NL2035284B1 - Product and a method for producing the product - Google Patents
Product and a method for producing the product Download PDFInfo
- Publication number
- NL2035284B1 NL2035284B1 NL2035284A NL2035284A NL2035284B1 NL 2035284 B1 NL2035284 B1 NL 2035284B1 NL 2035284 A NL2035284 A NL 2035284A NL 2035284 A NL2035284 A NL 2035284A NL 2035284 B1 NL2035284 B1 NL 2035284B1
- Authority
- NL
- Netherlands
- Prior art keywords
- product
- water glass
- filler
- phosphorus
- water
- Prior art date
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Classifications
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/24—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing alkyl, ammonium or metal silicates; containing silica sols
- C04B28/26—Silicates of the alkali metals
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B33/00—Clay-wares
- C04B33/02—Preparing or treating the raw materials individually or as batches
- C04B33/13—Compounding ingredients
- C04B33/132—Waste materials; Refuse; Residues
- C04B33/135—Combustion residues, e.g. fly ash, incineration waste
- C04B33/1355—Incineration residues
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/34—Non-metal oxides, non-metal mixed oxides, or salts thereof that form the non-metal oxides upon heating, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/3427—Silicates other than clay, e.g. water glass
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
- C04B2235/72—Products characterised by the absence or the low content of specific components, e.g. alkali metal free alumina ceramics
- C04B2235/727—Phosphorus or phosphorus compound content
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Materials Engineering (AREA)
- Structural Engineering (AREA)
- Organic Chemistry (AREA)
- Combustion & Propulsion (AREA)
- Environmental & Geological Engineering (AREA)
- Dispersion Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Inorganic Chemistry (AREA)
- Processing Of Solid Wastes (AREA)
Abstract
The invention relates to a product comprising a hardened composition of a water glass, wherein a content of the water glass is at least 15% by weight of the product, and a filler, wherein a content of the filler is maximally 85% by weight of the product, and wherein the filler is at least partially embedded in the water glass.
Description
Product and a method for producing the product
The present invention relates to a product and a method for producing the product.
Waste water treatment plants must deal with increasing amounts of sludge. The sludge is coming from among other households. Due to among others an increasing number of inhabitants the amount of sludge increases. The sludge contains a plurality of elements, such as phosphorus and heavy metals. Some of the elements are useful and/or valuable, such as phosphorus. Phosphorus can be used for several purposes, such as a raw material for fertilizer or batteries.
Sludge can be processed via for example a dry or a wet process. In the wet process the sludge is fermented wherein the residual product may contain pathogens. This is a disadvantage of the wet process.
Inthe dry process, the sludge can be incinerated. An advantage of the dry process over the wet process is that in the dry process electricity may be generated. A further advantage of the dry process is a smaller residual flow compared to the wet process.
The dry process may involve incineration of sludge. The sludge incineration ash, such as incinerated sewage sludge ash, can be used as an ingredient for several purposes, such as concrete and asphalt. For these purposes, valuable elements such as phosphor are part of the ash incorporated in for example concrete or asphalt.
The object of the invention is to find a suitable application for sludge incineration ash, wherein the sludge incineration ash is not limited to one specific composition of substances.
The invention thereto proposes a product comprising a hardened composition of: - a water glass, wherein a content of the water glass is at least 15% by weight of the product, and - afiller, wherein a content of the filler is maximally 85% by weight of the product, and wherein the filler is at least partially embedded in the water glass.
The product according to the present invention can be a modular construction product, for example a stone, block, brick, tile, panel. The product can also be a semi-finished product. The product can be used for several purposes, such as an insulating cavity wall, stones with insulating properties, lightweight stones, lightweight aggregate.
An advantage of the application of water glass is a self-hardening process. The hardening of a product comprising water glass can already occur in reaction with normal air. The temperature of the air might be ambient temperature.
A lurther advantage of water glass is that water glass has a relatively short duration of a product's hardening process. A further advantage of combining the filler to water glass is that the pH-value of the mixture of filler and water glass declines with respect to the pH-value of water glass. This allows the hardening time of the product to decrease as well. Based on several test results, the optimal content of water glass is 15% by weight of the product. At least one of the advantages of water glass is advantageous for the production of the product wherein water glass is applied.
The product according to the present invention may comprise a filler, wherein the filler is at least one of: - aresidue comprising a sludge incineration ash wherein a content of phosphorus in the sludge incineration ash by weight of the sludge incineration ash is limited, preferably below 20%, more preferably below 10% even more preferably below 5% and most preferably zero %, - a sludge incineration ash, or a combination thereof.
