WO2021149076A1 - A vegetal concrete masonry unit and method and system for manufacture thereof - Google Patents

A vegetal concrete masonry unit and method and system for manufacture thereof Download PDF

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Publication number
WO2021149076A1
WO2021149076A1 PCT/IN2021/050055 IN2021050055W WO2021149076A1 WO 2021149076 A1 WO2021149076 A1 WO 2021149076A1 IN 2021050055 W IN2021050055 W IN 2021050055W WO 2021149076 A1 WO2021149076 A1 WO 2021149076A1
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WIPO (PCT)
Prior art keywords
binder
vegetal
stalk
masonry unit
crop
Prior art date
Application number
PCT/IN2021/050055
Other languages
French (fr)
Inventor
Tarun Jami
Original Assignee
Greenjams Buildtech Private 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 Greenjams Buildtech Private Limited filed Critical Greenjams Buildtech Private Limited
Priority to EP21744222.7A priority Critical patent/EP4093714A4/en
Priority to AU2021210697A priority patent/AU2021210697A1/en
Priority to US17/793,579 priority patent/US20230054357A1/en
Priority to BR112022014329A priority patent/BR112022014329A2/en
Priority to GB2212128.9A priority patent/GB2607775A/en
Priority to MX2022008966A priority patent/MX2022008966A/en
Publication of WO2021149076A1 publication Critical patent/WO2021149076A1/en
Priority to ZA2022/09336A priority patent/ZA202209336B/en

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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
    • C04B28/08—Slag 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
    • C04B12/00—Cements not provided for in groups C04B7/00 - C04B11/00
    • C04B12/005—Geopolymer cements, e.g. reaction products of aluminosilicates with alkali metal hydroxides or silicates
    • 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
    • C04B18/04—Waste materials; Refuse
    • C04B18/06—Combustion residues, e.g. purification products of smoke, fumes or exhaust gases
    • C04B18/10—Burned or pyrolised refuse
    • C04B18/105—Gaseous combustion products or dusts collected from waste incineration, e.g. sludge resulting from the purification of gaseous combustion products of waste incineration
    • C04B18/106—Fly ash from waste incinerators
    • 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
    • C04B18/04—Waste materials; Refuse
    • C04B18/14—Waste materials; Refuse from metallurgical processes
    • C04B18/141—Slags
    • 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
    • C04B28/005—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 gelatineous or gel forming binders, e.g. gelatineous Al(OH)3, sol-gel binders
    • 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
    • C04B28/006—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 mineral polymers, e.g. geopolymers of the Davidovits type
    • 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
    • C04B28/10—Lime cements or magnesium oxide cements
    • C04B28/12—Hydraulic lime
    • 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
    • C04B7/00—Hydraulic cements
    • C04B7/34—Hydraulic lime cements; Roman cements ; natural 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
    • C04B2103/00—Function or property of ingredients for mortars, concrete or artificial stone
    • C04B2103/0068—Ingredients with a function or property not provided for elsewhere in C04B2103/00
    • C04B2103/0091—Organic co-binders for mineral binder compositions
    • 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
    • C04B2103/00—Function or property of ingredients for mortars, concrete or artificial stone
    • C04B2103/10—Accelerators; Activators
    • 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
    • C04B2111/00017—Aspects relating to the protection of the environment
    • 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
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P40/00—Technologies relating to the processing of minerals
    • Y02P40/10—Production of cement, e.g. improving or optimising the production methods; Cement grinding
    • 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 a product and process for the preparation of a building material and in particular relates to environmentally sustainable eco-friendly green concrete building blocks made of bio-composite materials comprising geopolymers, lime, agricultural and industrial waste. More particularly, the present invention relates to method and system for manufacturing a vegetal concrete masonry unit.
  • Green buildings made from materials using agricultural waste or industrial waste proffer numerous environmental, technical and economic benefits such as increased strength and durability, improved workability, reduced permeability, superior resistance to acid attack and fire, minimum requirement of energy, improved thermal behavior, cost- effectiveness, 80% fewer carbon dioxide emission than normal concrete there by reducing environment pollution, can also contribute to improved indoor and outdoor air quality and a healthy and more productive indoor environment.
  • the prior art documents on agricultural waste building materials include hydraulic lime, calcic lime and other commercial lime -based binders, and also include geopolymer as binders, which is an alkali-activated mineral material produced through polycondensation of inorganic compounds at ambient or slightly elevated temperatures.
  • An example of such a reaction includes aluminosilicate with an alkaline activator such as concentrated alkali hydroxide, silicate, carbonate, or sulfate.
  • the most promising feature of the geopolymer is its formulation using waste materials such as pulverized fuel ashes, and ground granulated blast furnace slag (GGBFS) as resource materials.
  • GGBFS ground granulated blast furnace slag
  • vegetal matter such as fibers in concrete improves tensile strength, ductility and post-fracture behavior of composite concretes.
  • vegetal geopolymer concretes could be provided as an additional layer to an existing structural wall for providing reinforcement of the structural frame and for insulating purpose.
  • One of the primary objects of the present invention is to provide a novel, environmentally sustainable and viable process for the preparation of a vegetal concrete masonry unit thereof with performance related advantage over existing products.
  • Another object of the present invention relates to a novel vegetal concrete masonry unit comprising of crop residues and an alkali activated mineral binder comprised of lime and industrial co-products from steel and power plants.
  • Another object of the present invention relates to improvement in the mechanical performance of vegetal concrete masonry unit made using the crop residues and an alkali activated mineral binder comprised of lime and industrial co-products from steel and power plants.
  • Another object of the present invention is to increase the structural durability and structural integrity of the vegetal concrete masonry unit.
  • Another object of the present invention is to provide a vegetal concrete masonry unit with good thermal insulation.
  • Another object of the present invention is to provide a vegetal concrete masonry unit with increased load-bearing function and a higher compressive strength.
  • Another object of the present invention is to utilize agricultural waste to manufacture a vegetal concrete masonry unit with the intention to recycle and resolve agricultural waste pollution problem.
  • Another object of the present invention is to use following as raw materials for the preparation of a vegetal concrete masonry unit: (a) Crop residues: paddy straw, wheat straw, bagasse, cotton stalk, com stover, sugar cane trash, sunflower stalk, soy stalk, chia stalk, kenaf stalk, hemp stalk and jute stalk and/or a combination thereof (b) Binder: ground granulated blast furnace slag and hydrated lime and/or a combination thereof (c) Other raw materials: fly ash, anhydrous sodium silicate, sodium hydroxide, water and/or a combination thereof.
