WO2008049642A2 - Améliorations relatives aux résidus - Google Patents

Améliorations relatives aux résidus Download PDF

Info

Publication number
WO2008049642A2
WO2008049642A2 PCT/EP2007/009375 EP2007009375W WO2008049642A2 WO 2008049642 A2 WO2008049642 A2 WO 2008049642A2 EP 2007009375 W EP2007009375 W EP 2007009375W WO 2008049642 A2 WO2008049642 A2 WO 2008049642A2
Authority
WO
WIPO (PCT)
Prior art keywords
residue
sieve
dry weight
particle size
admixture
Prior art date
Application number
PCT/EP2007/009375
Other languages
English (en)
Other versions
WO2008049642A3 (fr
Inventor
Roland Weippert
Franz Josef Winkler
Original Assignee
Geodur International Ag
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 Geodur International Ag filed Critical Geodur International Ag
Publication of WO2008049642A2 publication Critical patent/WO2008049642A2/fr
Publication of WO2008049642A3 publication Critical patent/WO2008049642A3/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
    • 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
    • C04B18/02—Agglomerated materials, e.g. artificial aggregates
    • C04B18/021—Agglomerated materials, e.g. artificial aggregates agglomerated by a mineral binder, e.g. cement
    • 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
    • C04B18/02—Agglomerated materials, e.g. artificial aggregates
    • 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
    • C04B28/02—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 hydraulic cements other than calcium sulfates
    • 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

