WO2009024826A1 - Production d'agrégats secondaires - Google Patents

Production d'agrégats secondaires Download PDF

Info

Publication number
WO2009024826A1
WO2009024826A1 PCT/GB2008/050733 GB2008050733W WO2009024826A1 WO 2009024826 A1 WO2009024826 A1 WO 2009024826A1 GB 2008050733 W GB2008050733 W GB 2008050733W WO 2009024826 A1 WO2009024826 A1 WO 2009024826A1
Authority
WO
WIPO (PCT)
Prior art keywords
process according
carbon dioxide
waste
materials
tumbling
Prior art date
Application number
PCT/GB2008/050733
Other languages
English (en)
Inventor
Colin Hills
Paula Carey
Original Assignee
University Of Greenwich
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 University Of Greenwich filed Critical University Of Greenwich
Publication of WO2009024826A1 publication Critical patent/WO2009024826A1/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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B09—DISPOSAL OF SOLID WASTE; RECLAMATION OF CONTAMINATED SOIL
    • B09B—DISPOSAL OF SOLID WASTE NOT OTHERWISE PROVIDED FOR
    • B09B3/00—Destroying solid waste or transforming solid waste into something useful or harmless
    • B09B3/20—Agglomeration, binding or encapsulation of solid waste
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B09—DISPOSAL OF SOLID WASTE; RECLAMATION OF CONTAMINATED SOIL
    • B09B—DISPOSAL OF SOLID WASTE NOT OTHERWISE PROVIDED FOR
    • B09B3/00—Destroying solid waste or transforming solid waste into something useful or harmless
    • B09B3/20—Agglomeration, binding or encapsulation of solid waste
    • B09B3/25—Agglomeration, binding or encapsulation of solid waste using mineral binders or matrix
    • 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 production of secondary aggregates by combined carbonation and tumbling of wastes and residues from metal processing and metal extraction, referred to herein in general terms as 'metallic wastes'.
  • the commercially available product Aardelite is manufactured using the pozzolanic properties of residues such as fly-ash.
  • a binder for example lime, and processing at a temperature of 90° C, the silica and alumina in the residue are transformed into cementitious minerals.
  • the present invention is based on the finding that secondary aggregates can be prepared from metallic wastes, using a combination of accelerated carbonation and tumbling, such that aggregate particles composed of successive layers of solid carbonate-based reaction products form a hard aggregate suitable for use in concrete after only minutes of exposure to carbon dioxide.
  • the present invention provides a process for the preparation of aggregates useful in the manufacture of concrete, comprising tumbling C ⁇ 2 -reactive i.e. carbonatable, metallic wastes, or metallic wastes and a C ⁇ 2 -reactive i.e. carbonatable, binder in the presence of moisture and carbon dioxide, such that the carbonatable materials and the carbon dioxide react as the tumbling proceeds to form successive layers of hardened carbonates around core particles.
  • further waste and/or binder is added to the system until the aggregate reaches a size which is suitable for its intended use, for example, aggregate for use in preparation of concrete, or aggregate used in road-making.
  • a useful carbonatable binder is ordinary Portland cement (OPC).
  • the process may be operated by tumbling single loads, or by batchwise addition of materials during the tumbling process, or by continuous feeding of carbonatable materials with continuous removal of aggregated product.
  • Figure 1 is a photograph showing untreated bauxite (left); and bauxite which has been tumbled with OPC and carbonated (right);
  • Figure 2 is a photograph showing untreated lead-contaminated waste (left); and lead- contaminated waste which has been tumbled with OPC and carbonated (right);
  • Figure 3 is a photograph showing untreated oil-drill cuttings (left); and oil-drill cuttings which have been tumbled with OPC and carbonated (right).
  • the present invention is a departure from the mixing required to implement the carbonation process of US Patent 5,997,629, in that it involves a tumbling action, typically by use of a rotating drum or tray.
  • the mixture when materials that are susceptible to accelerated carbonation are mixed with inert wastes/fines such as quarry or washing fines, the mixture is hardened in a CO 2 -rich gaseous environment, but in a way such that a series of successive layers of hardened material are formed (by the tumbling action) to produce a hard aggregated product, suitable as a replacement for stone, or sintered aggregate in, for example, concrete articles.
  • Metallic wastes usable in the invention include metal ore residues, such as bauxite, metal processing wastes, such as aluminium smelting residue (red mud), lead- contaminated waste, iron foundry/steel waste and zinc smelter waste, and oil-drill cuttings.
  • metal ore residues such as bauxite
  • metal processing wastes such as aluminium smelting residue (red mud), lead- contaminated waste, iron foundry/steel waste and zinc smelter waste, and oil-drill cuttings.
  • Carbonatable binders that may be used in this process include cement kiln dust and Portland cement, and CO 2 reactive materials such as quicklime, combustion ashes containing free lime and calcium silicate, or magnesium based minerals.
  • Portland cement that is deemed "out-of-date" for concrete manufacture may be used in this invention.
  • the residues suitably contain calcium or magnesium compounds, although carbonation can also occur with other metal compounds such as iron compounds.