  • Yet another object of the present invention is to reduce the amount of alkali activator used in the manufacture of the vegetal concrete masonry unit to make it a viable alternative to conventional masonry units.
  • a further object of the present invention is to lower the activator content making geopolymers and other geopolymer based vegetal concretes viable for use.
  • Another object of the present invention is to lower the activator content making geopolymer based vegetal concretes environmentally sustainable.
  • One aspect of the present invention relates to a vegetal concrete masonry unit which comprises of cooked crop residues, binder and pulverized fuel ash in a mass ratio of 1 : 1 : 1.5 to 1:1.5:3.
  • Another aspect of the present invention relates to a method for the preparation of a vegetal concrete masonry unit, the method comprising: cooking a crop residue in a cooker such as a pressure cooker with sodium hydroxide (NaOH) and water; mixing hydrated lime, Ground Granulated Blast Furnace Slag (GGBFS), and sodium silicate activator in a ribbon blender to constitute the binder; intermixing the digested crop residue, binder and pulverized fuel ash (PFA) together in a pan mixer with water to form an alkali activated homogeneous paste/gel; and molding the homogenous paste obtained in intermixing step using a high- pressure hydraulic press to form the vegetal concrete masonry unit.
  • a cooker such as a pressure cooker with sodium hydroxide (NaOH) and water
  • GGBFS Ground Granulated Blast Furnace Slag
  • PFA pulverized fuel ash
  • Yet another aspect of the present invention relates to a system for the manufacture of a vegetal concrete masonry unit, the system comprising: a lime silo containing hydrated lime; a activator powder in a ribbon blender to form a binder; a binder silo for storing the binder; a stainless steel cooker for cooking a raw crop residue; a pan mixer for obtaining the wet mix; a cooked crop residue hopper for obtaining the mixture obtained from the stainless steel cooker; wherein the cooked crop residues from hopper, binder from the binder silo and pulverized fuel ash, PFA, hopper are mixed with water in a pan mixer; wherein the wet mix of the pan mixer are casted into molds using hydraulic block machine with a high compacting pressure, and then transported to the stock yard.
  • the crop residues are cooked in a pulp digester with 20 percent NaOH and water at 150°C for a duration of 45 minutes.
  • the binder includes hydrated lime of at least 85 percent calcium hydroxide mixed with GGBFS in a 2:3 ratio.
  • the method also includes providing sodium silicate activator is in an amount equal to 2.5- 20% of the total mass of hydrated lime and GGBFS in a ribbon blender to constitute the binder.
  • the binder is further mixed with pulverized fuel ash, cooked crop residues, and water in a pan mixer and cast into molds using a high-pressure hydraulic press with a compacting pressure of up tolOMPa.
  • the alkali activated homogeneous paste/gel of the method is Calcium-Alumino-Silicate- Hydrate (C-A-S-H/CASH) gel/paste and wherein the PFA reacts with GGBFS in the presence of an activator powder to form Sodium-Alumino-Silicate-Hydrate (N-A-S- H/NASH) geopolymers, as well as CASH gel.
  • the activator powder is anhydrous sodium silicate powder.
  • the cooking or digesting of the crop residue is carried out in a stainless-steel container constructed with a pressure lock system and designed to withstand a total internal pressure of minimum 2 atm.
  • the binder comprises mixing hydrated lime, Ground Granulated Blast Furnace Slag, and sodium silicate activator in a mass ratio of 2:3:0.5 to 1:6:2.
  • Fig. 1 illustrates a system of manufacturing a vegetal concrete masonry unit according to the present invention.
  • Fig. 2 illustrates a process showing the steps of manufacturing a vegetal concrete masonry unit according to the present invention.
  • a novel, environmentally sustainable vegetal concrete masonry unit/brick and viable process and system for the preparation of the same with performance related advantage over existing products is disclosed.
  • the vegetal concrete masonry unit/brick of the present invention finds application in civil constructions in form of blocks and pre-cast wall panels.
  • This vegetal concrete masonry unit may be cast in a hybrid composite construction, where there shall be the core made of this material, encased in a steel frame. These hybrid panel will then be erected on site to make a pre-engineered building.
  • the present invention relates to an economically sustainable vegetal concrete masonry unit and the method for manufacturing the same, wherein the vegetal concrete masonry unit comprises of hydrated lime, Ground Granulated Blast Furnace Slag, pulverized fuel ash, cooked crop residues and sodium silicate used in defined amounts.
  • the process for the manufacture of vegetal concrete masonry unit employs a step of digesting the crop residue with alkali such as sodium hydroxide increasing the homogeneity of the material mixture and eliminates the set-retarding extracts from the crop residues; and on further addition of binder materials improves the compressive strength of the formed vegetal concrete masonry unit.
  • alkali such as sodium hydroxide
  • lime and Ground Granulated Blast Furnace Slag act as the main binding agent.
  • the addition of sodium silicate activates the reaction between lime and GGBFS to form Calcium-Alumino-Silicate-Hydrate (C-A-S-H/CASH) gel that creates the matrix to hold the aggregates in the concrete, which are vegetal matter and pulverized fuel ash (PFA).
  • C-A-S-H/CASH Calcium-Alumino-Silicate-Hydrate
  • PFA pulverized fuel ash
  • Formation of CASH gel is a desirable hydration product that occurs when building limes or Portland cements are mixed with water.
  • PFA also has an additional role to play. It acts as a fine aggregate as well as a binding agent.
  • the PFA reacts with GGBFS in the presence of the activator to form Sodium-Alumino-Silicate-Hydrate (N- A-S-H/NASH) geopolymers, as well as CASH gel.
  • N- A-S-H/NASH Sodium-Alumino-Silicate-Hydrate
  • CASH gel Sodium-Alumino-Silicate-Hydrate
  • lime calcium hydroxide
  • a part of the remaining calcium hydroxide in the mixture mineralizes the cooked crop residues and the other part subsequently turns into calcium carbonate through carbonation.
  • the crop residue is selected from a group of crop residues comprising paddy straw, wheat straw, bagasse, cotton stalk, com stover, sugar cane trash, sunflower stalk, soy stalk, chia stalk, kenaf stalk and jute stalk and/or a combination thereof. Therefore, changes in activator, lime, GGBFS and pulverized fuel ash content would result in varying amounts of CASH and NASH, thereby affecting the strength of the final vegetal concrete product.