Definitions

  • This invention relates to the use of residues as a substitute for natural resources. More specifically, though not exclusively, the invention relates to a method of making aggregates suitable for use in the construction field from residues, and to aggregates made thereby. Aggregates made in accordance with the invention may be granular and, for example, suitable for use in concrete or road construction, or may be used directly in wet form.
  • natural resources such as gravel
  • natural resources in general, and in particular aggregates having a specified grade are often only available in remote areas, resulting in the need for long distance transportation and, consequently, rising costs.
  • Liapor® Prior art processes for producing light weight aggregates are generally very energy intensive.
  • one process commonly used by Liapor® serves to produce man-made aggregates from clay and involves the steps of: (i) drying natural clay (ii) grinding the clay into a powder (iii) granulating the clay to form clay granules (iv) heating the clay granules to around 1200 degrees Celsius, whereby the granules bloat to five times their original size, and (v) firing the bloated clay granules.
  • the size, weight and hardness of Liapor® granules can be varied by adjusting the Liapor® process parameters. Since Liapor® granules consist essentially of fired clay, they are a pure ceramic product which is suitable for use as an aggregate in place of natural gravel.
  • Aardelite® process of Aarding Lightweight Granulates BV in which a binder, such as lime, is added to pulverised fly ash obtained from coal incineration to transform the silica and alumina in the fly ash into cementitious minerals to form an aggregate. This transformation takes place at a temperature of 90 degrees Celsius, considerably lower than the temperature required in the Liapor® process, but nonetheless still requiring a significant energy input. Additionally, the Aardelite® process typically involves pelletising the aggregate in a pelletising drum.
  • Residue is used herein to denote any by-product of industry, agriculture or mining which is suitable as a starting material in the making of an aggregate. Residues may be organic or inorganic in character.
  • inorganic residues is used herein to denote residues having a predominantly inorganic chemical composition.
  • Preferred inorganic residues in the context of the invention may be substantially free from organic matter that decays naturally at standard temperature and pressure. Examples of groups of such preferred inorganic residues are: fly ashes, bottom ashes and slags from incineration or co- incineration; air pollution control residues; foundry sands; and mining residues. Some inorganic residues may be pre-treated so as to prevent natural decay of organic content.
  • fly ashes is used herein to denote inorganic residues consisting of finely divided particles (at least 90% passing a 0.125 mm sieve) resulting from combustion (incineration or co-incineration) of matter such as coal, paper/paper pulp, municipal solid waste, sewage sludge, or bio-matter.
  • combustion incineration or co-incineration
  • matter such as coal, paper/paper pulp, municipal solid waste, sewage sludge, or bio-matter.
  • the physical and chemical properties of fly ashes are largely influenced by the properties of the combusted material. However, by way of example, all coal incineration fly ash falling within the exemplary ranges of Table 1 is specifically encompassed, as is all paper mill fly ash falling within the exemplary ranges of Table 2.
  • fly ashes in the context of the invention are defined by ASTM C618 Class F; ASTM C618 Class C; and EN450, all of which relate to coal incineration fly ash.
  • Other examples of fly ashes include municipal waste incinerator fly ash and fly ash from peat and untreated wood.
  • Exemplary European waste classification codes of fly ashes are 10 01 02; 10 01 03; 10 01 04; 10 01 16; 10 01 17; 19 01 13; and 19 01 14, which are all incorporated herein by reference.
  • bottom ashes is used herein to denote inorganic residues consisting of the substantially non-combustible residual material resulting from combustion (incineration or co-incineration) of matter such as coal, paper pulp, municipal waste, sewage sludge, or bio-matter.
  • bottom ashes encompasses both Furnace Bottom Ash (FBA), which is produced during the incineration of coal, and Incinerator Bottom Ash (IBA), which is produced during solid waste incineration.
  • FBA Furnace Bottom Ash
  • IBA Incinerator Bottom Ash
  • the physical and chemical properties of bottom ashes are largely influenced by the properties of the combusted material. However, by way of example, all FBA falling within the exemplary ranges of Table 3 is specifically encompassed.
  • bottom ashes in the context of the invention are defined by DIN 4226-2 and DIN EN 13055-1 , both relating to FBA.
  • Exemplary European waste classification codes of bottom ashes are 10 01 01 ; 10 01 14; 10 01 15; 19 01 11 ; 19 01 12; 19 01 15; and 19 01 16 all of which are incorporated herein by reference.
  • slags is used herein to denote a group of inorganic residues consisting of by-products formed in combustion treatment processes from impurities in the treated materials.
  • treated materials are metal ores, municipal solid waste and ceramics.
  • the physical and chemical properties of slags are largely influenced by the properties of the treated materials.
  • slag include iron and blast furnace slag, non-iron metal slag, and slag resulting from the production of ceramics or blocks.
  • Exemplary European waste classification codes of slags are 19 01 11 and 19 01 12, which are incorporated herein by reference.
  • mineral waste is used herein to denote all inorganic residues not falling within the groups of fly ashes, bottom ashes and slags.
  • all stone-based mineral waste falling within the exemplary ranges of Table 5 is specifically encompassed.
  • Other examples of mineral waste include: crushed demolition waste, recycled concrete, foundry sands and other recycled aggregates, quarry fines and debris from stone production.
  • Exemplary European waste classification codes of mineral waste are 01 04 08; 01 04 09; 01 04 10; 01 04 13; 10 01 24; 10 08 15; 10 08 16; 10 09 11 ; 10 09 12; 10 10 1 1 ; 10 10 12; 10 1 1 15; 10 11 16; 10 12 09; 10 12 10; 10 13 04; 10 13 06; 19 01 19; 19 04 01 ; and 19 12 09, all of which are incorporated herein by reference.
  • % by dry weight is used herein to denote an amount in weight/total weight %, with all water having been removed.
