WO2015176141A1 - Système et procédé relatifs à des déchets recyclés - Google Patents

Système et procédé relatifs à des déchets recyclés Download PDF

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Publication number
WO2015176141A1
WO2015176141A1 PCT/AU2015/050275 AU2015050275W WO2015176141A1 WO 2015176141 A1 WO2015176141 A1 WO 2015176141A1 AU 2015050275 W AU2015050275 W AU 2015050275W WO 2015176141 A1 WO2015176141 A1 WO 2015176141A1
Authority
WO
WIPO (PCT)
Prior art keywords
product
built environment
abmw
binder
mineral waste
Prior art date
Application number
PCT/AU2015/050275
Other languages
English (en)
Inventor
Manuel SANABRIA
Original Assignee
Mineraltec Pty Ltd
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
Priority claimed from AU2014901938A external-priority patent/AU2014901938A0/en
Application filed by Mineraltec Pty Ltd filed Critical Mineraltec Pty Ltd
Publication of WO2015176141A1 publication Critical patent/WO2015176141A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/165—Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber

Definitions

  • the present invention relates to recycled waste.
  • the present invention relates to the 3D printing of recycled glass in building products.
  • Used glass products such as bottles and the like, are often collected for recycling. Glass is generally crushed, and used where appropriate, to create new glass. Certain glass that has been received for recycling may be contaminated, or otherwise not suitable for making new glass products. Such contaminated glass is often dumped in land fill, which landfill is undesirable for environmental and other reasons.
  • Sandblasting is used to clean dirt, corrosion, paint or other coatings from a variety of surfaces. Sandblasting is commonly used in a variety of industries, including in metal foundries, motor engine repairs, mining, engineering workshops, and ship dockyards.
  • Heavy minerals like garnet, are commonly used as abrasive media in sandblasting, and are generally used to clean a metal surface.
  • sandblasting is often used to remove surface coatings, such as paint, or rust from metal.
  • the surface coatings can include various chemicals, such as anti-corrosion agents, which in turn can comprise heavy metals.
  • a problem with sandblasting is that significant amounts of used abrasive media, also referred to as abrasive blasting media waste (ABMW), is generated.
  • ABMW can contain materials from the cleaned surface which, as mentioned above can include heavy metals, and are thus hazardous.
  • marine paints often contain heavy metals which act as anti-fouling and anti-corrosion agents. When the metal surfaces are sandblasted, the heavy metals of the paint become part of the waste ABMW.
  • the present invention is directed to a built environment product, which may at least partially overcome at least one of the abovementioned disadvantages or provide the consumer with a useful or commercial choice.
  • the present invention resides broadly in a built environment product formed using three-dimensional printing, the built environment product including:
  • a binder for binding the powdered mineral waste.
  • the powdered mineral waste media may be glass powder.
  • a substantial portion of the particles of the powdered mineral waste media may be less than 600 microns in diameter.
  • the built environment product may be 3D printed from a sintered powder comprising the powdered mineral waste media and the binder.
  • the built environment product may be 3D printed using a powdered bed of the sintered powder.
  • the sintered powder may be applied by a spray nozzle.
  • the sintered powder may be extruded.
  • the built environment product may be a building product.
  • the binder may be polymer based.
  • the binder may be concrete based.
  • the powdered mineral waste media may be abrasive blasting media waste (ABMW), wherein the ABMW is encapsulated by the binder.
  • ABMW abrasive blasting media waste
  • the ABMW may comprise garnet that has been used for sandblasting.
  • the built environment product may comprise at least 30% powdered mineral waste media.
  • the built environment product may include at least one surface substantially saturated with powdered mineral waste media.
  • the saturated ABMW may provide a frictional surface on the building product.
