 25 mixture when mixed with an aqueous composition or water. Prior to use, during transport and storage, the pozzolanic binder composition is preferably low in water content. It is preferred that it contains less than 5 wt%, more preferably less than 1 wt%, most preferably less than 0.5 wt% of water, based on the total weight of the composition. Preferably, it contains no water at all, prior to use.
30 The pozzolanic binder composition is further described in terms of its preferred components below. These are industrial waste or by-products.
I k 6
Fly ash
The pozzolanic binder composition contains fly ash. Under environmental laws and regulations, it is necessary to remove fly ash from flue gases before discharge of the flue gases to the atmosphere. Fly ash is a mixture of minerals, such as calcium, alumina 5 and silica, residues of incompletely combusted carbon based iuels and various metallic oxides. Fly ash is a well-recognised term in the field; after all, it has been applied widely in cement and concrete applications. It is preferably present in amounts of 20 -50 wt%, more preferably 25 - 45 %, most preferably 30 - 40 % of the dry weight of the composition.
10 In one embodiment, fly ash is used as the fine particulate non-combustible product that is produced by the combustion of powdered coal with a forced draft, and that is generally carried off with the flue gases exhausted from the furnace in which the coal is burned.
However, in a preferred embodiment, the fly ash is obtained as a ‘waste’ or by- 15 product from bio-energy, energy power plants or industrial processes. In one embodiment, the fly ash is so-called ‘poederkoolvliegas’ (Dutch; powdered coal fly ash).
Metakaolin 20 The pozzolanic binder composition contains metakaolin. Metakaolin is known to those of ordinary skill in the art and can be prepared by calcining hydrous kaolin, which is generally represented by the formula Al2O3.2SiO2.2H2O, where the water is present as interstitial water. Metakaolin can be used as prepared by calcination at temperatures from about 350 °C to about 1000 °C, more typically from about 500 °C to about 900 25 °C. The terms "metakaolin" and "metakaolinite" are used herein to mean an activated product of kaolinite, produced thermally or by any other means; these terms are considered interchangeable within the present context. The abbreviated formula for metakaolin can be written by using the standard symbols A and S (A=Al203 and S=SiC>2) as AS2.
30 Metakaolin is preferably provided from incinerated paper residue, preferably from metakaolin-containing residual materials. The metakaolin-containing material provided here is preferably used as obtained or obtainable after thermal treatment, such as obtained by incineration in a fluidised bed installation at a temperature of preferably • » 7 720 - 850 °C, preferably making use of a freeboard in the presence of oxygen gas, wherein the temperature of the freeboard is 850 °C or lower, and wherein the fluidised bed is provided with means for promoting heat transfer. Preferably, such treated material is substantially free from (unconverted) kaolin. It is preferred that kaolin is 5 present in amounts less than 1 wt%, more preferably less than 0.5 wt% of the total dry weight of the composition of the invention. Preferably, the composition is free from unconverted kaolin.
It is preferred to use a metakaolin-containing composition comprising about 5 -20 %, preferably up to 12 % quicklime, 15 - 35 % metakaolin, and 30 - 50 % calcium 10 carbonate, based on the total weight of this composition. The remainder may comprise silica, talc, muscovite, gypsum and/or dolomite, and optionally other inert materials. Preferably, the metakaolin-containing composition consists of quicklime, metakaolin and calcium carbonate, and inert materials. The metakaolin is preferably provided from paper residue materials, as explained above. It is preferred to use such metakaolin-15 containing material in amounts of 40 - 80 %, more preferably 45 - 70 %, most preferably at least 50 %, based on dry weight of the pozzolanic binder composition according to the invention.
Application 20 The pozzolanic binder composition may be applied in a method of treating/ stabilising hazardous waste materials, for example APC residues, contaminated soils and sludge’s, waste materials, hazardous waste products like MSWI residues and industrial effluents of by-products. The binder composition and the hazardous waste materials may be mixed to form monolithic materials or a granular stable mixture. It may also find 25 application as filler/binder replacement material in cement binders.