  • Residues containing carbonatable materials may also be supplemented with carbonatable binders, such as OPC, which may be essential if a carbonatable component is absent or minimal in the residue.
  • water is added to achieve a weight ratio to solids of not more than 0.5:1 , possibly not more than 0.4:1 or 0.3:1.
  • the water to solids ratio is at least 0.01 :1 typically at least 0.1 or 0.2:1.
  • the water to solids ratio may be assessed as an overall value for the process. In a continuous process the indicated water to solids ratio is preferably observed for the feed materials throughout the process. Also, in a batchwise process the indicated water to solids ratio is preferably observed for each batch of material added to the tumbler while building up a layer structure for the aggregate.
  • the process of the invention is carried out in an atmosphere that has a carbon dioxide content greater than that of natural air, for example containing at least 20%, 30% or 40% by weight carbon dioxide.
  • carbon dioxide is the predominant component of the tumbling atmosphere, that is at 50%, 60%, 70% or 80% by weight.
  • the atmosphere substantially consists of carbon dioxide, that is at 90%, 95% or 99% by weight. Waste combustion gases with a high content of carbon dioxide may be suitable as the tumbling atmosphere.
  • the carbonation step is preferably carried out at or around atmospheric pressure, or up to a pressure not exceeding 30 psi (2 bar).
  • the use of a CO 2 atmosphere at higher pressure does not greatly advance the process and requires more complex apparatus.
  • the tumbled materials are able to combine with CO 2 in the presence of moisture, at ambient temperature and pressure. It is not usually necessary or desirable to employ heating or cooling during the tumbling.
  • the aggregate product does not retain hydraulic properties. Furthermore the product is preferably essentially non-hydrated in that the aggregate layers are formed by non-hydraulic hardening due to reaction with carbon dioxide.
  • the carbon dioxide used may be supplied from conventional sources of liquid or pressurised carbon dioxide.
  • CO 2 rich gases discharged or recycled from processes such as cement making, or as combustion waste gases may be used with the simultaneous environmental benefits of reducing greenhouse gas emissions.
  • the process is carried out by loading the starting materials into a cylindrical drum that is rotatable about an axis that is horizontal or slightly inclined to the horizontal.
  • the cylinder may be sealed at both ends so that its interior may be charged with a carbon dioxide atmosphere, or mounted within a larger vessel that holds a carbon dioxide atmosphere.
  • the material resting at the lowest point of the cylinder begin to "climb" the cylinder wall and then tumble back to the lowest level under gravity. Aggregates are formed as coatings on core particles as the tumbling proceeds, and the coatings are hardened by in situ formation of carbonates by reaction with the carbon dioxide.
  • the materials to be treated, and optionally water may be added to the drum as a single batch or in more than one portion.
  • the load, or each portion is drummed until suitably hardened and, if necessary with addition of another portion, until the desired size is reached for use as an aggregate in concrete manufacture or, for example, as road-stone or gravel substitute.
  • the load When the rotational axis is inclined to the horizontal, the load is able to pass down the incline during rotation.
  • the angle of inclination and the length of the drum is selected so that the time of travel of a load added at the higher end of the drum is such that it is aggregated to a suitable size as it discharges from the lower end of the drum.
  • the materials may be added as a single load, or more preferably as a continuous supply. This process may be carried out in a static CO 2 atmosphere or by circulating a CO 2 rich atmosphere through the drum.
  • the process may be carried out using rotating pelletising pans or trays having a circular base and an upstanding peripheral wall around the circumference of the base.
  • the base of the tray or pan may be horizontal, or inclined to the horizontal so that a tumbling action is imparted by the movement of the wall, as well as of the base.
  • an intermediate scale plant may be based on a tumbler drum of 1.5m diameter x 4.0m length with its main axis at an inclination of 1 -5 degrees from the horizontal. Operating at 1-5 RPM and velocity of 0.08-0.4 m/s, it is anticipated that a continuous feed of 1000-5000 kg/hr is feasible with a process time of 10 to 30 minutes, depending on waste.
  • Such an apparatus may be mounted on pairs of rollers or wheels, which support the drum while allowing it to rotate. The drum may be rotated by a motor which drives one or more of the support rollers or wheels.
  • This pilot scale plant may be scaled up in conventional manner for larger throughputs on an industrial scale, for example around 100 tonnes/hour.
  • the CU 2 -reactive component used may usefully be out-of-date Portland cement.
  • cement-kiln dusts, flue dusts and slag can also be used in the process of the invention, in which aggregates are produced using a rotary drum mixer with a tumbling/rolling action charged with carbon dioxide with the internal pressure at around atmospheric.
  • the product size range can vary between that of a granular soil-like material (millimetres in diameter) and pellets (millimetres to centimetres in diameter).
  • Bauxite aluminium oxide
  • Ordinary Portland Cement as an example of a carbonatable binder