  • the built environment product may comprise one of a wall panel, a benchtop, a sound dampening panel, a tile, a brick, a block, panel, an architectural fagade, a barrier, a paver, a tabletop, a render mix, an instant concrete mix, a retaining wall and sleeper, a fencing panel, a footpath, a prefab wall, floor and roof housing panel, an ornament, a furniture, a plastic based product, a rubber based product, a polyurethane based product, a concrete based product, and a grout.
  • the invention resides in a method of forming a built environment product, the method comprising:
  • the method may comprise mixing the binder and the powdered glass to form the mixture.
  • the 3D printing mixture may comprise a sintered mixture.
  • the invention resides broadly in a 3D printing powdered media, for 3D printing a built environment product, comprising:
  • a binder for binding the powdered mineral waste.
  • the invention resides broadly in a method of forming a product, the method comprising:
  • the invention resides broadly in a built environment product including:
  • ABSMA abrasive blasting media waste
  • a binder for binding the ABMW
  • embodiments of the present invention enable abrasive blasting media waste to be utilised in built environment products. Utilization of landfill for abrasive blasting media waste may thus be reduced, which in turn may reduce costs associated with abrasive blasting. Furthermore, the encapsulation of the ABMW by the binder may immobilize any hazardous content in the ABMW thus making the built environment product safe and environmentally friendly, and prevent leeching of hazardous content from the built environment product.
  • the built environment product is a building product.
  • the ABMW is microencapsulated by the binder.
  • Encapsulation or microencapsulation of the ABMW by the binder may prevent any harmful residues in the ABMW from escaping into the environment.
  • heavy metals may be safely contained by encapsulation with the binder.
  • the ABMW may comprise garnet that has been used for sandblasting.
  • the ABMW may comprise staurolite.
  • the binder may be polymer based.
  • the binder may be concrete based.
  • the binder may comprise asphalt, polyester resin, polyurethane resin, thermoset plastic (e.g. polyester, vinyl ester, modified acrylic, epoxy, phenolic, urethane), synthetic elastomer, polysiloxane, sol-gel (e.g., polyceram), geopolymer and/or Portland cement.
  • the binder may comprise unsaturated polyester resin that has been cured using a Methyl Ethyl Ketone (MEK) Peroxide catalyst.
  • MEK Methyl Ethyl Ketone
  • the binder may include reinforcing fibres, for reinforcing the built environment product.
  • the built environment product may comprise at least 30% ABMW.
  • the built environment product may comprise at least 50% ABMW, at least 75% ABMW, at least 90% ABMW, or at least 95% ABMW.
  • the built environment product may include at least one surface comprising polished binder.
  • the at least one surface may comprise a surface coating.
  • the surface coating may comprise a lacquer or paint.
  • the built environment product may include at least one surface substantially saturated with ABMW.
  • the saturated ABMW may provide a frictional surface on the building product.
  • the built environment product may comprise a wall panel, a benchtop, a sound dampening panel, a tile, a brick, a block, panel, an architectural fagade, a barrier, a paver, a tabletop, a render mix, an instant concrete mix, a retaining wall and sleeper, a fencing panel, a footpath, a prefab wall, floor and roof housing panel, an ornament, a furniture, a plastic based product, a rubber based product, a polyurethane based product, a concrete based product, or a grout.
  • the present invention resides broadly in a method of forming a built environment product, the method comprising:
  • ABS abrasive blasting media waste
  • the mixed ABMW particles and binder can be cured in a mould. [0041] The curing may be accelerated by a catalyst. [0042] The method may include mixing a colour with the ABMW particles and binder. [0043] According to certain embodiments, the method further comprises:
  • the mixed ABMW particles and binder may be at least partially cured in a curing chamber.
  • the present invention resides broadly in a built environment product including:
  • ABSMA abrasive blasting media waste
  • a binder for binding the ABMW
  • the building product mainly comprises ABMW.
  • Figure 1 illustrates a schematic of a system for producing a building material, according to an embodiment of the present invention
