WO2023092246A1

WO2023092246A1 - Aquaculture waste ecopanel having passive fire protection properties and compressive and flexural strength

Info

Publication number: WO2023092246A1
Application number: PCT/CL2022/050118
Authority: WO
Inventors: Begoña PECEÑO CAPILLA; Carlos LEIVA FERNÁNDEZ; Bernabé ALONSO FARIÑAS
Original assignee: Universidad Católica Del Norte; Universidad De Sevilla
Priority date: 2021-11-26
Filing date: 2022-11-21
Publication date: 2023-06-01
Also published as: CL2021003157A1

Abstract

The present invention relates to a lightweight and biodegradable ecopanel having passive fire protection properties and compressive and flexural strength. Said ecopanel makes it possible to reduce the amount of sea shell waste and contribute to environmental decontamination caused by the aquaculture industry, and it comprises between 10% and 30% of sea shell waste and between 90% and 70% of gypsum. Likewise, the invention comprises a method for manufacturing the ecopanel, and its use in the construction industry.

Description

ECOPANEL WITH AQUACULTURE WASTE WITH PROPERTIES OF PASSIVE PROTECTION AGAINST FIRE AND RESISTANCE TO COMPRESSION AND FLEXURE.

TECHNICAL FIELD OF THE INVENTION

[001] The present invention is aimed at an ecopanel manufactured from seashell waste with passive fire protection properties, lightweight and biodegradable. Additionally, the invention provides a method for manufacturing the ecopanel and its use in the construction industry.

BACKGROUND OF THE INVENTION

[002] The panels are a fundamental input for construction, such as for the manufacture of dividing panels, low ceilings, interior partitions, ceiling and wall coverings, among others. Therefore, there is a high demand for panels for construction.

[003] For a panel to be suitable for use in construction, it must possess a series of characteristics, such as a high resistance to superior compression and superior flexion. For example, in the case of Chile, according to the NCh 143 standards, the panels must have a compressive strength greater than 12.75 MPa and a flexural strength greater than 3.43 MPa. Likewise, it is desirable that the panels have properties of thermal and acoustic insulation, fire retardant, that are light and biodegradable.

[004] On the other hand, there is a large amount of seashell waste that is discarded by the aquaculture industry, which produces more than 8,000,000 tons annually worldwide. Such waste accumulates in landfills or is dumped into the ocean. Therefore, it is desirable to have alternative uses for seashell waste, such as the case of ecopanels for construction.

[005] In this context, although a series of procedures have been described in the state of the art technologies aimed at using marine shell residues in construction materials, none of them has been adequately oriented to the manufacture of ecopanels with characteristics and properties that make them useful for effective use in construction.

[006] For example, patent JPH11228206A discloses a method for the production of a concrete product based on residues of marine shells, cement, water and inorganic agents for its hardening. ¹

[007] Likewise, patent CN1 10835256A describes a high-strength, difficult-to-crack and high-strength concrete, comprising 250-320 parts of cement, 950-1080 parts of stone, 150-200 parts of coarse river sand, 20-30 parts fine river sand, 30-50 parts asphalt, and 70-90 parts gypsum, 100-120 parts fly ash, 30-50 parts bentonite, 20-30 parts seashell dust, 10 -20 parts of thetanolamine, 10-20 parts of magnesium oxide, 20-25 parts of calcium lignosulfonate, 30-40 parts of diketone, 20-30 parts of sodium styrene sulfonate, 10-15 parts of defoaming agent, 10-12 parts early strength agent, 130-170 parts water. ²

[008] On the other hand, Tayeh and collaborators (2020), developed an alternative material for the production of concrete that allows reducing environmental pollution caused by the large amount of marine debris that exists on the coasts. Particularly, a composition comprising 95% cement and 5% clam shells (Glycymeris Nummariá) and fine and coarse aggregates was elaborated for the preparation of concrete. ³

[009] As can be seen, although the state of the art discloses construction methods and materials based on seashell residue, they consist of concrete or concrete materials, whose physical characteristics, uses, and technical challenges are absolutely different from those of ecopanels.