  • Figure 1 discloses a system 10 for manufacturing of a vegetal masonry unit according to the present invention, wherein the system comprising a lime silo 12 containing hydrated lime which is mixed with ground granulated blast furnace slag 14 and a activator powder 16 in a ribbon blender 18 to form a binder which is stored in a binder silo 20, a raw crop residue from the storage 22 is mixed with water 24 and sodium hydroxide 26 in the stainless steel cooker 28, the mixture obtained from the stainless steel cooker 28 is fed to the wet washing 30 and subsequently to the cooked crop residue hopper 32.
  • the system comprising a lime silo 12 containing hydrated lime which is mixed with ground granulated blast furnace slag 14 and a activator powder 16 in a ribbon blender 18 to form a binder which is stored in a binder silo 20, a raw crop residue from the storage 22 is mixed with water 24 and sodium hydroxide 26 in the stainless steel cooker 28, the mixture obtained from the stainless steel cooker 28 is fed to the wet washing 30 and subsequently to
  • the cooked crop residues from hopper 32, binder from the binder silo 20 and PFA pulverized fuel ash hopper 36 are mixed with water 38 in a pan mixer 34, wherein, the wet mix of the pan mixer 34 are casted into molds using hydraulic block machine 40 with a high compacting pressure, and then transported to the stock yard.
  • the crop residues are cooked in a cooker with 20 percent sodium hydroxide (NaOH) and water at 150°C for a duration of 45 minutes; wherein the binding materials -includes hydrated lime of at least 85 percent calcium hydroxide which is mixed with GGBFS in a 2:3 ratio, and sodium silicate activator of an amount equal to 2.5-20% of the total mass of hydrated lime and GGBFS in a ribbon blender to constitute the binder; wherein the binder is further mixed with pulverized fuel ash, cooked crop residues, and water in a pan mixer and cast into molds with using a high-pressure hydraulic press with a compacting pressure of lOMPa.
  • NaOH sodium hydroxide
  • Figure 2 illustrates a process that shows the steps of manufacturing of vegetal concrete masonry unit according to the present invention which are as below :
  • Each kilogram of crop residues are added to 5 liters of 0.2M to 10M NaOH solution in a stainless-steel container constructed with a pressure lock system and designed to withstand a total internal pressure of minimum 2 atm.
  • the stainless-steel container containing the crop residues and NaOH solution is heated to a temperature of 150°C and 2 atm pressure. The temperature and pressure are applied for a duration of 15 to 45 minutes, after which, the crop residues are removed from the container and washed until the water runs clear. The washed residues are de-watered to a saturated condition.
  • Hydrated lime consisting of at least 85% calcium hydroxide is mixed with ground granulated blast furnace slag (GGBFS) having a specific surface area of at least 400 m 2 /kg in a ratio of 1:6 to 2:3, respectively.
  • GGBFS ground granulated blast furnace slag
  • Anhydrous sodium silicate powder of amount equal to 5% to 20% of the combined mass of hydrated lime and GGBFS is added to the mix. The three constituents are blended together for a duration of at least 5 minutes.
  • the processed crop residues in the wet form, the binder, dry fly ash and water are added to a pan mixer in quantities as set out in table 1.
  • the constituents are mixed at least for a duration of 3 minutes.
  • the wet mix is transferred to a hydraulic block making machine consisting of a metal die, metal press and hydraulic jack capable of delivering a compression force of 2 MPa to 10 MPa.
  • Step 1 Processing of crop residues
  • Each kilogram of paddy straw is added to 5 litres of 1M NaOH solution and heated to a temperature of 150°C in a stainless-steel container. The temperature is maintained for a duration of 45 minutes, after which the paddy straw is removed from the container and washed thoroughly, until the water flows clear. The straw is squeezed and excess water is drained.
  • Step 2 Preparation of binder Hydrated lime consisting of at least 85% calcium hydroxide is mixed with ground granulated blast furnace slag (GGBFS) having a specific surface area of at least 400 m 2 /kg in a ratio of 2:3, respectively.
  • GGBFS ground granulated blast furnace slag
  • Anhydrous sodium silicate powder of amount equal to 20% of the combined mass of hydrated lime and GGBFS is added to the mix. The three constituents are blended together for a duration of at least 5 minutes.
  • the processed crop residues in the wet form, the binder, fly ash and water are added to a pan mixer in quantities as set out in table 2.
  • Step 4 Production of vegetal concrete masonry unit
  • the wet mix is transferred to a hydraulic block making machine consisting of a metal die, metal press and hydraulic jack capable of delivering a compression force of 2 MPa.
  • Step 1 Processing of crop residues
  • Each kilogram of paddy straw is added to 5 litres of 0.5M NaOH solution and heated to a temperature of 150°C in a stainless-steel container with a pressure lock lid, with a capacity to withstand 2 atm of pressure.
  • the lid is closed tight, and the temperature is maintained for a duration of 45 minutes, after which the paddy straw is removed from the container and washed thoroughly, until the water flows clear.
  • the straw is squeezed and excess water is drained.
  • Hydrated lime consisting of at least 85% calcium hydroxide is mixed with ground granulated blast furnace slag (GGBFS) having a specific surface area of at least 400 m 2 /kg in a ratio of 2:3, respectively.
  • Anhydrous sodium silicate powder of amount equal to 20% of the combined mass of hydrated lime and GGBFS is added to the mix. The three constituents are blended together for a duration of at least 5 minutes.
  • the processed crop residues in the wet form, the binder, fly ash and water are added to a pan mixer in quantities as set out in table 3.
  • the constituents are mixed for a duration of 3 minutes.
  • Step 4 Production of vegetal concrete masonry unit
  • the wet mix is transferred to a hydraulic block making machine consisting of a metal die, metal press and hydraulic jack capable of delivering a compression force of 2 MPa.
  • Step 1 Processing of crop residues
  • Each kilogram of paddy straw is added to 5 litres of 0.5M NaOH solution and heated to a temperature of 150°C in a stainless-steel container with a pressure lock lid, with a capacity to withstand 2 atm of pressure.
  • the lid is closed tight, and the temperature is maintained for a duration of 45 minutes, after which the paddy straw is removed from the container and washed thoroughly, until the water flows clear.
  • the straw is squeezed and excess water is drained.
  • Hydrated lime consisting of at least 85% calcium hydroxide is mixed with ground granulated blast furnace slag (GGBFS) having a specific surface area of at least 400 m 2 /kg in a ratio of 1 :5.67, respectively.
