WO2018037422A1 - Matériau de plâtre prêt à l'emploi préparé à l'aide de déchets industriels - Google Patents

Matériau de plâtre prêt à l'emploi préparé à l'aide de déchets industriels Download PDF

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Publication number
WO2018037422A1
WO2018037422A1 PCT/IN2017/050157 IN2017050157W WO2018037422A1 WO 2018037422 A1 WO2018037422 A1 WO 2018037422A1 IN 2017050157 W IN2017050157 W IN 2017050157W WO 2018037422 A1 WO2018037422 A1 WO 2018037422A1
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WO
WIPO (PCT)
Prior art keywords
ready
range
mix
plaster material
plaster
Prior art date
Application number
PCT/IN2017/050157
Other languages
English (en)
Inventor
Satish. N JAJOO
Rajesh Tiwari
Saseendran P. K.
Original Assignee
Hindalco Industries Limited
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 Hindalco Industries Limited filed Critical Hindalco Industries Limited
Publication of WO2018037422A1 publication Critical patent/WO2018037422A1/fr

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—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
    • C04B28/04—Portland cements
    • 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
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00482—Coating or impregnation materials
    • 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
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00663—Uses not provided for elsewhere in C04B2111/00 as filling material for cavities or the like
    • C04B2111/00672—Pointing or jointing materials
    • 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