  • sieve and the various sieve sizes mentioned herein are to be interpreted based on the International Standard ISO 3310-1 Wire Mesh Series. Where a percentage of a material passing a sieve is mentioned herein, this denotes the percentage by dry weight of the material that passes an ISO 3310-1 sieve with the relevant nominal aperture size.
  • the invention broadly resides in a method of making an aggregate for use in construction, the method including: providing an admixture comprising: a first residue selected from the group of fly ashes, the first residue making up 20% to 85% by dry weight of the admixture, and a second residue selected from the group of inorganic residues, the second residue making up 10% to 80% by dry weight of the admixture and having a particle size distribution defined by at most 50% of the second residue passing a 0.125 mm sieve; mixing the admixture; adjusting the moisture content of the admixture by adding an amount of water to form a wet mix; and processing the wet mix to form the aggregate.
  • the method of the first aspect of the invention enables the creation of an aggregate for use in construction using two residues as starting materials. It thus offers not only the benefit of providing an aggregate but also the secondary advantage of effective residue disposal.
  • the fly ash particles of the first residue have pozzolanic properties that, in the presence of the other components of the admixture and the water, result in the formation of a cementitious aggregate without any requirement for heat input.
  • the method of the first aspect of the invention is advantageously particularly energy-efficient. Additionally, toxic materials that may form part of the first or second residue are typically bound as a result of chemical interactions within the wet mix.
  • the first residue and the second residue also act in synergy by virtue of their physical characteristics. Specifically, the relatively coarse particles of the second residue typically act as agglomeration seeds for the fly ash particles of the first residue. During processing of the wet mix the particles of the first residue begin to coat the particles of the second residue to form granules, which can further increase in size by absorbing more particles and other granules to form the aggregate.
  • the defined particle size distribution of the second residue is vital in assisting agglomeration.
  • the inventors have found that inorganic particles having a size greater than 0.125 mm have the requisite properties to serve as effective agglomeration seeds. It is for this reason that at least half of the second residue (by weight) should be comprised of particles having a size greater than 0.125 mm.
  • the second residue may preferably have a particle size distribution defined by at most 35% of the second residue passing a 0.125 mm sieve.
  • the second residue may advantageously have a particle size distribution defined by between 10% and 30% of the second residue passing a 0.125 mm sieve.
  • the second residue may be preferable for the second residue to contain an even higher proportion of particles having a size greater than 0.125 mm.
  • the second residue may advantageously have a particle size distribution defined by: at most 60%, preferably 45%, of the second residue passing a 0.25 mm sieve.
  • the second residue may advantageously have a particle size distribution defined by between 15% and 40% of the second residue passing a 0.25 mm sieve.
  • the second residue may advantageously have a particle size distribution defined by: at most 60%, preferably 45%, of the second residue passing a 0.5 mm sieve.
  • the second residue may advantageously have a particle size distribution defined by between 15% and 40% of the second residue passing a 0.5 mm sieve.
  • the second residue may advantageously have a particle size distribution defined by: at most 80% of the second residue passing a 1 mm sieve.
  • the second residue may advantageously have a particle size distribution defined by between 20% and 50% of the second residue passing a 1 mm sieve.
  • the second residue may advantageously have a particle size distribution defined by at most 80% of the second residue passing a 2 mm sieve.
  • the second residue may advantageously have a particle size distribution defined by between 20% and 50% of the second residue passing a 2 mm sieve.
  • the second residue may advantageously have a particle size distribution defined by at most 90% of the second residue passing a 4 mm sieve.
  • a particle size distribution defined by at most 90% of the second residue passing a 4 mm sieve.
  • the second residue may preferably have a particle size distribution defined by at most 10% of the second residue passing a 2 mm sieve and by at least 90% of the second residue passing a 4 mm sieve.
  • the second residue may preferably have a particle size distribution defined by at most 10% of the second residue passing a 0.125 mm sieve, or preferably a 0.25 mm sieve, and by at least 90% of the second residue passing a 4 mm sieve.
  • the second residue may advantageously have a particle size distribution defined by 100% of the second residue passing a 40 mm sieve, or preferably a 10 mm sieve.
  • the first residue may advantageously have a particle size distribution defined by at least 90% of the first residue passing a 0.063 mm sieve. Similarly, the first residue may preferably have a particle size distribution defined by at least 99% of the first residue passing a 0.125 mm sieve. To ensure excellent pozzolanic properties, the first residue may conveniently have a particle size distribution such that 40% to 60% of the first residue has a maximum diameter between 0 and 1 ⁇ m.
  • the first residue and/or the second residue may advantageously contain the following: AI 2 O 3 10-30% by dry weight
  • Chloride Cl " 0-0.2% by dry weight
  • the second residue may be selected from the groups of bottom ashes and/or slags and/or mineral wastes. These residues are readily available and perform well in synergy with the first residue.
  • the first residue may be a paper mill fly ash or a fly ash from coal incineration and the second residue may be a furnace bottom ash from coal incineration.
  • the admixture it is preferred for the admixture to comprise 40% to 80% by dry weight of the paper mill fly ash or fly ash from coal incineration and 10% to 50% by dry weight of the furnace bottom ash from coal incineration.
  • the admixture may comprise 45% to 55% by dry weight of the paper mill fly ash or fly ash from coal incineration and 35% to 50% by dry weight of the furnace bottom ash from coal incineration.
  • the first residue is a paper mill fly ash or fly ash from coal incineration and the second residue is a municipal waste incineration slag.
  • the admixture it is preferred for the admixture to comprise 20% to 60% by dry weight of the paper mill fly ash or fly ash from coal incineration and 40% to 80% by dry weight of the municipal waste incineration slag.
