WO2024153732A1 - New sustainable plasterboards - Google Patents
New sustainable plasterboards Download PDFInfo
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- WO2024153732A1 WO2024153732A1 PCT/EP2024/051119 EP2024051119W WO2024153732A1 WO 2024153732 A1 WO2024153732 A1 WO 2024153732A1 EP 2024051119 W EP2024051119 W EP 2024051119W WO 2024153732 A1 WO2024153732 A1 WO 2024153732A1
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- Prior art keywords
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- fly ash
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- 238000010276 construction Methods 0.000 claims abstract description 181
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- 238000000034 method Methods 0.000 claims abstract description 25
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- 238000009413 insulation Methods 0.000 description 1
- 150000002500 ions Chemical class 0.000 description 1
- 239000002655 kraft paper Substances 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 150000002739 metals Chemical group 0.000 description 1
- 239000010852 non-hazardous waste Substances 0.000 description 1
- 238000005192 partition Methods 0.000 description 1
- 125000002080 perylenyl group Chemical group C1(=CC=C2C=CC=C3C4=CC=CC5=CC=CC(C1=C23)=C45)* 0.000 description 1
- CSHWQDPOILHKBI-UHFFFAOYSA-N peryrene Natural products C1=CC(C2=CC=CC=3C2=C2C=CC=3)=C3C2=CC=CC3=C1 CSHWQDPOILHKBI-UHFFFAOYSA-N 0.000 description 1
- OFNHPGDEEMZPFG-UHFFFAOYSA-N phosphanylidynenickel Chemical compound [P].[Ni] OFNHPGDEEMZPFG-UHFFFAOYSA-N 0.000 description 1
- 231100000614 poison Toxicity 0.000 description 1
- 230000007096 poisonous effect Effects 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 230000003014 reinforcing effect Effects 0.000 description 1
- 229940082569 selenite Drugs 0.000 description 1
- MCAHWIHFGHIESP-UHFFFAOYSA-L selenite(2-) Chemical compound [O-][Se]([O-])=O MCAHWIHFGHIESP-UHFFFAOYSA-L 0.000 description 1
- 229910052711 selenium Inorganic materials 0.000 description 1
- 229910052814 silicon oxide Inorganic materials 0.000 description 1
- 229910052708 sodium Inorganic materials 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 230000003068 static effect Effects 0.000 description 1
- 229910052712 strontium Inorganic materials 0.000 description 1
- CIOAGBVUUVVLOB-UHFFFAOYSA-N strontium atom Chemical compound [Sr] CIOAGBVUUVVLOB-UHFFFAOYSA-N 0.000 description 1
- 229910052600 sulfate mineral Inorganic materials 0.000 description 1
- 231100000331 toxic Toxicity 0.000 description 1
- 230000002588 toxic effect Effects 0.000 description 1
- 238000012384 transportation and delivery Methods 0.000 description 1
- 238000009423 ventilation Methods 0.000 description 1
- 238000004078 waterproofing Methods 0.000 description 1
- 238000001238 wet grinding Methods 0.000 description 1
- NWONKYPBYAMBJT-UHFFFAOYSA-L zinc sulfate Chemical compound [Zn+2].[O-]S([O-])(=O)=O NWONKYPBYAMBJT-UHFFFAOYSA-L 0.000 description 1
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
- C04B20/00—Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups C04B14/00 - C04B18/00 and characterised by shape or grain distribution; Treatment of materials according to more than one of the groups C04B14/00 - C04B18/00 specially adapted to enhance their filling properties in mortars, concrete or artificial stone; Expanding or defibrillating materials
- C04B20/02—Treatment
- C04B20/023—Chemical treatment
-
- 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
- C04B28/021—Ash cements, e.g. fly ash cements ; Cements based on incineration residues, e.g. alkali-activated slags from waste incineration ; Kiln dust 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
- 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
- C04B28/14—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 calcium sulfate 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
- 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
- C04B28/14—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 calcium sulfate cements
- C04B28/142—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 calcium sulfate cements containing synthetic or waste calcium sulfate 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
- 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
- C04B28/14—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 calcium sulfate cements
- C04B28/145—Calcium sulfate hemi-hydrate with a specific crystal form
-
- 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
- C04B2111/00612—Uses not provided for elsewhere in C04B2111/00 as one or more layers of a layered structure
- C04B2111/0062—Gypsum-paper board like materials
Definitions
- Gypsum is typically heated, dehydrated, and converted to hemihydrate before being milled into gypsum powder, which is the process of dehydration and hardness of gypsum, in order to produce gypsum gelled material.
- the hydrating process of gypsum results in the creation of dihydrate gypsum (solid) when hemi-hydrate gypsum (powder) absorbs water.
- the coal fly ashes are described to comprise 1.6-28 % calcium oxide, 3.9-46 % ion oxide, 13 to about 27% aluminium oxide and 33-66% silicon oxide P452859PC00 2 (column 4, l.27-30).
- the purpose of adding fly ash to the gypsum board appears to be described as sag reduction.
- CN107032732A appears to describe a gypsum board comprising 7-9 parts of fly ash (claim 1).
- the plaster board of the invention has the advantages of compression strength, static bending strength, large screw holding capability and breaking resistant elasticity modulus, low heat conductivity coefficient, good antibacterial property, anti- electromagnetic radiation property and anti-friction property.
- Example 1 describes a manufacture temperature of 55 °C
- example 2 describes a manufacture temperature of 65 °C
- example 3 describes a manufacture temperature of 60°C.
- CN114380552 appears to describe a concrete wallboard comprising 200-300 parts of fly ash (claim 1). The fly ash appear to be subjected to pretreatment, which may comprise decarbonizing and desulfurization treatment.
- CN110903070A appears to describe a partition board comprising phosphogypsum and 16-20 parts by weight of fly ash (claim 1).
- EP0344430A2 appears to describe a process for producing a flue gas desulfurization gypsum plaster wherein the inert fillers may comprise fly ash (claim 1 + claim 6). Summary of the invention The present invention is related to a new product with a difference in material composition compared to other construction material. According to an embodiment, the construction material innovatively replaces a significant portion of gypsum binder with ash. This substantial shift in material P452859PC00 3 composition introduces an important variation in the environmental profile of the two products. This change may have far-reaching implications throughout the entire product life cycle, from raw material extraction to disposal. The composition and production parameters of the fly ash board are further optimized to achieve enhanced performance and broader application potential.
- P452859PC00 4 Table 1 Phase Common Formula Stability Remarks name(s) range Gypsum Selenite, CaSO4 + ⁇ 60-90 o C Formed alabaster 2H2O in air spontaneously ⁇ 40-60 o C upon in H2O precipitation from solution under ambient conditions Bassanite Hemihydrate ⁇ -CaSO4 + Metastable Formed by 0.5H2O in H2O heating gypsum in air at >60-90 o C; readily rehydrates to gypsum Plaster of ⁇ -CaSO4 + Metastable Formed by Paris 0.5H2O in H2O heating gypsum in water at >90 oC; readily rehydrates to gypsum Anhydrite AIII, Soluble ⁇ -CaSO4 Metastable Formed by anhydrite in H2O and heating air gypsum in air at >100-130 oC; readily rehydrates to P452859PC00 5 hemihydrate or g
- the temperature input is necessary to transfer the gypsum phase into the 5 desired calcium sulfate phase, for instance, bassanite and anhydrite.
- the bassanite as, hemihydrate and plaster of paris are important because they have a semi-amorphous structure.
- Semi-amorphous structures increase the mechanical properties of the gypsum as a final product since the semi- amorphous structure works as an active binding material.
- 10 Fly-ash is known for their good mechanical properties, since the fly-ash exists as an semi-amorphous silicon structure, hence is an active binding material.
- the construction element according to the invention comprises purified fly- ash comprising silicium (Si) in an amount of about 139.000 – 140.500 mg/kg.
- the invention concerns a construction element comprising gypsum and purified fly ash, wherein said purified fly ash comprises less than 35.000 ppm heavy metals, and wherein said purified fly ash comprises 100.000 – 200.000 ppm Silicon.
- the invention concerns a process for producing a construction element according to the invention, said process comprising the steps of: a. Providing a fly ash material; b.
- Pre-treatment of said fly ash material thereby providing a purified fly ash composition, a metal containing fraction and a saltwater solution; c. Providing a gypsum binder; d. Combining said stabilized fly ash composition and said gypsum binder into a gypsum binder slurry; e. Compressing said gypsum binder slurry into a flat material which is cutted and dried into said construction element.
- the invention concerns a construction element comprising gypsum and purified fly ash, wherein said purified fly ash comprises less than 35.000 ppm heavy metals, and wherein said purified fly ash comprises 100.000 – 200.000 ppm Silicon.
- Gypsum may be defined as a soft sulfate mineral composed of calcium sulfate dihydrate, with the chemical formula CaSO 4 ⁇ 2H2O.
- Fly ash is the fine powder formed from the mineral matter in coal, consisting of the non-combustible matter in coal and a small amount of carbon that P452859PC00 7 remains. Fly ash are the particulates that are driven out of coal-fired boilers together with the flue gases.
- heavy metal may refer to any metallic chemical element that has a relatively high density (e.g. greater than 5 g cm -3 ) and is toxic or poisonous at low concentrations.
- Example of heavy metals include mercury (Hg), cadmium (Cd), arsenic (As), chromium (Cr), thallium (TI) or lead (Pb).
- the invention concerns a construction element, wherein said purified fly ash comprises less than 30.000 ppm heavy metals, less than 29.000, 28.000, 27.000, 26.000, 25.000, 24.000, 23.000, 22.000, 21.000, 20.000, 19.500, 19.000, 18.500, 18.000, 17.500 or preferably less than 17.000 ppm heavy metals.
- the invention concerns a construction element comprising gypsum and purified fly ash, wherein said purified fly ash comprises less than 20.000 ppm heavy metals, and wherein said purified fly ash comprises about 139.000 – 140.500 ppm Silicon.
- the invention concerns a construction element, wherein said construction element is a plasterboard.
- P452859PC00 8 According to an embodiment, the invention concerns a construction element, wherein said purified fly ash has a neutral pH value, preferably said pH values is 6 – 8, 6.5 – 7.5 or about 7.
- the invention concerns a construction element, wherein said purified fly ash has a thermal conductivity factor of 0.050 – 0.120 [W/mK], 0.060 – 0.110, 0.070 – 0.100, or preferably 0.080 – 0.090 [W/mK].
