BRPI0802973A2 - METHODS OF WASTE FOR THE USE OF NATURAL STONE ALUMINA SULPHATE PREPARATION FOR THE MANUFACTURE OF CONSTRUCTION MATERIALS - Google Patents

Abstract

METHODS OF USING THE WASTE FOR THE PREPARATION OF NATURAL ROCK ALUMINUM SULPHATE FOR MANUFACTURING CIVIL CONSTRUCTION MATERIALS. Refers to compositions and technologies for the manufacture of new building materials, based on natural waste, rich in aluminum sulfate, for the production of different building materials. The present patent includes three types of methods (compositions and technologies) for producing materials of different composition and manufacturing technologies: 1. the production of solid bricks and holes with bricks by means of waste compaction methods named above with waste from fell, either with market lime, or with Potrland cement or other locally available materials with binder properties; 2. the production of tailings blocks from the Portland cement aluminum sulfate-making process, similar to concrete blocks, by compacting mixtures in chosen and homogenized percentages, hydrating and compacting them in vibration-presses or presses; 3. the production of tailings mortars named with lime production residues, or with market-dropped virgin, or Portland cement, or mixtures thereof in varying proportions to achieve desirable and economically pleasing mechanical properties.

Description

METHODS OF USING THE WASTE FOR THE PREPARATION OF ALUMINUM SULFATODE PREPARATION FOR THE MANUFACTURE OF CIVIL CONSTRUCTION MATERIALS.

The present invention relates to methods (compositions and technology), called METHODS OF USE OF NATURAL ROCK ALUMINUM SULPHATE PREPARATION FOR MANUFACTURING CIVIL CONSTRUCTION MATERIALS, for the construction of natural rocks, based on waste rich with aluminum sulfate, for the production of different building materials - blocks, solid bricks, hole bricks, blocks, mortars, sleepers, etc.At the end of the aluminum sulfate separation technological process (approximately 20 - 30% by weight) of natural rock), the tailings of this process are represented as a mixture of quartz of different particle size (from 3-20 mm) to silt and clay in various proportions, contaminated with aluminum sulfate. The final destination of large quantities (70 - 80% or more of ore rock weight) of this waste has generated major environmental and economic problems.

Residues from lime production are composed of lime with total oxides in the volatile basement (CaO + MgO) <88%, ie with total content of other chemical elements, badly burnt limestone, etc., more than 12% (NBR-6453). . Lime-producing wastes used in this study have more than 18% CaC03. However, the CaC03 content may differ and depends on the quality of limestone burning, the time after lime manufacture and the conditions under which it is stored. Waste from lime production generates major environmental problems. The objectives of the present patent are:

1. use more waste from the aluminum sulfate manufacturing process in combination with other local industrial waste or market materials to make them building materials and contribute to environmental protection;

2. Develop new material compositions for civil construction applications with greater economic utilization and sufficient characteristic properties according to NBR-8953 and NBR-13279.The present patent includes three types of methods (compositions and technologies) using these tailings as main raw materials. Production of civil construction materials with different initial mix compositions and different manufacturing technologies: 1. the production of solid bricks and holes with bricks by decomposing tailings methods named above with lime production residues, or (in case of lack lime production site as the main binder material or to increase end product strength) with market lime, or with Potrland cement or other locally available materials with binder properties. Components need to be mixed in different proportions in advance chosen to meet the demands of end product characteristics. The compaction of homogenized and hydrated mixtures can be performed with single or double-sided (better) presses. Curing bricks with lime or virgin lime residue may occur in the open air. Portland cement brick curing can be performed in damp chambers or with synthetic brick coverings for moisture conservation as long as possible;

2. The production of Portland cement tailings blocks, similar to concrete blocks, by compacting mixtures in chosen and homogenized percentages, hydrating and compacting them in vibration-presses or presses. Curing of these blocks can also be performed in damp or wet coverings of synthetic materials for moisture conservation as long as possible;

3. the production of tailings mortars named with lime production residues, or market-based lime, or Portland cement, or mixtures thereof in varying proportions to achieve desirable and economically pleasing mechanical properties.