  • GGBFS ground granulated blast furnace slag
  • Anhydrous sodium silicate powder of amount equal to 15% of the combined mass of hydrated lime and GGBFS is added to the mix. The three constituents are blended together for a duration of at least 5 minutes.
  • the processed crop residues in the wet form, the binder, fly ash and water are added to a pan mixer in quantities as set out in table 4.
  • the constituents are mixed for a duration of 3 minutes.
  • Step 4 Production of vegetal concrete masonry unit
  • the wet mix is transferred to a hydraulic block making machine consisting of a metal die, metal press and hydraulic jack capable of delivering a compression force of 2 MPa.
  • Table 4 Paddy straw based vegetal concrete, Example 3
  • Step 1 Processing of crop residues
  • Each kilogram of wheat straw is added to 5 litres of 0.5M NaOH solution and heated to a temperature of 150°C in a stainless-steel container with a pressure lock lid, with a capacity to withstand 2 atm of pressure.
  • the lid is closed tight, and the temperature is maintained for a duration of 35 minutes, after which the wheat straw is removed from the container and washed thoroughly, until the water flows clear.
  • the straw is squeezed and excess water is drained.
  • Hydrated lime consisting of at least 85% calcium hydroxide is mixed with ground granulated blast furnace slag (GGBFS) having a specific surface area of at least 400 m 2 /kg in a ratio of 2:3, respectively.
  • Anhydrous sodium silicate powder of amount equal to 20% of the combined mass of hydrated lime and GGBFS is added to the mix. The three constituents are blended together for a duration of at least 5 minutes.
  • Step 4 Production of vegetal concrete masonry unit
  • the wet mix is transferred to a hydraulic block making machine consisting of a metal die, metal press and hydraulic jack capable of delivering a compression force of 2 MPa.
  • Step 1 Processing of crop residues
  • Each kilogram of bagasse is added to 5 litres of 0.5M NaOH solution and heated to a temperature of 150°C in a stainless-steel container with a pressure lock lid, with a capacity to withstand 2 atm of pressure.
  • the lid is closed tight, and the temperature is maintained for a duration of 15 minutes, after which the bagasse is removed from the container and washed thoroughly, until the water flows clear.
  • the washed bagasse is squeezed, and excess water is drained.
  • Hydrated lime consisting of at least 85% calcium hydroxide is mixed with ground granulated blast furnace slag (GGBFS) having a specific surface area of at least 400 m 2 /kg in a ratio of 1 :5.67, respectively.
  • GGBFS ground granulated blast furnace slag
  • Anhydrous sodium silicate powder of amount equal to 20% of the combined mass of hydrated lime and GGBFS is added to the mix. The three constituents are blended together for a duration of at least 5 minutes.
  • the processed crop residues in the wet form, the binder, fly ash and water are added to a pan mixer in quantities as set out in table 6.
  • the constituents are mixed for a duration of 3 minutes.
  • Step 4 Production of vegetal concrete masonry unit
  • the wet mix is transferred to a hydraulic block making machine consisting of a metal die, metal press and hydraulic jack capable of delivering a compression force of 2 MPa.

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Abstract

The present invention relates to an economically sustainable vegetal masonry unit and the method and system (10) for manufacturing of the same wherein the vegetal masonry unit comprises of crop residues, binder and PFA pulverized fuel ash along with water, wherein the system comprising a lime silo (12) containing hydrated lime which is mixed with ground granulated blast furnace slag (14) and a activator powder (16) in a ribbon blender (18) to form a binder which is stored in a binder silo (20), a raw crop residue from the storage (22) is mixed with water (24) and sodium hydroxide (26) in the stainless steel cooker (28), the mixture obtained from the stainless steel cooker (28) is fed to the wet washing (30) and subsequently to the cooked crop residue hopper (32). The cooked crop residues from hopper (32), binder from the binder silo (20) and PFA pulverized fuel ash hopper (36) are mixed with water (38) in a pan mixer (34), wherein, the wet mix of the pan mixer (34) are casted into molds using hydraulic block machine (40) with a high compacting pressure, and then transported to the stock yard.

Description

TITLE OF THE INVENTION: A VEGETAL CONCRETE MASONRY UNIT AND METHOD AND SYSTEM FOR MANUFACTURE THEREOF
FIELD OF THE INVENTION
The present invention relates to a product and process for the preparation of a building material and in particular relates to environmentally sustainable eco-friendly green concrete building blocks made of bio-composite materials comprising geopolymers, lime, agricultural and industrial waste. More particularly, the present invention relates to method and system for manufacturing a vegetal concrete masonry unit.
BACKGROUND OF THE INVENTION
Rapid industrialization and urbanization in present-day society has spurred construction at an alarming rate, boosting the demand for construction materials. Typically, cement-based concretes containing coarse and fine aggregates, which are usually comprised of stone, sand and water, are the materials most abundantly used in building construction. Continuous production of such aggregates has led to serious depletion of natural resources and is an emerging problem in recent times. In addition, conventional building materials account for high production costs, high greenhouse gas emissions, and generate a high demand of energy and water resources, all of which have a significantly negative environmental impact. For instance, production of conventional building materials contributes to increased emissions of noxious pollutants, acceleration of climate change and depletion of topsoil through mining. Concurrently, on the other hand, amassing of unmanageable quantities of industrial and agricultural solid waste, particularly in developing countries has intensified environmental concerns relating to their disposal. For example, routine burning of unwanted agricultural crop residue is a global phenomenon and an important contributor to abject air quality worldwide. Lack of effective and environmentally sustainable management of industrial and agricultural residues and waste is a mounting risk for the environment and causes air, surface water and ground water pollution.
Drawbacks of conventional concrete materials, need for conservation of natural resources, availability of limited landfill spaces, unmanageable industrial and agricultural solid waste and the desire of nations to reduce green-house gas emission has spurred the demand for alternative high quality concrete products. The gradual depletion of raw materials has fostered increased demand for recycled building materials which can replace traditional building products. Hence, recycling of wastes into sustainable environmentally friendly construction materials could be a feasible and potentially cost-effective solution to not only combat waste pollution problem by keeping them out of the waste stream, but also as an economical alternative to the design of green sustainable concrete buildings.
In recent years, the application of green building materials has become popular in many countries. Green buildings made from materials using agricultural waste or industrial waste proffer numerous environmental, technical and economic benefits such as increased strength and durability, improved workability, reduced permeability, superior resistance to acid attack and fire, minimum requirement of energy, improved thermal behavior, cost- effectiveness, 80% fewer carbon dioxide emission than normal concrete there by reducing environment pollution, can also contribute to improved indoor and outdoor air quality and a healthy and more productive indoor environment.