- the invention concerns a construction element, wherein said purified fly ash comprises Phosphor, Fluoride, Chloride, Silicon, SiO, SiO2, Al2O, Al2O3, Fe2O2, Fe2O3, FeO3, MgO, Na2O, K2O, SO3, LOI, CeO, MgO and/or CaO.
- the invention concerns a construction element, wherein said construction element comprises less than 50.000 ppm chloride, less than 40.000, 30.000, 20.000, 15.000, 10.000, 5.000, 2.500, 2.000, 1.500 or preferably less than 1000 ppm chloride.
- the invention concerns a construction element, wherein said construction element comprises less than 100.000 ppm aluminium, less than 90.000, 80.000, 70.000, 60.000, 50.000, 40.000, 30.000, 20.000, 15.000, 10.000, 5.000, 2.500, 2.000, 1.500 or preferably less than 1000 ppm aluminium.
- the invention concerns a construction element, wherein said construction element comprises less than 50.000 ppm antimony, less than 40.000, 30.000, 20.000, 15.000, 10.000, 5.000, 2.500, 2.000, 1.500 or preferably less than 1000 ppm antimony.
- the invention concerns a construction element, wherein said construction element comprises less than 50.000 ppm arsenic, less than 40.000, 30.000, 20.000, 10.000, 5.000, 2.500, 2.000, 1.500, 1.000, 900, 800, 700, 600, 500, 400, 350, 300, 250, 200, 150, 140, 130, 120, 110, 100, 90, 80, 70, 60, 50, 40, 30, 25, 20 or preferably less than 15 ppm arsenic.
- the invention concerns a construction element, wherein said construction element comprises less than 50.000 ppm chrome, P452859PC00 10 less than 40.000, 30.000, 20.000, 10.000, 5.000, 2.500, 2.000, 1.500, 1.000, 900, 800, 700, 600, 500, 400, 350, 300, 250, 200, 150, 140, 130, 120, 110, 100, 90, 80, 70, 60, 50, 40, 30, 25, 20 or preferably less than 15 ppm chrome.
- the invention concerns a construction element, wherein said construction element comprises less than 50.000 ppm cobalt, less than 40.000, 30.000, 20.000, 10.000, 5.000, 2.500, 2.000, 1.500, 1.000, 900, 800, 700, 600, 500, 400, 350, 300, 250, 200, 150, 140, 130, 120, 110, 100, 90, 80, 70, 60, 50, 40, 30, 25, 20 or preferably less than 15 ppm cobalt.
- the invention concerns a construction element, wherein said construction element comprises less than 50.000 ppm iron, less than 40.000, 30.000, 20.000, 15.000, 10.000, 5.000, 2.500, 2.000, 1.500 or preferably less than 1000 ppm iron.
- the invention concerns a construction element, wherein said construction element comprises less than 50.000 ppm mercury less than 40.000, 30.000, 20.000, 10.000, 5.000, 2.500, 2.000, 1.500, 1.000, 900, 800, 700, 600, 500, 400, 350, 300, 250, 200, 150, 140, 130, 120, 110, 100, 90, 80, 70, 60, 50, 40, 30, 25, 20 or preferably less than 15 ppm mercury.
- the invention concerns a construction element, wherein said construction element comprises less than 50.000 ppm manganese less than 40.000, 30.000, 20.000, 10.000, 5.000, 2.500, 2.000, 1.500, 1.000, 900, 800, 700, 600, 500, 400, 350, 300, 250, 200, 150, 140, 130, 120, 110, 100, 90, 80, 70, 60, 50, 40, 30, 25, 20 or preferably less than 15 ppm manganese.
- the invention concerns a construction element, wherein said construction element comprises less than 50.000 ppm molybdenum less than 40.000, 30.000, 20.000, 10.000, 5.000, 2.500, 2.000, 1.500, 1.000, 900, 800, 700, 600, 500, 400, 350, 300, 250, 200, 150, 140, 130, 120, 110, 100, 90, 80, 70, 60, 50, 40, 30, 25, 20 or preferably less than 15 ppm molybdenum.
- the invention concerns a construction element, wherein said construction element comprises less than 50.000 ppm nickel less than 40.000, 30.000, 20.000, 10.000, 5.000, 2.500, 2.000, 1.500, 1.000, 900, 800, 700, 600, 500, 400, 350, 300, 250, 200, 150, 140, 130, 120, 110, 100, 90, 80, 70, 60, 50, 40, 30, 25, 20 or preferably less than 15 ppm nickel.
- the invention concerns a construction element, wherein said element comprises 1 – 70 % w/w purified fly ash, 5 – 65, 10 – 60, 15 – 55, 20 – 50, 25 – 50, 30 – 45, 35 – 45, 35 – 40 or about 40 %w/w purified fly ash.
- the invention concerns a construction element, wherein said element comprises 1 – 50 % w/w calcium sulfate, 5 – 45, 10 – 40, 15 – 35, 20 – 35, 20 – 30, 25 – 30 or about 30 % w/w calcium sulfate.
- the invention concerns a construction element, wherein said element comprises 1 – 50 % w/w recycled calcium sulfate dehydrate, 5 – 45, 10 – 40, 15 – 35, 20 – 30, 20 – 25 or about 20 % w/w recycled calcium sulfate dehydrate.
- the invention concerns a construction element, wherein said element comprises 0.1 – 4 % w/w water, 0.5 – 3.5 %, 0.5 – 3% or about 0.5 – 2.5 % w/w water.
- the invention concerns a construction element, wherein said element comprises raw hemihydrate; and/or is made with raw hemihydrate, hemihydrate or calcium sulfate hemihydrate.
- the invention concerns a construction element comprising gypsum/calcium sulfate. Hemihydrate or calcium sulfate hemihydrate is used during manufacture and transformed into gypsum during processing, by hydration.
- the invention concerns a construction element, wherein said element comprises a foaming agent.
- the invention concerns a construction element, wherein said element comprises 1 – 35 % w/w foaming agent, 2.5 – 32.5, 5 – 30, 7.5 – 27.5, 10 – 25, 12.5 – 22.5, 15 – 20 or about 17.5 % w/w foaming agent.
- the invention concerns a construction element, wherein said element comprises ⁇ 1% foaming agent. Foaming agent and a part of the mixing water and air may be used to create a foam. This regenerated foam is then added into the mixer together with gypsum binder, water and other additives.
- the invention concerns a construction element, wherein said element comprises fibres.
- the invention concerns a construction element, wherein said fibres are selected among hemp fibres, paper fibres, recycled paper fibres and cellulosic fibres.
- P452859PC00 13 According to an embodiment, the invention concerns a construction element, wherein said fibres are glass fibers. According to an embodiment, the invention concerns a construction element, wherein said element comprises 1 – 35 % w/w fibres, 2.5 – 32.5, 5 – 30, 7.5 – 27.5, 10 – 25, 10 – 22.5, 10 – 20, 10 – 15, 10 – 12.5 or about 10 % w/w fibres, preferably wherein said fibres are hemp fibres.
- the invention concerns a constructions element, wherein said element comprises 0.1 – 5 % w/w fibers. According to an embodiment, the invention concerns a constructions element, wherein said element comprises 0.01 – 10 % w/w fibers, 0.05 – 7 % w/w or preferably about 0.07 – 6 % w/w fibers. According to an embodiment, the invention concerns a construction element, wherein said purified fly ash is obtained from fly ash by a process comprising the following steps: a. Separation b. Rinsing; and c. precipitation.
- the invention concerns a construction element, wherein said construction element has a thickness of about 1 – 35 mm, 5 – 30 mm or preferably about 10 – 25 mm.
- the invention concerns a construction element, wherein said construction element has a thickness of about 10 mm, about 12,5 mm, about 15 mm or about 18 mm.
- P452859PC00 14 According to an embodiment, the invention concerns a construction element, wherein said element has a thermal conductivity factor of less than 0.090 [W/mK], less than 0.085, less than 0.080 or preferably less than 0.075 [W/mK].
- the invention concerns a construction element, wherein said element has a flexural strength of at least 100 Newton, at least 150, 200, 250, 300, 350, 400, 450 or preferably at least 500 Newton in transverse direction.
- the invention concerns a construction element, wherein said element has a flexural strength of at least 100 Newton, 200, 250, 300, 350, 400, 450, 500, 550, 600, 650, 700, 750, 800, 850, 900, 950 or preferably at least 1000 Newton in longitudinal direction.
- flexural strength flexural breaking load
- the flexural breaking load may be used to describe the flexural strength of plasterboards.
- the invention concerns a construction element, wherein said element comprises about 40 % w/w purified fly ash, about 10 % w/w CaSO4, about 20 % w/w recycled CaSO4 ⁇ 2H2O, about 10 % w/w fiber, about 17.5 % w/w foaming agent and about 2.5 % w/w water.
- the invention concerns a process for producing a construction element according to the invention, said process comprising the steps of d. Providing a fly ash material; P452859PC00 15 e.
- Pre-treatment of said fly ash material thereby providing a purified fly ash composition, a metal containing fraction and a saltwater solution; f. Providing a gypsum binder; g. Combining said stabilized fly ash composition and said gypsum binder into a gypsum binder slurry; h. Compressing said gypsum binder slurry into a flat material which is cutted and dried into said construction element.
- a gypsum binder/basanite/calcium sulfate hemihydrate may be used. Gypsum is formed during hydration of gypsum binder.
- Purified fly ash may be understood as treated fly ash, wherein said fly ash is treated to remove one or more unwanted components.
- the accompanying examples are provided to explain rather than limit the present invention. When describing the embodiments of the present invention, the combinations of all possible embodiments have not been explicitly described. Nevertheless, the mere fact that certain measures are recited in mutually different dependent claims or described in different embodiments does not indicate that a combination of these measures cannot be used to advantage. The present invention envisages all possible combinations and permutations of the described embodiments.
- Example 1 – pretreatment of fly ash A processes technology is used for the fly ash to eliminate the substances that are responsible for the fly ash's current classification as a hazardous waste, accordance with the waste landfill directive ⁇ s acceptance criteria 2003/33/EC.
- the fly-ash processes technology treatment goes through several stages, such as separation, rinsing, and precipitation.
- the stages separate hazardous waste from none-hazardous waste.
- the treated fly ash is extended from hazardous waste to non-hazardous waste in accordance with landfill acceptance requirements, the treated fly ash can be deposited at local landfill. Additionally, the treated fly is designated as non-hazardous in accordance with CLP regulations, allowing it10 to be recycled in items like construction materials.
