WO2004050578A2 - Materiau de construction - Google Patents

Materiau de construction Download PDF

Info

Publication number
WO2004050578A2
WO2004050578A2 PCT/GB2003/005155 GB0305155W WO2004050578A2 WO 2004050578 A2 WO2004050578 A2 WO 2004050578A2 GB 0305155 W GB0305155 W GB 0305155W WO 2004050578 A2 WO2004050578 A2 WO 2004050578A2
Authority
WO
WIPO (PCT)
Prior art keywords
compact
glass
product material
recycled glass
firing
Prior art date
Application number
PCT/GB2003/005155
Other languages
English (en)
Other versions
WO2004050578A3 (fr
Inventor
David Joseph Read
Michael Anderson
David Dowler
Original Assignee
Staffordshire University
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 Staffordshire University filed Critical Staffordshire University
Priority to EP03777012A priority Critical patent/EP1565412A2/fr
Priority to AU2003286269A priority patent/AU2003286269A1/en
Publication of WO2004050578A2 publication Critical patent/WO2004050578A2/fr
Publication of WO2004050578A3 publication Critical patent/WO2004050578A3/fr

Links

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
    • 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
    • C04B28/24—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 alkyl, ammonium or metal silicates; containing silica sols
    • C04B28/26—Silicates of the alkali metals
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C1/00—Ingredients generally applicable to manufacture of glasses, glazes, or vitreous enamels
    • C03C1/002—Use of waste materials, e.g. slags
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C14/00—Glass compositions containing a non-glass component, e.g. compositions containing fibres, filaments, whiskers, platelets, or the like, dispersed in a glass matrix
    • C03C14/004—Glass compositions containing a non-glass component, e.g. compositions containing fibres, filaments, whiskers, platelets, or the like, dispersed in a glass matrix the non-glass component being in the form of particles or flakes
    • 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
    • C04B32/00—Artificial stone not provided for in other groups of this subclass
    • C04B32/005—Artificial stone obtained by melting at least part of the composition, e.g. metal
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C2214/00—Nature of the non-vitreous component
    • C03C2214/04—Particles; Flakes
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C2214/00—Nature of the non-vitreous component
    • C03C2214/14—Waste material, e.g. to be disposed of
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C2214/00—Nature of the non-vitreous component
    • C03C2214/30—Methods of making the composites