It is conceivable that the product comprises sludge incineration ash. From an economic, environmental and societal perspective it is advantageous to use sludge incineration ash in a product, such as a modular construction product. Even more when this use of the sludge incineration ash is compared to an alternative use of the sludge incineration ash wherein the sludge incineration ash is dumped.
A further advantage of the product is the relatively simple composition by applying at least water glass and sludge incineration ash. Another advantage of the invention is that by weight of the product relatively more sludge incineration ash can be incorporated compared to a current application of sludge incineration ash in for example concrete or asphalt. This may lead to more efficient processing of the sludge incineration ash flows. Based on several test results, when the content of the sludge incineration ash is 85% by weight of the product, an optimal amount of sludge incineration ash can be processed in the product. it is conceivable that sludge incineration ash comprises phosphorus. lt is also conceivable that the content of phosphorus in the sludge incineration ash can be limited. The phosphorus can be (partially) removed from the sludge incineration ash. After the removal of phosphorus, a residue remains. A residue comprises sludge incineration ash with a limited content of phosphorus. In the context of an economical and climate perspective, there is need for a useful application of the residue. The application for the residue needs to be economically cost-effective. In case an economically cost-effective perspective to deal with the residue is lacking, the residue might be dumped. In the context of a circular economy, this is an undesirable situation.
In this context, it is an advantage to use a residue in a product, such as a modular construction product. The ash of the residue can be reused in this product. The residue can be used in an economic, environmental and societal advantageous manner. Even more when this use of the residue is compared to the alternative use of the residue wherein the residue is dumped.
A further advantage of the product is the relatively simple composition by applying at least water glass and a residue comprising sludge incineration ash with a limited content of phosphor. Based on several test results, when the content of the residue is 85% by weight of the product, an optimal amount of residue can be processed in the product.
The content of phosphorus in the sludge incineration ash by weight of the sludge incineration ash is limited. An advantage of a limited content of phosphorus in the product entails that phosphor can be used for other purposes, such as a raw material for fertilizer or batteries. it is conceivable that a product comprises a sludge incineration ash and a residue.
The average particle size of the product comprising the residue and the sludge incineration ash might be larger than the average particle size of the product comprising the residue. In a transition phase, wherein for example products are produced comprising sludge incineration ash and/or residue, it might be advantageous to apply both the residue and the sludge incineration ash in a product. Also, the ratio between the residue and the sludge incineration ash can varied. The ratio can be varied for example to achieve desired properties, for example physical properties, of the product.
The filler is at least partially embedded in, or enveloped by, the water glass. By embedding the filler in the water glass, the filler is enveloped by the water glass, such that even though less water glass is used it still mostly has the appearance of glass. Additionally, embedding the filler in the water glass allows for a proper distribution of the filler in the glass.
The product according to the present invention may comprise a content of phosphorus in the residue that is maximally 20%, preferably 10%, more preferably maximally 5%, most preferably zero % by weight of the residue. The content of phosphorus in the residue by weight of the residue is maximally 20%, which entails an advantage that phosphor can be used for other purposes, such as a raw material for fertilizer or batteries.
Preferably, the filler is substantially homogeneously distributed throughout the water glass.
This includes an advantage that the physical properties of the product are substantially uniform. A further advantage is that the amount of filler is optimized with respect to the applied amount of water glass.
In the product according to the present invention the content of the water glass is at least 20%, preferably at least 30%, more preferably at least 40%, most preferably at least 50% by weight of the product. An advantage of a higher content of water glass by weight of the product is that the hardening time of the product decreases.
In the product according to the present invention the content of a filler lies between 50% and 85% by weight of the product, preferably between 65% and 85%. An advantage of a content of the filler of 50% by weight of the product is that the hardening time is relatively short. An advantage of a content of the filler of 85% by weight of the product is that an optimal amount of filler can be processed in the product. This may lead to more efficient processing of the residual and/or sludge incineration ash flows. A further advantage is that the physical strength of the product increases when the content of the filler by weight of the product shifts towards one outer limit 85% of the range. 5
In the product according to the present invention a porosity of the product lies between 5% and 40%, preferably between 15% and 30%.
A porosity of the product near 30-40% is advantageous when the product is applied for among other insulating purposes, such as insulating cavity wall, stones with insulating properties. The insulating properties of the product may increase when the porosity shifts within the range towards one outer limit 30-40%.
A porosity of the product near 5-15% is advantageous when the product is applied for for example load-bearing purposes.