  • the present invention relates to the field of building materials and more particularly to a ready-mix plaster material prepared using industrial wastes.
  • the ready- mix plaster material of the present invention can be used as mortar for brick jointing and wall plaster by just adding water to the ready-mix powdered plaster material.
  • the industrial wastes used for preparing ready-mix plaster material are red mud, fly ash and bottom ash which allow replacing high amounts of natural sand material used in conventional building materials.
  • plaster are the most commonly used materials in infrastructure development throughout the world. They are globally accepted construction material in all types of Civil Engineering structures. Plaster is a building material and generally used for the jointing of bricks in making wall and protective cover on walls and ceiling.
  • plaster is manufactured as a dry powder and mixed with water to form a workable paste just before it is applied to the surface.
  • Plaster is not a strong material and it is not bearing any load of structure on which it is applied.
  • plaster there are many type of plaster available in practice such as gypsum plaster, lime plaster, cements plaster etc. All of these plasters more or less serve the same purpose.
  • plaster used in construction is a mixture of cement and sand mixed in a certain ratio.
  • EP 2105420A1 discloses a composition for building material comprising more than 70% of fly ash and bottom ash in combination, a chemical activator and 2-18% of additive material.
  • EP 2105420A1 is based on chemical route/activator using hydroxide, sulphate, acetate or chloride salt.
  • the chemical activator reacts with fly ash and forms binding matrix suitable for the production cold setting fly ash building construction materials like bricks, block concrete and other high strength construction materials but not plaster material.
  • Said chemical activator must contain at least two anions, especially at least three anions such as chloride, hydroxyl and sulfate ions or hydroxyl, sulfate and acetate ions.
  • the nature and dosages of activator play a crucial role in setting and hardening process of plaster.
  • Cipheral Patent Application number CN103693924A discloses a mixed Bayer red mud plastering mortar dry mix using ordinary portland cement (19-13%), Bayer red mud (2-6%), fly ash (2-6%), cellulose ethers (0.05-0.15%), latex powder (0.19-0.54%), modified attapulgite (0.57-1.22%) and river sand (approximately 73%) composition.
  • CN 103693924A requires 73.65-74.42% of natural sand for preparation of the plaster. Therefore, CN 103693924A uses a very high amount of river sand which is not desirable to overcome the environmental effects due to use of natural sand resources.
  • the present invention relates to a ready-mix plaster material prepared by using industrial wastes such as red mud, fly ash and bottom ash thereby replacing a major portion of natural sand and cement used in a conventional plaster.
  • a ready-mix plaster material comprising ingredients:
  • red mud in the range of 5-12 w/w%
  • fly ash in the range of 20-30 w/w% ;
  • Another aspect of the present invention provides a process for preparing ready- mix plaster material comprising mixing red mud in the range of 5-12 w/w%; fly ash in the range of 20-30 w/w% ; bottom ash in the range of 25-45 w/w%; portland cement in the range of 11-17 w/w%; and natural sand in the range of 12-18 w/w% in a plough shear mixer to obtain a premix; and adding an additive in the range of 0.05-0.2 wt% of the premix in the plough shear mixer to obtain the ready-mix plaster material.
  • the mixing may be carried out for at least 5 minutes to obtain a homogenous dry mixture of ready-mix plaster material.
  • the present invention relates to a ready-mix plaster material prepared by using industrial wastes such as red mud, fly ash and bottom ash in place of natural sand.
  • the present invention provides a ready-mix plaster material comprising: comprising ingredients:
  • red mud in the range of 5-12 w/w%
  • fly ash in the range of 20-30 w/w% ;
  • the ready-mix plaster material of present application is a homogeneous composition of well graded mix of red mud, fly ash, bottom ash, natural sand, portland cement and some part of additive.
  • the mixture is prepared in powdered form. It is ready to use by mixing desired quantity of water in the powdered ready-mix plaster material.
  • Red mud is a waste -product generated in process of extraction of alumina from Bauxite ore using Bayer's process. It is approx 45 to 55% of Bauxite used for alumina extraction. Tonnes of red mud is generated annually and is difficult to dispose off or recycle satisfactorily. However, worldwide studies are going on for its fruitful use. The conventional method of disposal of red mud in ponds has often adverse environmental impacts. For example, in monsoons, the waste red mud may be carried to the surface water courses and as a result leaching may cause contamination of ground water if not disposed in environmentally proven manner. Further, the disposal of large quantities of red mud poses increasing problems of storage occupying a lot of space.
  • red mud After drying and sieving the red mud (collected from pond) up to desired particle size (95% particles smaller than or equal to 600 microns and 84% particles smaller than or equal to 300 microns), it is ready to use in ready-mix plaster material of present application.
  • red mud is used in the range of 5-12% w/w.
  • Fly ash is very fine material generated in thermal power plant in process of burning coal in boilers to produce thermal energy.
  • the total ash generation is normally 35% of total coal fed in boilers.
  • the fly ash generation is approx 80% of total ash generation. Normally it is collected through electrostatic precipitators.
  • This fly ash has very fine particle size and is directly mixed in ready-mix plaster.
  • the preferable size of fly ash has 97% particles smaller than or equal to 150 microns and 80% particles smaller than or equal to 75 microns.
  • fly ash is used in the range of 20-30 %w/w.
  • Bottom ash is also a by-product of coal burning in boilers of thermal plant. It is part of the non-combustible residue of combustion in furnace and is coarser in nature. Bottom ash generation is 20% of total ash generation in thermal power plant and is usually disposed along with fly ash. Fly ash being a major proportion of ash generated in coal fired thermal power plant, has been used recently in portland pozzolona cement manufacturing, road building and agriculture, land and mine filling etc. However, there are not many studies using bottom ash component separately especially for providing construction materials. The inventors of the present invention have used bottom ash in higher amounts to replace a major portion of natural sand.
  • bottom ash was used after drying and sieving with suitable mesh up to desired particle size (93% particles smaller than or equal to 600 microns and 83% particles smaller than or equal to 300 microns). In an embodiment of the present invention, bottom ash is used in the range of 25-45 %w/w.
  • Natural sand is found in river bed. The dried sand is cleaned with sieve size of 1.50 mm for any foreign materials known in the art, again sieved with suitable mesh size up to required particle size corresponding to grading Zone IV (as per IS: 383-1970), and then it is ready to use in ready-mix plaster. It is required to improve the workability of material.
  • natural sand is used in the range of 12-18 %w/w.
  • the natural sand as per grading Zone IV has particle size distribution as shown in Table 1.
  • Table 1 Particle size distribution of natural sand as per grading Zone IV of IS: 383- 1970
  • additive Very small quantity of additive is mixed directly as it is a ready-made product available in market. It strengthens the consistency of materials which are based on hydraulic binders. It also influences the rheology behaviour of the binder matrix in water, changing the yield point, flow parameters and water retention.