  • the admixture may advantageously comprise 40% to 60% by dry weight of the first residue and 40% to 50% by dry weight of the second residue.
  • the admixture may advantageously further comprise 5% to 15% by dry weight of a binder, preferably cement.
  • an amount of conventional concrete liquefier additive may preferably be provided and mixed with the water before the water is added to the admixture.
  • the method of the first aspect of the invention enables the creation of tailor-made aggregates.
  • the first and second residues may preferably have chemical and physical properties falling within predetermined parameters according to an intended building use of the aggregate.
  • the first and second residues may comprise a defined amount of a heavy metal or another toxic material, consistent with providing an aggregate that meets a regulatory standard.
  • 95% to 100% of the chemical " composition of the first and second residues may be determined, for example with the aim of ensuring regulatory compliance of the aggregate.
  • Some pozzolanic reactions involving the first residue may be dependent on free lime (CaO). Accordingly, an amount of free lime in the first and second residues may preferably be determined and an amount of binder (if any) to be included in the admixture may advantageously be determined based on said amount of free lime.
  • the amount of water to be added to the admixture may vary in dependence on a number of factors including the water content of the first and second residues. Hence, the water content of the first and second residues may optionally be determined and the amount of water that is added to the admixture may be calculated based on said water content.
  • the amount of water may optionally be determined using the following algorithm:
  • WDa is the actual water demand
  • WDt is the theoretical water demand
  • WC is the water content of the admixture.
  • WDt the theoretical water demand
  • Z is the combined weight of the first residue.
  • the amount of water can be determined by gradual dosing with water until the wet mix is substantially homogenised, with no dry admixture remaining.
  • the quality of the first and second residues may sometimes be adversely affected by a water content that exceeds about 10% by weight.
  • the first and second residues may preferably comprise 90% to 100% DS (i.e. dry solids by weight).
  • the mixing of the admixture may advantageously lead the admixture to become substantially homogenised before the water is added.
  • the method of the first aspect of the invention does not require any heat input.
  • the wet mix may be processed at ambient conditions, i.e. a temperature in the range of 20 to 50 degrees Celsius, most preferably 25 to 45 degrees Celsius.
  • Processing of the wet mix may conveniently comprise agitating the wet mix. Due to the interaction of the first and second residues, agitating the wet mix may advantageously cause the wet mix to be granulated, as comparatively fine particles of the first residue agglomerate around comparatively coarse particles of the second residue to form a plurality of cementitious granules.
  • the method of the first aspect also encompasses other methods of granulation or pelletisation. Processing of the wet mix may also advantageously comprise aerating the wet mix.
  • the grain size distribution of the aggregate may be varied, for example, by controlling the duration of agitation during processing.
  • the wet mix may be processed such that the first and second residues are agglomerated to form a granular aggregate having a grain size distribution defined by 100% of the aggregate passing a 16 mm sieve, most preferably 10 mm.
  • the aggregates need not be granulated.
  • the wet mix may alternatively be homogenised and used as an aggregate in the formation of a concrete body such as a block.
  • Processing of the wet mix may comprise curing the wet mix, either at ambient conditions or at elevated temperatures such as 100 degrees Celsius.
  • the method of the first aspect of the invention is not limited with regard to the number of aggregates in the admixture.
  • the admixture may, for example, conveniently further comprise a third residue to provide yet further opportunities for residue disposal, or in order to achieve desired aggregate properties.
  • the third residue may preferably be inorganic, with a particle size defined by at most 50% of the third residue passing a 0.125 mm sieve, and the second and third residues together making up 10% to 80% by dry weight of the admixture.
  • the third residue may be selected from the group of fly ashes, with the first and third residues together making up 20% to 85% of the admixture.
  • the invention broadly resides in an aggregate obtainable by any method described herein.
  • the invention broadly resides in an aggregate for use in construction comprising: 40% to 85% by dry weight of paper mill fly ash and/or fly ash from coal incineration; and 10% to 50% by dry weight of furnace bottom ash from coal incineration.
  • the invention broadly resides in an aggregate for use in construction comprising: 20% to 60% by dry weight of paper mill fly ash and/or fly ash Jrom coal incineration; and 40% to 80% by weight of municipal waste incineration slag.
  • the invention broadly resides in a concrete product comprising an aggregate according to the second, third or fourth aspect of the invention.
  • relevant concrete products are concrete, paving blocks, masonry blocks, insulation, mortar or plaster.
  • aggregates are prepared by compiling an admixture comprising pre-selected first and second residues and optionally cement, homogenising the admixture by mixing, adding an amount of water to the homogenised admixture to form a wet mix, and processing the wet mix by agitation to homogenise the wet mix and form a granulated cemetitious aggregate.
  • the pre-selected first residue makes up 20% to 80% by dry weight of the admixture and is a fly ash having pozzolanic properties.
  • the pre-selected second residue makes up 10% to 80% by dry weight of the admixture and is inorganic, with a particle size distribution defined by at most 50% of the second residue passing a 0.125 mm sieve.
  • the amount of water to be added to the admixture is determined using the following algorithm:
  • WDa is the actual water demand
  • WDt is the theoretical water demand
  • WC is the water content of the admixture.
  • gradual dosing is used to determine the required amount of water.
  • a first paper mill fly ash (PMFA1) used in Examples 1 to 10 was obtained from a commercial paper mill.
  • the results of an initial analysis of PFMA1 are shown in Table 6.
