BRPI0802987A2 - METHODS OF USING WATER TREATMENT STATUS AS A MAIN COMPONENT OF CERAMIC PRODUCTION AND NEW CONCRETE MATERIAL - Google Patents

Abstract

METHODS OF USE OF WATER TREATMENT STATION AS A MAIN COMPONENT OF CERAMIC PRODUCTION AND NEW TYPE OF CONCRETE MATERIAL. Refers to compositions and technologies for the manufacture of new materials such as bricks and ceramics for application in civil construction, based on waste from municipal and industrial water treatment plants (ETA iodine) with high humidity (usually up to 80% or more). The ETA sludge content as a major component of starting mixtures can be as high as 60% or more depending on the properties and percentages of the other components used to prepare these starting mixtures and the demands on the mechanical properties of fabricated materials. To decrease moisture in mixtures, wood burning ash (or oil shale ash, or coal ash, or rice husk burning ash or other grass and other water absorbers) can be used. For the production of concrete-like materials such as ETA Iodine binders, lime or steel slag or Portland cement tailings may be used, either independently or in combination. For the production of ceramics it is necessary to incorporate natural clay, usually in the range of 10 - 20%.

Description

METHODS OF USING WATER TREATMENT STATION SLUDGE AS A MAIN COMPONENT OF CERAMIC PRODUCTION AND NEW KIND OF CONCRETE MATERIAL.

The present invention relates to the method (compositions and technology), called METHODS OF USE OF WATER TREATMENT STATION AS A MAIN CERAMIC PRODUCTION COMPONENT AND NEW TYPE OF CONCRETE SIMILAR MATERIAL FOR waste base from municipal and industrial water treatment plants - ETA sludge - to save high costs on this technological process.

Usually to sediment the particles of solid substances all Stations use aluminum or iron sulfates. There are some methods of using ETA sludge as production components of bricks with sludge content between 4 and 8 wt. But this percentage cannot correspond to the demands of environmental preservation. Because of the lack of economically and environmentally sufficient methods practically all WTP Iodine accumulates in landfills, contaminating the environment or, even worse, back into river streams slightly below the location of the Treatment Stations and thus create a larger water contamination of natural reservoirs (rivers and lakes).

The objectives of the present patent are:

1. use more sludge and ETA in combination with other industry wastes to make them building materials and contribute to the protection of the environment;

2. Develop new materials compositions for application in civil construction with greater economic use, and sufficient characteristic properties in accordance with NBR-8953 and NBR-13279.

In this patent the ETA sludge content as a main component of starting mixtures can reach the level of 80% or more depending on the properties and percentages of other components used and the demands on the mechanical properties of fabricated materials.

To overcome pathogenic bacteria in water from rivers or lakes there is a strong need for chemicals such as sodium hypochlorite in quantity depending on the level of bacterial contamination. This patent includes two types of new building materials with different initial mix compositions and with different manufacturing technologies.

The first patented material METHODS OF USE OF WATER TREATMENT STATION AS A MAIN CERAMIC PRODUCTION COMPONENT AND NEW TYPE OF CONCRETE MATERIAL are solid bricks, with holes and blocks with properties similar to concrete properties.

For the realization of the first patent product (bricks with properties similar to concrete properties) at industrial level can be used as dry raw material, the materials are always available being environmentally pure (without heavy metals above NBR):

• ETA sludge with usual moisture content (up to 75 - 80% water content) without preliminary drying;

• lime production wastes (or virgin market lime, or steel slag from different technological processes, or Portland cement);

• wood burning ash (or shale ash, or coal ash, or rice husk burning ash or other grass and other relatively inexpensive and locally available ETA sludge water absorbers),

• natural sand or clay.

Silt, gravel, shearing and polishing tailings from natural rocks or other aggregate types with partial decrease in ETA sludge percentage may also be used.

Lime production residues are composed of lime with total oxides in non-volatile base (CaO + MgO) <88%, ie with total content of other chemical elements, badly burnt limestone, etc., more than 12% (NBR-6453 ). Waste from lime production used in this study has more than 18% of CaC03. However, the CaC03 content may differ and depends on the quality of limestone burning, the time after lime manufacture and the storage conditions. The final destination of this waste has generated major environmental and economic problems.

The manufacturing technology of WATER TREATMENT STATE SLUDE METHODS "concretes" as a MAIN CERAMIC PRODUCTION COMPONENT and NEW CONCRETE MATERIAL TYPE includes component homogenization as a percentage of components until the final product is reached. present the best features required for your application. ETA sludge content can reach level up to 80% by weight with real sludge moisture up to 85% without preliminary drying.

Technological processes for manufacturing materials similar to the concrete of this patent include the following operations:

1. dosage of mixing components in desirable percentage, which depends on expected property values of the end products;

2. Mix homogenization of the above components;

3. compaction of homogenized mixture with experimentally determined formation pressure;

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

The homogenized mixture will be compacted by the pressing method with different compaction forces on one side or (much better) on two sides. Two-sided ready-mix compaction enhances 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 open air cure time.

The uniaxial compressive strength of samples from different compositions of this study on the 3rd day of cure usually ranges between 3 and 5 MPA, on the 14th day -7-8 MPa and on the 28th day between 9-11 MPa. Resistance continues to grow for a 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 lime, commercial lime or Portland cement waste content of technological processes (increasing the degree of particle size in the grinding of waste). production of lime or steel slag, forming pressure, or the use of two-sided material pressing method, etc.), analogous to concrete.