The waste content of the aluminum sulphate manufacturing process as the main component of the initial mixtures can be as high as 85% or more, depending on the binder properties used, compaction methods, water / solids ratio in the mixtures, curing conditions and requirements. In order to avoid the tailings drying dumps, they can be used damp.The material properties of NATURAL ROCK ALUMINUM SULPHATE WASTE METHODS FOR CONSTRUCTION CONSTRUCTION MATERIALS MANUFACTURING virtually the same properties as concrete. Materials using lime or virgin lime production residues have values of mechanical properties much lower, but always equal or above NBR requirements to the materials produced (bricks, tiles, mortar, etc.). For the realization of the first patent product ( bricks, slabs, etc.) With the use of tailings from the aluminum sulphate manufacturing process at the industrial level, locally available and environmentally pure materials (without heavy metal content above the NBR demands) can be used as raw material:

• Lime production residues (or market virgin lime or milled steel slag from different high-Ca2 technological processes or Portland cement);

• wood burning ash (or oil shale ash, or charcoal ash, or rice husk burning ash or other relatively inexpensive grasses);

• natural sand, silt, gravel or clay.

Natural rock cutting and polishing tailings or other aggregate types may also be used.

TECHNOLOGY FOR MANUFACTURING BRICK AND TILES METHODS OF WASTE FOR THE USE OF ROCKNATURAL ALUMINUM SULPHATE FOR CIVIL CONSTRUCTION MANUFACTURINGincludes component homogenization to achieve the best application characteristics, which yields the best features. Tailings ector of aluminum sulfate manufacturing process can reach level up to 90% by weight with tailings moisture without preliminary drying.

The technological processes of brick and tile manufacturing of this patent include the following operations: 1. dosage of components of the mixture as a desirable percentage, which depends on the expected properties of the end products; mixture homogenization of components;

3. compacting the homogenized mixture with experimentally determined forming pressure;

4. depositing the compacted materials in open air at ambient temperature or autoclaving under conditions (temperature and pressure determined in advance) in case of use as residual lime binders or virgin market lime; deposit of the compacted materials in the humid environment (in case of use as binder Portland cement or slag).

The homogenized mixture will be compacted by the pressing method with different one-sided or two-sided compaction efforts (much better). Compaction of the two-sided ready mix increases the mechanical properties of the end product. The compaction force in this study was 10 MPa with traditional uniaxial pressure on one side. Mechanical property values increase with curing time in open air. Uniaxial compressive strength of samples of different compositions from this study using as a binder the lime production residue on the 3rd curing day usually ranges from 3 to 5 MPA at 14 ° C. day - 7-8 MPa and on the 28th day between 9-11 MPa. Resistance continues to grow up to one year or more. According to NBR 7170 (1983) the uniaxial strength of solid bricks should be as follows: Class A <2.5 MPa,

Class B 2.5 <4.0 MPa Class C> 4.0 MPa.

The strength value of this material may be increased by changing the percentage of the components of initial mixtures, especially the content of lime, commercial lime or Portland cement, steel slag, and other binder materials, or by changing technological processes (increasing the degree of granulometry in the milling of lime production or steel slag, forming pressure, or use of two-sided material pressing method, etc.), analogous to concrete.

The materials have high values of water resistance and low coefficient of dedication.

The second patented material in NATURAL ROCK ALUMINUM SULPHATE WASTE REMEMBER WASTE METHODS FOR MANUFACTURING CIVIL CONSTRUCTION MATERIALS are the blocks, developed from blends of the pre-drying moisture-free aluminum sulphate tailing process tailings up to 90% by weight of initial mixtures.

The technological processes of block making of this patent include the following operations:

• dosing of components (Portland starting aluminum sulfate tailings and water) of the desired percentage mixture, which depends on the expected properties of the end products;

• homogenization of the mixture of components;

• compaction of the homogenized mixture with vibration press or single or double sided press for experimentally determined time;

• These blocks can be cured in damp chambers or covered with synthetic materials to maintain moisture as long as possible.