  • the specific physical properties and chemical properties of PMFA1 varied between the Examples: as aforesaid, the precise properties of fly ashes tend to fluctuate as variations in the combustion process from which they originate occur.
  • the particle size distribution of PFMA1 was defined by at least 99% of PFMA1 passing a 0.125 mm sieve.
  • a first furnace bottom ash (FBA1) used in Examples 1 , 2, 5 and 6 was obtained from a commercial coal incineration power station.
  • the results of an initial analysis of FBA1 are shown in Table 7.
  • the specific physical properties and chemical properties of FBA1 varied between the Examples: as aforesaid, the precise properties of bottom ashes tend to fluctuate as variations in the combustion process from which they originate occur.
  • the particle size distribution of FBA1 was defined by at most 50% of FBA1 passing a 0.125 mm sieve.
  • FBA1 had a particle size distribution between 0 and 4 mm throughout.
  • FBA2 A second furnace bottom ash (FBA2) used in Examples 3 was obtained from a commercial coal incineration power station. Before use it was ensured that the particle size distribution of FBA2 was defined by at most 50% of FBA2 passing a 0.125 mm sieve. FBA2 had a particle size distribution between 0 and 2 mm.
  • a third furnace bottom ash (FBA3) used in Example 4 was obtained from a commercial coal incineration power station.
  • FBA3 had a particle size distribution between 2 and 4 mm.
  • MSWIS1 Municipal solid waste incineration slag
  • Example 9 A first stone-based mineral waste (MW1) used in Example 9 was obtained commercially. The results of an initial analysis of MW1 are shown in Table 10. Before each use it was ensured that the particle size distribution of MW 1 was defined by at most 50% of MW 1 passing a 0.125 mm sieve.
  • a first cement (CEM1 ) used in Examples 1 to 4 was commercially obtained Schwenk Cement CEM I 42.5 R.
  • a second cement (CEM2) used in Examples 5, 7 and 8 was commercially obtained Schwenk Cement CEM Il 32.5 R
  • a conventional concrete liquefier additive (ADD1) used in Examples 2 to 5 was commercially obtained lsola BV 10 K.
  • wet mix was mixed further for 2 minutes in the mixing machine at 70 rpm to form a homogenised wet mix.
  • the homogenised wet mix was granulated by further mixing in the mixing machine to form a cementitious granulated aggregate of varying grain size having a particle size distribution between about 0 to about 5 mm.
  • the aggregate was dried under ambient conditions and divided by sieving into a first aggregate E1 a, having a maximum grain size of 2 mm, and E1 b, having a minimum grain size of 2 mm and a maximum grain size of 5 mm.
  • a substantially dry admixture of 15 kg of PMFA1 , 12 kg of FBA1 and 3 kg of CEM1 was compiled and substantially homogenised by mixing in a mixing machine (Elba Labor Einwellenmischer 60 L) at 50 rpm mixer revolution for 1 minute.
  • a mixing machine Elba Labor Einwellenmischer 60 L
  • 7.4 kg of water and 0.06 kg of ADD1 were premixed and added to the substantially homogenised admixture. Further mixing in the mixing machine at 70 rpm for 1 minute led to the formation of a wet mix.
  • wet mix was mixed further for 2 minutes in the mixing machine at 70 rpm to form a homogenised wet mix.
  • the homogenised wet mix was granulated by further mixing in the mixing machine to form a cementitious granulated aggregate of varying grain size having a particle size distribution between about 0 to about 5 mm.
  • the granulated aggregate was dried under ambient conditions and divided by sieving into a first aggregate E2a, having a maximum grain size of 2 mm, and E2b, having a minimum grain size of 2 mm and a maximum grain size of 5 mm.
  • test cubes were allowed to dry for 28 days under ambient conditions and then analysed. The analysis of the physical properties of the test cubes is shown in Table 10.
  • ii. 8.4 kg of water and 0.06 kg of ADD1 were premixed and added to the substantially homogenised admixture. Further mixing in the mixing machine at 70 rpm for 1 minute led to the formation of a wet mix. iii. Following a first consistency check, the wet mix was mixed further for 2 minutes in the mixing machine at 70 rpm to form a homogenised wet mix.
  • the homogenised wet mix was granulated by further mixing in the mixing machine to form a cementitious granulated aggregate of varying grain size having a particle size distribution between about 0 to about 5 mm.
  • the granulated aggregate was dried under ambient conditions and divided by sieving into a first aggregate E3a, having a maximum grain size of 2 mm, and
  • E3b having a minimum grain size of 2 mm and a maximum grain size of 5 mm.
  • Each of aggregates E3a and E3b was then combined with cement to form three respective test cubes C3a and C3b having dimensions 15mm x 15mm x 15mm.
  • the test cubes were allowed to dry for 28 days under ambient conditions and then analysed. The analysis of the physical properties of the test cubes is shown in Table 10.
  • wet mix was mixed further for 2 minutes in the mixing machine at 70 rpm to form a homogenised wet mix.
  • the wet mix was mixed further for 2 minutes in the mixing machine at 70 rpm to form a homogenised wet mix.
  • the homogenised wet mix was granulated by further mixing in the mixing machine to form a cementitious granulated aggregate of varying grain size having a particle size distribution between about 0 to about 5 mm.
  • the granulated aggregate was dried under ambient conditions and divided by sieving into a first aggregate E4a, having a maximum grain size of 2 mm, and E4b, having a minimum grain size of 2 mm and a maximum grain size of 5 mm.
  • wet mix was mixed further for 2 minutes in the mixing machine at 70 rpm to form a homogenised wet mix.
  • the wet mix was granulated by further mixing in the mixing machine to form a cementitious granulated aggregate of varying grain size having a maximum particle size of about 10 mm.
  • the granulated aggregate was dried under ambient conditions and sieved to provide an aggregate E5 having a maximum grain size of 10 mm.
  • Example 6 Production of Granulated Lightweight Aggregate (M14) i.
  • a substantially dry admixture of 18 kg of PMFA1 , and 12 kg of FBA1 was compiled and substantially homogenised by mixing in a mixing machine (Elba Labor Einwellenmischer 60 L) at 50 rpm mixer revolution for 1 minute.
  • wet mix was mixed further for 2 minutes in the mixing machine at 70 rpm to form a homogenised wet mix.
  • the wet mix was granulated by further mixing in the mixing machine to form a cementitious granulated aggregate of varying grain size having a maximum particle size of about 10 mm.