- the pre-treated fly ash comprises the materials provided in Table 2, and is a commercially available product purchased from HaloSep AB. 15 Table 2 Inorganic compounds Unit DL. Density [g/cm 3 ] Phosphor, total 5000 mg/kg ts.
- the added water can vary between 20 – 45 %.
- exemplary combination of the materials of the gypsum slurry is provided below: - Purified fly ash, 40 % w/w - CaSO4, 10 % w/w - Recycled Gypsum (Dihydrat), 20 % w/w - Fiber, 10 % w/w - Foaming agent, 17.5 % w/w - Water, 2.5 % w/w.
- the gypsum slurry may also be without CaSO4 and/or with 0.1 – 5 % w/w fiber and/or ⁇ 1% foaming agent.
- the gypsum slurry is often applied on a lower-facing sheet that advances continuously, such as kraft paper.
- Bio-based fibers are frequently incorporated into the slurry to reinforce the gypsum core after it has dried or been set.
- Bio-based materials and additives are added to the slurry to strengthen the bond between the facing and the gypsum core.
- P452859PC00 19 The gypsum is covered with an upper face layer that advances continually.
- the upper and bottom facing sheets' edges are then adhered to one another, possible using suitable glue.
- Gypsum slurry and facing sheets are moved between parallel upper and lower forming plates or rolls to create a sandwich of unset gypsum that is integrated and continuous throughout the composite.
- composition of the invention may comprise the following materials: Table 4 Input Ratio Purified/rinsed/processed ash 1 – 70 % Calcium sulfate phases 1 - 50 % Water 1 - 45 % Bio-based fibers (e.g.
- the construction element according to the invention may have a thickness of between 4 -25 mm. After slicing, the composite materials are put into drying ovens or kilns to remove any remaining water. The composites are blasted with hot drying air inside the drying ovens. Gypsum composites that have dried in ovens are taken out, their ends are clipped, and they are then cut to the necessary sizes to create final gypsum boards. The panels may be used in the building industry in the shape of sheets.
- the mechanical qualities of the gypsum board are ideal and can withstand forces during production, delivery, and installation, and use flexural strength, moreover, the boards are light and fire-resistance.
- the water content may be between 0.5 – 2.5 %
- the production method described about is more energy sufficient than traditional production methods, inter alia, due to the restricted use of binder, hence less need for calcination.
- the construction elements described herein require less water, as ash requires less water than traditional calcined slurry mixture.
- Bassanite may be used as a binder.
- Starch may be used as an additive that improves the cohesion of the microstructure and the bond between gypsum core and cover sheets.
- Binders may be modified starch or anhydrite binders. Examples of modified starches being starch ethers and starch esters.
- Example 3 - gypsum boards As exemplary combination of the materials of an embodiment of the invention is provided below: 1. Fly ash: 0,1-80 % 2. Hydratable calcium sulphate/ gypsum binder 1-90% 3. Recycled gypsum binder 1-50% 4. Slaked lime Ca(OH): 1-20% 5. Clay:1-60% 6. Additives: 1-10% 7. Water: 1-50% P452859PC00 21 8.
- Fire line additives 1-40% minerals additive such as kaolin, illite, quartz, dolomite, micronized or unexpanded vermiculite, hydrated alumina or and boric acid, and such mineral adittives
- LC3 cement 1-80% 10.
- Fibers additives 1-30% Plaster boards Thickness The plaster boards thickness may be ranging from 10-25 mm, providing versatility for various applications.
- Finess of materials The fly ash fineness ranges from 10- ⁇ m -2mm , ensuring a fine and uniform composition.
- Production/mixing process Utilizing a wet milling process, the production method ensures optimal blending of materials, enhancing the overall quality of the fly ash board.
- Activation of Fly ash through Fly ash drying, milling, burning, and particle size distribution adding activating materials and other practices.
- Ash Any rinsed fly ash or biobased fly ash undergoes a cleansing process or do not undergo cleansing process. The cleansed/ rinsed ash is transitioning from hazardous to non-hazardous classification, contributing to a safer and more sustainable production process.
- Activation of fly ash • Ash drying • Ash milling • Ash burning P452859PC00 22 • Ash particle size distribution • Or other activation methods
- Function Types of ash plasterboard material may have the functions of coverage of a surface in a building, structural support, noise insulation, water resistance and fire resistance.
- the aesthetic type may have cork material 1-5 mm size: 10-60% Density:
- the board can have a density between: 400-900kg or more /m’3 Production stage First, the gypsum binder is heated and dried to add water, fibres, and the additives. After that, the gypsum binder faced with the paper to manufacture the gypsum binder board. The final step is to heat and dry the board creating the final product.
- Example 4 – Ash from the combustion of wood pellets Component Results Unit DL Method Dry matter 63 % 1 DS 204 EN 13656 Phosphorus (P), total 960 mg/kg ts. 100 ICP-OES DS 259:2003, SM 3120 Lead (Pb) 5 mg/kg ts.
- MS M 0319 (MST MB1 Sum of 9 PAH's (Poly 2008) GC- Aromatic Hydrocarbons) > 470 mg/kg ts.
- MS Example 5 Ash from burning seed husks (residues from grain husks) Sample 1: 5 Sample size: 1484,0 g.
Landscapes
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Abstract
The present invention is related to a gypsum board used in building constructions as well as a method for producing it. More specifically, it relates to a gypsum board comprising purified/processed/rinsed ash, that has improved fire resistance due to a low thermal conductivity factor. The gypsum board may be 100 percent bio-based and environmentally beneficial. Additionally, the present invention is related to a construction element comprising gypsum and purified fly ash, wherein said purified fly ash comprises less than 20.000 ppm heavy metals, and wherein said purified fly ash comprises 100.000 - 200.000 ppm Silicon, as well as a process for producing said construction element..
Description
P452859PC00 1 New sustainable plasterboards The present invention is related to a gypsum board used in building constructions as well as a method for producing it. More specifically, it relates to a gypsum board comprising purified/processed/rinsed ash, that has improved fire resistance due to a low thermal conductivity factor. The gypsum board may be 100 percent bio-based and environmentally beneficial. Background Gypsum is a kind of hydrating material. Part or all of its water can evaporate when it is heated to the right temperature, transforming it into plaster of gypsum. When the gypsum is combined with water, it transforms into dihydrate, which is condensed and hardened gypsum. The technological foundation of the gypsum composed of two processes known as hardening and hydration. Gypsum is typically heated, dehydrated, and converted to hemihydrate before being milled into gypsum powder, which is the process of dehydration and hardness of gypsum, in order to produce gypsum gelled material. In contrast, the hydrating process of gypsum results in the creation of dihydrate gypsum (solid) when hemi-hydrate gypsum (powder) absorbs water. Ramesh C. Joshi et al, “Properties of gypsum wallboards containing fly ash”, Journal of Materials in Civil Engineering, Vol.4, No.2, May 1992, appears to describe properties of gypsum wallboards containing fly ash. US4403006A appears to describe a gypsum board consisting essentially of a monolithic cellular core of set gypsum and a fiberous cover sheet, the gypsum core comprises coal fly ash in an amount of about 1-20 % by weight (abstract), preferably in an amount of 5% by weight (column 5, l.15-16). The coal fly ashes are described to comprise 1.6-28 % calcium oxide, 3.9-46 % ion oxide, 13 to about 27% aluminium oxide and 33-66% silicon oxide
P452859PC00 2 (column 4, l.27-30). The purpose of adding fly ash to the gypsum board appears to be described as sag reduction. CN107032732A appears to describe a gypsum board comprising 7-9 parts of fly ash (claim 1). According to CN107032732A the plaster board of the invention has the advantages of compression strength, static bending strength, large screw holding capability and breaking resistant elasticity modulus, low heat conductivity coefficient, good antibacterial property, anti- electromagnetic radiation property and anti-friction property. Additionally it is stated that the raw material of the plasterboard are safe and reliable, environment-friendly and easily-accessible, and that the cost is low (abstract). Example 1 describes a manufacture temperature of 55 °C, example 2 describes a manufacture temperature of 65 °C, example 3 describes a manufacture temperature of 60°C. CN114380552 appears to describe a concrete wallboard comprising 200-300 parts of fly ash (claim 1). The fly ash appear to be subjected to pretreatment, which may comprise decarbonizing and desulfurization treatment. CN110903070A appears to describe a partition board comprising phosphogypsum and 16-20 parts by weight of fly ash (claim 1). EP0344430A2 appears to describe a process for producing a flue gas desulfurization gypsum plaster wherein the inert fillers may comprise fly ash (claim 1 + claim 6). Summary of the invention The present invention is related to a new product with a difference in material composition compared to other construction material. According to an embodiment, the construction material innovatively replaces a significant portion of gypsum binder with ash. This substantial shift in material
P452859PC00 3 composition introduces an important variation in the environmental profile of the two products. This change may have far-reaching implications throughout the entire product life cycle, from raw material extraction to disposal. The composition and production parameters of the fly ash board are further optimized to achieve enhanced performance and broader application potential. By utilizing ash would decrease the longer pollute landfills. Producing plasterboards needs significant energy, however the fly ash qualities can save firing energy and conserve gypsum material, conserving natural resources. There is a need for a sustainable lightweight construction element, with a low carbon footprint, wherein said construction element is safe for humans. During manufacturing of traditional plasterboards, a very high temperature is usually required, resulting in a high carbon footprint. Traditional plasterboards comprises a high amount of gypsum. There is a need for a plasterboard comprising less gypsum and cement, and more recyclable material, and thus constitute a more sustainable construction element. There is a need for a plasterboard being safe for humans, thus being fireproof and not comprising any material harmful for human health. Further, there is a need for a construction element improving ventilations of buildings, and having good sound absorption. Incineration of waste generates fly ash containing heavy metals, chlorides and contaminated acid. Fly ash are usually deposited, resulting in contamination. There is a need for a sustainable lightweight construction element, with a low carbon footprint, wherein said construction element does not comprise heavy metals, chlorides and contaminated acid. Properties of the different structural types of calcium sulfate phases, gypsum, basanite and anhydrite are listed in table 1.