The prior art documents on agricultural waste building materials include hydraulic lime, calcic lime and other commercial lime -based binders, and also include geopolymer as binders, which is an alkali-activated mineral material produced through polycondensation of inorganic compounds at ambient or slightly elevated temperatures. An example of such a reaction includes aluminosilicate with an alkaline activator such as concentrated alkali hydroxide, silicate, carbonate, or sulfate. The most promising feature of the geopolymer is its formulation using waste materials such as pulverized fuel ashes, and ground granulated blast furnace slag (GGBFS) as resource materials. The application of vegetal matter such as fibers in concrete improves tensile strength, ductility and post-fracture behavior of composite concretes. Hence, vegetal geopolymer concretes could be provided as an additional layer to an existing structural wall for providing reinforcement of the structural frame and for insulating purpose.
However, previous prior art processes suffer from problems such as structurally weak- quality material with low compressive strength and non-uniform mechanical performance. Large amounts of activators in traditional geopolymer based vegetal concretes also negate the environmental benefits offered and make them unviable alternatives. There is a constant need to provide a novel, environmentally sustainable and viable process for the preparation of a vegetal concrete masonry unit thereof with better structural or load-bearing function, good thermal insulation and higher compressive strength.
OBJECTS OF THE INVENTION
One of the primary objects of the present invention is to provide a novel, environmentally sustainable and viable process for the preparation of a vegetal concrete masonry unit thereof with performance related advantage over existing products.
Another object of the present invention relates to a novel vegetal concrete masonry unit comprising of crop residues and an alkali activated mineral binder comprised of lime and industrial co-products from steel and power plants.
Another object of the present invention relates to improvement in the mechanical performance of vegetal concrete masonry unit made using the crop residues and an alkali activated mineral binder comprised of lime and industrial co-products from steel and power plants.
Another object of the present invention is to increase the structural durability and structural integrity of the vegetal concrete masonry unit.
Another object of the present invention is to provide a vegetal concrete masonry unit with good thermal insulation.
Another object of the present invention is to provide a vegetal concrete masonry unit with increased load-bearing function and a higher compressive strength.
Another object of the present invention is to utilize agricultural waste to manufacture a vegetal concrete masonry unit with the intention to recycle and resolve agricultural waste pollution problem. Another object of the present invention is to use following as raw materials for the preparation of a vegetal concrete masonry unit: (a) Crop residues: paddy straw, wheat straw, bagasse, cotton stalk, com stover, sugar cane trash, sunflower stalk, soy stalk, chia stalk, kenaf stalk, hemp stalk and jute stalk and/or a combination thereof (b) Binder: ground granulated blast furnace slag and hydrated lime and/or a combination thereof (c) Other raw materials: fly ash, anhydrous sodium silicate, sodium hydroxide, water and/or a combination thereof.
Yet another object of the present invention is to reduce the amount of alkali activator used in the manufacture of the vegetal concrete masonry unit to make it a viable alternative to conventional masonry units.
A further object of the present invention is to lower the activator content making geopolymers and other geopolymer based vegetal concretes viable for use.
Another object of the present invention is to lower the activator content making geopolymer based vegetal concretes environmentally sustainable.
These and other objects of the present invention will become readily apparent upon further review of the following description.
SUMMARY OF THE INVENTION
One aspect of the present invention relates to a vegetal concrete masonry unit which comprises of cooked crop residues, binder and pulverized fuel ash in a mass ratio of 1 : 1 : 1.5 to 1:1.5:3.
Another aspect of the present invention relates to a method for the preparation of a vegetal concrete masonry unit, the method comprising: cooking a crop residue in a cooker such as a pressure cooker with sodium hydroxide (NaOH) and water; mixing hydrated lime, Ground Granulated Blast Furnace Slag (GGBFS), and sodium silicate activator in a ribbon blender to constitute the binder; intermixing the digested crop residue, binder and pulverized fuel ash (PFA) together in a pan mixer with water to form an alkali activated homogeneous paste/gel; and molding the homogenous paste obtained in intermixing step using a high- pressure hydraulic press to form the vegetal concrete masonry unit.
Yet another aspect of the present invention relates to a system for the manufacture of a vegetal concrete masonry unit, the system comprising: a lime silo containing hydrated lime; a activator powder in a ribbon blender to form a binder; a binder silo for storing the binder; a stainless steel cooker for cooking a raw crop residue; a pan mixer for obtaining the wet mix; a cooked crop residue hopper for obtaining the mixture obtained from the stainless steel cooker; wherein the cooked crop residues from hopper, binder from the binder silo and pulverized fuel ash, PFA, hopper are mixed with water in a pan mixer; wherein the wet mix of the pan mixer are casted into molds using hydraulic block machine with a high compacting pressure, and then transported to the stock yard.
The crop residues are cooked in a pulp digester with 20 percent NaOH and water at 150°C for a duration of 45 minutes. The binder includes hydrated lime of at least 85 percent calcium hydroxide mixed with GGBFS in a 2:3 ratio.
The method also includes providing sodium silicate activator is in an amount equal to 2.5- 20% of the total mass of hydrated lime and GGBFS in a ribbon blender to constitute the binder. The binder is further mixed with pulverized fuel ash, cooked crop residues, and water in a pan mixer and cast into molds using a high-pressure hydraulic press with a compacting pressure of up tolOMPa.
The alkali activated homogeneous paste/gel of the method is Calcium-Alumino-Silicate- Hydrate (C-A-S-H/CASH) gel/paste and wherein the PFA reacts with GGBFS in the presence of an activator powder to form Sodium-Alumino-Silicate-Hydrate (N-A-S- H/NASH) geopolymers, as well as CASH gel. The activator powder is anhydrous sodium silicate powder.
The cooking or digesting of the crop residue is carried out in a stainless-steel container constructed with a pressure lock system and designed to withstand a total internal pressure of minimum 2 atm. The binder comprises mixing hydrated lime, Ground Granulated Blast Furnace Slag, and sodium silicate activator in a mass ratio of 2:3:0.5 to 1:6:2.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
Fig. 1 illustrates a system of manufacturing a vegetal concrete masonry unit according to the present invention.
Fig. 2 illustrates a process showing the steps of manufacturing a vegetal concrete masonry unit according to the present invention.