Definitions

  • This invention concerns a method of making a building product material, such a material, a method of making an article from such a building product material, and such an article.
  • waste glass A significant amount of waste glass is now available for recycling. However, difficulties are often encountered in attempting to use this material. For example, contaminants are often present in such a material. These contaminants can include labels caps etc mixed with the waste bottles and jars. With automobile glass products, problems can be encountered with contaminants such as laminating layers. A significant amount of glass from discarded cathode ray tubes is also available but appropriate uses for this are not readily identifiable, particularly due to the high lead barium and strontium content of such glass. Furthermore when such recycled glass has been used in the past to produce products such as tiles, organic binders have invariably been incorporated which in themselves can produce difficulties in terms of toxic emissions during firing, and hence produce increased cost implications.
  • a method of making a building product material including forming a compact of a product material, the product material including particulate recycled glass and an inorganic binder, and firing the compact.
  • the product material preferably includes greater than 95% recycled glass.
  • the recycled glass may be colour sorted.
  • the recycled glass may be obtained from one or more of: container glass such as bottles or jars; glass used in cathode ray tubes; vehicle windscreen or window glass; flat plate glass.
  • the product material may comprise a mixture of one or more different types of recycled glass .
  • the recycled glass in the product material may have a particle size of less than 4mm.
  • the recycled glass may be crushed prior to formation of the compact.
  • the recycled glass may be primary milled following crushing.
  • the recycled glass may be secondary milled following primary milling.
  • Contaminants are preferably removed during and/or after crushing and/or milling.
  • the recycled glass may be coloured, and may be coloured by the addition of a colouring material which may be in the form of metallic oxides, pigments, or stains.
  • the recycled glass is preferably mixed with the colouring material prior to mixing with the binder.
  • the inorganic binder may be cured during or following formation of the compact but prior to firing.
  • the inorganic binder may comprise sodium silicate, desirably in liquid form. Preferably less than 3.5% inorganic binder is included, and desirably less than 2%.
  • the sodium silicate may be cured by carbon dioxide gas.
  • the carbon dioxide gas is desirably introduced at a pressure of between 1 and 4 Bar, and for a time period of between one and twenty seconds.
  • the pressing pressure is preferably in the range 15.4 to 61.8 MPa.
  • the compact may be formed by pressing the product material in a mould space.
  • the inorganic binder is preferably cured following pressing or ramming of the compact, but whilst the compact is still in the mould space.
  • a perforated punch, other permeable item, or inlet into the mould space, may be provided through which carbon dioxide is passed to enter the compact.
  • One or more surfaces of the compact may be profiled. This may be achieved by using any of a profiled punch, a profiled mould, or a profiled former provided in the mould space. Alternatively or in addition, a surface of the compact can be treated prior to firing, and desirably by any of brushing, compressed air or glass blasting.
  • a different product material may be provided just near a surface of the compact, and this can be achieved by initially filling the mould space with the different material, or finally filling the mould space with the different material.
  • a surface of the compact may be decorated and this can be achieved by spraying, atomisation, brushing, and/or printing and in particular screen printing.
  • the compact can be finished following firing, and by any of edge grinding, surface grinding, surface polishing and/or cutting.
  • Material rejected during formation is preferably recycled in the method.
  • Firing preferably takes place at a peak temperature of between 600 and 725°c, with a peak temperature dwell of between five and sixty minutes.
  • the invention also provides a building product material made by a method according to any of the preceding nineteen paragraphs.
  • the invention further provides a method of making an article, the method comprising using a method according to any of said nineteen paragraphs, with a mould space of a required shape to form the article.
  • the invention further provides an article made by such a method.
  • the article may comprise a building product, including any of interior/exterior bricks, pavers, blocks, cladding or garden ware.
  • a compact is formed by pressing a product material formed largely of particulate recycled glass.
  • the compact is formed in the apparatus 10 shown in the accompanying drawing.
  • the apparatus 10 includes a press table 12 which mounts a mould box 14 which defines a pressing space 16.
  • a lower punch 18 is provided in the bottom of the space 16.
  • product material 20 to be pressed is located in the space 16 above the lower punch 18.
  • An upper punch 22 is located in the spacer 26 on the top of the material 20, and pressing takes place.
  • the upper punch 22 is raised to the position shown in the drawing and an inflating seal 24 which extends around the perimeter of the upper punch 22 and in this position remains in the space ⁇ 6, is inflated.
  • An accelerant which in this instance is carbon dioxide to cure the inorganic binder in the product material 20, is introduced from a supply 26 through a channel 28 into the mould space 16.
  • a sealing valve 30 is provided over the opening of the channel 18 leading into the space 16, to prevent product material entering the channel 28.
  • injection of the gas is stopped and the seal 24 is deflated.
  • the upper punch 22 is then fully withdrawn from the mould box and the hardened product is ejected from the mould box by the lower punch 18.
  • the inflating seal 24 around the upper punch 22 ensures that the accelerant gas is retained in the mould space 16.
  • the product material is pressed to a specific pressure depending on the material recipe and type.
  • the material includes a binder which in all of the following examples is sodium silicate in liquid form.