[010] On the other hand, patent ES 2351451 B1 discloses the obtaining of materials from waste from the canning industry, which contain more than 40% by weight on a dry basis of mollusk shells, plaster, vermiculite, fiberglass , with passive properties against fire. Although this patent application describes a product to based on shells of mollusks, presents a series of drawbacks. For example, the disclosed product fails to achieve adequate percentages of resistance to compression and flexion to be used in the construction industry. Indeed, the flexural strength only reaches 2.04 MPa, while the compressive strength only reaches 2.17 MPa. On the other hand, the composition disclosed in this application includes elements that could affect the ability of the material to be biodegradable, for example, fiberglass. ⁴

[01 1 ] In view of the above, it is desirable to have eco-panels that are friendly to the environment, which allows the reuse of seashell waste and also have passive fire protection properties, resistance to compression and flexion , light and biodegradable, as well as with adequate processes for its production and use in the construction industry.

REFERENCES

1.- JP19980030847 (1998) Production of concrete product and concrete product produced by the same. MOA GREEN KK.

2.- CN20191 1221487 (2019) High-strength concrete and preparation method therefore. SHANDONG KOUTIAN ENVIRONMENTAL PROTECTION EQUIPMENT TECH CO LTD.

3.- Durability and mechanical properties of seashell partially replaced cement (2020). Tayeh, B. A., Hasaniyah, M. W., Zeyad, A. M., Awad, M. M., Alaskar, A., Mustafa, A., & Alyousef, R. Journal of Building Engineering, 31. https://doi.Org/10.1016/j. jobe.2020.101328.

4.- ES 2351451 B1 (2009) Obtaining fire-resistant materials from waste from the canning industry. Sevilla University.

BRIEF DESCRIPTION OF THE INVENTION

[012] The present invention is aimed at an ecopanel with properties of passive fire protection, resistant to compression and bending, lightweight and biodegradable, comprising: between 10% and 30% seashell debris; and between 90% and 70% plaster.

[013] In another aspect, the invention comprises a process for manufacturing an ecopanel with passive fire protection properties, resistant to compression and flexion, lightweight and biodegradable, which allows the reuse of seashell waste and contributes to environmental decontamination. , which includes the following steps: a) dispose of marine shell waste; b) wash with 2 liters of water for each Kg of seashell residue; c) subjecting the marine shell waste from stage b), to a heat treatment at 300°C for 5 h; d) crushing and sifting the marine shell waste from stage c), to obtain a powder with a granulometry of less than 600 pm; e) prepare a homogeneous mixture [Mixture 1] comprising:

- between 10% to 30% of marine shell waste from stage d); and

- between 90% to 70% plaster; f) incorporate into Mixture 1, water in a water/solid ratio of 0.25% v/p; g) make a first kneading of Mixture 1 for 10 min until obtaining a homogeneous mixture [Mixture 2]; h) add water to Mixture 2 in a water/solid ratio of 0.25% v/p [Mixture 3]; i) mix Mixture 3 for a second time for 10 min until a homogeneous mixture is obtained; j) fill a mold with the dimensions of a panel with Mixture 3 and let it rest for at least 10 h; k) remove the ecopanel from the mold and leave it to set for a period of 28 days.

[014] Additionally, the invention includes the use of an ecopanel with passive fire protection properties, with superior compression and flexural resistance, lightweight and biodegradable, because it is useful for the construction of dividing panels, ceilings, partitions interiors, ceiling and wall coverings, among others. BRIEF DESCRIPTION OF THE FIGURES

[015] The above and other objects, features and advantages of the invention will become apparent from the following description of the preferred embodiments of the invention, as illustrated in the accompanying figures.

[016] Figure No. 1 shows the behavior of the compressive strength of different ecopanels made with residues of marine shells between 0 and 60% and plaster between 40 and 100%. The residues used were from marine shells of Argopecten purpuratus, Concholepas concholepas, Mesodesma donacium, Argopecten purpuratus with fiber, Concholepas concholepas with fiber, and Mesodesma donacium with fiber. NCh 143: Official Chilean Standard 143, 1999.

[017] Figure No. 2 shows the behavior of the flexural resistance of different ecopanels made with residues of marine shells between 0 and 60% and plaster between 40 and 100%. The residues used were from marine shells of Argopecten purpuratus, Concholepas concholepas, Mesodesma donacium, Argopecten purpuratus with fiber, Concholepas concholepas with fiber, and Mesodesma donacium with fiber. NCh 143: Official Chilean Standard 143, 1999.

[018] Figure No. 3 shows the behavior of the density of different ecopanels made with residues of seashells between 10 and 60% and gypsum between 40 and 90%. The residues used were from marine shells of Argopecten purpuratus, Concholepas concholepas and Mesodesma donacium.