P452859PC00 4 Table 1 Phase Common Formula Stability Remarks name(s) range Gypsum Selenite, CaSO4 + <60-90 oC Formed alabaster 2H2O in air spontaneously <40-60 oC upon in H2O precipitation from solution under ambient conditions Bassanite Hemihydrate α-CaSO4 + Metastable Formed by 0.5H2O in H2O heating gypsum in air at >60-90 oC; readily rehydrates to gypsum Plaster of β-CaSO4 + Metastable Formed by Paris 0.5H2O in H2O heating gypsum in water at >90 oC; readily rehydrates to gypsum Anhydrite AIII, Soluble У-CaSO4 Metastable Formed by anhydrite in H2O and heating air gypsum in air at >100-130 oC; readily rehydrates to
P452859PC00 5 hemihydrate or gypsum AII, Insoluble β-CaSO4 Stable Natural anhydrite <~1200 oC anhydrite formed at the Earth’s surface AI α-CaSO4 Stable Converts >~1200 oC immediately into β-CaSO4 on cooling below ~1200 oC As seen in table 1, the temperature transforming value varies between 60 – 130 C°, depending on the desired calcium sulfate phase. The temperature input is necessary to transfer the gypsum phase into the 5 desired calcium sulfate phase, for instance, bassanite and anhydrite. The bassanite as, hemihydrate and plaster of paris are important because they have a semi-amorphous structure. Semi-amorphous structures increase the mechanical properties of the gypsum as a final product since the semi- amorphous structure works as an active binding material. 10 Fly-ash is known for their good mechanical properties, since the fly-ash exists as an semi-amorphous silicon structure, hence is an active binding material. The construction element according to the invention comprises purified fly- ash comprising silicium (Si) in an amount of about 139.000 – 140.500 mg/kg. 15 Thus, less basanite and anhydrite are required, less energy for heating is required and thus the construction element according to the invention is more environmentally friendly than traditional plaster boards.
P452859PC00 6 According to an aspect, the invention concerns a construction element comprising gypsum and purified fly ash, wherein said purified fly ash comprises less than 35.000 ppm heavy metals, and wherein said purified fly ash comprises 100.000 – 200.000 ppm Silicon. According to another aspect, the invention concerns a process for producing a construction element according to the invention, said process comprising the steps of: a. Providing a fly ash material; b. Pre-treatment of said fly ash material, thereby providing a purified fly ash composition, a metal containing fraction and a saltwater solution; c. Providing a gypsum binder; d. Combining said stabilized fly ash composition and said gypsum binder into a gypsum binder slurry; e. Compressing said gypsum binder slurry into a flat material which is cutted and dried into said construction element. Detailed description of the invention The invention will hereafter be described by way of the following non-limiting items. According to an embodiment, the invention concerns a construction element comprising gypsum and purified fly ash, wherein said purified fly ash comprises less than 35.000 ppm heavy metals, and wherein said purified fly ash comprises 100.000 – 200.000 ppm Silicon. Gypsum may be defined as a soft sulfate mineral composed of calcium sulfate dihydrate, with the chemical formula CaSO 4·2H2O. Fly ash is the fine powder formed from the mineral matter in coal, consisting of the non-combustible matter in coal and a small amount of carbon that
P452859PC00 7 remains. Fly ash are the particulates that are driven out of coal-fired boilers together with the flue gases. The term heavy metal may refer to any metallic chemical element that has a relatively high density (e.g. greater than 5 g cm-3) and is toxic or poisonous at low concentrations. Example of heavy metals include mercury (Hg), cadmium (Cd), arsenic (As), chromium (Cr), thallium (TI) or lead (Pb). According to an embodiment, the invention concerns a construction element, wherein said purified fly ash comprises less than 30.000 ppm heavy metals, less than 29.000, 28.000, 27.000, 26.000, 25.000, 24.000, 23.000, 22.000, 21.000, 20.000, 19.500, 19.000, 18.500, 18.000, 17.500 or preferably less than 17.000 ppm heavy metals. According to an embodiment, the invention concerns a construction element, wherein said purified fly ash comprises 110.000 – 190.000 ppm silicon, 120.000 – 180.000, 130.000 – 170.000, 140.000 – 160.000, 140.000 – 150.000 or about 139.000 – 140.500 ppm silicon. According to an embodiment, the invention concerns a construction element, wherein said construction element comprises 110.000 – 190.000 ppm silicon, 120.000 – 180.000, 130.000 – 170.000, 140.000 – 160.000, 140.000 – 150.000 or about 139.000 – 140.500 ppm silicon. According to an embodiment, the invention concerns a construction element comprising gypsum and purified fly ash, wherein said purified fly ash comprises less than 20.000 ppm heavy metals, and wherein said purified fly ash comprises about 139.000 – 140.500 ppm Silicon. According to an embodiment, the invention concerns a construction element, wherein said construction element is a plasterboard.
P452859PC00 8 According to an embodiment, the invention concerns a construction element, wherein said purified fly ash has a neutral pH value, preferably said pH values is 6 – 8, 6.5 – 7.5 or about 7. According to an embodiment, the invention concerns a construction element, wherein said purified fly ash has a thermal conductivity factor of 0.050 – 0.120 [W/mK], 0.060 – 0.110, 0.070 – 0.100, or preferably 0.080 – 0.090 [W/mK]. According to an embodiment, the invention concerns a construction element, wherein said purified fly ash comprises Phosphor, Fluoride, Chloride, Silicon, SiO, SiO2, Al2O, Al2O3, Fe2O2, Fe2O3, FeO3, MgO, Na2O, K2O, SO3, LOI, CeO, MgO and/or CaO. According to an embodiment, the invention concerns a construction element wherein said heavy metals has a density greater than 5 g/cm3. According to an embodiment, the invention concerns a construction element, wherein said heavy metals are selected among antimony (Sb), Arsenic (As), Lead (Pb), Cadmium (Cd), Chrome (Cr), Cobalt (Co), Iron (Fe), Mercury (Hg), Manganese (Mn), Molybdenum (Mo), Nickle (Ni) and combinations thereof. According to an embodiment, the invention concerns a construction element, wherein said heavy metals are selected among Mercury (Hg), Arsenic (As), Lead (Pb), Chrome (Cr) and combinations thereof. According to an embodiment, the invention concerns a construction element, wherein said construction element comprises less than 50.000 ppm chloride, less than 40.000, 30.000, 20.000, 15.000, 10.000, 5.000, 2.500, 2.000, 1.500 or preferably less than 1000 ppm chloride.
P452859PC00 9 According to an embodiment, the invention concerns a construction element, wherein said construction element comprises less than 100.000 ppm aluminium, less than 90.000, 80.000, 70.000, 60.000, 50.000, 40.000, 30.000, 20.000, 15.000, 10.000, 5.000, 2.500, 2.000, 1.500 or preferably less than 1000 ppm aluminium. According to an embodiment, the invention concerns a construction element, wherein said construction element comprises less than 50.000 ppm antimony, less than 40.000, 30.000, 20.000, 15.000, 10.000, 5.000, 2.500, 2.000, 1.500 or preferably less than 1000 ppm antimony. According to an embodiment, the invention concerns a construction element, wherein said construction element comprises less than 50.000 ppm arsenic, less than 40.000, 30.000, 20.000, 10.000, 5.000, 2.500, 2.000, 1.500, 1.000, 900, 800, 700, 600, 500, 400, 350, 300, 250, 200, 150, 140, 130, 120, 110, 100, 90, 80, 70, 60, 50, 40, 30, 25, 20 or preferably less than 15 ppm arsenic. According to an embodiment, the invention concerns a construction element, wherein said construction element comprises less than 50.000 ppm lead, less than 40.000, 30.000, 20.000, 15.000, 10.000, 5.000, 2.500, 2.000, 1.500 or preferably less than 1000 ppm lead. According to an embodiment, the invention concerns a construction element, wherein said construction element comprises less than 50.000 ppm cadmium, less than 40.000, 30.000, 20.000, 10.000, 5.000, 2.500, 2.000, 1.500, 1.000, 900, 800, 700, 600, 500, 400, 350, 300, 250, 200, 150, 140, 130, 120, 110, 100, 90, 80, 70, 60, 50, 40, 30, 25, 20 or preferably less than 15 ppm cadmium. According to an embodiment, the invention concerns a construction element, wherein said construction element comprises less than 50.000 ppm chrome,
P452859PC00 10 less than 40.000, 30.000, 20.000, 10.000, 5.000, 2.500, 2.000, 1.500, 1.000, 900, 800, 700, 600, 500, 400, 350, 300, 250, 200, 150, 140, 130, 120, 110, 100, 90, 80, 70, 60, 50, 40, 30, 25, 20 or preferably less than 15 ppm chrome. According to an embodiment, the invention concerns a construction element, wherein said construction element comprises less than 50.000 ppm cobalt, less than 40.000, 30.000, 20.000, 10.000, 5.000, 2.500, 2.000, 1.500, 1.000, 900, 800, 700, 600, 500, 400, 350, 300, 250, 200, 150, 140, 130, 120, 110, 100, 90, 80, 70, 60, 50, 40, 30, 25, 20 or preferably less than 15 ppm cobalt. According to an embodiment, the invention concerns a construction element, wherein said construction element comprises less than 50.000 ppm iron, less than 40.000, 30.000, 20.000, 15.000, 10.000, 5.000, 2.500, 2.000, 1.500 or preferably less than 1000 ppm iron. According to an embodiment, the invention concerns a construction element, wherein said construction element comprises less than 50.000 ppm mercury less than 40.000, 30.000, 20.000, 10.000, 5.000, 2.500, 2.000, 1.500, 1.000, 900, 800, 700, 600, 500, 400, 350, 300, 250, 200, 150, 140, 130, 120, 110, 100, 90, 80, 70, 60, 50, 40, 30, 25, 20 or preferably less than 15 ppm mercury. According to an embodiment, the invention concerns a construction element, wherein said construction element comprises less than 50.000 ppm manganese less than 40.000, 30.000, 20.000, 10.000, 5.000, 2.500, 2.000, 1.500, 1.000, 900, 800, 700, 600, 500, 400, 350, 300, 250, 200, 150, 140, 130, 120, 110, 100, 90, 80, 70, 60, 50, 40, 30, 25, 20 or preferably less than 15 ppm manganese.
