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Title:
POLYMERIC CONSTRUCTION MATERIAL ON THE BASIS OF FLOTATION WASTE FROM COPPER ORE FLOTATION AND WASTE SULFUR
Document Type and Number:
WIPO Patent Application WO/2011/149368
Kind Code:
A1
Abstract:
Polymeric construction material on the basis of flotation waste from copper ore flotation and waste sulfur with the addition of waste phosphogypsum as pH regulator of flotation waste, with mineral filler added to the mixture, comprising 20-50% by weight of waste sulfur, 10-50% of flotation waste from flotation of copper ore of granulation of about 0.06 mm mixed beforehand with waste phosphogypsum; at the temperature of 130- 150 °C modification of sulfur by metals and their sulfides contained in flotation waste such as copper, lead, iron, arsenic, cadmium, zinc, nickel, molybdenum, vanadium, cobalt, occurs.

Inventors:
JANICZEK ANDRZEJ (PL)
MYSLOWSKI WLODZIMIERZ (PL)
Application Number:
PCT/PL2010/000107
Publication Date:
December 01, 2011
Filing Date:
November 02, 2010
Export Citation:
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Assignee:
MYSLOWSKI WLODZIMIERZ (PL)
JANICZEK ANDRZEJ (PL)
International Classes:
C04B28/36
Domestic Patent References:
WO2002081377A22002-10-17
Foreign References:
EP1065185A12001-01-03
JP2000053461A2000-02-22
JPH07290024A1995-11-07
US4058500A1977-11-15
US4348313A1982-09-07
Other References:
UMEMURA, K. ET AL: "Building material from indusrial waste gypsum", CHEMICAL ABSTRACTS, vol. 85, no. 8, 23 August 1976 (1976-08-23), pages 291, XP000185813, ISSN: 0009-2258
Attorney, Agent or Firm:
RYGIEL, Andrzej (ul. Bohaterów Warszawy 26 Lok. F, Bielsko-Biala, PL)
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Claims:
Patent Claim

The method of production of polymeric construction material on the basis of flotation waste from copper ore flotation and waste sulfur c h a r a c t e r i s e d b y t h a t it is a product of modification of waste sulfur with metals contained in flotation waste from copper ore flotation, such as copper, lead, zinc, nickel in the form of simple or mixed sulfides and some amount of trace elements such as copper, lead, iron, arsenic, cadmium, zinc, nickel, molybdenum, vanadium, cobalt, comprising 20-50% by weight of waste sulfur, 10-50% by weight of flotation waste from flotation of copper ore of granulation of about 0.06 mm, 3-25% by weight of waste phosphogypsum as pH regulator, 10-40% by weight of mineral filler, mixed together at the temperature of 130-150X for about 30 minutes with rotational speed of the agitator of 20 rpm.