Landscapes

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

Abstract

L'invention concerne des agrégats secondaires qui sont préparés à partir de déchets métalliques, tels que des déchets ou des résidus contenant des composés métalliques résultant d'une extraction de métal ou d'un traitement de métal, utilisant une combinaison de carbonatation accélérée et un culbutage, de telle sorte que des particules agrégées constituées par des couches successives de produits de réaction à base de carbonate solides forment un agrégat dur approprié pour une utilisation dans du béton. Le procédé peut être mis en œuvre par chargement des matériaux de départ, et, si nécessaire, d'eau, dans un tambour cylindrique qui peut tourner autour de son axe horizontal. L'intérieur est chargé d'une atmosphère de dioxyde de carbone, ou le tambour est monté à l'intérieur d'un récipient plus grand qui contient une atmosphère de dioxyde de carbone. Des agrégats sont formés sous la forme de revêtements sur des particules de cœur lorsque le culbutage est conduit, et les revêtements sont durcis par formation in-situ de carbonates par réaction avec le dioxyde de carbone.
PCT/GB2008/050733 2007-08-22 2008-08-21 Production d'agrégats secondaires WO2009024826A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB0716360.3 2007-08-22
GB0716360A GB0716360D0 (en) 2007-08-22 2007-08-22 Production of secondary aggregates

Publications (1)

Publication Number Publication Date
WO2009024826A1 true WO2009024826A1 (fr) 2009-02-26

Family

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Family Applications (1)

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Country Status (2)

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GB (1) GB0716360D0 (fr)
WO (1) WO2009024826A1 (fr)

Cited By (27)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2461622A (en) * 2008-05-29 2010-01-13 Calera Corp Rocks and aggregate, and methods of making and using the same
US7744761B2 (en) 2007-06-28 2010-06-29 Calera Corporation Desalination methods and systems that include carbonate compound precipitation
US7749476B2 (en) 2007-12-28 2010-07-06 Calera Corporation Production of carbonate-containing compositions from material comprising metal silicates
US7754169B2 (en) 2007-12-28 2010-07-13 Calera Corporation Methods and systems for utilizing waste sources of metal oxides
US7753618B2 (en) 2007-06-28 2010-07-13 Calera Corporation Rocks and aggregate, and methods of making and using the same
US7771684B2 (en) 2008-09-30 2010-08-10 Calera Corporation CO2-sequestering formed building materials
US7790012B2 (en) 2008-12-23 2010-09-07 Calera Corporation Low energy electrochemical hydroxide system and method
US7815880B2 (en) 2008-09-30 2010-10-19 Calera Corporation Reduced-carbon footprint concrete compositions
US7829053B2 (en) 2008-10-31 2010-11-09 Calera Corporation Non-cementitious compositions comprising CO2 sequestering additives
US7875163B2 (en) 2008-07-16 2011-01-25 Calera Corporation Low energy 4-cell electrochemical system with carbon dioxide gas
US7887694B2 (en) 2007-12-28 2011-02-15 Calera Corporation Methods of sequestering CO2
WO2011020927A2 (fr) 2009-08-21 2011-02-24 Recoval Belgium Procédé de traitement d'une matière granulaire alcaline apte à être carbonatée
US7939336B2 (en) 2008-09-30 2011-05-10 Calera Corporation Compositions and methods using substances containing carbon
US7966250B2 (en) 2008-09-11 2011-06-21 Calera Corporation CO2 commodity trading system and method
US7993511B2 (en) 2009-07-15 2011-08-09 Calera Corporation Electrochemical production of an alkaline solution using CO2
US7993500B2 (en) 2008-07-16 2011-08-09 Calera Corporation Gas diffusion anode and CO2 cathode electrolyte system
US8137444B2 (en) 2009-03-10 2012-03-20 Calera Corporation Systems and methods for processing CO2
ITVE20110041A1 (it) * 2011-05-31 2012-12-01 Veneta Depuratori E Affini S Ve D A Soc Procedimento di trattamento di ceneri pesanti o scorie in genere.-
US8357270B2 (en) 2008-07-16 2013-01-22 Calera Corporation CO2 utilization in electrochemical systems
WO2013060870A1 (fr) 2011-10-26 2013-05-02 Carbstone Innovation Procédé pour la production d'un article lié comprenant un matériau granulaire carbonaté moulé par pressage
US8491858B2 (en) 2009-03-02 2013-07-23 Calera Corporation Gas stream multi-pollutants control systems and methods
EP2708520A1 (fr) * 2012-09-14 2014-03-19 Cemex Research Group AG Procédé de fabrication de supplément et de carbonate de calcium à partir d'un agrégat de béton et dispositif de réalisation du procédé
US8834688B2 (en) 2009-02-10 2014-09-16 Calera Corporation Low-voltage alkaline production using hydrogen and electrocatalytic electrodes
US8869477B2 (en) 2008-09-30 2014-10-28 Calera Corporation Formed building materials
US9133581B2 (en) 2008-10-31 2015-09-15 Calera Corporation Non-cementitious compositions comprising vaterite and methods thereof
US9260314B2 (en) 2007-12-28 2016-02-16 Calera Corporation Methods and systems for utilizing waste sources of metal oxides
WO2020260568A1 (fr) 2019-06-26 2020-12-30 Orbix Productions Procédé de production d'un article compacté à liaison carbonate

