TH94705B - A filter material formula derived from coal ash heavy ash and sodium silicate. - Google Patents

Abstract

DC60 (12/06/2014) is a synthetic filter material formulated with coal ash and sodium silicate. The preparation process involves dry grinding the ash to a specified size range, mixing the ash and sodium silicate solution thoroughly with a stirrer, molding it into granules, and calcining. The resulting granules are composed of calcium aluminosilicate compounds, calcium iron aluminosilicate compounds, quartz, and sodium aluminosilicate compounds, possessing suitable properties for use as a filter material in biological water treatment. The resulting granules exhibit a pore size distribution and effective surface area comparable to coral. Production is more energy-efficient, resulting in lower energy costs. This material can be used as a replacement for natural filter materials such as harvested coral or synthetic filter materials such as ceramic rings made from natural resources, offering superior efficiency. This invention utilizes waste or discarded materials as raw materials, creating added value, reducing energy consumption in production, and conserving invaluable natural resources. The synthetic filter material formula consists of coal ash and sodium silicate. The preparation process involves dry grinding the ash to a specified size range, mixing the ash and sodium silicate solution using a stirrer, molding it into granules, and then calcining it. The resulting granules are composed of calcium aluminosilicate compounds, calcium iron aluminosilicate compounds, quartz, and sodium aluminosilicate compounds, possessing suitable properties for use as a filter material in biological water treatment. The resulting granules exhibit a pore size distribution and usable surface area comparable to coral and can be produced with reduced energy consumption. This results in lower energy costs for production, and the material can be used as a water treatment material, replacing natural filter materials such as coral harvested from the sea, or as a replacement for synthetic filter materials such as ceramic rings made from natural resources, which are more efficient. This invention utilizes waste or discarded materials as raw materials, creating added value, reducing energy consumption in production, and helping to conserve invaluable natural resources.

Claims (8)

Claims (12/06/2014) 1. A filter material formula derived from coal ash composting, consisting of 80-90% coal ash heavy ash by dry weight and 10-20% sodium silicate by dry weight. 2. A filter material formulation derived from coal ash heavy ash, as per claim 1, in which the coal ash heavy ash contains 35-45 percent by weight silica, 16-23 percent by weight alumina, 14-22 percent by weight calcium, 11-16 percent by weight iron oxide, 3-5 percent by weight alkaline and alkaline earth oxides, and 1-5 percent by weight other trace oxide compounds. 3. The filter material formulation is made from coal ash heavy ash as per claim 1 or 2, where the coal ash heavy ash used in such preparation has the following particle size and quantity before molding: particle size 2-4 mm, quantity 2.5-12 percent by dry weight; particle size 1-2 mm, quantity 4-10 percent by dry weight; particle size 0.5-1 mm, quantity 10-25 percent by dry weight; and particle size 0.001-0.5 mm, quantity 55-85 percent by dry weight. 4. The process for preparing filter material from coal ash heavy ash, as per claim 1, involves the following steps: a. Dry grinding of coal ash heavy ash, controlling the moisture content to 5% by weight. b. Mixing the coal ash heavy ash with a sodium silicate solution containing a silica to sodium oxide ratio of 1:3.0-3.2, and thoroughly mixing. c. Forming the mixture into pellets. d. Firing the pellets at a temperature of 850-950 degrees Celsius. 5. Preparation method for coal ash filter material as per claim 4, where the said coal ash heavy ash consists of coal ash heavy ash with the following particle sizes and quantities: particle size 2-4 mm, quantity 2.5-12 percent by dry weight; particle size 1-2 mm, quantity 4-10 percent by dry weight; particle size 0.5-1 mm, quantity 10-25 percent by dry weight; and particle size 0.001-0.5 mm, quantity 55-85 percent by dry weight. 6. The process for preparing the filter material from coal ash heavy ash, as per claim 5, where coal ash heavy ash of the specified particle size is prepared by grinding the coal ash heavy ash and then filtering it through an open sieve to obtain the desired size. 7. The preparation method for coal ash heavy ash filter material under claim 4, where the mixture of coal ash heavy ash and sodium silicate solution is formed into granules by a choice of centrifugal force, molding, extrusion, or rolling, either individually or in combination. 8. The filter material obtained by the process specified in Patent 4 consists of a compound of calcium aluminosilicate, calcium iron aluminosilicate, sodium aluminosilicate, and quartz.