  • Figure 2 illustrates a partial cross section of a building product, according to an embodiment of the present invention
  • Figure 3 illustrates a partial cross section of a building product, according to an alternative embodiment of the present invention.
  • Figure 4 illustrates a method of forming a building product, according to an embodiment of the present invention.
  • Figure 1 illustrates a schematic of a system 100 for producing a building material, according to an embodiment of the present invention.
  • the system 100 can be used for manufacturing building materials using Abrasive blasting media waste (ABMW).
  • ABMW Abrasive blasting media waste
  • the system 100 includes a mix dispenser 105 for receiving and mixing resin from a resin source 110, catalyst from a catalyst source 115, colour from a colour source 120 and ABMW from an ABMW source 125.
  • the resin can comprise an unsaturated polyester resin, or any other resin suitable for binding the ABMW.
  • the catalyst can comprise Methyl Ethyl Ketone (MEK) Peroxide, or any other suitable catalyst.
  • the resin and catalyst bind the ABMW and colour to form a solid building product, such as a wall panel, a benchtop, a sound dampening panel, a tile, a brick, a block, panel, an architectural fagade, a barrier or a paver a render mix, an instant concrete mix, a retaining wall and sleeper, a fencing panel, a footpath, a prefab wall, floor and roof housing panel.
  • the system 100 can be for producing any suitable built environment product including an ornament, a furniture, a plastic based product, a rubber based product, a polyurethane based product, a concrete based product, or a grout.
  • the term built environment product refers to products that provide the setting for human activity, including building products, and products used in parks or green space such as outdoor furniture.
  • the ABMW can, for example, comprise spent garnet.
  • the ABMW may comprise spent staurolite.
  • the garnet and/or staurolite may be contaminated with paint particulate, protective coating particulate and other debris that has been stripped from a structure during sandblasting.
  • the colour can, for example, comprise any suitable pigment, which enables the building material to be coloured to a desired colour.
  • the colour can comprise powdered colourant, acrylic colour or the like.
  • the mix dispenser 105 is further configured to dispense the mixed ABMW, resin, catalyst and colour into moulds 125 for curing.
  • the moulds 125 may be shaped to form the building material directly, or to form a component of the building material.
  • the filled moulds 125 are transported to a curing chamber 130 by a first conveyor 135a.
  • the curing chamber 130 is configured to assist in curing the building material by raising a temperature of the material.
  • the skilled addressee will, however, readily appreciate that the curing chamber 130 may also provide an increase in humidity, or any other change to the environment in the curing chamber 130 to assist in curing the building product.
  • the cured building materials are then transported from the curing chamber 130 using a second conveyor 135b, for packaging and distribution.
  • the system 100 further includes an ABMW dispenser 140, for selectively dispensing ABMW directly onto the uncured building material.
  • ABMW dispenser 140 for selectively dispensing ABMW directly onto the uncured building material. This enables the ABMW to provide a texture, such as a non-grip surface, to the building material. In such case, the ABMW is denser at a surface of the building material which provides a rough surface.
  • Figure 2 illustrates a partial cross section of a building product 200, according to an embodiment of the present invention.
  • the building product 200 can, for example, comprise a benchtop.
  • the building product 200 includes ABMW particles 205 encapsulated by a binder 210. Such encapsulation may prevent any harmful residues in the ABMW particles 205 from escaping into the environment.
  • the ABMW particles 205 can comprise used garnet from sandblasting and the binder can comprise resin.
  • the ABMW particles 205 are microencapsulated by the binder.
  • AMBW particles 205 (or small groups of AMBW particles 205) are individually encapsulated by the binder. Microencapsulation may further prevent any harmful residues in the ABMW particles 205 from escaping into the environment.