P452859PC00 11 According to an embodiment, the invention concerns a construction element, wherein said construction element comprises less than 50.000 ppm molybdenum less than 40.000, 30.000, 20.000, 10.000, 5.000, 2.500, 2.000, 1.500, 1.000, 900, 800, 700, 600, 500, 400, 350, 300, 250, 200, 150, 140, 130, 120, 110, 100, 90, 80, 70, 60, 50, 40, 30, 25, 20 or preferably less than 15 ppm molybdenum. According to an embodiment, the invention concerns a construction element, wherein said construction element comprises less than 50.000 ppm nickel less than 40.000, 30.000, 20.000, 10.000, 5.000, 2.500, 2.000, 1.500, 1.000, 900, 800, 700, 600, 500, 400, 350, 300, 250, 200, 150, 140, 130, 120, 110, 100, 90, 80, 70, 60, 50, 40, 30, 25, 20 or preferably less than 15 ppm nickel. According to an embodiment, the invention concerns a construction element, wherein said element comprises 1 – 70 % w/w purified fly ash, 5 – 65, 10 – 60, 15 – 55, 20 – 50, 25 – 50, 30 – 45, 35 – 45, 35 – 40 or about 40 %w/w purified fly ash. According to an embodiment, the invention concerns a construction element, wherein said element comprises 1 – 50 % w/w calcium sulfate, 5 – 45, 10 – 40, 15 – 35, 20 – 35, 20 – 30, 25 – 30 or about 30 % w/w calcium sulfate. According to an embodiment, the invention concerns a construction element, wherein said element comprises 1 – 50 % w/w recycled calcium sulfate dehydrate, 5 – 45, 10 – 40, 15 – 35, 20 – 30, 20 – 25 or about 20 % w/w recycled calcium sulfate dehydrate. According to an embodiment, the invention concerns a construction element, wherein said element comprises 0.1 – 4 % w/w water, 0.5 – 3.5 %, 0.5 – 3% or about 0.5 – 2.5 % w/w water.
P452859PC00 12 According to an embodiment, the invention concerns a construction element, wherein said element comprises raw hemihydrate; and/or is made with raw hemihydrate, hemihydrate or calcium sulfate hemihydrate. According to an embodiment, the invention concerns a construction element comprising gypsum/calcium sulfate. Hemihydrate or calcium sulfate hemihydrate is used during manufacture and transformed into gypsum during processing, by hydration. According to an embodiment, the invention concerns a construction element, wherein said element comprises a foaming agent. According to an embodiment, the invention concerns a construction element, wherein said element comprises 1 – 35 % w/w foaming agent, 2.5 – 32.5, 5 – 30, 7.5 – 27.5, 10 – 25, 12.5 – 22.5, 15 – 20 or about 17.5 % w/w foaming agent. According to an embodiment, the invention concerns a construction element, wherein said element comprises ≤1% foaming agent. Foaming agent and a part of the mixing water and air may be used to create a foam. This regenerated foam is then added into the mixer together with gypsum binder, water and other additives. According to an embodiment, the invention concerns a construction element, wherein said element comprises fibres. According to an embodiment, the invention concerns a construction element, wherein said fibres are selected among hemp fibres, paper fibres, recycled paper fibres and cellulosic fibres.
P452859PC00 13 According to an embodiment, the invention concerns a construction element, wherein said fibres are glass fibers. According to an embodiment, the invention concerns a construction element, wherein said element comprises 1 – 35 % w/w fibres, 2.5 – 32.5, 5 – 30, 7.5 – 27.5, 10 – 25, 10 – 22.5, 10 – 20, 10 – 15, 10 – 12.5 or about 10 % w/w fibres, preferably wherein said fibres are hemp fibres. According to an embodiment, the invention concerns a constructions element, wherein said element comprises 0.1 – 5 % w/w fibers. According to an embodiment, the invention concerns a constructions element, wherein said element comprises 0.01 – 10 % w/w fibers, 0.05 – 7 % w/w or preferably about 0.07 – 6 % w/w fibers. According to an embodiment, the invention concerns a construction element, wherein said purified fly ash is obtained from fly ash by a process comprising the following steps: a. Separation b. Rinsing; and c. precipitation. According to an embodiment, the invention concerns a construction element, wherein said construction element has a thickness of about 1 – 35 mm, 5 – 30 mm or preferably about 10 – 25 mm. According to an embodiment, the invention concerns a construction element, wherein said construction element has a thickness of about 10 mm, about 12,5 mm, about 15 mm or about 18 mm.
P452859PC00 14 According to an embodiment, the invention concerns a construction element, wherein said element has a thermal conductivity factor of less than 0.090 [W/mK], less than 0.085, less than 0.080 or preferably less than 0.075 [W/mK]. According to an embodiment, the invention concerns a construction element, wherein said element has a flexural strength of at least 100 Newton, at least 150, 200, 250, 300, 350, 400, 450 or preferably at least 500 Newton in transverse direction. According to an embodiment, the invention concerns a construction element, wherein said element has a flexural strength of at least 100 Newton, 200, 250, 300, 350, 400, 450, 500, 550, 600, 650, 700, 750, 800, 850, 900, 950 or preferably at least 1000 Newton in longitudinal direction. Determination of flexural strength (flexural breaking load): The flexural breaking load may be used to describe the flexural strength of plasterboards. Samples (400 x 300 mm) cut off the boards must withstand a load that is raised gradually until failure occurs According to an embodiment, the invention concerns a construction element, wherein said element comprises about 40 % w/w purified fly ash, about 10 % w/w CaSO4, about 20 % w/w recycled CaSO₄·2H₂O, about 10 % w/w fiber, about 17.5 % w/w foaming agent and about 2.5 % w/w water. According to an embodiment, the invention concerns a process for producing a construction element according to the invention, said process comprising the steps of d. Providing a fly ash material;
P452859PC00 15 e. Pre-treatment of said fly ash material, thereby providing a purified fly ash composition, a metal containing fraction and a saltwater solution; f. Providing a gypsum binder; g. Combining said stabilized fly ash composition and said gypsum binder into a gypsum binder slurry; h. Compressing said gypsum binder slurry into a flat material which is cutted and dried into said construction element. During the process of manufacturing a construction element, a gypsum binder/basanite/calcium sulfate hemihydrate may be used. Gypsum is formed during hydration of gypsum binder. Purified fly ash may be understood as treated fly ash, wherein said fly ash is treated to remove one or more unwanted components. The accompanying examples are provided to explain rather than limit the present invention. When describing the embodiments of the present invention, the combinations of all possible embodiments have not been explicitly described. Nevertheless, the mere fact that certain measures are recited in mutually different dependent claims or described in different embodiments does not indicate that a combination of these measures cannot be used to advantage. The present invention envisages all possible combinations and permutations of the described embodiments. Example 1 – pretreatment of fly ash A processes technology is used for the fly ash to eliminate the substances that are responsible for the fly ash's current classification as a hazardous waste, accordance with the waste landfill directive´s acceptance criteria 2003/33/EC.
P452859PC00 16 The fly-ash processes technology treatment goes through several stages, such as separation, rinsing, and precipitation. The stages separate hazardous waste from none-hazardous waste. 5 The treated fly ash is extended from hazardous waste to non-hazardous waste in accordance with landfill acceptance requirements, the treated fly ash can be deposited at local landfill. Additionally, the treated fly is designated as non-hazardous in accordance with CLP regulations, allowing it10 to be recycled in items like construction materials. The pre-treated fly ash comprises the materials provided in Table 2, and is a commercially available product purchased from HaloSep AB. 15 Table 2 Inorganic compounds Unit DL. Density [g/cm3] Phosphor, total 5000 mg/kg ts. 100 1.8 Fluoride 3.9 mg/l 0.05 1.7 Fluoride, water soluble 29 mg/kg ts. 1 1.7 Chloride, water soluble 1200 mg/l 3.2 Chloride, water soluble 9000 mg/kg ts. 5 3.2 Metals Unit DL. Density [g/cm3] Aluminium (Al) 31000 mg/kg ts. 10 2.7 Antimony (Sb) 1100 mg/kg ts. 0.3 6.7 Arsenic (As) 280 mg/kg ts. 2 5.7 Barium (Ba) 480 mg/kg ts. 1 3.5
P452859PC00 17 Lead (Pb) 2000 mg/kg ts. 2 11.3 Cadmium (Cd) 72 mg/kg ts. 0.05 8.6 Calcium (Ca) 120000 mg/kg ts. 50 1.6 Chrome (Cr) 160 mg/kg ts. 1 7.2 Cobalt (Co) 20 mg/kg ts. 1 8.9 Iron (Fe) 12000 mg/kg ts. 5 11.3 Potassium (K) 7600 mg/kg ts. 50 0.9 Copper (Cu) 1200 mg/kg ts. 2 4.9 Mercury (Hg) 22 mg/kg ts. 0.01 13.6 Magnesium (Mg) 8100 mg/kg ts. 10 1.7 Manganese (Mn) 680 mg/kg ts. 1 7.2 Molybdenum (Mo) 13 mg/kg ts. 2 10.3 Sodium (Na) 5300 mg/kg ts. 5 1 Nickel (Ni) 52 mg/kg ts. 1 8.9 Selenium (Se 6.0 mg/kg ts. 0.3 4.8 Silicon (Si) 140000 mg/kg ts. 500 2.7 Strontium (Sr) 390 mg/kg ts. 10 2.6 Sulphur (S) 51000 mg/kg ts. 50 2 DL: Detection limit Table 3 shows the chemical constituent of two typical fly-ashes. 5 Table 3 Mass (%) Chemical constituent Fly-ash type 1 Fly-ash type 2 SiO2 48-57 46-52 Al2O 19-26 22-28 Fe2O3 5-6 4-5 CeO 12-13 12-14 MgO 1.2-1.5 0.9-1.2
P452859PC00 18 SO3 0.2-0.4 0.2-0.8 Na2O 3.2-5.3 2.1-2.4 K2O 1.0-1.5 0.9-1.1 Loss on ignition 0.5-0.8 0.2-0.8 Example 2 - gypsum boards Calcium sulfate phases, water, rinsed ash and other substances and additives, which may include set accelerators, waterproofing agents, reinforcing minerals, hemp fibers, dispersants and the like, are first mixed to create a gypsum slurry in a mechanical mixer. During production water is added into the dry powder recipe mixture. The added water can vary between 20 – 45 %. As exemplary combination of the materials of the gypsum slurry is provided below: - Purified fly ash, 40 % w/w - CaSO4, 10 % w/w - Recycled Gypsum (Dihydrat), 20 % w/w - Fiber, 10 % w/w - Foaming agent, 17.5 % w/w - Water, 2.5 % w/w. The gypsum slurry may also be without CaSO4 and/or with 0.1 – 5 % w/w fiber and/or ≤1% foaming agent. The gypsum slurry is often applied on a lower-facing sheet that advances continuously, such as kraft paper. Bio-based fibers are frequently incorporated into the slurry to reinforce the gypsum core after it has dried or been set. Bio-based materials and additives are added to the slurry to strengthen the bond between the facing and the gypsum core.