DETAILED DESCRIPTION OF THE INVENTION

[019] The present invention is aimed at an ecopanel with passive fire protection properties, resistant to compression and bending, lightweight and biodegradable, comprising:

- between 10% and 30% of marine shell waste; and

- between 90% and 70% plaster.

[020] An ecopanel manufactured based on a composition as described above, it will meet the standards of the NCh 143 standard, namely, a compressive strength greater than 12.75 MPa and a flexural strength greater than 3.43 MPa.

[021] In a preferred embodiment of the invention, the marine shells comprising the ecopanel can be selected from shells of Concholepas concholepas, Argopecten purpuratus and Mesodesma donacium.

[022] In a preferred embodiment of the invention, the ecopanel comprises 20% marine shells. Preferably in a ratio of 20% seashells and 80% gypsum.

[023] In a preferred embodiment of the invention, the ecopanel comprises marine shells with a granulometry of less than 600 pm.

[024] Based on the foregoing, the inventors determined that the optimal proportion of seashells that an ecopanel should contain, to optimize its physical and mechanical properties to be used as a construction material, is from 10% to 30% of sea shells. In particular, the inventors determined that the optimal composition for the manufacture of an ecopanel is achieved with 20% seashells with a granulometry of less than 600 pm, and with 80% gypsum. Indeed, said formulation makes it possible to achieve a compressive strength greater than 15 MPa, a flexural resistance greater than 4.75 MPa and a density of 1,480 Kg/m ³ .

[025] Finally, even more preferably, the inventors determined that the optimal composition of the ecopanel is achieved when (with the concentrations indicated above) the seashells used are from Concholepas concholepas. Indeed, said formulation makes it possible to achieve a compressive strength greater than 16 MPa, a flexural strength of 5 MPa and a density of 1,520 kg/m ³ .

[026] In a preferred embodiment of the invention, the ecopanel has dimensions of 0.3 cm wide, 120 cm long and 240 cm high. Alternatively, the ecopanel can take any measure that is necessary to be useful for construction, such as for making dividing panels, ceilings, interior partitions, cladding ceilings and walls, among others.

[027] In another aspect, the invention consists of a process for manufacturing an ecopanel with passive fire protection properties, resistant to compression and flexion, lightweight and biodegradable, which allows the reuse of seashell waste and contributes to decontamination. environmental, which includes the following steps: a) dispose of marine shell waste; b) wash with 2 liters of water for each Kg of seashell residue; c) subjecting the marine shell waste from stage b), to a heat treatment at 300°C for 5 h; d) crushing and sifting the marine shell waste from stage c), to obtain a powder with a granulometry of less than 600 pm; e) prepare a homogeneous mixture [Mixture 1] comprising:

- between 10% to 30% of marine shell waste from stage d); and

[028] In a preferred modality, stage j) of the process is left to rest for 24 h, in the presence of approximate humidity between 40 to 80% and in the presence of a temperature of 20 ± 2 ^S C.

[029] In another aspect, the invention comprises the use of an ecopanel with passive fire protection properties, with superior compression and flexural resistance, lightweight and biodegradable, which is useful for the construction of dividing panels, soffits , interior partitions, ceiling and wall coverings, among others. EXAMPLES

Example 1: Preparation of an ecopanel with aquaculture residues.

[030] In order to manufacture an ecopanel with passive fire protection properties, resistant to compression and flexion, lightweight and biodegradable, formulated based on seashells, and thus contribute to the environmental decontamination caused by the aquaculture industry, the inventors devised the following procedure.

[031] First, different aquaculture residues were collected, in particular, seashells of Argopecten purpuratus, Concholepas concholepas, Mesodesma donacium. Likewise, seaweed was collected as a source of fiber.

[032] Then, 1 Kg of each type of seashell debris (Argopecten purpuratus, Concholepas concholepas, Mesodesma donacium) was washed using 2 L of water to remove impurities.

[033] Subsequently, the residues of each type of previously washed seashells were subjected to a heat treatment at 300 °C for 5 h. The objective of this was to favor the following crushing and sifting step, in which the marine shell waste was crushed until obtaining a powder with a granulometry of less than 600 pm.

[034] Next, different mixtures were made with different concentrations of residues of seashells, plaster and water, as can be seen in the following Table N° 1:

Table No. 1. Compositions of Ecopanels with aquaculture waste.