  • the building product 200 includes an outer surface 215 formed of the binder 210, such that the ABMW particles 205 are not exposed.
  • the outer surface 215 may comprise polished binder 210.
  • the outer surface 215 comprises a surface coating.
  • the surface coating may comprise a lacquer or paint.
  • the ABMW particles 205 are evenly distributed in the binder 210.
  • the building product 200 can comprise at least 30% ABMW.
  • the building product can comprise at least 50% ABMW, at least 75% ABMW, at least 90% ABMW or at least 95% ABMW.
  • Figure 3 illustrates a partial cross section of a building product 300, according to an alternative embodiment of the present invention.
  • the building product 300 can, for example, comprise a tile or paver.
  • the building product 300 includes ABMW particles 205 encapsulated by a binder 210, similar to the building product 200 of Figure 2. However, the building product 300 includes an outer surface 315 that is textured.
  • the building product 300 includes ABMW particles 205 that are saturated at the outer surface 315.
  • ABMW may be applied to a surface of uncured mixed ABMW particles 205 and binder 210, prior to curing. The ABMW will then sink into the uncured mixture such that the ABMW is also encapsulated by the binder 210. This provides a rough surface to the building product 300.
  • Figure 4 illustrates a method of forming a building product, according to an embodiment of the present invention.
  • Abrasive blasting media waste (ABMW) particles are mixed with a binder.
  • the ABMW can comprise garnet and the binder can comprise resin and a catalyst.
  • the mixed ABMW and binder is poured into a mould.
  • the mould may be shaped as the building product, or a component thereof.
  • ABMW is applied to a surface of the mixed ABMW particles and binder, prior to curing.
  • the ABMW is advantageously allowed to settle in a surface of the mixed ABMW particles and binder thus allowing the ABMW to be encapsulated by the binder while providing a rough surface to the building product.
  • the mixed ABMW particles and binder are cured, for example in a curing chamber.
  • step 415 need not be performed if a smooth surface is desired.
  • the mixed ABMW and binder is pressed. As such, a high percentage of AMBW can be introduced into the building product thus providing a very strong and dense building product.
  • a level of contamination of the ABMW is identified prior to use.
  • an XRF instrument may identify heavy metals such as silver, arsenic, barium, bismuth, cadmium, chromium, iron, manganese, nickel, lead, copper, selenium, and/or zinc or organic substances such as dioxins, furans and polychlorinated biphenyls (PCB)s.
  • Highly contaminated ABMW can then be diluted with ABMW that is less contaminated until a desired level of contamination is reached.
  • highly contaminated ABMW can be treated, chemically or otherwise, including by heating the ABMW to a high temperature to melt and separate the heavy metals from the ABMW.
  • the ABMW, binder, catalyst and colour is heated to a temperature of up to 2200°C to obtain a homogeneous mixture prior to curing.
  • the ABMW, binder, catalyst and colour may be heated to a temperature of approximately 1000°C.
  • reinforcing fibres are added to the ABMW and binder to add strength the building product.
  • the building product may be introduced into various moulds or direct products using spraying, casting, extrusion or 3D printing.
  • the mixture may be cured at room temperature or at a higher or lower temperature in a curing chamber.
  • the building product comprises a sound dampening barrier for dampening sound from a road.
  • the sound dampening barrier can be provided between a motorway and a housing estate, to reduce road noise front the motorway in the estate.
  • the sound dampening barrier may have a similar construction to a wall panel, discussed above, and be configured to extend upwardly from the ground by one or more supports.
  • the sound dampening barrier includes algae, for absorbing carbon dioxide from vehicles on the motorway.
  • the sound dampening barrier may improve air quality adjacent to the motorway in addition to dampening road noise.
  • a mould is filled with a liquid synthetic resin mixed with ABMW and allowed to harden.
  • Resin casting may be used in the production industrial products.