For the realization of a third patent product - mortar - with properties equal to or higher than conventional mortar properties at the industrial level, the following materials may be used as raw material:

• rejection of the process of elaboration of aluminum sulfate;

• wastes from the production of lime (or market-based lime, or fine slag from different technological processes, or Portland cement or different mixtures thereof),

• Sand, natural silt or similar materials, such as cutting tailings and peeling of natural rocks or other types of natural or industrial materials. For the use of aluminum sulphate processing process tailings as the main raw material for mortars, it is necessary to separate the fractions from them. most desirable with the screening method. Other mortar manufacturing processes are about the same as conventional mortar preparation processes.

The utilization of these composites of industrial waste mentioned above used as raw material for the manufacture of bricks, blocks and mortar allows the obtaining of building materials with characteristics similar to or superior to those of traditional materials, but with lower costs.

The biggest advantages of METHODS OF USING NATURAL ROCK ALUMINUM SULPHATE WASTE FOR MANUFACTURING CIVIL CONSTRUCTION MATERIALS over traditional methods of producing solid bricks and ceramic blocks are:

1. energetic: for the production of developed concrete-like materials no high temperatures are required for solid brick making with high energy loss;

2. Mechanical strength: The experimental results of this patent include research results exclusively with ETA sludge and lime-producing residues. Undoubtedly, traditional binder materials (Portlande market lime cement) can significantly increase the strength values of new materials;

3. economical: very low cost of raw materials - industrial waste (ETA sludge, ashes of different fuels, steel slag and lime production waste) ensuring a high economic effect of producing these materials;

4. Environmental: The method developed in this patent is based on the maximum use of various industrial wastes and therefore has strong contribution to environmental protection issues;

5. social: use of all industrial landfill waste as the components

New materials can undoubtedly improve the quality of life of the local population. In addition, for the production of new developed materials it is necessary to create a network of new companies with generation of new jobs.

The products obtained by the methods of use of natural aluminum rock sulfate elaboration for the manufacture of civil construction materials are based on the maximum use of non-hazardous industrial waste class II and therefore have a strong contribution to the issues that concern the use of non-hazardous industrial waste. of the environment.

Claims (4)

1. METHODS FOR USING THE WASTE FOR THE PREPARATION OF NATURAL ROCK ALUMINUM SULPHATE FOR THE MANUFACTURE OF CIVIL CONSTRUCTION MATERIALS These are various compositions and technologies characterized by the mixtures of the following materials: • Natural aluminum sulfate rejection process; • residues from the production of lime (or market-based lime, or milled steel slag from different technological processes with high CaO content, or Portland cement) • wood burning ash (or oil shale ash, or coal ash, or ash) burning rice husk or other relatively inexpensive grasses) • natural sand, silt, gravel or clay.The technological processes for the manufacture of bricks and tiles of this patent include the following operations: -1. dosage of mixing components in desirable percentage, which depends on the expected property values of the end products; homogenization of the mixture of components; compaction of the homogenised mixture with experimentally determined formation pressure; depositing the compacted materials in open air at ambient temperature or autoclaving under conditions (temperature and pressure determined in advance) in the case of use as residual lime binders or market virgin lime; depositing the compacted materials in the wet environment (in case of use as Portland cement binder or steel slag). The technological processes of block manufacturing of this patent include the following operations: • the dosing of components (Portland cement aluminum sulfate tailings and desired percentage mixture, which depends on the expected property values of the end products • the homogenization of the component mixture • the compaction of the homogenized mixture with a vibro-press or single or double sided press for an experimentally determined time; • Curing of these blocks can be performed in damp chambers or coverings of materials with synthetic materials to conserve moisture for as long as possible. For the realization of the third patent product - mortar - with equal or higher properties it is necessary to separate the desired fractions from the waste with sift nto. Other mortar manufacturing processes are practically the same as conventional mortar preparation processes.