[035] Each of the mixtures was prepared as follows:

[036] A first mixture (Mixture 1) was prepared that included the percentages of aquaculture waste and gypsum indicated in Table N° 1, plus water in a water/solid ratio of 0.25% v/p. Then, Mixture 1 was kneaded for 10 minutes until a homogeneous mixture was obtained, obtaining a second mixture (Mixture 2).

[037] Subsequently, water was added to Mixture 2 in a water/solids ratio of 0.25% v/p and a second kneading was performed for 10 min until a homogeneous mixture was obtained (Mixture 3). Then, with the mixture obtained, a mold was filled to form the ecopanel, and it was left to rest for 24 h, in the presence of humidity of approximately 50 % and 20 ± 2 ^S C. Finally, the ecopanel was disassembled from the mold and it was left to set for a period of 28 days.

[038] Once the ecopanel was dried, tests were carried out to determine its physical properties, such as compressive strength (Figure No. 1), flexural strength (Figure No. 2) and ecopanel density (Figure No. 3 ).

[039] When analyzing the results obtained, it was observed that the behavior of the ecopanels produced is different. Particularly, it was identified that the incorporation of fiber in the different compositions generated a decrease in compressive strength. For this reason, it is relevant that the ecopanel does not include fibers, such as those that come from marine algae, or materials other than plaster, such as cement or concrete.

[040] In the same way, it was possible to determine that the behavior of the ecopanel, when measuring the resistance to compression and flexion, depends on the type of aquaculture waste that is used and the proportion of these in relation to the amount of plaster used, such as can be seen in Figure No. 1 and Figure No. 2. [041] Likewise, it was observed that the behavior of the ecopanel, when measuring the resistance to compression and flexion, generates a curve dependent on the percentage of the incorporation of aquaculture waste (Figure No. 1 and No. 2).

[042] Indeed, although it was expected that the resistance to compression and flexion would increase as the percentage of seashell debris increased, the results allowed us to determine that the greatest resistance to compression and flexion occurs when using 20% seashell waste. Likewise, it was determined that the type of shells that gives the best results is that of Concholepas concholepas. Indeed, by using 20% shell residue from Concholepas concholepas and 80% gypsum, it is possible to obtain a compressive strength of more than 16 MPa and a flexural strength of 5 MPa, much higher than what is established. by Chilean Standard 143.

[043] Finally, it was observed that the ecopanels made with 10 to 20% shell residue from Concholepas concholepas, reached a high density of more than 1,250 Kg/m ³ .

[044] In short, the indicated results allowed to determine that the ecopanels object of the present invention can be used in the construction industry for the elaboration of dividing panels, low ceilings, interior partitions, ceiling and wall coverings, among others.

Claims

CLAIMS SHEET

1.- An ecopanel with properties of passive fire protection, resistance to compression and bending, lightweight and biodegradable, CHARACTERIZED because it comprises:

- between 10% and 30% of marine shell waste; and

- between 90% and 70% plaster.

2.- The ecopanel according to claim 1, CHARACTERIZED in that the seashells can be selected from among shells of Concholepas concholepas, Argopecten purpuratus and Mesodesma donacium.

3.- The ecopanel according to any of the preceding claims,

CHARACTERIZED because it comprises 20% marine shells.

4.- The ecopanel according to any of the preceding claims,

CHARACTERIZED because it comprises a proportion of 20% marine shells and 80% plaster.

5. The ecopanel according to claim 1, CHARACTERIZED in that the seashells have a granulometry of less than 600 pm.

6.- A procedure to manufacture an ecopanel with properties of passive fire protection, resistance to compression and bending, lightweight and biodegradable, which allows reusing seashell waste and contributing to environmental decontamination, CHARACTERIZED because it includes the following steps : a) dispose of marine shell waste; b) wash with 2 liters of water for each Kg of seashell residue; c) subjecting the marine shell waste from stage b), to a heat treatment at 300°C for 5 h; d) crushing and sifting the marine shell waste from stage c), to obtain a powder with a granulometry of less than 600 pm; e) prepare a homogeneous mixture [Mixture 1] comprising:

- between 10% to 30% of marine shell waste from stage d); and

7.- Use of an ecopanel with passive fire protection properties, with superior resistance to compression and flexion, lightweight and biodegradable, according to claim 1, CHARACTERIZED because it is useful for the construction of dividing panels, low ceilings , interior partitions, ceiling and wall coverings, among others.