P452859PC00 19 The gypsum is covered with an upper face layer that advances continually. The upper and bottom facing sheets' edges are then adhered to one another, possible using suitable glue. Gypsum slurry and facing sheets are moved between parallel upper and lower forming plates or rolls to create a sandwich of unset gypsum that is integrated and continuous throughout the composite. For a few minutes, the composite is transported across a series of continuously moving belts and rollers, during which time the core starts to hydrate back to gypsum. The continuous composite is sliced into shorter lengths, or even individual boards or panels of a specific length, once the gypsum core has sufficiently hardened. The composition of the invention may comprise the following materials: Table 4 Input Ratio Purified/rinsed/processed ash 1 – 70 % Calcium sulfate phases 1 - 50 % Water 1 - 45 % Bio-based fibers (e.g. Hemp fiber) 1 - 35 % Additives and foaming agents 1 - 35 % Recycled gypsum - contains no paper 1 - 80 % The ratios of the materials can be adjusted and changed within the intervals shown in the table above. The construction element according to the invention may have a thickness of between 4 -25 mm. After slicing, the composite materials are put into drying ovens or kilns to remove any remaining water. The composites are blasted with hot drying air inside the drying ovens. Gypsum composites that have dried in ovens are taken out, their ends are clipped, and they are then cut to the necessary sizes to create final gypsum boards. The panels may be used in the building industry in the shape of sheets.
P452859PC00 20 The mechanical qualities of the gypsum board are ideal and can withstand forces during production, delivery, and installation, and use flexural strength, moreover, the boards are light and fire-resistance. When the product is in dry conditions, then the water content may be between 0.5 – 2.5 % The production method described about is more energy sufficient than traditional production methods, inter alia, due to the restricted use of binder, hence less need for calcination. The construction elements described herein require less water, as ash requires less water than traditional calcined slurry mixture. Bassanite may be used as a binder. Starch may be used as an additive that improves the cohesion of the microstructure and the bond between gypsum core and cover sheets. Binders may be modified starch or anhydrite binders. Examples of modified starches being starch ethers and starch esters. Example 3 - gypsum boards As exemplary combination of the materials of an embodiment of the invention is provided below: 1. Fly ash: 0,1-80 % 2. Hydratable calcium sulphate/ gypsum binder 1-90% 3. Recycled gypsum binder 1-50% 4. Slaked lime Ca(OH): 1-20% 5. Clay:1-60% 6. Additives: 1-10% 7. Water: 1-50%
P452859PC00 21 8. Fire line additives 1-40% ( minerals additive such as kaolin, illite, quartz, dolomite, micronized or unexpanded vermiculite, hydrated alumina or and boric acid, and such mineral adittives) 9. LC3 cement 1-80% 10. Fibers additives 1-30% Plaster boards Thickness The plaster boards thickness may be ranging from 10-25 mm, providing versatility for various applications. Finess of materials: The fly ash fineness ranges from 10- µm -2mm , ensuring a fine and uniform composition. Production/mixing process: Utilizing a wet milling process, the production method ensures optimal blending of materials, enhancing the overall quality of the fly ash board. Activation of Fly ash through Fly ash drying, milling, burning, and particle size distribution, adding activating materials and other practices. Ash Any rinsed fly ash or biobased fly ash undergoes a cleansing process or do not undergo cleansing process. The cleansed/ rinsed ash is transitioning from hazardous to non-hazardous classification, contributing to a safer and more sustainable production process. Activation of fly ash: • Ash drying • Ash milling • Ash burning
P452859PC00 22 • Ash particle size distribution • Or other activation methods Function: Types of ash plasterboard material may have the functions of coverage of a surface in a building, structural support, noise insulation, water resistance and fire resistance. The aesthetic type may have cork material 1-5 mm size: 10-60% Density: The board can have a density between: 400-900kg or more /m’3 Production stage First, the gypsum binder is heated and dried to add water, fibres, and the additives. After that, the gypsum binder faced with the paper to manufacture the gypsum binder board. The final step is to heat and dry the board creating the final product. Example 4 – Ash from the combustion of wood pellets Component Results Unit DL Method Dry matter 63 % 1 DS 204 EN 13656 Phosphorus (P), total 960 mg/kg ts. 100 ICP-OES DS 259:2003, SM 3120 Lead (Pb) 5 mg/kg ts. 2 ICP-OES DS Cadmium (Cd) 1,4 mg/kg ts. 0,03 259:2003,
P452859PC00 23 SM 3120 ICP-OES DS 259:2003, SM 3120 Chrome (Cr) 59 mg/kg ts. 1 ICP-OES DS 259:2003, SM 3120 Potassium (K) 6400 mg/kg ts. 50 ICP-OES SM 3112 Mercury (Hg) < 0.01 mg/kg ts. 0,01 CV-AAS DS 259:2003, SM 3120 Nickel (Ni) 65 mg/kg ts. 1 ICP-OES M 0319 (MST MB1 2008) GC- Acenaphthen > 33 mg/kg ts. 0,1 MS M 0319 (MST MB1 2008) GC- Fluorine > 6 mg/kg ts. 0,1 MS M 0319 (MST MB1 2008) GC- Phenanthrene > 130 mg/kg ts. 0,1 MS M 0319 Fluoranthene > 80 mg/kg ts. 0,1 (MST MB1
P452859PC00 24 2008) GC- MS M 0319 (MST MB1 2008) GC- Pyrene > 90 mg/kg ts. 0,1 MS M 0319 (MST MB1 2008) GC- Benzo(b+j+k)fluoranthene > 35 mg/kg ts. 0,1 MS M 0319 (MST MB1 2008) GC- Benzo(a)pyrene > 40 mg/kg ts. 0,1 MS M 0319 (MST MB1 2008) GC- Indeno(1,2,3-cd)pyrene > 15 mg/kg ts. 0,1 MS M 0319 (MST MB1 2008) GC- Benzo(g,h,i)perylene > 36 mg/kg ts. 0,1 MS M 0319 (MST MB1 Sum of 9 PAH's (Poly 2008) GC- Aromatic Hydrocarbons) > 470 mg/kg ts. MS Example 5 - Ash from burning seed husks (residues from grain husks) Sample 1: 5 Sample size: 1484,0 g.
P452859PC00 25 Upper calorific value: DS/EN ISO 18125: 4,88 kWh/ kg~ 4198 kcal/kg~ 17,58 MJ/kg Effective calorific value: 4,47 kWh/kg~ 3842 kcal/kg~ 16,09 MJ/kg Effective calorific value, water free sample: 5,15 kWh/kg~ 4432 kcal/kg~ 18,55 MJ/kg Effective calorific value, water free and ash free sample: 5,44 kWh/ kg~ 4680 kcal/kg~ 19,59 MJ/kg Sample 2: Sample size: 1487,4 g. Upper calorific value: DS/EN ISO 18125: 5,11 kWh/ kg~ 4398 kcal/kg~ 18,41 MJ/kg Effective calorific value: 4,70 kWh/kg~ 4040 kcal/kg~ 16,91 MJ/kg Effective calorific value, water free sample: 5,33 kWh/kg~ 4582 kcal/kg~ 19,18 MJ/kg Effective calorific value, water free and ash free sample: 5,52 kWh/ kg~ 4742 kcal/kg~ 19,86 MJ/kg Sample 3: Sample size: 1484,9 g. Upper calorific value: DS/EN ISO 18125: 4,92 kWh/ kg~ 4230 kcal/kg~ 17,71 MJ/kg Effective calorific value: 4,50 kWh/kg~ 3870 kcal/kg~ 16,20 MJ/kg Effective calorific value, water free sample: 5,24 kWh/kg~ 4504 kcal/kg~ 18,86 MJ/kg Effective calorific value, water free and ash free sample: 5,48 kWh/ kg~ 4714 kcal/kg~ 19,74 MJ/kg Each of the samples 1, 2 and 3 had the following values:
P452859PC00 26 Parameter Method repeatability Limit of limit, r reproducibility, R Water, total DS/EN ISO < 10 % water: - 18134-1: 2015 0,5 % w/w > 10 % water: 5 % of mean Water, sample DS/EN ISO 0,2 % w/w - 18134-3: 2015 Ash DS/EN ISO < 1 % ash: 0,1 % < 1 % ash: 0,2 % 18122:2015 w/w w/w > 1 % ash: 10 % > 1 % ash: 20 % of of mean mean Sulphur (S) DS/EN ISO < 0,05 % S: < 0,05 % S: 0,01 % 16994:2016 0,005 % w/w w/w > 0,05 % S: 10 > 0,05 % S: 20 % % of mean of mean DS/EN ISO < 0,10 % S: 16994:2016 0,005 % w/w < 0,15 % S: 0,03 % Kap.4.4 (Eltra > 0,10 % S: 5 % w/w CS-500) of mean > 0,15 % S: 20 % of mean Volatile DS/EN ISO 1 % of mean 3 % of mean components 18123:2015 Carbon (C) DS/EN ISO 0,5 % w/w 1,5 % w/w 16948:2015 Hydrogen (H) DS/EN ISO 0,25 % w/w 0,5 % w/w 16948:2015 Nitrogen (N) DS/EN ISO < 0,5 % N: 0,05 < 0,5 % N: 0,1 % 16948:2015 % w/w w/w > 0,5 % N: 10 % > 0,5 % N: 20 % of of mean mean
P452859PC00 27 Chlorine (Cl) DS/EN ISO < 0,05 % Cl: < 0,05 % Cl: 0,01 16994:2016 0,005 % w/w % w/w > 0,05 % Cl: 10 > 0,05 % Cl: 20 % % of mean of mean Chloride (Ci-) DS/EN ISO < 0,05 %Cl: < 0,05 % Cl·: 0,01 16995:2015 0,005 % w/w % w/w > 0,05 % Cl·: 10 > 0,05 % Cl·: 20 % % of mean of mean Calorific value DS/EN ISO 120 J/g 300 J/g 18125:2017 The melting DS/EN ISO 30 °C - process of the 21404:2020 ash Repeatability limit, r: Indicates the maximum deviation of a double determination made by the same person with the same equipment on the same test within a short period of time. 5 Limit of reproducibility, R: Indicates the maximum deviation for the mean of duplicate determinations made in two different laboratories on representative subsamples of the same sample 10 Sample 4 Sample size: 8727.1 g. Parameter Result Unit DL Reference +/ - Dry matter, TS 46 WW 0,02 DS 10 % 2D4:1980+drying at 105°C-g/kg Total Nitrogen 2800 mg/kg 1000 DS/EN 15 TS 16168:2012+M02 3
