Login| Sign Up| Help| Contact|

Patent Searching and Data


Title:
MANUFACTURE OF CONSTRUCTION MATERIALS AND PRODUCTS
Document Type and Number:
WIPO Patent Application WO/2002/006181
Kind Code:
A2
Abstract:
Manufacture of construction materials and products solves the technical problem of a more rational usage of the production scrap and/or consumption of natural and/or artificial substances. Natural and/or artificial substances from the production and/or consumption are classified considering their risk (radiation, toxicity) to people and the environment. They are then crushed and sorted regarding the size and mass of the grains. Smaller grains (less than 0.1) are formed into granules of sand and/or aggregates of higher, medium and lower quality, as products of the first phase. The first granules are pressed and formed into construction products such as brick products, or are left to harden as the basic component in preparing plastic mixutres to be built into the construction facilities or wet masses for the manufacture of prefabricates of equal or better technical properties compared to brick.

Inventors:
BASARIC ISO (HR)
DOJINCEVIC JASMINKA (HR)
BASARIC MIRELA (HR)
BASARIC NINO (HR)
Application Number:
PCT/HR2001/000032
Publication Date:
January 24, 2002
Filing Date:
June 26, 2001
Export Citation:
Click for automatic bibliography generation   Help
Assignee:
BASARIC ISO (HR)
DOJINCEVIC JASMINKA (HR)
BASARIC MIRELA (HR)
BASARIC NINO (HR)
International Classes:
B01J2/20; C02F11/00; C04B18/02; (IPC1-7): C04B18/04
Attorney, Agent or Firm:
Basaric, Iso (Lastovska 5 Zagreb, HR)
Download PDF:
Claims:
CLAIMS
1. Manufacture of construction materials and products, primarily based on the waste from natural and/or artificial substances, characterised by the fact that grains smaller than 0.1 mm are formed into granules of sand and aggregate or other products thereof.
2. Manufacture according to requirement in item 1, characterised by the mixture of liquid being sprayed on the mixture of powder the grains of which roll, slide or fall, forming smaller and bigger granules.
3. Manufacture according to requirement in item 2, characterised by the liquid consisting of three or more components, binders and fillers with volumetric mass less than 1200 kg/m3 and grains smaller than 4 mm.
4. Manufacture according to requirement in item 3, characterised by the filler consisting of a mixture of two or more types of powder with one or two types also having the properties of binding materials.
5. Manufacture according to requirement 1, characterised by the granules of sand and aggregate being pressed and extruded through an extruder onto a table for final forming and hardening of the product suitable for a square.
6. Manufacture according to requirement in item 5, characterised by granules of sand and aggregate being heated at a temperature of 25... 65°C, in the gas mixture flow with 10... 30% carbon dioxide.
7. Manufacture according to requirement 6, characterised by the granules as final product being dried until humidity is reduced to 4... 6% of free water and screened through sieves of adequate sizes.
8. Manufacture according to requirement 1 to 8, characterised by the mixtures of liquid and powder, granules and products thereof being classified into three classes of allowed risk to people and environment.
Description:
MANUFACTURE OF CONSTRUCTION MATERIALS AND PRODUCTS Technical Field Industry and craft of construction materials and products, such as filler (1), sand, aggregate (2,3), light concretes (4), concrete industrial products (5) and brick (6).

Technical Problem Preparation of the liquefied mixture (solution and/or suspension, waste (7) and silt (8) and the mixture of powders of suitable physical and chemical properties for the manufacture of fillers, sand, aggregates and/or plastic-wet mass for the construction of components of building structures or products.

Technical Background Similar manufacture of fillers, (1), sand and aggregates (2,3), light concretes (4), concrete industrial products (5) and brick manufacture (6) is known. Most similar is the preparation of raw material for the manufacture of brick and the manufacture itself of brick products (6).

Preparation of raw materials for the manufacture of bricks consists in mining the clay,- letting it stand for a certain period of time, preferably during winter, mixing it and crushing with additives and water, grinding and removing harmful organic matter or other ingredients.

The prepared, sufficiently plastic. clay is fed into a press to be compressed and compacted. The compressed mass of clay, water and air is then extruded through the extruder -the cross-section forming tool, onto a table where it is sliced to a certain length, and the result is raw clay semi-product, that is then dried (excessive moisture is eliminated), to the optimal resistance for further procedure. The semi-product is dried in the air at a temperature of 25°C/ 90% relative humidity, and then at 50°C and lower humidity whereas in the third phase the clay products are dried at a temperature of ca. 80°C and then they are cooled to a temperature of ca. 30°C.

The dried clay product is then fired at a temperature of 900... 1100°C, depending on the type of brick product, in order to obtain the final form and technical properties (strength, hardness, resistance to atmospheric impact, porosity, insulation properties).

Dry clay products (bricks) are fired in kilns. The simples are the field kilns that consume more fuel for less uniform quality of the product. More recently, the bricks are fired in tunnel kilns, which operate continuously in order to save fuel (the heat from the flue gases is used to heat the kilns).

Disclosure of the Invention The liquefied mixture prepared from two or more artificial substances, such as waste from the consumption of natural substances and/or products thereof (further in the text: binders) is sprayed on the mixture prepared of artificial substances (further in the text: fillers), whose particles roll, slide, fall and/or float in a suitable device forming smaller or bigger groups of binders and fillers (further in the text: granules), whose properties depend on the type and amount of the binder, temperature and humidity of these mixtures.

Clay, bentonite, plaster of Paris, cement, lime, magnesium oxide, sodium silicate, sodium hydroxide, ferrous chloride, tar, sulphur, molasses, carbon dioxide and others as well as the combination of two or more of these is used for the hardening of granules. The binders are added separately, into the binder and/or filler. The preparation of binders and fillers is determined by the manufacturing project (performance): granule, as product of the first phase, mixture of the first phase and the new binder, as product of the second phase and/or final product as the third phase.