It is conceivable that a product comprising a residue is advantageous regarding the load-bearing properties of the product. It is conceivable that a product comprising a sludge incineration ash is advantageous regarding the insulating properties of the product. It is also conceivable that a product comprises a residue and a sludge incineration ash, wherein the ratio between the residue and the sludge incineration ash can be varied. The ratio can be varied, for example to achieve desired insulation and/or load-bearing properties of the product.
In the product according to the present invention, the product may further comprise at least one admixture. The purpose of adding an admixture to the product is for example dispersion, retarding, accelerating, air-entrainment, water resisting, corrosion inhibiting, shrinkage-reducing, anti-washout, pumping aids, spraying, foaming. By adding an admixture to the product, at least one specific property of the product may improve. This might be advantageous in case of a specific application of the product.
Inthe product according to the present invention, the product may further comprise water. In the context of the processibility of the product, it is advantageous to add water to the product.
The invention further relates to a method for producing a product, such as a product of the present invention, that comprises the steps of:
- A) applying the water glass to the filler, wherein a ratio water glass to filler lies between 20:80 and 50:50, - B) pouring a composition of the water glass and the filler in a mold, - C) hardening of the composition of the water glass and the filler in the mold.
An advantage of the application of water glass is a self-hardening process. The hardening of a product comprising water glass can already occur in reaction with normal air. The temperature of the air might be ambient temperature.
A further advantage of water glass is that it has a relatively short duration of the hardening process of a product. A further advantage of combining the filler to water glass is that the pH-value of the mixture of filler and water glass declines with respect to the pH-value of water glass. This allows the hardening time of the product to decrease as well.
Preferably, step A) of the present invention is preceded by the following step leaching at least a part of the phosphorus from the filler. The obtained phosphorus can be (re)used for several purposes, such as fertilizer or batteries.
In order to leach at least a part of the phosphorus from the filler, a leaching agent can be applied to the product. The leaching agent can be an acid solution, such as sulfuric acid, phosphoric acid, hydrochloric acid, perchloric acid, hydrofluoric acid, nitric acid. Sulfuric acid does not react well with cement, for example due to ettringite formation. Sulfuric acid reacts well with water glass. This is an advantage of water glass over the application of cement. After the leaching, the leach solution needs to be separated from the undissolved residue. The undissolved residue can be further used for step B and further.
In an embodiment of the method according to the present invention in step A) the water glass is a water glass in a liquid state. It is conceivable that water glass is a potassium-based water glass or a sodium-based water glass, or a modification of both aforementioned types of water glass, or a water glass with another base.
In an embodiment of the method according to the present invention in step A) the water glass is a dissolvable powdered water glass. The dissolvable powdered water glass can be applied to the filler. The water glass and the filler have a powdery state. These substances can be mixed. The powdery state allows a substantially homogenously distribution of the substances in a mixture. A fluid can be added to the mixture. After a fluid is added to the mixture, the mixture can be hardened having a substantially homogenously distribution of the substances. It is also conceivable that a pressure is applied to the mixture of the substance in order to obtain a hardened product.
In an embodiment of the method according to the present invention, step B) comprises squeezing a composition of the water glass and the filler in a mold.
A product wherein a filler comprises sludge incineration ash or residue and sludge incineration ash, might have an average particle size that is larger than the average particle size of the product comprising the residue. In order to put the composition of the water glass and the sludge incineration ash or residue and sludge incineration ash in a mold, this might be done by squeezing the composition. Also, in case of a ratio water glass to filler that is shifting towards one outer limit 20:80 of the range, preferably the composition of the water glass and filler might be squeezed in a mold.
In an embodiment of the method according to the present invention, step A) further comprises applying water and/or at least one admixture, wherein the composition of step B) further comprises water and/or at least one admixture, wherein the composition of step C) further comprises water and/or at least one admixture. In the context of the processibility of the product, it is advantageous to add water to the product.
The purpose of adding an admixture to the product is for example dispersion, retarding, accelerating, air-entrainment, water resisting, corrosion inhibiting, shrinkage-reducing, anti-washout, pumping aids, spraying, foaming. By adding an admixture to the product, at least one specific property of the product may improve.
This might be advantageous in case of a specific application of the product.
An embodiment of the method according to the present invention further comprises astep D) of leaching at least a part of the phosphorus from the product.
The product allows the (limited content of) phosphorus to be stored. The storage of phosphorus can be permanent or temporarily. After a certain period, the (limited content of) phosphorus can be removed from the product, for example by leaching the phosphorus. Consequently, the obtained phosphorus can be (rejused for several purposes, such as fertilizer or batteries.