  • a thermosetting resin may be used that polymerizes by mixing with a curing agent (polymerization catalyst) at room temperature and normal pressure.
  • suitable resins include polystyrene resin, polyurethane resin, epoxy resin, unsaturated polyester resin, acrylic resin and silicone resin.
  • Polyester resin 2%- 90%
  • MEKP Methyl Ethyl Keytone Peroxide
  • the catalyst (MEKP) is thoroughly mixed with the polyester resin before adding the ABMW.
  • Part A activator/Part B Resin 5-90% (Part A and Part B 1: 1)
  • Part B Resin is thoroughly mixed with the ABMW before adding Part A activator.
  • Part A activator/Part B epoxy resin 5-90%
  • Part B resin and Part A activator (hardener) is mixed thoroughly before adding the AMBW.
  • Part B resin and Part A activator hardener
  • Part A activator / Part B Silicon Resin 5-90%
  • EXAMPLE 2 CONCRETE AND MORTAR GROUT MIXES
  • BASIC MIX blend of Portland cement, aggregate and ABMW in a 1:2:4 proportion to achieve maximum strength (i.e. 1 part cement, 2 parts ABMW, 4 parts gravel and water).
  • Portland cement may be mixed with ABMW at ratios of between 1: 1 and 1:6.
  • high strength concrete can be mixed according to:
  • the polymer can assist in encapsulating the AMBW by making the cement substantially waterproof. As such, any heavy metals (or other impurities) in the AMBW are unable to leech out of the building product.
  • Geopolymer cement is an alternative to Portland cement and can be used to produce Geopolymer concrete by adding ABMW to a geopolymer cement slurry.
  • ABMW inorganic aluminosilicate
  • asphalt bituminous materials can be used as the binder.
  • the above systems and methods may be used with powdered recycled glass, or any other suitable powdered mineral waste media, instead of garnet.
  • the invention relates to a method for producing a powdered glass product from waste glass, for use in three dimensional (3D) printing.
  • the product may comprise a 3D printing powdered media to be used for 3D printing in the building industry, such as building panels and the like.
  • the waste glass may be recovered and recycled from household and commercial waste, to produce a recycled sintered glass sand and powder, for 3D printing of building materials and the like.
  • Crushed glass sand may be screened, cleaned, crushed, sieved, vibrated and sorted to produce a recycled glass powder in which a substantial portion of the powder is less than 600 microns in diameter.
  • the powdered glass is then mixed with a binder, such as UV resins, polymer resins, Portland cements, geopolymers, alloy powders, and carbon fibre and basalt powders.
  • a binder such as UV resins, polymer resins, Portland cements, geopolymers, alloy powders, and carbon fibre and basalt powders. This process is done through uniform dispersion and sintering, with glass powder as the main ingredient, to form a 3D printing powder media.
  • the 3D printing powder media generally comprises of more than 30% glass powder, more than 50% glass powder, and can be used to produce a unique printable high strength building material.
  • suitable 3D printing methods can be used, including the following.
  • sintered recycled glass powder media is spread and layered on a printer bed, potentially layer by layer, and activating by lasers, electron beams or nozzle jet spray binders.
  • precision robotic spray machines may be used to layer deposits of 3D sintered glass powder media for structural reinforcement, fire resistance, water proofing and protective coating of a building product.
  • the spray method is particularly suited for larger volume and area coverage, as large amounts and large areas may be sprayed.
  • the deposits of 3D sintered glass powder may be applied manually, using a spray gun or the like.
  • the spray gun may be portable, which enables spraying of media on site, for example during construction.
  • 3D sintered glass powder media is combined with binder at an extrusion head, and extruded by a robotic extrusion head into a building product.
  • the product may be formed layer by layer.
  • recycled glass sand or powder is mixed with Portland cement and geopolymers to produce a high strength concrete, suitable for forming panels of the building industry.
  • a cementitious building product designed to achieve strengths of between 40MPA to 150MPA is provided.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Optics & Photonics (AREA)
  • Processing Of Solid Wastes (AREA)