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0367914A1 (fr) * 1988-10-15 1990-05-16 Hubert Eirich Procédé pour la fabrication d'agglomérats resistant au lessivage
FR2732910A1 (fr) * 1995-04-13 1996-10-18 Viafrance Sa Procede de traitement des machefers d'incineration en vue de les valoriser
WO1997013735A1 (fr) * 1995-10-06 1997-04-17 Imperial College Of Science, Technology & Medicine Traitement de matieres dangereuses
WO2002057008A1 (fr) * 2001-01-17 2002-07-25 Forkers Limited Traitement d'un materiau solide avec un fluide
WO2007096671A1 (fr) * 2006-02-21 2007-08-30 University Of Greenwich Fabrication d'agregats secondaires

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0367914A1 (fr) * 1988-10-15 1990-05-16 Hubert Eirich Procédé pour la fabrication d'agglomérats resistant au lessivage
FR2732910A1 (fr) * 1995-04-13 1996-10-18 Viafrance Sa Procede de traitement des machefers d'incineration en vue de les valoriser
WO1997013735A1 (fr) * 1995-10-06 1997-04-17 Imperial College Of Science, Technology & Medicine Traitement de matieres dangereuses
WO2002057008A1 (fr) * 2001-01-17 2002-07-25 Forkers Limited Traitement d'un materiau solide avec un fluide
WO2007096671A1 (fr) * 2006-02-21 2007-08-30 University Of Greenwich Fabrication d'agregats secondaires

