JAHANDIDEH ZAHRA (IR)
KAMALI ABOOZAR (IR)
| What we claim is: Nano-cement with organic and inorganic activators 1- Nano-cement with organic and inorganic activators, clinker, gypsum and nanoparticles. 2- According to claim 1, organic activator containing is the naphthalene based modified polymeric derivatives (which are capable of complexation through sulfonate groups on the polymeric chain with calcium cations on the surface of cement particles) and the presence of polyethylene glycol chains optimizes their properties. After the cement particles are covered completely, the electrostatic gravity and the energy of agglomeration are minimized and the conditions to achieve nanoparticles are provided. Another group of organic modifiers includes comb like polycarboxylates which are able to complex with calcium cation and act as the same of the first group. This depends on their structure and higher percent of hydrophilic groups than the lipophilic ones. 3- According to claim 1, inorganic activator includes fly ash, slags (iron and steel), sand, silica, quartz, silicate bore, silica fume, silicon carbide, amorphous silica, carbon black and other inorganic additives with higher hardness than the clinker. 4- According to claim 1, nano-cement contains nanoparticles including Fe2C>3, CuO, montmorillonite, nano-cellulose, nano calcium carbonate, calcium carbonate, AI2O3, SiCh, carbon nano tube, T1O2, ZnO or their mixture. 5- According to claim 1, nano-cement can be produced by organic modifier, inorganic modifier, clinker, nanomaterial or their mixture. 6- According to claim 1, nanoparticles can decrease 30-50% of cement consumption. 7- According to claim 1, nano-cement formulation is based on: 0-80% inorganic activator 0-10% organic activator 0-15% clinker 8- According to claim 1, nano-cement can be produced by only polymeric modifier with desirable properties, but it is not cost effective. 9- Nano-cement producing process includes mechano-chemical activation of clinker particles in the presence of polymeric modifiers: 0-10% of 800 ppm solution of two organic modifiers with a ratio of 1:1 (glycerin and sorbitol), is sprayed on the input feed of mill and prevents static electricity generation. The water contained in this suspension not only cools clinker, but also absorb the organic compounds on the hydroxylated surface of clinker. This also causes complexation of surface calcium ions, hydrogen bonding and multipolar interactions. The addition of 0-10% of an organic modifier prevents the adhesion of the cement powder to the steel balls and consequently increases the power of the balls and saves energy consumption. This is due to the sulfonate functional groups on the polymer surface and the formation of a complex with calcium ions on the surface of the clinic. Organic modifier is adsorbed on the hydroxylated surface of clinker through chemical interactions. Adsorption decreases electrostatic charge and as a result agglomeration energy decreases. Decrease in agglomeration energy prevents particle agglomeration. 0-60% silica sand with higher hardness than the clinker acts as an abrasive aid and increases abrasion efficiency. In fact, the use of silica in this cycle helps to fragmentize clinker in the milling cycle (small mechanical balls increase mechanical abrasion of materials). The presence of silica in the cement mortar increases the compressive strength of the product by about 70% (increasing compressive strength from 45 MPa to 60-90 MPa within 24 hours and 70% increasing the 28-days concrete resistance within 72 hours). In order to analysis the produced nano-cement, six concrete production planning with 400 and 292 Kg nano-cement and Fars Cement was performed with and without aerated additives and then the 15 x 15cm2 samples were produced to measure their strength. The specific weight of Fars Cement was about 1.108 g/cm3 and was 1.091 g/cm3 for nano-cement. Table.1. Weight ratio of plan per cubic meter. Table.2. B200 concrete plan with water-cement ratio of 0.6 has the problem of decreasing slump and inefficiency. On the other hand, as the water content increases, cement consumption increases and it is not cost effective. As can be observed from the above Figures, four IS * 15 samples containing 3600 g water were prepared. Table.3. B200 concrete plan containing nano-cement with water-cement ratio of 0.32 and less water content about 83 Lit. Concrete slump containing nano-cement with les water of 83 Lit is about 4cm, showing high efficiency of nano-cement and more decreasing the water-cement ratio. Therefore, the content of cement can be decreased significantly. Table.4. B200 concrete plan containing nano-cement with water-cement ratio of 0.41 and less water content about 55 Lit. In order to increase concrete slump containing nano-cement, 500g water was added which is equal to 28Lit per lm3 volume. Then slump block measurement was performed and concrete loss was obtained as 17cm. Now, It can be alter water content to the slump block. |
1- Producing nano-cement
2- Field of activity: With the ability to exploit the cement industry (the field of construction industry).