  • the additive can be selected from the group consisting of starch ether powder, cellulose ether etc. In an embodiment of the present invention, additive is over and above a total mix of red mud, fly ash, bottom ash, portland cement and natural sand.
  • Portland cement is a standard material available in market. It is a binding material commonly used in building construction industries. It is directly added in ready-mix plaster of the present invention as a binding material. In an embodiment of the present invention, Portland cement is used in the range of 11-17 %w/w.
  • the present invention provides a process for preparation of ready-mix plaster material comprising mixing red mud in the range of 5-12 w/w%; fly ash in the range of 20-30 w/w% ; bottom ash in the range of 25-45 w/w%; portland cement in the range of 11-17 w/w%; and natural sand in the range of 12-18 w/w% in a plough shear mixer to obtain a premix; and adding an additive in the range of 0.05-0.2 wt% of the premix in the plough shear mixer to obtain the ready-mix plaster material.
  • the additive is added over and above the total amount of red mud, fly ash, bottom ash, portland cement and natural sand.
  • the mixing the plough shear mixer may be carried out for at least 5 minutes to obtain a homogenous dry mixture of ready-mix plaster material.
  • Yet another embodiment of the present invention provides a process in which red mud, bottom ash and natural sand have moisture level in the range of 0.01% to 2%.
  • the present invention provides a ready-mix plaster material in powdered form which can be instantaneously used as a construction material by mixing with desired quantity of water.
  • Red mud collected from alumina refinery, bottom ash collected from thermal power plant, and natural sand having close to zero moisture level (about 0.01%) were sieved individually with a mesh size as per sieve designation in IS: 383-1970 to obtain a desired particle size: red mud having 95% particles smaller than or equal to 600 microns and 84% particles smaller than or equal to 300 microns; bottom ash having 93% particles smaller than or equal to 600 microns and 83% particles smaller than or equal to 300 microns; natural sand having particle size as per grading Zone IV of IS: 383- 1970 code.
  • the red-mud, bottom ash and natural sand, thus obtained, were mixed together in a plough shear mixer.
  • the ready-mix plaster material obtained in the powder form was then packed using an air tight bag as a ready-to-use-plaster material.
  • the powdered mixture can be used as mortar, when required, by mixing desired quantity of water, for brick jointing and wall plaster.
  • the ready-to-use-plaster material was tested in accordance with the Indian Standard code IS: 2250: 1981 and other ASTM international code.
  • Sample was prepared by adding water in dry mortar. The water was added in the dry sample as per Manufacturer's Specification as follows: Water-Powder (W/p) ratio - 0.17; Specimen size: 25 x 25 x 250 mm; Curing condition: Normal water bath curing. Three specimens of each sample were tested for Drying Shrinkage.
  • Pull Off Strength Test for Adhesion (Test method ASTM D 4541): Samples were prepared by applying ready-mix Plaster in between 2 AAC blocks & air cured for 28 days; Specimen size: 50 x 50 mm; Curing condition Air Curing; Equipment used - Pull Off Tester. Three specimens of each sample were tested for Pull Off Strength Test. Pull off test is used to measure the adhesion strength between coating and a substrate. In our case coating is plaster material.
  • Compressive Strength and Flow Test Sample was prepared by adding water in received dry mortar. The water was added in the dry sample for water quantity. W/p ratio - 0.17; Specimen size: 70.6 x 70.6 x 70.6 mm; Curing condition: Normal water bath curing. Flow test is used to determine the consistency of mortar i.e. ease of workability.
  • the present invention provides a plaster material having good fluidity, water retention, low shrinkage, good adhesion strength as well as good compressive strength.
  • the ready-mix plaster of the present invention falls in Grade MM3 to MM7.5 mortar mix as per IS 2250: 1981.
  • the present invention thus provides a ready-mix plaster material which allows minimum wastage of construction materials used conventionally, using the industrial wastes as well as replacing a large amount of natural sand.
  • Such a plaster material not only provides a solution for industrial waste management but also provides overall economic benefit by reducing cost of raw materials as compared to conventionally used plaster material and also protects ecosystem by conserving natural resources.
  • compositions 1 , 2 and 3 obtained in Example 1 were prepared to assess the effect of various components used in the compositions.
  • Variant compositions A to D were prepared by removing red mud, fly ash, bottom ash and natural sand, respectively, from each of the composition 1, 2 and 3 as obtained in Example 1.
  • the variant compositions were prepared in accordance with the Table 4-6 as below showing number of units or parts of each component used to obtain the respective variant compositions.
  • Table 4 Components along with number of units or parts of each component used for preparation of variations of Composition 1 of ready-mix plaster material
  • Table 5 Components along with number of units or parts of each component used for preparation of variations of Composition 2 of ready-mix plaster material
  • Table 6 Components along with number of units or parts of each component used for preparation of variations of Composition 3 of ready-mix plaster material
  • Table 7 Results of Compressive Strength (28 days) (N/mm2) for the variants of the compositions 1-3.
  • test results obtained for ready-mix plaster of the present application were also compared with the plaster mortar disclosed in the document CN 103693924A.
  • the comparative data is provided in table 8 below.
  • the plaster material of present invention shows 5 comparative properties with respect to the plaster material of CN 103693924A having higher amounts of natural sand (73.65 -74.42%).
  • the present invention uses only 10-18 % of natural sand and still provides the mortar/ plaster which falls in Grade MM3 to MM7.5 mortar mix as per IS: 2250: 1981. 0
  • Table 8 Comparative properties of the plaster material of CN 103693924A with the plaster material of the present invention
  • CN 103693924A does not use bottom ash as a separate component. It only uses fly ash, that too in small amounts of 2.86-5.45 %.
  • the present invention uses fly ash in the range of 20-30 w/w% and bottom ash in the range of 25-45 w/w%; and provides comparable properties of plaster material, thus allowing replacing about 82 to 88 % of natural sand from the plaster material. This allows conservation of the natural resources and protects the ecosystem for production of plaster material.
  • the plaster material of present invention is eco- friendly and also has economic significance as it uses waste materials.
  • the present invention provides a plaster material which can be readily and easily used by just adding desired quantity of water when required for construction purposes. This allows less wastage of resources compared to traditional cement-sand plaster.
  • the ready-mix plaster of present application is obtained using a large percentage of industrial waste materials and very less percentage of natural sand, thereby allowing conservation of the natural resources i.e. natural sand, which is depleting very fast due to unmanaged utilization, resulting in disturbance of ecosystem. Therefore, the present invention allows effective utilization and recycling of industrial waste, which otherwise pose a risk to environment due to disposal of such industrial waste materials in water or as landfills.
  • the ready-mix plaster of present application is produced in powdered form to be readily used for construction purposes and can also be used in making bricks, blocks, tiles, sheets, etc. using compaction and casting known in the art to produce other such construction materials of interest.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)
  • Processing Of Solid Wastes (AREA)