Description:
POLYMERIC CONSTRUCTION MATERIAL ON THE BASIS OF FLOTATION WASTE FROM COPPER ORE FLOTATION AND WASTE SULFUR

The object of the invention is polymeric construction material on the basis of flotation waste from copper ore flotation and waste sulfur. Manufactured polymeric construction material is a material similar to traditional concrete but of better functional properties such as: high resistance to compression and bending, short setting time, low absorbability, good tightness and, above all, resistance to acidic environments to which most of construction materials are not resistant. There are known methods of production of sulfur binders: US Patents No 4058500 and No 4348313 demonstrate sulfur binder where sulfur is modified with olefin hydrocarbons, that is, an organic modifier. The same, sulfur binders manufactured in Poland are based on organic modifiers of olefin hydrocarbon type. Such solutions are dangerous in use due to the risk of fire or explosion during the modification process. Another disadvantage is their toxic effect on personnel. The most important quality of the new solution "Polymeric construction material on the basis of flotation waste from copper ore flotation and waste sulphur" is that waste sulfur, waste from copper flotation in KGHM Polska Miedz S.A. and waste phosphogypsum as flotation waste pH regulator are used in the production process. It affects reduction of the accumulated noxious waste amounts and allows to utilize them in an environmentally safe way. Polymeric construction material according to the invention is obtained by adding dried flotation waste from copper ore flotation to waste sulfur in liquid state at the temperature of 130-150°C with simultaneous mixing of these ingredients. Flotation waste has got pH of about 8.5, that is why it is subjected to a pH regulation process with the use of waste phosphogypsum to pH of about 6.0, that is, to slightly acid reaction. Flotation waste from flotation of copper ore in KGHM Polska Miedz S.A. possess composition depending on the type of floted ore; however, they all are suitable for modification of waste sulfur due to fine crushing and metals contained in them, which appear in the form of simple or mixed sulfides. And so copper occurs in the form of chalcocite - CU2S, bornite - Cu 5 FeS , chalcopyrite - CuFeS 2 , covellite - CuS, lead occurs mostly in the form of galena— PbS, and zinc and nickel in the form of sulfides and silicates. Flotation waste contain some amounts of trace elements such as Cu, Pb, Fe, AS, Cd, Zn, Ni, Mo, Co and V; moreover, post-flotation waste contain about 13% by weight of CaO, about 5% by weight of MgO. The ingredients specified above constitute the mixture of sulfur modifiers; moreover, about 40% by weight of Si0 2 , 29% by weight of dolomite, about 7% by weight of calcite, which are good mineral filler for the polymeric construction material obtained according hereto can be found in waste. Sulfur, as an element of a remarkably electronegative character, reacts vigorously with metals. Copper is already in reaction with sulfur at the room temperature and in increased temperatures sulfur combines with almost all elements. Moreover, flotation waste from copper ore flotation has got pH of about 8.5 in contrast to blast-furnace slag from steel smelting where pH amounts to 10.5; it is very significant in the process of sulfur modification, since it is easier to obtain pH lower than 7 with the use of waste phosphogypsum, that affects favourably the modification itself and the properties of polymeric construction material formed on the basis hereof. In specific technical conditions, that is, at high temperature, destruction of closed rings from sulfur atoms into open chains resulting from opening of these rings at temperatures higher in the temperature range of 130- 50°C, occurs. In the temperature range of 130-150°C sulfur Sx cyclic structure dominates in place of the rhombic structure. Metals such as copper, lead, zinc, nickel, contained in flotation waste from copper ore flotation, which occur in the form of simple or mixed sulfides and some amounts of trace elements such as copper, lead, iron, arsenic, cadmium, zinc, nickel, molybdenum, cobalt and vanadium, which are sulfur modifiers, undergo copolymerisation reaction with chain-structured sulfur creating a copolymer of highly-molecular compound properties which occurs in polymeric materials. Polymeric construction material on the basis of flotation waste from copper ore flotation and waste sulfur being the object of the invention comprises: 20-50 % by weight of waste sulfur, 10-50% by weight of flotation waste from copper ore flotation in KGHM Polska Miedz S.A. of granulation of about 0.06 mm comprising about 13% by weight of CaO, about 5% by weight of MgO, about 40% by weight of S1O2, about 29% by weight of dolomite, about 7% by weight of calcite, some amounts of metals such as copper, lead, zinc, nickel in the form of simple or mixed sulphides, and some amounts of trace elements such as copper, lead, iron, arsenic, cadmium, zinc, nickel, molybdenum, vanadium and cobalt mixed with pH regulator of flotation waste which is waste phosphogypsum, as a result of which a change of pH of the flotation waste from alkaline to slightly acid reaction occurs. Waste sulfur is loaded to a horizontal mixer heated by heating oil, and after it is melted, previously weighed amounts of dried floatation waste mixed beforehand with pH regulator, which is waste phosphogypsum in the amount of 3-25% by weight, are dosed. In the mixer, at the temperature of 130- 50°C at constant mixing of about 20 rpm, modification of chain sulfur with the use of metals and their sulfides contained in flotation waste from copper ore flotation, occurs. Copolymer of highly-molecular compound properties is formed. Polymeric construction material, which, depending on needs, can be poured into a mould or poured onto a specified surface, mainly for road foundations in place of concrete on the basis of traditional cements, or used for production of road surface mixes, is obtained by adding specific amounts of mineral fillers in the amount of 10-40% by weight to the mixer. Construction material in the above version intended for a mould or for pouring onto a specified surface differs in its percentage composition from polymeric construction material intended for production of road surface mixes on the basis of road asphalts and polymeric construction material intended for repair and production of new road surfaces. The amount of mineral filler is reduced in it to 10% by weight of granulation of 0-1 mm. Addition of proper amount of polymeric construction material on the basis of flotation waste from copper ore flotation and waste sulfur to surface road mixes reduces the amount of road asphalt in these surfaces by about 3% by weight, and thus, reduces costs of road construction. Additionally, polymeric construction material increases the temperature of road surface softening, preventing its rutting, that extends the time of road service life. Polymeric construction material on the basis of flotation waste from copper ore flotation and waste sulfur possesses very good functional properties, that is, compression strength of about 50-60 MPa, much higher than that of traditional concretes, breaking strength of about 6 MPa, bending strength of about 8 MPa, low water absorbability of about 1 %, good frost resistance and proper roughness, resistance to sea salt, acids and oils. Polymeric construction material has excellent adhesion to the ground and to construction materials used in highway engineering. It is used for production of road foundation and road binder. Furthermore, it fills cracks and hollows of concrete and road surfaces tightly. Compounds of copper, magnesium and iron contained in polymeric construction material are inhibitors of hydrogen sulfide emission at mixing of polymeric construction material with asphalt, that improves industrial safety during preparation of road mixes. Unexpected properties of such big improvement of mechanical compressive strength, resistance to aggressive media, i.e., acids, salts, oils in comparison to concrete on the basis of Portland cement and ability to form road mixes are due to flotation waste from copper ore flotation, which is a source of metals such as copper, lead, zinc, nickel in the form of simple or mixed sulfides and some amount of trace elements such as copper, lead, iron, arsenic, cadmium, zinc, nickel, molybdenum, vanadium, cobalt, which are sulfur modifiers. As a result of heating up sulfur, cyclic sulfur decomposes into simple chains, which with modifiers contained in flotation waste from copper ore flotation form a copolymer of linear or cross-linked structure of typical properties of a highly-molecular compound which occurs in polymeric materials. The flotation waste from copper ore flotation in KGHM Polska Miedz S.A. contains about 13% by weight of CaO, about 5% by weight of MgO, about 40% by weight of Si0 2 , about 29% by weight of dolomite, about 7% by weight of calcite, some amounts of metals such as copper, lead, zinc, nickel in the form of simple or mixed sulfides and some amounts of trace elements such as copper, lead, iron, arsenic, cadmium, zinc, nickel, molybdenum, vanadium, cobalt. Waste phosphogypsum is the waste from industrial production of phosphatic fertilizers. Waste sulfur is a product of natural gas or crude oil desulfurization. The method of production of polymeric construction material on the basis of flotation waste from copper ore flotation and waste sulfur according to the invention has been defined more closely in the example of embodiment.