  • the granulated aggregate was dried under ambient conditions and sieved to provide an aggregate E6 having a maximum grain size of 10 mm.
  • the wet mix was mixed further for 2 minutes in the mixing machine at 70 rpm to form a homogenised wet mix.
  • the wet mix was granulated by further mixing in the mixing machine to form a cementitious granulated aggregate of varying grain size having a maximum particle size of about 10 mm.
  • the granulated aggregate was dried under ambient conditions and sieved to provide an aggregate E7 having a maximum grain size of 10 mm.
  • wet mix was mixed further for 2 minutes in the mixing machine at 70 rpm to form a homogenised wet mix.
  • the wet mix was granulated by further mixing in the mixing machine to form a cementitious granulated aggregate of varying grain size having a maximum particle size of about 10 mm.
  • the granulated aggregate was dried under ambient conditions and sieved to provide an aggregate E8 having a maximum grain size of 10 mm.
  • MW1 was compiled and substantially homogenised by mixing in a mixing machine (Elba Labor Einwellenmischer 60 L) at 50 rpm mixer revolution for 1 minute.
  • wet mix was mixed further for 2 minutes in the mixing machine at 70 rpm to form a homogenised wet mix.
  • the wet mix was granulated by further mixing in the mixing machine to form a cementitious granulated aggregate of varying grain size having a maximum particle size of about 10 mm.
  • the granulated aggregate was dried under ambient conditions and sieved to provide an aggregate E9 having a maximum grain size of 10 mm.
  • wet mix was mixed further for 2 minutes in the mixing machine at 70 rpm to form a homogenised wet mix.
  • the wet mix was granulated by further mixing in the mixing machine to form a cementitious granulated aggregate of varying grain size having a maximum particle size of about 10 mm.
  • the granulated aggregate was dried under ambient conditions and sieved to provide a granular aggregate E10 having a maximum grain size of 10 mm.
  • a first residue of the admixture is a paper mill fly ash having pozzolanic properties (this could be substituted, for example, with fly ash from coal incineration or another pozzolanic residue such as a mineral waste).
  • a second residue of the admixture is inorganic, with a particle size distribution defined by at most 50% of the second residue passing a 0.125 mm sieve.
  • first and second residues act in synergy in the Examples to form aggregates of the present invention.
  • One synergistic technical effect is that the relatively coarse particles of the second residue act as agglomeration seeds: during agitation of the wet mix the pozzolanic particles of the first residue begin to coat the particles of the second residue to form granules, which then rapidly increase in size by absorbing more particles and other smaller granules.
  • the cement if present, acts as an additional binder, which aids the growth and strength of the granules.
  • the pre-defined particle size distribution of the second residue is vital to the formation of aggregates according to the present invention.
  • the wet mix of the present invention would not granulate effectively by mere agitation. Rather, more complicated and costly granulating or pelletising techniques would be required.
  • inorganic particles having a size greater than 0.125 mm have the requisite properties to serve as effective agglomeration seeds.
  • effectiveness of particles as agglomeration seeds increases with increasing size of the particles. This was noted as a result of monitoring the amount of fine particulate matter in the aggregates: aggregates in which the second pre-selected residues respectively contained a greater proportion of particles larger than 0.5 mm, 1 mm and 2 mm respectively contained an increasingly lower proportion of fine particulate matter due to more efficient agglomeration.
  • the minimum mixing time to achieve a given granulation size was found to be inversely proportional to the particle sizes of the pre-selected second residue.
  • Example 4 an emphasis has been placed on using particularly readily available residues to maximise the benefit of residue disposal. Therefore, the second residues of all Examples except Example 4 were tested to ensure that their particle size distributions were defined by at most 50% passing a 0.125 mm sieve.
  • the skilled person will appreciate in light of the disclosure herein that the Examples could easily be modified to set a different standard of particle size distribution in the second residue, for example in order to enhance agglomeration efficiency or aggregate grain strength yet further. Any desired balance may be struck between the advantages of enhanced residue disposal and enhanced agglomeration efficiency and/or grain strength, depending on the desired purpose.
  • Table 10 demonstrates that the aggregates of the Examples have excellent grain strengths that make them suitable for use in the field of construction, for example as additive to concrete. Additionally it is noted that the granular aggregates are all lightweight, with a bulk density of less than 1000 kg/m3. By comparison, normal weight aggregates have typical bulk densities of 1 ,650 kg/m3. Hence the granular aggregates of the Examples can all reduce dead weight by up to 50% with no loss in strength when compared to normal aggregates. It will be noted that the weight of the resultant aggregates is directly proportional to the average size of the particles of the second residue.
  • a further synergistic technical effect observed in Examples 1 to 10 as a result of combining the pre-selected first and second residues is that toxic materials, particularly when contained in the second residues, are effectively bound as a result of the agglomeration process.
  • the particles of the admixtures of the Examples, and in particular the pozzolanic particles of the first residues undergo reactions such as oxidation, reduction, complexation and hydration in the wet mix, which bind toxic materials such as heavy metals within the matrix of the resultant aggregate. This is particularly important in negating a potential disadvantage of the second residues of the Examples, namely that, although they are very cheap to obtain, they may contain relatively high levels of toxic substances.
  • the pozzolanic nature of the first residues essentially ensures, as a result of chemical interactions, that any toxicity of the second residues, or indeed the first residues, is mitigated for the purposes of providing an aggregate for use in construction. Additionally the inventors have found that the puzzolanic properties of the first residue lead to a pH buffering effect, adding additional alkalinity to the aggregates. Low cost aggregates are consequently enabled.