Cited By (41)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7914685B2 (en) 2007-06-28 2011-03-29 Calera Corporation Rocks and aggregate, and methods of making and using the same
US7744761B2 (en) 2007-06-28 2010-06-29 Calera Corporation Desalination methods and systems that include carbonate compound precipitation
US7931809B2 (en) 2007-06-28 2011-04-26 Calera Corporation Desalination methods and systems that include carbonate compound precipitation
US7753618B2 (en) 2007-06-28 2010-07-13 Calera Corporation Rocks and aggregate, and methods of making and using the same
US7887694B2 (en) 2007-12-28 2011-02-15 Calera Corporation Methods of sequestering CO2
US7749476B2 (en) 2007-12-28 2010-07-06 Calera Corporation Production of carbonate-containing compositions from material comprising metal silicates
US7754169B2 (en) 2007-12-28 2010-07-13 Calera Corporation Methods and systems for utilizing waste sources of metal oxides
US8333944B2 (en) 2007-12-28 2012-12-18 Calera Corporation Methods of sequestering CO2
US9260314B2 (en) 2007-12-28 2016-02-16 Calera Corporation Methods and systems for utilizing waste sources of metal oxides
GB2461622A (en) * 2008-05-29 2010-01-13 Calera Corp Rocks and aggregate, and methods of making and using the same
GB2461622B (en) * 2008-05-29 2011-04-13 Calera Corp Rocks and aggregate, and methods of making and using the same
US7875163B2 (en) 2008-07-16 2011-01-25 Calera Corporation Low energy 4-cell electrochemical system with carbon dioxide gas
US7993500B2 (en) 2008-07-16 2011-08-09 Calera Corporation Gas diffusion anode and CO2 cathode electrolyte system
US8357270B2 (en) 2008-07-16 2013-01-22 Calera Corporation CO2 utilization in electrochemical systems
US8894830B2 (en) 2008-07-16 2014-11-25 Celera Corporation CO2 utilization in electrochemical systems
US7966250B2 (en) 2008-09-11 2011-06-21 Calera Corporation CO2 commodity trading system and method
US7815880B2 (en) 2008-09-30 2010-10-19 Calera Corporation Reduced-carbon footprint concrete compositions
US8431100B2 (en) 2008-09-30 2013-04-30 Calera Corporation CO2-sequestering formed building materials
US8869477B2 (en) 2008-09-30 2014-10-28 Calera Corporation Formed building materials
US8006446B2 (en) 2008-09-30 2011-08-30 Calera Corporation CO2-sequestering formed building materials
US7939336B2 (en) 2008-09-30 2011-05-10 Calera Corporation Compositions and methods using substances containing carbon
US8603424B2 (en) 2008-09-30 2013-12-10 Calera Corporation CO2-sequestering formed building materials
US8470275B2 (en) 2008-09-30 2013-06-25 Calera Corporation Reduced-carbon footprint concrete compositions
US7771684B2 (en) 2008-09-30 2010-08-10 Calera Corporation CO2-sequestering formed building materials
US7829053B2 (en) 2008-10-31 2010-11-09 Calera Corporation Non-cementitious compositions comprising CO2 sequestering additives
US9133581B2 (en) 2008-10-31 2015-09-15 Calera Corporation Non-cementitious compositions comprising vaterite and methods thereof
US7790012B2 (en) 2008-12-23 2010-09-07 Calera Corporation Low energy electrochemical hydroxide system and method
US8834688B2 (en) 2009-02-10 2014-09-16 Calera Corporation Low-voltage alkaline production using hydrogen and electrocatalytic electrodes
US9267211B2 (en) 2009-02-10 2016-02-23 Calera Corporation Low-voltage alkaline production using hydrogen and electrocatalytic electrodes
US8491858B2 (en) 2009-03-02 2013-07-23 Calera Corporation Gas stream multi-pollutants control systems and methods
US8883104B2 (en) 2009-03-02 2014-11-11 Calera Corporation Gas stream multi-pollutants control systems and methods
US8137444B2 (en) 2009-03-10 2012-03-20 Calera Corporation Systems and methods for processing CO2
US7993511B2 (en) 2009-07-15 2011-08-09 Calera Corporation Electrochemical production of an alkaline solution using CO2
WO2011020927A2 (fr) 2009-08-21 2011-02-24 Recoval Belgium Procédé de traitement d'une matière granulaire alcaline apte à être carbonatée
ITVE20110041A1 (it) * 2011-05-31 2012-12-01 Veneta Depuratori E Affini S Ve D A Soc Procedimento di trattamento di ceneri pesanti o scorie in genere.-
WO2013060870A1 (fr) 2011-10-26 2013-05-02 Carbstone Innovation Procédé pour la production d'un article lié comprenant un matériau granulaire carbonaté moulé par pressage
WO2014040852A1 (fr) * 2012-09-14 2014-03-20 Cemex Research Group Ag Procédé de fabrication de granulat et de carbonate de calcium à partir de particules de béton, et dispositif permettant la mise en oeuvre dudit procédé
EP2708520A1 (fr) * 2012-09-14 2014-03-19 Cemex Research Group AG Procédé de fabrication de supplément et de carbonate de calcium à partir d'un agrégat de béton et dispositif de réalisation du procédé
US9664446B2 (en) 2012-09-14 2017-05-30 Cemex Research Group Ag Method for producing aggregate and calcium carbonate from concrete composite materials, and a device for carrying out said method
WO2020260568A1 (fr) 2019-06-26 2020-12-30 Orbix Productions Procédé de production d'un article compacté à liaison carbonate
EP3757083A1 (fr) 2019-06-26 2020-12-30 ORBIX Productions Procédé de production d'un article compacté lié par des carbonates

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