Abstract

La présente invention concerne un matériau de plâtre prêt à l'emploi préparé à l'aide de déchets industriels. Le matériau de plâtre prêt à l'emploi de la présente invention peut être utilisé comme mortier pour le jointoiement de briques et comme enduit de mur par simple ajout d'eau au matériau de plâtre en poudre prêt à l'emploi. Les déchets industriels utilisés pour la préparation du matériau de plâtre prêt à l'emploi sont de la boue rouge, des cendres volantes et des cendres résiduelles qui permettent de remplacer les grandes quantités des matériaux sableux d'origine naturelle utilisés dans les matériaux de construction classiques.
PCT/IN2017/050157 2016-08-22 2017-05-03 Matériau de plâtre prêt à l'emploi préparé à l'aide de déchets industriels WO2018037422A1 (fr)

Applications Claiming Priority (2)

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IN201611028580 2016-08-22

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Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN113696306A (zh) * 2021-09-10 2021-11-26 上海百奥恒再生资源有限公司 蒸压加气混凝土砌块高效增强工艺
CN114787099A (zh) * 2019-08-22 2022-07-22 印度铝工业有限公司 红砖和用于制备其的方法
CN115288780A (zh) * 2022-07-14 2022-11-04 山东杰控电气技术有限公司 赤泥固废在富水矿山充填采矿中利用优化设计方法
CN116947441A (zh) * 2023-09-20 2023-10-27 福建省协鑫环保科技有限公司 一种洗沙泥基的水泥混合材料及其成型方法

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN103693924A (zh) * 2013-12-10 2014-04-02 同济大学 一种掺有拜耳法赤泥的干混抹灰砂浆及其使用方法
WO2016012686A1 (fr) * 2014-07-24 2016-01-28 Saint-Gobain Weber Composition de mortier pour enduit ou revetement d'interieur

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN103693924A (zh) * 2013-12-10 2014-04-02 同济大学 一种掺有拜耳法赤泥的干混抹灰砂浆及其使用方法
WO2016012686A1 (fr) * 2014-07-24 2016-01-28 Saint-Gobain Weber Composition de mortier pour enduit ou revetement d'interieur

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN114787099A (zh) * 2019-08-22 2022-07-22 印度铝工业有限公司 红砖和用于制备其的方法
EP4017838A4 (fr) * 2019-08-22 2023-10-11 Hindalco Industries Ltd Brique rouge et son procédé de préparation
CN113696306A (zh) * 2021-09-10 2021-11-26 上海百奥恒再生资源有限公司 蒸压加气混凝土砌块高效增强工艺
CN115288780A (zh) * 2022-07-14 2022-11-04 山东杰控电气技术有限公司 赤泥固废在富水矿山充填采矿中利用优化设计方法
CN116947441A (zh) * 2023-09-20 2023-10-27 福建省协鑫环保科技有限公司 一种洗沙泥基的水泥混合材料及其成型方法
CN116947441B (zh) * 2023-09-20 2023-12-15 福建省协鑫环保科技有限公司 一种洗沙泥基的水泥混合材料及其成型方法

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