Landscapes

  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Civil Engineering (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Processing Of Solid Wastes (AREA)

Abstract

L'objet de la présente invention concerne un procédé de fabrication d'un agrégat utilisable dans la construction, le procédé comprenant : la fourniture d'un adjuvant constitué d'un premier résidu choisi dans le groupe des cendres volantes, le premier résidu constituant entre 20 et 85 % du poids sec de l'adjuvant, et un second résidu choisi dans le groupe des résidus non organiques, le second résidu constituant entre 10 et 80 % du poids sec de l'adjuvant et présentant une taille de particules telle que 50 % au plus du second résidu traverse un tamis de 0,125 mm. Le procédé comprend également le mélange de l'adjuvant, la rectification de la teneur en humidité de l'adjuvant par ajout d'un certain volume d'eau de manière à former un mélange humide, et enfin le traitement de ce mélange humide en vue de réaliser l'agrégat. Les agrégats obtenus grâce à ce procédé sont également examinés.
PCT/EP2007/009375 2006-10-27 2007-10-29 Améliorations relatives aux résidus WO2008049642A2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB0621467.0 2006-10-27
GB0621467A GB0621467D0 (en) 2006-10-27 2006-10-27 Improvements relating to residues

Publications (2)

Publication Number Publication Date
WO2008049642A2 true WO2008049642A2 (fr) 2008-05-02
WO2008049642A3 WO2008049642A3 (fr) 2008-08-21

Family

ID=37546132

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/EP2007/009375 WO2008049642A2 (fr) 2006-10-27 2007-10-29 Améliorations relatives aux résidus

Country Status (2)

Country Link
GB (1) GB0621467D0 (fr)
WO (1) WO2008049642A2 (fr)

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2010017583A1 (fr) * 2008-08-11 2010-02-18 Glosstone Pty Ltd Béton
ES2526136A1 (es) * 2013-07-02 2015-01-07 Valorización De Escorias Para La Construcción, S.A. Método de obtención de un material granular formulado a partir de escorias estabilizadas y cenizas volantes APC
CN111662020A (zh) * 2020-06-09 2020-09-15 河北工程大学 一种高性能轻质混凝土及其制备方法
CN112341029A (zh) * 2020-10-23 2021-02-09 山东鲁桥建材有限公司 一种改性再生粗骨料的制备方法
CN113582569A (zh) * 2021-07-14 2021-11-02 深圳大学 一种以垃圾焚烧底灰为原料的人造骨料及其制备方法
EP4049984A1 (fr) 2021-02-24 2022-08-31 Vilniaus Gedimino technikos universitetas Liant hydraulique pour routes avec cendres résiduelles mswi et son procédé de production
FR3144130A1 (fr) * 2022-12-21 2024-06-28 Néolithe Procédé de fabrication d’un granulat à base organique ou organique/minérale, granulat à base organique ou organique/minérale et applications de ces granulats
FR3144129A1 (fr) * 2022-12-21 2024-06-28 Néolithe Procédé de fabrication d’un granulat minéral reconstitué, granulat minéral reconstitué et applications de ces granulats

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE1296072B (de) * 1963-12-11 1969-05-22 Wienen & Thiel Gmbh Verfahren zur Herstellung von waermedaemmenden Zuschlagstoffen fuer Beton oder Leichtbeton
US4344796A (en) * 1979-06-20 1982-08-17 L. John Minnick Cementitious compositions and aggregate derivatives from said compositions
EP0301661A2 (fr) * 1987-07-22 1989-02-01 Hoogovens Technical Services Energy & Environment BV Durcissement à température élevée d'un matériau granulé
US4917732A (en) * 1986-12-22 1990-04-17 Shell Oil Company Flyash treatment
US5196620A (en) * 1991-06-13 1993-03-23 Municipal Services Corporation Fixation and utilization of ash residue from the incineration of municipal solid waste
DE10307780A1 (de) * 2003-02-23 2004-09-09 Schwetlick, Wolfgang, Dr. Verfahren zur Herstellung von Pellets aus Reststoffen für die Verwendung als alternative Baustoffe

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE1296072B (de) * 1963-12-11 1969-05-22 Wienen & Thiel Gmbh Verfahren zur Herstellung von waermedaemmenden Zuschlagstoffen fuer Beton oder Leichtbeton
US4344796A (en) * 1979-06-20 1982-08-17 L. John Minnick Cementitious compositions and aggregate derivatives from said compositions
US4917732A (en) * 1986-12-22 1990-04-17 Shell Oil Company Flyash treatment
EP0301661A2 (fr) * 1987-07-22 1989-02-01 Hoogovens Technical Services Energy & Environment BV Durcissement à température élevée d'un matériau granulé
US5196620A (en) * 1991-06-13 1993-03-23 Municipal Services Corporation Fixation and utilization of ash residue from the incineration of municipal solid waste
DE10307780A1 (de) * 2003-02-23 2004-09-09 Schwetlick, Wolfgang, Dr. Verfahren zur Herstellung von Pellets aus Reststoffen für die Verwendung als alternative Baustoffe