P452859PC00 28 Phosphorus, total 23000 mg/kg 100 DS/EN ISO 15 TS 11885:2009 + DS 259:2003 Lead 8,2 mg/kg 2 DS 11885:2009, 30 TS DS 259:2003, ICP+M021 Cadmium 1,7 mg/kg 0,03 DS 11885:2009, 30 TS DS 259:2003, ICP+M021 Chrome, Total 11 mg/kg 3 DS 11885:2009, 30 TS DS 259:2003, ICP+M021 Copper 170 mg/kg 10 DS 11885:2009, 30 TS DS 259:2003, ICP+M021 Nickel 6,5 mg/kg 1 DS 11885:2009, 30 TS DS 259:2003, ICP+M021 Zinc 200 mg/kg 10 DS 11885:2009, 30 TS DS 259:2003, ICP+M021 Lead phosphorus 350 mg/kg DS 11885:2009, related total P DS 259:2003, ICP Cadmium phosphorus 74 mg/kg DS 11885:2009, related total P DS 259:2003, ICP Nickel phosphorus 280 mg/kg DS 11885:2009, related total P DS 259:2003, ICP Mercury <0,03 mg/kg 0,03 DS 259:2003, 30 TS DS/EN ISO
P452859PC00 29 17852:2008+M02 1 Mercury phosphorus . mg/kg DS 259:2003, related total P DS/EN ISO 17852:2OO8 Acenaphthene <0,01 mg/kg 0,01 DS/lSO 30 TS 13859:2014+M06 7 Fluorine <0,01 mg/kg 0,01 DS/lSO 30 TS 13859:2014+M06 7 Phenanthrene 0,079 mg/kg 0,01 DS/lSO 30 TS 13859:2014+M06 7 Fluoranthene 0,15 mg/kg 0,01 DS/lSO 30 TS 13859:2014+M06 7 Pyrene 0,15 mg/kg 0,01 DS/lSO 30 TS 13859:2014+M06 7 Benz(b+j+k)fluoranthen 0,54 mg/kg 0,01 DS/lSO 30 e TS 13859:2014+M06 7 Benzo(a)pyrene 0,084 mg/kg 0,01 DS/lSO 30 TS 13859:2014+M06 7 Indeno(1,2,3-cd)pyrene 0,10 mg/kg 0,01 DS/lSO 30 TS 13859:2014+M06 7
P452859PC00 30 Dibenz(a,h)anthracene <0,01 mg/kg 0,01 DS/lSO 30 TS 13859:2014+M06 7 Benz(g,h,i)perylene 0,11 mg/kg 0,01 DS/lSO 30 TS 13859:2014+M06 7 Sum of PAH (11 stk.) 1,2 mg/kg DS/lSO TS 13859:2014+M06 7 PCB 28 <0,00 mg/kg 0,00 DS/EN 30 3 TS 3 15308:2008 PCB 52 <0,00 mg/kg 0,00 DS/EN 30 3 TS 3 15308:2008 PCB 101 <0,00 mg/kg 0,00 DS/EN 30 3 TS 3 15308:2008 PCB 118 <0,00 mg/kg 0,00 DS/EN 30 3 TS 3 15308:2008 PCB 138 <0,00 mg/kg 0,00 DS/EN 30 3 TS 3 15308:2008 PCB 153 <0,00 mg/kg 0,00 DS/EN 30 3 TS 3 15308:2008 PCB 180 <0,00 mg/kg 0,00 DS/EN 30 3 TS 3 15308:2008 PCB (sum 7 stk.) - mg/kg DS/EN TS 15308:2008 DEHP <0,5 mg/kg 0,5 DS/CEN/TS 50 TS 16182:2012+M05 4
P452859PC00 31 NPE - mg/kg 0,2 DS/CEN/TS 50 TS 16182:2012+M05 4 LAS 54 mg/kg 50 DS/CEN/TS 50 TS 16189:2012+M05 5
Claims
P452859PC00 32 Claims 1. A construction element comprising gypsum and purified fly ash, wherein said purified fly ash comprises less than 35.000 ppm heavy metals. 2. A construction element comprising gypsum and purified fly ash, wherein said purified fly ash comprises less than 35.000 ppm heavy metals, and wherein said purified fly ash comprises 100.000 – 200.000 ppm Silicon. 3. The construction element according to claim 1, wherein said purified fly ash comprises less than 30.000 ppm heavy metals, less than 29.000, 28.000, 27.000, 26.000, 25.000, 24.000, 23.000, 22.000, 21.000, 20.000, 19.500, 19.000, 18.500, 18.000, 17.500 or preferably less than 17.000 ppm heavy metals. 4. The construction element according to any of the claims above, wherein said purified fly ash comprises 110.000 – 190.000 ppm silicon, 120.000 – 180.000, 130.000 – 170.000, 140.000 – 160.000, 140.000 – 150.000 or about 139.000 – 140.500 ppm silicon. 5. The construction element according to any of the claims above, wherein said construction element comprises 110.000 – 190.000 ppm silicon, 120.000 – 180.000, 130.000 – 170.000, 140.000 – 160.000, 140.000 – 150.000 or about 139.000 – 140.500 ppm silicon. 6. The construction element according to any of the claims above, wherein said purified fly ash comprises less than 20.000 ppm heavy metals, and wherein said purified fly ash comprises about 139.000 – 140.500 ppm Silicon.
P452859PC00 33 7. The construction element according to any of the claims above, wherein said construction element is a plasterboard. 8. The construction element according to any of the claims above, wherein said purified fly ash has a neutral pH value, preferably said pH values is 6 – 8, 6.5 – 7.5 or about 7. 9. The construction element according to any of the claims above, wherein said purified fly ash has a thermal conductivity factor of 0.050 – 0.120 [W/mK], 0.060 – 0.110, 0.070 – 0.100, or preferably 0.080 – 0.090 [W/mK]. 10.The construction element according to any of the claims above, wherein said construction element has an effective calorific value of about 4 – 6 kWh/kg. 11.The construction element according to any of the claims above, wherein said purified fly ash is fly ash from the combustion of wood pellets. 12.The construction element according to any of the claims above, wherein said purified fly ash is fly ash from the combustion of seed husks. 13.The construction element according to any of the claims above, wherein said purified fly ash comprises Phosphor, Fluoride, Chloride, Silicon, SiO, SiO2, Al2O, Al2O3, Fe2O2, Fe2O3, FeO3, MgO, Na2O, K2O, SO3, LOI, CeO, MgO and/or CaO.
P452859PC00 34 14.The construction element according to any of the claims above, wherein said heavy metals has a density greater than 5 g/cm3. 15.The construction element according to any of the claims above, wherein said heavy metals are selected among antimony (Sb), Arsenic (As), Lead (Pb), Cadmium (Cd), Chrome (Cr), Cobalt (Co), Iron (Fe), Mercury (Hg), Manganese (Mn), Molybdenum (Mo), Nickle (Ni) and combinations thereof. 16.The construction element according to any of the claims above, wherein said heavy metals are selected among Mercury (Hg), Arsenic (As), Lead (Pb), Chrome (Cr) and combinations thereof. 17.The construction element according to any of the claims above, wherein said construction element comprises less than 50.000 ppm chloride, less than 40.000, 30.000, 20.000, 15.000, 10.000, 5.000, 2.500, 2.000, 1.500 or preferably less than 1000 ppm chloride. 18.The construction element according to any of the claims above, wherein said construction element comprises less than 100.000 ppm aluminium, less than 90.000, 80.000, 70.000, 60.000, 50.000, 40.000, 30.000, 20.000, 15.000, 10.000, 5.000, 2.500, 2.000, 1.500 or preferably less than 1000 ppm aluminium. 19.The construction element according to any of the claims above, wherein said construction element comprises less than 50.000 ppm antimony, less than 40.000, 30.000, 20.000, 15.000, 10.000, 5.000, 2.500, 2.000, 1.500 or preferably less than 1000 ppm antimony. 20.The construction element according to any of the claims above, wherein said construction element comprises less than 50.000 ppm
P452859PC00 35 arsenic, less than 40.000, 30.000, 20.000, 10.000, 5.000, 2.500, 2.000, 1.500, 1.000, 900, 800, 700, 600, 500, 400, 350, 300, 250, 200, 150, 140, 130, 120, 110, 100, 90, 80, 70, 60, 50, 40, 30, 25, 20 or preferably less than 15 ppm arsenic. 21.The construction element according to any of the claims above, wherein said construction element comprises less than 50.000 ppm lead, less than 40.000, 30.000, 20.000, 15.000, 10.000, 5.000, 2.500, 2.000, 1.500 or preferably less than 1000 ppm lead. 22.The construction element according to any of the claims above, wherein said construction element comprises less than 100 ppm lead, less than 50 ppm lead, less than 40, 30, 20, 10 or preferably less than 7 ppm lead. 23.The construction element according to any of the claims above, wherein said construction element comprises less than 50.000 ppm cadmium, less than 40.000, 30.000, 20.000, 10.000, 5.000, 2.500, 2.000, 1.500, 1.000, 900, 800, 700, 600, 500, 400, 350, 300, 250, 200, 150, 140, 130, 120, 110, 100, 90, 80, 70, 60, 50, 40, 30, 25, 20 or preferably less than 15 ppm cadmium. 24.The construction element according to any of the claims above, wherein said construction element comprises less than 14 ppm cadmium, less than 12, 10, 8, 6, 4, or preferably less than 2 ppm cadmium. 25.The construction element according to any of the claims above, wherein said construction element comprises less than 50.000 ppm chrome, less than 40.000, 30.000, 20.000, 10.000, 5.000, 2.500, 2.000, 1.500, 1.000, 900, 800, 700, 600, 500, 400, 350, 300, 250, 200,
P452859PC00 36 150, 140, 130, 120, 110, 100, 90, 80, 70, 60, 50, 40, 30, 25, 20 or preferably less than 15 ppm chrome. 26.The construction element according to any of the claims above, wherein said construction element comprises less than 50.000 ppm cobalt, less than 40.000, 30.000, 20.000, 10.000, 5.000, 2.500, 2.000, 1.500, 1.000, 900, 800, 700, 600, 500, 400, 350, 300, 250, 200, 150, 140, 130, 120, 110, 100, 90, 80, 70, 60, 50, 40, 30, 25, 20 or preferably less than 15 ppm cobalt. 27.The construction element according to any of the claims above, wherein said construction element comprises less than 50.000 ppm iron, less than 40.000, 30.000, 20.000, 15.000, 10.000, 5.000, 2.500, 2.000, 1.500 or preferably less than 1000 ppm iron. 28.The construction element according to any of the claims above, wherein said construction element comprises less than 50.000 ppm mercury less than 40.000, 30.000, 20.000, 10.000, 5.000, 2.500, 2.000, 1.500, 1.000, 900, 800, 700, 600, 500, 400, 350, 300, 250, 200, 150, 140, 130, 120, 110, 100, 90, 80, 70, 60, 50, 40, 30, 25, 20 or preferably less than 15 ppm mercury. 29.The construction element according to any of the claims above, wherein said construction element comprises less than 14 ppm mercury, less than 12 ppm, 10 ppm, 8 ppm, 6 ppm, 4 ppm, 2 ppm, 0.1 ppm or preferably less than 0.01 ppm mercury. 30.The construction element according to any of the claims above, wherein said construction element comprises less than 50.000 ppm manganese less than 40.000, 30.000, 20.000, 10.000, 5.000, 2.500, 2.000, 1.500, 1.000, 900, 800, 700, 600, 500, 400, 350, 300, 250, 200,