DETAILED DESCRIPTION OF THE PRESENT INVENTION
A novel, environmentally sustainable vegetal concrete masonry unit/brick and viable process and system for the preparation of the same with performance related advantage over existing products is disclosed. The vegetal concrete masonry unit/brick of the present invention finds application in civil constructions in form of blocks and pre-cast wall panels. This vegetal concrete masonry unit may be cast in a hybrid composite construction, where there shall be the core made of this material, encased in a steel frame. These hybrid panel will then be erected on site to make a pre-engineered building.
Thus, the present invention relates to an economically sustainable vegetal concrete masonry unit and the method for manufacturing the same, wherein the vegetal concrete masonry unit comprises of hydrated lime, Ground Granulated Blast Furnace Slag, pulverized fuel ash, cooked crop residues and sodium silicate used in defined amounts. Further, the process for the manufacture of vegetal concrete masonry unit employs a step of digesting the crop residue with alkali such as sodium hydroxide increasing the homogeneity of the material mixture and eliminates the set-retarding extracts from the crop residues; and on further addition of binder materials improves the compressive strength of the formed vegetal concrete masonry unit.
In the present invention, lime and Ground Granulated Blast Furnace Slag (GGBFS) act as the main binding agent. The addition of sodium silicate activates the reaction between lime and GGBFS to form Calcium-Alumino-Silicate-Hydrate (C-A-S-H/CASH) gel that creates the matrix to hold the aggregates in the concrete, which are vegetal matter and pulverized fuel ash (PFA). Formation of CASH gel is a desirable hydration product that occurs when building limes or Portland cements are mixed with water. The addition of PFA also has an additional role to play. It acts as a fine aggregate as well as a binding agent. The PFA reacts with GGBFS in the presence of the activator to form Sodium-Alumino-Silicate-Hydrate (N- A-S-H/NASH) geopolymers, as well as CASH gel. For the reaction between GGBFS and pulverized fuel ash, the presence of lime (calcium hydroxide) also creates a suitable pH environment to facilitate the reaction. A part of the remaining calcium hydroxide in the mixture mineralizes the cooked crop residues and the other part subsequently turns into calcium carbonate through carbonation. The crop residue is selected from a group of crop residues comprising paddy straw, wheat straw, bagasse, cotton stalk, com stover, sugar cane trash, sunflower stalk, soy stalk, chia stalk, kenaf stalk and jute stalk and/or a combination thereof. Therefore, changes in activator, lime, GGBFS and pulverized fuel ash content would result in varying amounts of CASH and NASH, thereby affecting the strength of the final vegetal concrete product.
Figure 1 discloses a system 10 for manufacturing of a vegetal masonry unit according to the present invention, wherein the system comprising a lime silo 12 containing hydrated lime which is mixed with ground granulated blast furnace slag 14 and a activator powder 16 in a ribbon blender 18 to form a binder which is stored in a binder silo 20, a raw crop residue from the storage 22 is mixed with water 24 and sodium hydroxide 26 in the stainless steel cooker 28, the mixture obtained from the stainless steel cooker 28 is fed to the wet washing 30 and subsequently to the cooked crop residue hopper 32. The cooked crop residues from hopper 32, binder from the binder silo 20 and PFA pulverized fuel ash hopper 36 are mixed with water 38 in a pan mixer 34, wherein, the wet mix of the pan mixer 34 are casted into molds using hydraulic block machine 40 with a high compacting pressure, and then transported to the stock yard.
The crop residues are cooked in a cooker with 20 percent sodium hydroxide (NaOH) and water at 150°C for a duration of 45 minutes; wherein the binding materials -includes hydrated lime of at least 85 percent calcium hydroxide which is mixed with GGBFS in a 2:3 ratio, and sodium silicate activator of an amount equal to 2.5-20% of the total mass of hydrated lime and GGBFS in a ribbon blender to constitute the binder; wherein the binder is further mixed with pulverized fuel ash, cooked crop residues, and water in a pan mixer and cast into molds with using a high-pressure hydraulic press with a compacting pressure of lOMPa.
Figure 2 illustrates a process that shows the steps of manufacturing of vegetal concrete masonry unit according to the present invention which are as below :
1. Processing of crop residues
Each kilogram of crop residues, either individually or as a combination of paddy straw, wheat straw, bagasse, cotton stalk, com stover, sugar cane trash, sunflower stalk, soy stalk, chia stalk, kenaf stalk, hemp stalk and jute stalk are added to 5 liters of 0.2M to 10M NaOH solution in a stainless-steel container constructed with a pressure lock system and designed to withstand a total internal pressure of minimum 2 atm. The stainless-steel container containing the crop residues and NaOH solution is heated to a temperature of 150°C and 2 atm pressure. The temperature and pressure are applied for a duration of 15 to 45 minutes, after which, the crop residues are removed from the container and washed until the water runs clear. The washed residues are de-watered to a saturated condition.
2. Preparation of Binder
Hydrated lime consisting of at least 85% calcium hydroxide is mixed with ground granulated blast furnace slag (GGBFS) having a specific surface area of at least 400 m2/kg in a ratio of 1:6 to 2:3, respectively. Anhydrous sodium silicate powder of amount equal to 5% to 20% of the combined mass of hydrated lime and GGBFS is added to the mix. The three constituents are blended together for a duration of at least 5 minutes.
3. Preparation of vegetal concrete mix
The processed crop residues in the wet form, the binder, dry fly ash and water are added to a pan mixer in quantities as set out in table 1. The constituents are mixed at least for a duration of 3 minutes.
Figure imgf000010_0001
Figure imgf000011_0001
Table 1: Vegetal concrete, comprehensive
4. Production of vegetal masonry unit
The wet mix is transferred to a hydraulic block making machine consisting of a metal die, metal press and hydraulic jack capable of delivering a compression force of 2 MPa to 10 MPa.
In order to more clearly describe the nature of the present invention, specific examples will hereinafter be described. It should be understood, however, that this is done solely by way of example, and is intended neither to delineate the scope of the invention nor limit the ambit of the appended claims.
Specific Examples:
Example 1 (Paddy Straw):
Step 1: Processing of crop residues
Each kilogram of paddy straw is added to 5 litres of 1M NaOH solution and heated to a temperature of 150°C in a stainless-steel container. The temperature is maintained for a duration of 45 minutes, after which the paddy straw is removed from the container and washed thoroughly, until the water flows clear. The straw is squeezed and excess water is drained.
Step 2: Preparation of binder Hydrated lime consisting of at least 85% calcium hydroxide is mixed with ground granulated blast furnace slag (GGBFS) having a specific surface area of at least 400 m2/kg in a ratio of 2:3, respectively. Anhydrous sodium silicate powder of amount equal to 20% of the combined mass of hydrated lime and GGBFS is added to the mix. The three constituents are blended together for a duration of at least 5 minutes.