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2010017583A1 (fr) * 2008-08-11 2010-02-18 Glosstone Pty Ltd Béton
ES2526136A1 (es) * 2013-07-02 2015-01-07 Valorización De Escorias Para La Construcción, S.A. Método de obtención de un material granular formulado a partir de escorias estabilizadas y cenizas volantes APC
CN111662020A (zh) * 2020-06-09 2020-09-15 河北工程大学 一种高性能轻质混凝土及其制备方法
CN111662020B (zh) * 2020-06-09 2022-01-18 河北工程大学 一种高性能轻质混凝土及其制备方法
CN112341029A (zh) * 2020-10-23 2021-02-09 山东鲁桥建材有限公司 一种改性再生粗骨料的制备方法
CN112341029B (zh) * 2020-10-23 2021-09-28 山东鲁桥建材有限公司 一种改性再生粗骨料的制备方法
EP4049984A1 (fr) 2021-02-24 2022-08-31 Vilniaus Gedimino technikos universitetas Liant hydraulique pour routes avec cendres résiduelles mswi et son procédé de production
CN113582569A (zh) * 2021-07-14 2021-11-02 深圳大学 一种以垃圾焚烧底灰为原料的人造骨料及其制备方法
FR3144130A1 (fr) * 2022-12-21 2024-06-28 Néolithe Procédé de fabrication d’un granulat à base organique ou organique/minérale, granulat à base organique ou organique/minérale et applications de ces granulats
FR3144129A1 (fr) * 2022-12-21 2024-06-28 Néolithe Procédé de fabrication d’un granulat minéral reconstitué, granulat minéral reconstitué et applications de ces granulats

Also Published As

Publication number Publication date
GB0621467D0 (en) 2006-12-06
WO2008049642A3 (fr) 2008-08-21

Similar Documents

Publication Publication Date Title
US10131575B2 (en) Use of quarry fines and/or limestone powder to reduce clinker content of cementitious compositions
Tang et al. Employing cold bonded pelletization to produce lightweight aggregates from incineration fine bottom ash
US11168029B2 (en) Use of mineral fines to reduce clinker content of cementitious compositions
US10737980B2 (en) Use of mineral fines to reduce clinker content of cementitious compositions
CN108218272B (zh) 源于废物的环保人造集料（骨料）
Jayaranjan et al. Reuse options for coal fired power plant bottom ash and fly ash
WO2008049642A2 (fr) Améliorations relatives aux résidus
CA2577564C (fr) Liant pour residus miniers, sable alluvionnaire et autres materiaux semblables
Garg et al. Green concrete: Efficient & eco-friendly construction materials
US10730805B2 (en) Use of quarry fines and/or limestone powder to reduce clinker content of cementitious compositions
US8535435B2 (en) Method of fabrication of construction materials from industrial solid waste
KR101941319B1 (ko) 인산비료 및 인산비료의 제조방법
WO2004108627A1 (fr) Melanges a base de ciment et procedes d'utilisation correspondants
CA2981423A1 (fr) Pouzzolane naturelle fabriquee amelioree, ciment a base de pouzzolane fabriquee amelioree et methode de fabrication et utilisation associee
US20220017419A1 (en) Use of mineral fines to reduce clinker content of cementitious compositions
Wang et al. Sustainable and efficient stabilization/solidification of Pb, Cr, and Cd in lead-zinc tailings by using highly reactive pozzolanic solid waste
JP2007308322A (ja) 廃棄物を用いた肥料の製造方法及び肥料
US20180002229A1 (en) Mortar or concrete produced with a hydraulic binder
Bahoria et al. Comprehensive literature review on use of waste product in concrete
JPH11171628A (ja) 下水汚泥焼却灰を用いたセメント組成物およびこのセメ ント組成物の使用方法とこの組成物を用いた成形物およ び構造物
CN113149377A (zh) 一种脱水污泥固化剂、制备方法与使用方法
CN101670619A (zh) 一种活性污泥无害化制造免烧砖的方法
KR101867471B1 (ko) 고로슬래그 미분말 다량치환 순환골재 콘크리트 2차제품 및 그의 제조방법
US20240174567A1 (en) Binder for building materials, method for production thereof and plant for carrying out this method
KR20010025183A (ko) 폐기물의 중금속 용출방지를 위한 고형체 제조방법 및이에 의해 제조된 고형체

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 07819416

Country of ref document: EP

Kind code of ref document: A2

NENP Non-entry into the national phase

Ref country code: DE

122 Ep: pct application non-entry in european phase

Ref document number: 07819416

Country of ref document: EP

Kind code of ref document: A2