  • the binder is cured by exposing the pressed material to carbon dioxide at specified pressures and time duration, prior to removal from the mould space. The pressure and duration of exposure to carbon dioxide gas depends on the thickness of the material and the material permeability.
  • the green compact following removal from the mould space 16 is subsequently fired at required parameters for the material. Any reject compacts at any point are returned for recycling in the process.
  • the product material is initially prepared as follows.
  • the glass is coarsely crushed and contaminants may be removed.
  • the glass is then primary milled and contaminants again may be removed.
  • the glass is then secondary milled and then passed through a series of vibrating screens to provide fractions of required sizes. Oversize glass is returned to secondary milling.
  • a colour sorted glass with a particle size of less than 2mm was mixed with 2% liquid sodium silicate and pressed at a pressure of 30.9 MPa in the apparatus loto a thickness of 65mm. Carbon dioxide gas was fed into the space 16 following pressing at 2 Bar pressure for 5 seconds.
  • the green compact was ejected from the space 16 and fired at a rate of 30°C per minute to a peak temperature of 690°C with a dwell of 30 minutes, and a subsequent cooling rate of 3°C per minute.
  • a cathode ray tube glass with a particle size of less than 2mm was mixed with 2% liquid sodium silicate and pressed at a pressure of 61.8 Mpa in the apparatus 10 to a thickness of 50mm and carbon dioxide gas was fed into the space 16 under similar conditions as for example one.
  • the green compact was ejected from the space 16 and fired at a rate of 30°C per minute to a peak temperature of 630°C with a dwell of 30 minutes, and a subsequent cooling rate of 3°C per minute.
  • a 50:50 mixture of colour sorted (brown and colourless) container glasses was mixed with 3% sodium silicate and pressed at 30.9 MPa to a 10mm thickness.
  • Carbon dioxide was introduced as for example one.
  • the green compact was fired with 30°C per minute heating and 3°C per minute cooling rates to a peak temperature of 690°C and a dwell at peak temperature of thirty minutes.
  • the material obtained was surface ground and provided a material with an appearance of yellow and white marble, with water absorption of 6.1% and a modulus of rupture of 16.9 MPa.
  • a less than imm colour blended glass was mixed with a blue pigment and then 3% sodium silicate. This was pressed to a thickness of 5mm at 61.8 MPa and carbon dioxide was introduced as in example one. This was fired with 30°C per minute heating and 3°C per minute cooling rates to a peak temperature of 720°C and a peak temperature dwell of 30 minutes. This produced a material with a blue slate appearance, water absorption of 2.3% and a modulus of rupture of 17.8 MPa.
  • This process provides a novel method for producing commercial building products, from these novel glass raw materials.
  • the process intentionally uses solely glass(es) as the principal product structural material to: i) reduce the amount of binder required, because the glass is non-absorbent; ii) permit firing the product at a low temperature, because glasses begin to soften at relatively low temperature; iii) permit rapid heating of the product during firing, because the glass does not exhibit endothermic reactions during heating (which introduce thermal barriers to heat transfer); iv) reduce the energy required to raise the temperature of the product during firing, because glasses possess relatively low specific heat capacity and no endothermic reactions;
  • the glass raw material is intentionally milled to a relatively course size to: i) reduce milling energy consumption; ii) reduce wear on components of the milling equipment; iii) reduce the binder component requirement, by minimizing the surface area of the milled glass; iv) produce the required texture and pore size, promoting durability in the final product.
  • the products are intentionally compacted and then gassed under pressure whilst still in the press, to: i) reduce the magnitude of shrinkage during firing, though elimination of porosity during pressing; ii) reduce the maturing temperature and increase final strength, through elimination of porosity during pressing; iii) reduce the binder requirement, by increasing intimacy of particle contact; iv) simplify the hardening process, by facilitating gassing through existing standard press components; v) allow the rapid hardening of the product before removal from the mould box, to increase press production output.
  • the use of the inorganic sodium silicate binder provides a number of advantages. Firstly, relatively small proportions of this material are required, and this is a non volatile material which can thus be handled without the requirement for fume extraction and the like. During firing the sodium silicate is incorporated into the material. Therefore this binder and also the materials which have also already been fired at a higher temperature, produce very few emissions during firing. The sodium silicate once cured by carbon dioxide provides sufficient rigidity to the materials to be handled up to and during firing. The low proportions of sodium silicate mean that the materials can be fired immediately following pressing without any requirement for drying or other processing.
  • the materials formed can be readily pressed into required shapes to make products such as interior or exterior bricks, pavers, blocks, cladding products, or garden ware.
  • the surface of the compact can be coloured prior to firing by the application of a suitable colourant using for example conventional techniques of spraying, atomisation, brushing or printing etc., and particularly screen printing. It is to be realised that reject material or product can at any time be recycled in the process. If required the surface of the compact can be processed prior to firing by brushing, compressed air or glass blasting, with any removed material being returned into the process. Following firing the material can be finished by edge or surface grinding, surface polishing or cutting.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Organic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Structural Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • General Chemical & Material Sciences (AREA)
  • Geochemistry & Mineralogy (AREA)
  • Inorganic Chemistry (AREA)
  • Dispersion Chemistry (AREA)
  • Glass Compositions (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)
  • Processing Of Solid Wastes (AREA)