Although the pozzolanic binder composition of the invention finds particular use in stabilising hazardous and aggressive materials, the composition may well be applied in many other applications making use of pozzolanic materials. Non-limiting examples are stabilisation, solidification and/or immobilisation of industrial waste products (e.g, 30 APC residues, MSWI bottom ash or industrial fly ashes), building materials, soil and sludge stabilisation, and in cement mixtures (up to 20% cement replacement).
Hence, in one embodiment, the invention also pertains to a cementitious composition containing the pozzolanic binder composition according to the present • t 8 invention. Preferably, the weight ratio of cement to pozzolanic binder composition of the invention is in the range of 4:1 to 6:1. The pozzolanic binder composition thus proves an economically and environmentally-friendly alternative to cement.
5 EXAMPLES
Example 1 - Production pozzolanic binder composition
Quicklime, metakaolin-containing material obtained by incinerating kaolin-containing paper residue, and fly ash were blended in amounts of 8 -15 %, 50 - 65 % and 20 - 40 10 %, respectively. The metakaolin-containing composition comprised about 5-20 % quicklime, 15 - 35 % metakaolin, and 30-50 % calcium carbonate, and the remainder was formed from inert materials, such as silica, talc, gypsum, muscovite, dolomite. It was obtained by incinerating paper residue from paper industry in a fluidised bed installation at a temperature of about 780 °C (the conditions laid down in US 15 5,868,829). The metakaolin-containing composition was obtained from CDEM, the
Assignee behind US 5,868,829 and US 2005/0223950. The blended composition contained 65 wt% calcium salts, represented as CaO.
Example 2 - use 20 The pozzolanic binder composition as obtained in example 1 was applied in an amount of 10 tot 30% over 100% waste material to prepare stabilised hazardous waste (MSWI fly ash), according to standard production processes.
Comparative example I -compressive strength hazardous waste stabilisation 25 The pozzolanic binder composition of the invention was tested to stabilise hazardous waste and compared with the metakaolin-containing material alone. Example 2 was repeated using the metakaolin-containing material alone as the binder. Water levels were comparable. Both stabilised sample blocks were tested for compressive strength after 7 and 28 days after hardening.
30 Blocks obtained using metakaolin-containing material showed strengths of 1.1 and 1.5 MPa after 7 and 28 days, respectively. The blocks with the pozzolanic binder composition of the invention showed far better compressive strengths, yielding values of 1.8 and 3 MPa, respectively.
* f 9
Comparative example II - durability A block obtained with the pozzolanic mixture of example 1 was compared - in terms of monolithic durability - to one prepared using metakaolin-containing material alone: 5 both hardened blocks were monitored for disintegration using test method NEN 7345. Water levels were comparable.
The metakaolin-containing material block disintegrated within 10 days. In contrast, no disintegration was observed over the full length of the experiment, i.e. 64 days, for the pozzolanic binder composition of the invention.
10 2002282-
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NL2008605C2 (en) * | 2012-04-05 | 2013-10-09 | Cdem Minerals Group B V | Concrete and mortar pre-mixture. |
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JP2001048611A (en) * | 1999-08-09 | 2001-02-20 | Sumitomo Osaka Cement Co Ltd | Cement additive and cement additive mixture |
DE202004016270U1 (en) * | 2004-10-20 | 2005-02-24 | Krefelder Zement Gmbh | Building material such as concrete or limestone used in the building industry contains paper ash as a hydraulically binding agent |
US20050223950A1 (en) * | 2002-03-19 | 2005-10-13 | Cdem Holland B.V. | Method of improving material comprising a pozzolanic component |
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JP2001048611A (en) * | 1999-08-09 | 2001-02-20 | Sumitomo Osaka Cement Co Ltd | Cement additive and cement additive mixture |
US20050223950A1 (en) * | 2002-03-19 | 2005-10-13 | Cdem Holland B.V. | Method of improving material comprising a pozzolanic component |
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NL2008605C2 (en) * | 2012-04-05 | 2013-10-09 | Cdem Minerals Group B V | Concrete and mortar pre-mixture. |
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