P452859PC00 37 150, 140, 130, 120, 110, 100, 90, 80, 70, 60, 50, 40, 30, 25, 20 or preferably less than 15 ppm manganese. 31.The construction element according to any of the claims above, wherein said construction element comprises less than 50.000 ppm molybdenum less than 40.000, 30.000, 20.000, 10.000, 5.000, 2.500, 2.000, 1.500, 1.000, 900, 800, 700, 600, 500, 400, 350, 300, 250, 200, 150, 140, 130, 120, 110, 100, 90, 80, 70, 60, 50, 40, 30, 25, 20 or preferably less than 15 ppm molybdenum. 32.The construction element according to any of the claims above, wherein said construction element comprises less than 50.000 ppm nickel less than 40.000, 30.000, 20.000, 10.000, 5.000, 2.500, 2.000, 1.500, 1.000, 900, 800, 700, 600, 500, 400, 350, 300, 250, 200, 150, 140, 130, 120, 110, 100, 90, 80, 70, 60, 50, 40, 30, 25, 20 or preferably less than 15 ppm nickel. 33.The construction element according to any of the claims above, wherein said construction element comprises less than 5000 ppm copper less than 4000, 3000, 2000, 1000, 500, 400, 300 or preferably less than 200 ppm copper. 34.The construction element according to any of the claims above, wherein said construction element comprises less than 5000 ppm zinc less than 4000, 3000, 2000, 1000, 500, 400, 300 or preferably less than 200 ppm zinc. 35.The construction element according to any of the claims above, wherein said construction element comprises less than 5000 ppm acenaphthen, less than 4000, 3000, 2000, 1000, 500, 400, 300, 200, 100, 50 or preferably less than 40 ppm acenaphthen.
P452859PC00 38 36.The construction element according to any of the claims above, wherein said construction element comprises less than 1000 ppm fluorine, less than 500, 400, 300, 200, 100, 50, 40, 30, 20, 10 or preferably less than 6 ppm fluorine. 37.The construction element according to any of the claims above, wherein said construction element comprises less than 5000 ppm phenanthrene, less than 4000, 3000, 2000, 1000, 500, 400, 300, 200 or preferably less than 100 ppm phenanthrene. 38.The construction element according to any of the claims above, wherein said construction element comprises less than 5000 ppm fluoranthene, less than 4000, 3000, 2000, 1000, 500, 400, 300, 200 or preferably less than 100 ppm fluoranthene. 39.The construction element according to any of the claims above, wherein said construction element comprises less than 5000 ppm pyrene, less than 4000, 3000, 2000, 1000, 500, 400, 300, 200 or preferably less than 100 ppm pyrene. 40.The construction element according to any of the claims above, wherein said construction element comprises less than 5000 ppm of any one of benzo(b+j+k)fluoranthene, benzo(a)pyrene, indeno(1,2,3- cd)pyrene, dibenz(a,h)anthracene and/or benzo(g,h,i)perylene, less than 4000, 3000, 2000, 1000, 500, 400, 300, 200, 100, 90, 80, 70, 60, 50, 40, 30, 20, 10 or preferably less than 5 ppm of any one of benzo(b+j+k)fluoranthene, benzo(a)pyrene, indeno(1,2,3-cd)pyrene and/or benzo(g,h,i)perylene. 41.The construction element according to any of the claims above, wherein said construction element comprises less than 500 ppm, less
P452859PC00 39 than 400, less than 300, less than 200, less than 100, less than 50, less than 40, less than 30, less than 20, less than 10, less than 5 or preferably less than 2 Poly Aromatic Hydrocarbons. 42.The construction element according to any of the claims above, wherein said element comprises 1 – 70 % w/w purified fly ash, 5 – 65, 10 – 60, 15 – 55, 20 – 50, 25 – 50, 30 – 45, 35 – 45, 35 – 40 or about 40 %w/w purified fly ash. 43.The construction element according to any of the claims above, wherein said element comprises 1 – 50 % w/w calcium sulfate, 5 – 45, 10 – 40, 15 – 35, 20 – 35, 20 – 30, 25 – 30 or about 30 % w/w calcium sulfate. 44.The construction element according to any of the claims above, wherein said element comprises 1 – 50 % w/w recycled calcium sulfate dehydrate, 5 – 45, 10 – 40, 15 – 35, 20 – 30, 20 – 25 or about 20 % w/w recycled calcium sulfate dehydrate. 45.The construction element according to any of the claims above, wherein said element comprises 0.1 – 4 % w/w water, 0.5 – 3.5 %, 0.5 – 3% or about 0.5 – 2.5 % w/w water. 46.The construction element according to any of the claims above, wherein said element comprises 1-50 % w/w water. 47.The construction element according to any of the claims above, wherein said element comprises raw hemihydrate. 48.The construction element according to any of the claims above, wherein said element comprises a foaming agent.
P452859PC00 40 49.The construction element according to any of the claims above, wherein said element comprises 1 – 35 % w/w foaming agent, 2.5 – 32.5, 5 – 30, 7.5 – 27.5, 10 – 25, 12.5 – 22.5, 15 – 20 or about 17.5 % w/w foaming agent. 50.The construction element according to any of the claims above, wherein said element comprises ≤1% w/w foaming agent. 51.The construction element according to any of the claims above, wherein said element comprises fibres. 52.The construction element according to any of the claims above wherein said fibres are selected among hemp fibres, paper fibres, recycled paper fibres and cellulosic fibres. 53.The construction element according to any of the claims above wherein said fibers are glass fibers. 54.The construction element according to any of the claims above, wherein said element comprises 1 – 35 % w/w fibres, 2.5 – 32.5, 5 – 30, 7.5 – 27.5, 10 – 25, 10 – 22.5, 10 – 20, 10 – 15, 10 – 12.5 or about 10 % w/w fibres, preferably wherein said fibres are hemp fibres. 55.The construction element according to any of the claims above, wherein said element comprises 0.1 – 5 % w/w fibers. 56.The construction element according to any of the preceding claims, wherein said purified fly ash is obtained from fly ash by the a process comprising the following steps: a. Separation
P452859PC00 41 b. Rinsing; and c. precipitation. 57.The construction element according to any of the claims above, wherein said construction element has a thickness of about 1 – 35 mm, 5 – 30 mm or preferably about 10 – 25 mm. 58.The construction element according to any of the claims above, wherein said construction element has a thickness of about 10 mm, about 12,5 mm, about 15 mm or about 18 mm. 59.The construction element according to any of the claims above, wherein said element has a thermal conductivity factor of less than 0.090 [W/mK], less than 0.085, less than 0.080 or preferably less than 0.075 [W/mK]. 60.The construction element according to any of the preceding claims, wherein said element has a flexural strength of at least 100 Newton, at least 150, 200, 250, 300, 350, 400, 450 or preferably at least 500 Newton in transverse direction. 61.The construction element according to any of the preceding claims, wherein said element has a flexural strength of at least 100 Newton, 200, 250, 300, 350, 400, 450, 500, 550, 600, 650, 700, 750, 800, 850, 900, 950 or preferably at least 1000 Newton in longitudinal direction. 62.The construction element according to any of the preceding claims, wherein said element comprises about 40 % w/w purified fly ash, about 10 % w/w CaSO4, about 20 % w/w recycled CaSO₄·2H₂O, about 10 % w/w fiber, about 17.5 % w/w foaming agent and about 2.5 % w/w water.
P452859PC00 42 63.The construction element according to any of the preceding claims, wherein said element comprises slaked lime Ca(OH), preferably in an amount of 1-20 % w/w. 64.The construction element according to any of the preceding claims, wherein said element comprises clay, preferably in an amount of 1-60 % w/w. 65.The construction element according to any of the preceding claims, wherein said element comprises fire line additives, preferably in an amount of 1-40 % w/w. 66.The construction element according to any of the preceding claims, wherein said element comprises mineral additives such as kaolin, illite, quartz, dolomite, micronized or unexpanded vermiculite, hydrated alumina and/or boric acid. 67.The construction element according to any of the preceding claims, wherein said element comprises LC3 cement, preferably in an amount of 1-80 % w/w. 68.A process for producing a construction element according to any of the claims above, said process comprising the steps of a. Providing a fly ash material; b. Pre-treatment of said fly ash material, thereby providing a purified fly ash composition, a metal containing fraction and a saltwater solution; c. Providing a gypsum binder; d. Combining said stabilized fly ash composition and said gypsum binder into a gypsum binder slurry;
P452859PC00 43 e. Compressing said gypsum binder slurry into a flat material which is cutted and dried into said construction element. 69.The process according to any of the claims above, wherein said5 gypsum binder is a hydratable calcium sulphate and/or a recycled gypsum binder.
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| CN115417653A (en) * | 2022-09-13 | 2022-12-02 | 中冶南方都市环保工程技术股份有限公司 | Method for solidifying and stabilizing fly ash by cooperation of phosphogypsum and acid wastewater and post-treatment |
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2024
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