TH10526Y - Geopolymer materials from fly ash type C for construction. - Google Patents

Abstract

DC60 (10/04/2015) This invention develops a geopolymer material formulation from class C fly ash and a preparation process for use as a cement substitute material. The raw material is fly ash waste from power plants. The study investigates the effect of silica-to-alumina ratio and curing time on compressive strength. The invention consists of fly ash with two particle size ranges: 0.6 and/or 24 micrometers, in a quantity of 40-60% by weight; kaolin clay in a quantity of 60-40% by weight; and an alkaline activater solution in a quantity of 25-30% by weight of the solid mixture (fly ash and kaolin clay). The geopolymer production process according to this invention involves first thoroughly mixing the dry fly ash and kaolin clay, then gradually adding the alkaline activater solution and stirring until the mixture is homogeneous. The mixture is poured into molds and left to cure at 25-40°C for 20-24 hours. It is then baked at 60-90°C for 20-100 hours. This invention can produce geopolymer parts from fly ash with a compressive strength of 40 MPa, which is beneficial for applications in the construction industry. (Revised 10/04/2015) This invention develops a geopolymer material formula from class C fly ash and a preparation process. It is intended as a cement substitute material, using fly ash waste from power plants as the raw material. The study investigates the effect of the silica-to-alumina ratio and curing time on compressive strength. The invention consists of fly ash with particle sizes in two ranges: 0.6 and/or 24 micrometers (40-60% by weight), kaolin clay (60-40% by weight), and an alkaline activater solution (25-30% by weight of the solid mixture). (Fly ash and kaolin clay) The geopolymer production process described in this invention consists of thoroughly mixing dry fly ash and kaolin clay first, then gradually adding the alkaline activator solution. The mixture is stirred until homogeneous, poured into molds, and left to cure at 25-40°C for 20-24 hours. It is then baked at 60-90°C for 20-100°C for 20-100 hours. This invention can produce geopolymers from fly ash with a compressive strength of 40 MPa, which is beneficial for applications in the construction industry. ---------------------------------------------------- This invention develops a geopolymer material formulation from class C fly ash and a preparation process, which can be used as a cement substitute. The raw material is fly ash waste from power plants. The study investigates the silica-to-alumina ratio and curing time's effect on compressive strength. The invention comprises the following components: The solid mixture (fly ash and kaolin clay) consists of 40-60% by weight of dry fly ash and/or kaolin clay, 40-60% by weight of kaolin clay, and 25-30% by weight of alkaline activater solution. The geopolymer manufacturing process described in this invention involves thoroughly mixing the dry fly ash and kaolin clay, then gradually adding the alkaline activater solution, stirring until a homogeneous mixture is achieved, pouring it into molds, and letting it cure at 25-40°C for 20-24 hours. It is then baked at 60-90°C for 20-100°C for 20-100 hours. This invention can produce geopolymers from fly ash that are strong and have a compressive strength of 40 MPa, which is beneficial for applications in the construction industry.

Claims (10)

Revised 10/04/2015 1. Geopolymer material from fly ash type C for construction purposes with the following formulation: Solid mixture: Fly ash type C 40-60% by weight, kaolin clay 60-40% by weight. Liquid mixture: Alkaline activator solution 25-30% by weight of the solid mixture. 2. Geopolymer material from fly ash type C for construction purposes according to claim 1, where the formulation has a silica (SiO2) to alumina (Al2O3) ratio in the range of 2.60-3.00. 3. Geopolymer material from fly ash type C for construction purposes according to claim 1 or 2, where the optimal silica (SiO2) to alumina (Al2O3) ratio is 2.65. 4. Geopolymer material from fly ash type C for construction purposes. According to Recollection 1, the optimal ratio between Class C fly ash and kaolin is 50% Class C fly ash by weight and 50% kaolin by weight. 5. Geopolymer material from Class C fly ash for construction purposes, according to Recollection 1, where the said Class C fly ash has an optimal average particle size of 0.6 micrometers. 6. Geopolymer material from Class C fly ash for construction purposes, according to Recollection 1, where the said Class C fly ash has an optimal average particle size of 24 micrometers. 7. Geopolymer material from Class C fly ash for construction purposes, according to Recollection 1, where the said alkaline activator solution contains a mixture of sodium hydroxide solution, sodium silicate solution, and water. 8. Geopolymer material from Class C fly ash for construction purposes, according to Recollection 1 or 7, where the said alkaline activator solution has a ratio between sodium hydroxide to sodium silicate. 9. Class C fly ash geopolymer material for construction, according to claim 1, where the process for preparing class C fly ash geopolymer material involves the following steps: a. Mix fly ash and kaolin clay together. b. Add the alkaline activator solution to the mixture from step a. Then stir the mixture until it is homogeneous. c. Pour into molds and let stand at room temperature for approximately 1-2 hours. Then wrap the workpiece and mold with plastic film and let it rest at 25-40°C for 20-24 hours. d. Bake at 60-60°C for 20-100 hours. e. Remove from the molds and let it rest at room temperature for 28 days. 10. Class C fly ash geopolymer material for construction, according to claim 9, where the optimal baking conditions are 75°C for 96 hours. 1. Geopolymer material from class C fly ash for construction, with the following formula: Solid mixture: class C fly ash 40-60% by weight, kaolin clay 40-60% by weight. Liquid mixture: alkaline activator solution 25-30% by weight of the solid mixture. 2. Class C fly ash geopolymer material for construction purposes, as per claim 1, where the formulation has a silica (SiO2) to alumina (Al2O3) ratio in the range of 2.60-3.00. 3. Class C fly ash geopolymer material for construction purposes, pursuant to claim 1 or 2, where the optimal silica (SiO2) to alumina (Al2O3) ratio is 2.65. 4. Geopolymer material from class C fly ash for construction purposes, as per claim 1, where the optimal ratio between class C fly ash and kaolin is 50% class C fly ash by weight and 50% kaolin by weight. 5. Geopolymer material from class C fly ash for construction purposes, as per claim 1, where the class C fly ash has an optimal average particle size of 0.6 micrometers. 6. Geopolymer material from class C fly ash for construction purposes, as per claim 1, where the class C fly ash has an optimal average particle size of 24 micrometers. 7. Class C fly ash geopolymer material for construction purposes, pursuant to claim 1, in which a solution of sodium silica gate and water is used. 8. Class C fly ash geopolymer material for construction purposes, pursuant to claim 1 or 7, where the alkaline activator solution has a sodium hydroxide to sodium silicate to distilled water ratio of 1:1:4 by weight. 9. Class C fly ash geopolymer material for construction applications, as per Claim 1, whereby the preparation process for class C fly ash geopolymer material involves the following steps: a. Mix fly ash and kaolin clay together. b. Add the alkaline activator solution to the mixture from step a and stir until homogeneous. c. Pour into molds and let stand at room temperature for approximately 1-2 hours. Then wrap the workpiece and mold in plastic film and let it rest at 25-40°C for 20-24 hours. d. Bake at 60-90°C for 20-100 hours. e. Remove from molds and let stand at room temperature for 28 days. 10. Class C fly ash geopolymer material for construction purposes, as per claim 9, where the optimal curing conditions are 75°C for 96 hours.