Abstract

L'invention concerne un produit d'environnement construit, un procédé servant à former un produit d'environnement construit, et un milieu en poudre d'impression 3D permettant de former un produit d'environnement construit. Le produit d'environnement construit est formé par impression tridimensionnelle et comprend un milieu de déchets minéraux en poudre, par exemple verre ou grenat recyclé, et un liant servant à lier les déchets minéraux en poudre.
PCT/AU2015/050275 2014-05-23 2015-05-25 Système et procédé relatifs à des déchets recyclés WO2015176141A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
AU2014901938 2014-05-23
AU2014901938A AU2014901938A0 (en) 2014-05-23 Abrasive Blasting Media Waste System and Method

Publications (1)

Publication Number Publication Date
WO2015176141A1 true WO2015176141A1 (fr) 2015-11-26

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Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN105946110A (zh) * 2016-04-27 2016-09-21 广东工业大学 改善橡胶改性砂浆类材料中橡胶分布不均的方法
CN107901185A (zh) * 2017-11-02 2018-04-13 中国建筑股份有限公司 3d打印混凝土墙体表面的方法及其应用
CN111361154A (zh) * 2020-03-17 2020-07-03 崔锦霞 一种3d打印废料处理装置
CN114083693A (zh) * 2021-11-30 2022-02-25 同济大学 一种工程弃土快速识别并复配应用的方法
US11453161B2 (en) 2016-10-27 2022-09-27 Bridgestone Americas Tire Operations, Llc Processes for producing cured polymeric products by additive manufacturing
DE102021111789A1 (de) 2021-05-06 2022-11-10 Polycare Research Technology Gmbh & Co. Kg Polymerbetongemisch, Polymerbetonteil und Verfahren zu dessen Herstellung

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1997044291A1 (fr) * 1996-05-23 1997-11-27 Battelle Memorial Institute Procede de fabrication de forme libre par la gelification selective de suspensions en poudre
WO2013064826A1 (fr) * 2011-11-01 2013-05-10 Loughborough University Procédé et appareil pour l'écoulement de liant hydraulique
US20140050921A1 (en) * 2011-12-31 2014-02-20 The Boeing Company Method of reinforcement for additive manufacturing
WO2014160362A1 (fr) * 2013-03-14 2014-10-02 Tundra Composites, LLC Composite polymère comprenant une fibre à interface modifiée et une particule

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1997044291A1 (fr) * 1996-05-23 1997-11-27 Battelle Memorial Institute Procede de fabrication de forme libre par la gelification selective de suspensions en poudre
WO2013064826A1 (fr) * 2011-11-01 2013-05-10 Loughborough University Procédé et appareil pour l'écoulement de liant hydraulique
US20140050921A1 (en) * 2011-12-31 2014-02-20 The Boeing Company Method of reinforcement for additive manufacturing
WO2014160362A1 (fr) * 2013-03-14 2014-10-02 Tundra Composites, LLC Composite polymère comprenant une fibre à interface modifiée et une particule

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN105946110A (zh) * 2016-04-27 2016-09-21 广东工业大学 改善橡胶改性砂浆类材料中橡胶分布不均的方法
CN105946110B (zh) * 2016-04-27 2018-07-27 广东工业大学 改善橡胶改性砂浆类材料中橡胶分布不均的方法
US11453161B2 (en) 2016-10-27 2022-09-27 Bridgestone Americas Tire Operations, Llc Processes for producing cured polymeric products by additive manufacturing
CN107901185A (zh) * 2017-11-02 2018-04-13 中国建筑股份有限公司 3d打印混凝土墙体表面的方法及其应用
CN111361154A (zh) * 2020-03-17 2020-07-03 崔锦霞 一种3d打印废料处理装置
CN111361154B (zh) * 2020-03-17 2022-09-16 重庆大千汇鼎智能科技研究院有限公司 一种3d打印废料处理装置
DE102021111789A1 (de) 2021-05-06 2022-11-10 Polycare Research Technology Gmbh & Co. Kg Polymerbetongemisch, Polymerbetonteil und Verfahren zu dessen Herstellung
CN114083693A (zh) * 2021-11-30 2022-02-25 同济大学 一种工程弃土快速识别并复配应用的方法

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