Step 3: Preparation of vegetal concrete mix
The processed crop residues in the wet form, the binder, fly ash and water are added to a pan mixer in quantities as set out in table 2.
Step 4: Production of vegetal concrete masonry unit
The wet mix is transferred to a hydraulic block making machine consisting of a metal die, metal press and hydraulic jack capable of delivering a compression force of 2 MPa.
Table 2: Paddy straw based vegetal concrete, Example 1
Figure imgf000012_0001
Example 2 (Paddy Straw):
Step 1: Processing of crop residues
Each kilogram of paddy straw is added to 5 litres of 0.5M NaOH solution and heated to a temperature of 150°C in a stainless-steel container with a pressure lock lid, with a capacity to withstand 2 atm of pressure. The lid is closed tight, and the temperature is maintained for a duration of 45 minutes, after which the paddy straw is removed from the container and washed thoroughly, until the water flows clear. The straw is squeezed and excess water is drained.
Step 2: Preparation of binder
Hydrated lime consisting of at least 85% calcium hydroxide is mixed with ground granulated blast furnace slag (GGBFS) having a specific surface area of at least 400 m2/kg in a ratio of 2:3, respectively. Anhydrous sodium silicate powder of amount equal to 20% of the combined mass of hydrated lime and GGBFS is added to the mix. The three constituents are blended together for a duration of at least 5 minutes.
Step 3: Preparation of vegetal concrete mix
The processed crop residues in the wet form, the binder, fly ash and water are added to a pan mixer in quantities as set out in table 3. The constituents are mixed for a duration of 3 minutes.
Step 4: Production of vegetal concrete masonry unit The wet mix is transferred to a hydraulic block making machine consisting of a metal die, metal press and hydraulic jack capable of delivering a compression force of 2 MPa.
Table 3: Paddy straw based vegetal concrete, Example 2
Figure imgf000013_0001
Please note: In the above two examples, preparation of crop residues can happen with NaOH solution having molar concentration between 0.3M to 10M. The cooking time and cooking pressure will vary depending on the concentration of the solution.
Example 3 (Paddy Straw):
Step 1: Processing of crop residues
Each kilogram of paddy straw is added to 5 litres of 0.5M NaOH solution and heated to a temperature of 150°C in a stainless-steel container with a pressure lock lid, with a capacity to withstand 2 atm of pressure. The lid is closed tight, and the temperature is maintained for a duration of 45 minutes, after which the paddy straw is removed from the container and washed thoroughly, until the water flows clear. The straw is squeezed and excess water is drained.
Step 2: Preparation of binder
Hydrated lime consisting of at least 85% calcium hydroxide is mixed with ground granulated blast furnace slag (GGBFS) having a specific surface area of at least 400 m2/kg in a ratio of 1 :5.67, respectively. Anhydrous sodium silicate powder of amount equal to 15% of the combined mass of hydrated lime and GGBFS is added to the mix. The three constituents are blended together for a duration of at least 5 minutes.
Step 3: Preparation of vegetal concrete mix
The processed crop residues in the wet form, the binder, fly ash and water are added to a pan mixer in quantities as set out in table 4. The constituents are mixed for a duration of 3 minutes.
Step 4: Production of vegetal concrete masonry unit
The wet mix is transferred to a hydraulic block making machine consisting of a metal die, metal press and hydraulic jack capable of delivering a compression force of 2 MPa. Table 4: Paddy straw based vegetal concrete, Example 3
Figure imgf000015_0001
Example 4 (Wheat Straw):
Step 1: Processing of crop residues
Each kilogram of wheat straw is added to 5 litres of 0.5M NaOH solution and heated to a temperature of 150°C in a stainless-steel container with a pressure lock lid, with a capacity to withstand 2 atm of pressure. The lid is closed tight, and the temperature is maintained for a duration of 35 minutes, after which the wheat straw is removed from the container and washed thoroughly, until the water flows clear. The straw is squeezed and excess water is drained.
Step 2: Preparation of binder
Hydrated lime consisting of at least 85% calcium hydroxide is mixed with ground granulated blast furnace slag (GGBFS) having a specific surface area of at least 400 m2/kg in a ratio of 2:3, respectively. Anhydrous sodium silicate powder of amount equal to 20% of the combined mass of hydrated lime and GGBFS is added to the mix. The three constituents are blended together for a duration of at least 5 minutes.
Step 3: Preparation of vegetal concrete mix
The processed crop residues in the wet form, the binder, fly ash and water are added to a pan mixer in quantities as set out in table 5. The constituents are mixed for a duration of 3 minutes. Step 4: Production of vegetal concrete masonry unit
The wet mix is transferred to a hydraulic block making machine consisting of a metal die, metal press and hydraulic jack capable of delivering a compression force of 2 MPa.
Table 5: Wheat straw based vegetal concrete, Example 4
Figure imgf000016_0001
Example 5 (Bagasse):
Step 1: Processing of crop residues
Each kilogram of bagasse is added to 5 litres of 0.5M NaOH solution and heated to a temperature of 150°C in a stainless-steel container with a pressure lock lid, with a capacity to withstand 2 atm of pressure. The lid is closed tight, and the temperature is maintained for a duration of 15 minutes, after which the bagasse is removed from the container and washed thoroughly, until the water flows clear. The washed bagasse is squeezed, and excess water is drained.
Step 2: Preparation of binder
Hydrated lime consisting of at least 85% calcium hydroxide is mixed with ground granulated blast furnace slag (GGBFS) having a specific surface area of at least 400 m2/kg in a ratio of 1 :5.67, respectively. Anhydrous sodium silicate powder of amount equal to 20% of the combined mass of hydrated lime and GGBFS is added to the mix. The three constituents are blended together for a duration of at least 5 minutes. Step 3: Preparation of vegetal concrete mix
The processed crop residues in the wet form, the binder, fly ash and water are added to a pan mixer in quantities as set out in table 6. The constituents are mixed for a duration of 3 minutes.
Step 4: Production of vegetal concrete masonry unit
The wet mix is transferred to a hydraulic block making machine consisting of a metal die, metal press and hydraulic jack capable of delivering a compression force of 2 MPa.