3- The technical problem and the expression of goals: The invention of cement and concrete is a major achievement of mankind that makes possible construct the Industrial buildings, engineering facilities and highways around the planet. Today, almost everything is made with Portland cement: Annual production of more than 3 billion tons of cement and more than 11 billion tons of concrete, and it is still growing rapidly: Concrete dams and roads, terminals and airports, bridges and stadiums, television towers and skyscrapers and billions of meters of housing per year. Thousands of new companies in China, India, Latin America and other developing countries are added to thousands of existing cement factories. About 3 to 4 billion tons of cement is produced annually around the world with a rapid rise in demand. Production of such a large amount of cement is associated with enormous energy consumption, significant costs and greenhouse gas emissions to environment. Therefore, alternative extenders that are cost effective and environmentally friendly should be developed. Introduction the new technology for cement production methods that is consistent with the principles of sustainability can respond appropriately to this requirement. Considering that the world's cement industry is an energy dissipation industry (70 percent of energy dissipation is related to grind consuming materials), scientists are always looking for an optimal way to minimize the energy dissipation. Now, it should be noted that the major part of energy dissipation in the cement industry is in the milling section of raw materials constituting the cement (about 41% of energy dissipation is related to the process of clinker conversion to cement). As a result, the use of nanotechnology to produce nano-cement is considered as a potential approach in this regard.
4- Background of the invention
1- Sabdonoa and co-workers in 2014 found that the content of nano-cement had a significant effect on the compressive strength of the mortar.
2- Mistry and co-workers in 2014 studied the effect of nano-materials on the different properties of concrete compared with conventional cement materials. It has been shown that increasing the particle surface increases the compressive and flexural strength at early ages and decreases porosity and water absorption.
3- Bickabu and Shykun in 2015 showed that the properties of high strength concrete containing nano-cement increase significantly. Nano-cement reduces contraction and permeability and increases strength and the length of time. 4- Recently, Selva raj and co-workers have studied the reaction of nano-cement in concrete. They found that 30% of Portland cement replacement with nano-cement leads to excellent properties in concrete mortar. Therefore, nano-cement has been proven as an outstanding building material for many applications in the construction industry.
5- In 2012, certification of six types of nano-cement by adding special materials to cement by Rusnano Ltd was confirmed, so that the produced nano-cement confirmed the full compliance with the general technical conditions of nanomaterials (TU-5733-2012-66331738-067).
6- At the end of 2014, national pre-existing conditions for years 2014-2019 (the modified technical conditions for nanomaterials in Portland) were approved by the Russian Federation.
7- Katsioti and co-workers in a similar study investigated the effect of different additives on the process of clinker conversion to cement. Two types of additive used in their research (in addition to gypsum) were triethanolamine (TEA) and TIPA. They showed that the presence of TEA and TIPA increases grind-ability index by 14% and 26%, respectively. According to their report, TEA slightly reduces cement drying time (setting time), but TIPA delays hydration at the early stages and increases its time by about 15%.
4- The same result was not found on the website: patentscope.wipo.int/search/en/result.jsf
5- The same result was not found on the website: usp.gov/patent/process/search/index.jsp
6- The same result was not found on the website: epo.org/searching-for-patents.html
7- The same result was not found on the website: ip.ssaa.ir/patent/search.aspx
5- Technical solution and purpose statement
Regarding that today these problems are introduced as a global problem in the cement industry, it is imperative to find technical solutions to solve the problems of the cement industry. The solution considered in this invention is to use nanotechnology and nano-cement production instead of using Portland cement. As a result, this method can significantly reduce the consumption of cement, its products and environmental pollutants. On the other hand, Materials made with this type of cement have a very high strength and quality compared to Portland cement. Companies all over the world tend to higher strength concrete. The new concrete in the construction industry was named as the high performance Concrete (HPC). The structural and technical characteristics of these concretes increase builder facilities to construct the skyscrapers, bridges, tunnels, dams, mines and underground structures significantly.
6- Figures, drawings and charts
Figure 1. Nano-cement production line.
1: coal slag tank; 2: chalk warehouse; 3: sand warehouse; 4: clinker tank; 5,6,8: weight measurement; 7,11,18: Conveyor; 9: feeding tank; 10: pressure roller; 12: feeding tank for homogenization of the mixture; 13: corrector tank; 14: dividing belt; 15: mill; 16,17: filter.
7- Clear statement of claimed benefits
Thanks to the invention of this new cement, we can achieve a product which has higher strength. Furthermore, the processing of this cement reduces the emission of pollutants, energy consumption, and increases the efficiency of the mill.
8- Manufacturing method (presentation of solution)
Nano cement produces from sand and clinker by mixing mineral additives such as light weight ash, slag or silica with ground clinker or cement. Before the milling process, the moisture content of mixture should not exceed than 3%. This is done by preparing a mixture passing through a dryer unit attached to the production line. The mixture is milled for 30 to 40 minutes. Finally, nano-cement is produced as a result of the chemical reaction of the clinker particles with a modifier.
As shown in the figure, nano-cement is produced by adding one ton of Portland cement or ground clinker to one ton of the mixture containing sand or silica sand, and polymer and organic modifiers and then mineral additives as parts (300 mm in diameter) and gypsum with a moisture content of 5% to 6% (gypsum content of 0.3% and 6%).
Nano-cement production flow chart.
9- Application
The main purpose is to industrialize this method in the cement industry. Since, cement industry is one of the most energy consumption industries in the world; it can help reduce energy dissipation by 48% significantly.