1ST EXAMPLE Waste from the consumption of natural substances and/or products thereof are classified according to the size, form and density of the grain. Grains of dimensions greater than 4 mm are ground to smalier dimensions and returned back for re-classification. The grains treated in this way have polyhedron-like, needle-like, plate-like, spherical, ball-like or any other shape. At all events, the grains should preferably have minimal specific surface. The needle-like shape of the filler mixture component is used for micro-reinforcement of the binder and filler mixture.

Prior to classification, radioactivity and granulometric composition of the input materials, as well as of every first-phase component, is tested. Radioactivity is tested and/or controlled for all the materials and products that enter and leave the manufacturing process. Construction materials and products that leave the manufacturing process can be classified into three classes (further in the text: I, II, III). I-materials and products with radioactivity less than 1/3 of the allowed (Bq/l and/or Bq/kg) according to the ISO standard. II-materials and products with radioactivity 1/3 or less than 2/3 of the allowed according to ISO standard and III- construction materials and products with 2/3 or less than allowed according to the ISO standard.

Physical and chemical danger to people and the environment is tested and controlled at the manufacturer of waste as product, dealers as suppliers and manufacturer as re- manufacturer and/or processor of the waste, i. e. products thereof according to the ISO standard. Technical and functional properties of the product are analysed and controlled by the manufacturer's laboratory under continuous supervision and control by the internationally acknowledged-European institution.

The main component of the binder can be waste from the refinement of mineral raw materials (7), waste water silt (8) or similar residues in the form of liquid suspensions and hard particles. For the production of granules with grain sizes of 3,4... 7,8... 15 mm or other sizes, the liquid is sprayed, e. g. silt of chemical plaster of Paris onto the mixture of powder (80... 90% dolomite, limestone or?) and lime (20... 10%), quick or slake, and the particles roll, fall or slide within a rotating drum forming granules. From the rotating drum, the granules are then dried to optimal humidity, 4... 5% of moisture, and then left at a temperature of 25... 65°C in the gas mixture flow which contains 10... 30% carbon dioxide, until they begin to harden. These are then compressed and extruded through an extruder-to form the cross-section of the final product which is then brought to a cutting table and sliced to adequate lengths. These are then loaded onto an adequate pallet to be transported to the construction site or square.

As an alternative, the granules can be left in the gas mixture flow to harden completely, and then these can be screened and fractions obtained, in this example up to 3,4... 7,8... 15 mm. The evaporated substance, vapour of the liquid is condensed and returns back into the production process. The energy (temperature) from the smoke and the resulting carbon dioxide are used to dry the granules, as well as for the preparation of the liquefied mixture i. e. gas mixture (10... 30% carbon dioxide). In absence of proper smoke, smoke from the environment i. e. neighbouring industries can be used.

2""EXAMPLE Waste water silt as residue of concentrated waste substance, if necessary, is powder neutralised, e. g. living organisms by quick lime, acid by base and vice versa, base by acid, provided such product is used in solid and insoluble way.

Substances, that have greater radiation than allowed according to the ISO standard, are neutralised by substances that have no or less radiation, so that the new mixture of binders, fillers, granules and/or products can be classified into one of the three (I, II, III) acceptable classes. At any rate, the total radiation of all the nuclides, as well as other dangers should not exceed the radiation of the product well known on the local market. Thus, e. g. a product made of light concrete and/or baked clay having ca. 240 Bq/kg (300 Bq/kg allowed by ISO standard), in combination with 25% of binding material having 330 Bq/kg radioactivity and 70% powder having 21 Bq/kg total radioactivity can produce a second class mixture.

3RD EXAMPLE A mixture of binder, silt, waste, lime, cement, plaster of Paris, bentonite is sprayed on the filler, primarily of Pozzolanic properties, such as ash with adequate additives to regulate technological and technical properties. Powdered droplets of the binding material are left at a temperature of 25... 65°C to dry to optimal moisture which amounts to 4... 6%. Granules prepared in this way are introduced into an extruder i. e. a press, and further to a nozzle in order to form the cross-section, and in turn onto a table for cutting the extruded product to adequate dimensions.

1) V. Bedekovic, Uticaj punila, Tehnicka enciklopedija 1, Zagreb, Leksikografski zavod MIROSLAV KRLEZA, p. 426 2) ]. Hahamovi#, Kameni agregat, Tehni#ka enciklopedija 2, Zagreb, Leksikografski zavod MIROSLAV KRLE#A, pp. 2...3 3) D. Ocepek, Klasiranje, Tehnicka enciklopedija 7, Zagreb, Leksikografski zavod MIROSLAV KRLEZA, pp. 130... 140 4) J. Hhamovi#, Laki betoni, Tehni#ka enciklopedija 2, Zagreb, Leksikografski zavod MIROSLAV KRLE#A, pp. 15...16 5) S. Turk, Betonski industrijski proizvodi, Tehni#ka enciklopedija 2, Zagreb, Leksikografski zavod MIROSLAV KRLE#A, pp. 16...17 6) J. Zajc, Opeka, Tehni#ka enciklopedija 9, Zagreb, Leksikografski zavod MIROSLAV KRLE#A, pp. 604...608 7) R. Marusic, Oplemenjivanje mineralnih sirovina, Tehnicka enciklopedija 9, Zagreb, Leksikografski zavod MIROSLAV KRLEZA, pp. 608... 625 8) S. Tedeschi, Otpadne vode, Tehnicka enciklopedija 10, Zagreb, Leksikografski zavod MIROSLAV KRLEZA, pp. 64... 90