Abstract

L'invention concerne un procédé de fabrication d'un matériau de construction. Ce procédé consiste à mélanger du verre recyclé particulaire avec un liant à base de silicate de sodium, à comprimer le mélange en vue de former une masse compacte, à introduire du gaz de dioxyde de carbone en vue de durcir le liant immédiatement après compression et, à cuire ensuite la masse compacte.
PCT/GB2003/005155 2002-11-29 2003-11-26 Materiau de construction WO2004050578A2 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
EP03777012A EP1565412A2 (fr) 2002-11-29 2003-11-26 Materiau de construction
AU2003286269A AU2003286269A1 (en) 2002-11-29 2003-11-26 Building product material

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB0227823A GB0227823D0 (en) 2002-11-29 2002-11-29 Simulated stone material
GB0227823.2 2002-11-29

Publications (2)

Publication Number Publication Date
WO2004050578A2 true WO2004050578A2 (fr) 2004-06-17
WO2004050578A3 WO2004050578A3 (fr) 2004-07-29

Family

ID=9948733

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/GB2003/005155 WO2004050578A2 (fr) 2002-11-29 2003-11-26 Materiau de construction

Country Status (4)

Country Link
EP (1) EP1565412A2 (fr)
AU (1) AU2003286269A1 (fr)
GB (1) GB0227823D0 (fr)
WO (1) WO2004050578A2 (fr)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2005121041A1 (fr) * 2004-06-10 2005-12-22 Staffordshire University Materiau de construction et son procede de fabrication
ES2247954A1 (es) * 2005-08-19 2006-03-01 Colorobbia España, S.A. Pasta ceramica gresificable.
KR100855460B1 (ko) 2007-06-08 2008-09-01 유춘식 건축토목자재 소재용 펠릿과, 그 펠릿이 이용된 건축자재용패널과 인공어초용 블럭 및 그들의 제조방법
WO2010004049A1 (fr) * 2008-07-10 2010-01-14 Geofusion Group Limited Matériau de produit de construction
US8092593B2 (en) * 2009-06-17 2012-01-10 Mccombs Melvin Scott Architectural stone composition and method of use

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1999029485A1 (fr) * 1997-12-11 1999-06-17 Futuristic Tile, L.L.C. Precurseur industriel destine a la production de materiaux de construction et procede de production de ce precurseur
WO2000044685A1 (fr) * 1999-01-27 2000-08-03 Weihua Jin Liants inorganiques a base de verre recycle

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
SU1253965A1 (ru) * 1984-05-31 1986-08-30 Научно-Исследовательский Институт Организации И Управления В Строительстве При Московском Инженерно-Строительном Институте Им.В.В.Куйбышева Способ изготовлени декоративно-облицовочных плит
RU2168481C1 (ru) * 2000-03-06 2001-06-10 Институт химии твердого тела и механохимии СО РАН Способ изготовления безобжиговых строительных изделий

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1999029485A1 (fr) * 1997-12-11 1999-06-17 Futuristic Tile, L.L.C. Precurseur industriel destine a la production de materiaux de construction et procede de production de ce precurseur
WO2000044685A1 (fr) * 1999-01-27 2000-08-03 Weihua Jin Liants inorganiques a base de verre recycle

Non-Patent Citations (3)

* Cited by examiner, † Cited by third party
Title
CHEMICAL ABSTRACTS, vol. 105, no. 22, 1 December 1986 (1986-12-01), Columbus, Ohio, US; abstract no.: 196338, page 336 XP0000064681 & SU 1 253 965 A (NII ORGANIZATSII U V STR PRI M) 30 August 1986 (1986-08-30) *
DATABASE COMPENDEX [Online] ENGINEERING INFORMATION, INC., NEW YORK, NY, US; LIU LIHUI ET AL: "Application of a mechanochemical method for recycling waste glass with CO2 solidification" XP002276095 Database accession no. E2003427684523 & MECH. MATER. ENG. SCI. EXP.; MECHANICS AND MATERIAL ENGINEERING FOR SCIENCE AND EXPERIMENTS 2003, 11 August 2001 (2001-08-11), pages 209-213, *
DATABASE WPI Section Ch, Week 200146 Derwent Publications Ltd., London, GB; Class L02, AN 2001-431141 XP002276096 & RU 2 168 481 A (AS SIBE SOLID STATE CHEM & MECHANO-CHEM) 10 June 2001 (2001-06-10) *

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2005121041A1 (fr) * 2004-06-10 2005-12-22 Staffordshire University Materiau de construction et son procede de fabrication
ES2247954A1 (es) * 2005-08-19 2006-03-01 Colorobbia España, S.A. Pasta ceramica gresificable.
KR100855460B1 (ko) 2007-06-08 2008-09-01 유춘식 건축토목자재 소재용 펠릿과, 그 펠릿이 이용된 건축자재용패널과 인공어초용 블럭 및 그들의 제조방법
WO2010004049A1 (fr) * 2008-07-10 2010-01-14 Geofusion Group Limited Matériau de produit de construction
US8092593B2 (en) * 2009-06-17 2012-01-10 Mccombs Melvin Scott Architectural stone composition and method of use

Also Published As

Publication number Publication date
EP1565412A2 (fr) 2005-08-24
WO2004050578A3 (fr) 2004-07-29
AU2003286269A8 (en) 2004-06-23
AU2003286269A1 (en) 2004-06-23
GB0227823D0 (en) 2003-01-08

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