An embodiment of the method according to the present invention further comprises a step D) of removing at least a part of the phosphorus from the product by a heat treatment. The product allows the (limited content of) phosphorus to be stored. The storage of phosphorus can be permanent or temporarily. After a certain period, the (limited content of) phosphorus can be removed from the product, for example by a heat treatment of the product. Consequently, the obtained phosphorus can be {(re)used for several purposes, such as fertilizer or batteries.
The invention will be further elucidated by means of a non-limiting exemplary embodiment illustrated in the following figure. Figure 1 shows a representation of an embodiment of the product (1) of the present invention. A product wherein the filler (3) is at least partially embedded in the water glass (2).
Claims (17)
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| NL2035284A NL2035284B1 (en) | 2023-07-06 | 2023-07-06 | Product and a method for producing the product |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| NL2035284A NL2035284B1 (en) | 2023-07-06 | 2023-07-06 | Product and a method for producing the product |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| NL2035284B1 true NL2035284B1 (en) | 2025-01-13 |
Family
ID=88206974
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| NL2035284A NL2035284B1 (en) | 2023-07-06 | 2023-07-06 | Product and a method for producing the product |
Country Status (1)
| Country | Link |
|---|---|
| NL (1) | NL2035284B1 (en) |
Citations (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| AU538681B2 (en) * | 1979-03-21 | 1984-08-23 | P.F.I. (Aust.) Pty. Ltd. | Fire retardant panel |
| DE10129873C1 (en) * | 2001-06-21 | 2002-10-24 | Iff Weimar | Light building material used in the production of molded bodies for walls, ceilings and roofs consists of plant or mineral additives, and activated aluminosilicate compounds in the form of a reactive mixture |
| US20080006383A1 (en) * | 2004-11-05 | 2008-01-10 | Jong-Won Park | Pulp Sludge Ash Composition for Producing Building Materials |
| JP2008308396A (en) * | 2007-06-15 | 2008-12-25 | Natoo Kenkyusho:Kk | Water-containing composition, utilization and treatment method, and non-polluting water-resistant treated object |
| US20130029129A1 (en) * | 2010-03-05 | 2013-01-31 | Gmatek Co., Ltd. | Ceramic composition, porous ceramic heat insulating material using same, and preparation method thereof |
| WO2021185734A1 (en) * | 2020-03-16 | 2021-09-23 | Technische Universität Bergakademie Freiberg | Process for producing a geopolymer concrete and/or mortar |
| CN114591036A (en) * | 2022-03-09 | 2022-06-07 | 范冬晗 | Zeolite-based geopolymer ecological building block material and building block manufacturing method |
-
2023
- 2023-07-06 NL NL2035284A patent/NL2035284B1/en active
Patent Citations (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| AU538681B2 (en) * | 1979-03-21 | 1984-08-23 | P.F.I. (Aust.) Pty. Ltd. | Fire retardant panel |
| DE10129873C1 (en) * | 2001-06-21 | 2002-10-24 | Iff Weimar | Light building material used in the production of molded bodies for walls, ceilings and roofs consists of plant or mineral additives, and activated aluminosilicate compounds in the form of a reactive mixture |
| US20080006383A1 (en) * | 2004-11-05 | 2008-01-10 | Jong-Won Park | Pulp Sludge Ash Composition for Producing Building Materials |
| JP2008308396A (en) * | 2007-06-15 | 2008-12-25 | Natoo Kenkyusho:Kk | Water-containing composition, utilization and treatment method, and non-polluting water-resistant treated object |
| US20130029129A1 (en) * | 2010-03-05 | 2013-01-31 | Gmatek Co., Ltd. | Ceramic composition, porous ceramic heat insulating material using same, and preparation method thereof |
| WO2021185734A1 (en) * | 2020-03-16 | 2021-09-23 | Technische Universität Bergakademie Freiberg | Process for producing a geopolymer concrete and/or mortar |
| CN114591036A (en) * | 2022-03-09 | 2022-06-07 | 范冬晗 | Zeolite-based geopolymer ecological building block material and building block manufacturing method |
Non-Patent Citations (1)
| Title |
|---|
| "Sustainable Concrete Made with Ashes and Dust from Different Sources", 1 January 2022, ELSEVIER, ISBN: 978-0-12-824050-2, article TOLEDO FILHO ROMILDO DIAS ET AL: "Sewage sludge ash", pages: 233 - 279, XP093138099, DOI: 10.1016/B978-0-12-824050-2.00010-3 * |
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