Table 6: Bagasse based vegetal concrete, Example 5
Figure imgf000017_0001

Claims

Claims:
1. A method for the preparation of a vegetal concrete masonry unit, the method comprising: cooking or digesting a crop residue in a cooker with sodium hydroxide (NaOH) and water; mixing hydrated lime, Ground Granulated Blast Furnace Slag (GGBFS), and sodium silicate activator in a ribbon blender to constitute the binder; intermixing the digested crop residue, binder and pulverized fuel ash (PFA) together in a pan mixer with water to form an alkali activated homogeneous paste/gel; and molding the homogenous paste obtained in intermixing step using a high-pressure hydraulic press to form the vegetal concrete masonry unit.
2. The method as claimed in claim 1, wherein the crop residues are cooked in a cooker with 0.2M to 10M NaOH aqueous solution at 150°C for a duration of 15 to 45 minutes.
3. The method as claimed in claim 1, wherein the binder includes hydrated lime of at least 85 percent calcium hydroxide mixed with GGBFS in a 1:6 to 2:3 ratio.
4. The method as claimed in claim 1, wherein the sodium silicate activator is in an amount equal to 2.5-20% of the total mass of hydrated lime and GGBFS in a ribbon blender to constitute the binder.
5. The method as claimed in claim 1, wherein the binder is further mixed with pulverized fuel ash, cooked crop residues, and water in a pan mixer and cast into molds using a high- pressure hydraulic press with a compacting pressure of up to lOMPa.
6. The method as claimed in claim 1, wherein the alkali activated homogeneous paste/gel is Calcium-Alumino-Silicate-Hydrate (C-A-S-H/CASH) gel/paste.
7. The method as claimed in any of the preceding claims, wherein the PFA and GGBFS reacts with an activator powder to form Sodium-Alumino-Silicate-Hydrate (N-A-S- H/NASH) geopolymers, as well as CASH gel.
8. The method as claimed in claim 7, wherein the activator powder is anhydrous sodium silicate powder.
9. The method as claimed in claim 1, wherein the crop residue is selected from a group of crop residues comprising paddy straw, wheat straw, bagasse, cotton stalk, corn stover, sugar cane trash, sunflower stalk, soy stalk, chia stalk, kenaf stalk, hemp stalk and jute stalk and/or a combination thereof.
10. The method as claimed in claim 1, wherein the cooker is a stainless steel cooker.
11. The method as claimed in claim 1, wherein the step of cooking or digesting the crop residue is carried out in a stainless- steel container constructed with a pressure lock system and designed to withstand a total internal pressure of minimum 2 atm.
12. The method as claimed in claim 1, wherein the step of cooking or digesting the crop residue includes washing of crop residues until the water runs clear and de-watering of the washed residues to a saturated condition.
13. The method as claimed in claim 1, wherein the step of mixing comprises mixing Hydrated lime consisting of at least 85% calcium hydroxide with ground granulated blast furnace slag (GGBFS) having a specific surface area of at least 400 m2/kg in a ratio of 1:6 to 2:3, respectively.
14. The method as claimed in claim 13, wherein anhydrous sodium silicate powder of amount equal to 2.5% to 20% of the combined mass of hydrated lime and GGBFS is added to the mix and blended together for a duration of at least 5 minutes.
15. The method as claimed in claim 1, wherein the constituents of step of intermixing are mixed for at least a duration of 3 minutes.
16. The method as claimed in claim 1, wherein the step of moulding is carried out through a hydraulic block making machine consisting of a metal die, metal press and hydraulic jack capable of delivering a compression force of 2 MPa to 10 MPa.
17. A system (10) for the manufacture of a vegetal concrete masonry unit, the system comprising: a lime silo (12) containing hydrated lime; an activator powder (16) in a ribbon blender to form a binder; a binder silo (20) for storing the binder; a stainless steel cooker (28) for cooking a raw crop residue; a pan mixer (34) for obtaining the wet mix; a cooked crop residue hopper (32) for obtaining the mixture obtained from the stainless steel cooker (28); wherein the cooked crop residues from hopper (32), binder from the binder silo (20) and pulverized fuel ash, PFA, hopper (36) are mixed with water (38) in a pan mixer (34); and wherein the wet mix of the pan mixer (34) are casted into molds using hydraulic block machine (40) with a high compacting pressure, and then transported to the stock yard.
18. The system (10) as claimed in claim 17, wherein the hydrated lime is mixed with ground granulated blast furnace slag (14) and the activator powder (16) in a ribbon blender (18) to form a binder which is stored in a binder silo (20).
19. The system (10) as claimed in claim 17, wherein the raw crop residue from the storage (22) is mixed with water (24) and NaOH (26) in the stainless steel cooker (28).
20. The system (10) as claimed in claim 17, wherein the cooked crop residues from stainless steel cooker (28) is fed to wet washing (30).
21. A vegetal concrete masonry unit which comprises of cooked crop residues, binder and pulverized fuel ash in a mass ratio of 1:1: 1.5 to 1:1.5:3.
22. The vegetal concrete masonry unit as claimed in claim 21, wherein the crop residues are selected from a group comprising of paddy straw, wheat straw, bagasse, cotton stalk, com stover, sugar cane trash, sunflower stalk, soy stalk, chia stalk, kenaf stalk, hemp stalk and jute stalk and/or a combination thereof.
23. The vegetal concrete masonry unit as claimed in claim 21, wherein the binder comprises mixing hydrated lime, Ground Granulated Blast Furnace Slag, and sodium silicate activator in a mass ratio of 2:3:0.5 to 1:6:2.
24. The vegetal concrete masonry unit as claimed in claim 21, wherein the vegetal concrete masonry unit is manufactured by the method as claimed in claims 1 to 16.
PCT/IN2021/050055 2020-01-21 2021-01-21 A vegetal concrete masonry unit and method and system for manufacture thereof WO2021149076A1 (en)

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AU2021210697A AU2021210697A1 (en) 2020-01-21 2021-01-21 A vegetal concrete masonry unit and method and system for manufacture thereof
US17/793,579 US20230054357A1 (en) 2020-01-21 2021-01-21 A vegetal concrete masonry unit and method and system for manufacture thereof
BR112022014329A BR112022014329A2 (en) 2020-01-21 2021-01-21 VEGETABLE CONCRETE MASONRY UNIT AND MANUFACTURING METHOD AND SYSTEM
GB2212128.9A GB2607775A (en) 2020-01-21 2021-01-21 A vegetal concrete masonry unit and method and system for manufacture thereof
MX2022008966A MX2022008966A (en) 2020-01-21 2021-01-21 A vegetal concrete masonry unit and method and system for manufacture thereof.
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