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

The second patented material in WATER TREATMENT STATION SLUDE METHODS AS A MAIN CERAMIC PRODUCTION COMPONENT AND NEW TYPE OF CONCRETE SIMILAR MATERIAL are ceramic materials, developed from mixtures of ETA sludge with actual sludge moisture. 75-80%) without preliminary drying and with sludge content up to 80% by weight of initial mixtures. The technological processes for manufacturing ceramic materials of this patent include the following operations:

• dosage of mixing components in desirable percentage, which depends on the expected property values of the end products;

• homogenization of mixture of components;

• compaction of homogenized mixture with experimentally determined formation pressure;

• drying to constant weight;

• Burning with pre-chosen temperature and regime.

ETA sludge has been mixed with other types of readily available environmentally pure industrial waste (without heavy metals above NBR) named above as production components of concrete-like materials and other relatively inexpensive ETA sludge water absorbers incorporating clay. Natural.

The homogenised mixture must be compacted by the pressing or extrusion method and dried to constant weight. Dry products should be burned at approximately 700 to 950 ° C for up to 6 hours at maximum temperature.5 / 6

The three-point flexural strength values of the burnt samples range from 4 to 12 MPa. According to NBR 7171 (1992) the uniaxial strength of ceramic blocks must be as follows:

Class 15 = 1.5 <2.5 MPa,

Class 25 = 2.5 <4.5 MPa.

Experimental results of this patent demonstrate that materials obtained with the method of this patent can replace all solid bricks of classes A, B and C and ceramic blocks of classes 15 and 25.

Comparison of strengths of new ceramics with conventional ceramics demonstrates the advantage of ceramics of WATER TREATMENT STATION METHODS AS A MAIN COMPONENT OF CERAMIC PRODUCTION AND NEW TYPE OF CONCRETE MATERIAL.

The water absorption capacity (from 10.3 to 16.2%) also corresponds to the demand for NBR 7171 for ceramic masonry block (it should not be less than 8% or more than 25%).

All ceramic materials developed have heavy metal leaching much lower than the requirements defined in Brazilian and international standards. The low cost of raw materials (industrial waste) ensures a great economic effect for the production of these materials.

Resistance values and other mechanical properties of these materials can be increased by changing the percentage of the starting mix components and by changing technological processes (compaction pressure, temperature and burn time at maximum temperature, heating and cooling regime, etc.). ) according to the demands of civil construction or NBR.

The use of the abovementioned industrial waste composites, used as raw material for the manufacture of "concretes" and ceramics of this patent, allows the obtaining of building materials with characteristics equal to or superior to those of traditional materials (bricks, tiles, etc.). therefore presenting lower cost price.

The use of these industrial waste composites allows the obtaining of building materials with characteristics equal to and / or better than the characteristics of conventional building materials produced from traditional natural raw materials (natural stones, sand, silt, etc.) with higher commercial cost (Portland cement) .The biggest advantages of WATER TREATMENT STATION SLUDGE METHODS AS A MAIN CERAMIC PRODUCTION COMPONENT AND NEW TYPE OF CONCRETE MATERIAL compared to traditional solid brick and block production methods ceramics are:

1. energetic: for the production of materials similar to the developed concrete, it is not necessary to manufacture high temperatures of solid bricks with the loss of great energy;

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

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

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

5. Social: Utilization of all industrial landfill waste as components of new materials can undoubtedly improve the quality of life of the local population. In addition, for the production of new materials developed it is necessary to create a network of new companies with generation of new jobs.

The products obtained by WATER TREATMENT STATION SLUDE METHODS TECHNOLOGIES AS A MAIN CERAMIC PRODUCTION COMPONENT AND NEW CONCRETE LIKE MATERIAL are composites based on the maximum use of non-hazardous Class II industrial waste and therefore have strong contribution to environmental protection issues.

Claims (5)

1. METHODS OF USE OF WATER TREATMENT STATION AS A MAIN COMPONENT OF CERAMIC PRODUCTION AND NEW TYPE OF CONCRETE MATERIAL These are various compositions and technologies characterized by being obtained from mixtures of the following materials: -1. ETA sludge with usual moisture content (up to 75 - 80% water content) without preliminary drying, -2. wastes from the production of lime (or market - based lime, or steel slag from different technological processes, or Portland cement),. wood burning ash (or oil shale ash, or coal ash, or rice husk burning ash or other grass and other relatively inexpensive locally available ETA sludge water absorbers), - 4. natural sand or clay. Technological processes for the manufacture of materials similar to the concrete of this patent include the following operations: -1. dosage of mixing components in desirable percentage, which depends on expected property values of the end products; -2. homogenization of mixture of components; compaction of homogenized mixture with experimentally determined formation pressure; depositing the compacted materials in open air at ambient temperature or autoclaving under conditions (pre-determined temperature and pressure) in case of use as residual lime binders or virgin lime; deposit of compacted materials in a humid environment (in case of use as binder Portland cement or steel slag). The technological processes for manufacturing ceramic materials 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 mixture of components; compaction of homogenized mixture with experimentally determined formation pressure; drying to constant weight; burning with pre-selected temperature and regime.