Example I

Polymeric construction material on the basis of flotation waste from copper ore flotation and waste sulfur

Waste sulfur 30 %

Flotation waste 35 %

Waste phosphogypsum as pH regulator 5 %

mineral filler 0-10 mm

or waste slag 0-10 mm

from copper smelting 30 %

Prepared in the following way: weighed amounts of waste sulfur are delivered to the horizontal mixer. This mixer is heated indirectly with heating oil. The mixer possesses a rotating agitator of 20 rpm. At the temperature of 130-150°C, when all the sulfur assumes liquid form, weighed amounts of flotation waste, mixed beforehand with pH regulator which is waste phosphogypsum, are dosed to the mixer. At the temperature of 130-150°C in the molten sulfur zone a contact of flotation waste with liquid sulfur occurs. Mixing of ingredients lasts for about 20 minutes. The process of modification of waste sulfur with flotation waste from copper ore flotation by metals and sulfides contained it in, including copper, lead, zinc, nickel, iron, arsenic, cobalt, molybdenum, cobalt and vanadium, occurs. After 20 minutes of the modification process, mineral material or waste slag from copper smelting as a filler is added to the mixer and it is mixed for about 10 minutes. Thus, polymeric construction material on the basis of flotation waste from copper ore flotation and waste sulfur with the addition of mineral filler or waste slag from copper smelting, which is poured from the mixer to a mould or onto a specified surface, a road foundation included, is formed. The material produced this way is grey, possesses high mechanical compressive strength of 50-60 MPa and resistance to acids, oils and salts.

Example II

Polymeric construction material on the basis of flotation waste from copper ore flotation and waste sulfur

Waste sulfur 50 %

Floatation waste 25 %

Waste phosphogyspum as pH regulator 20 %

Mineral filler from 0-1 mm 5 %

The method of preparation identical as in Example I; the difference is that polymeric construction material is directed from the mixer to granulation. Granulate, after mixing with road asphalt, is used to prepare the road binder used in production of road surfaces of increased softening temperature and high resistance to rutting.

Composition of the binder: road asphalt 20% by weight, polymeric construction material 80% by weight.