WO2024209454A1

WO2024209454A1 - Effective use of incinerated bottom ash as a cement substitute in concrete products

Info

Publication number: WO2024209454A1
Application number: PCT/IB2024/055118
Authority: WO
Inventors: Bahar BAGHERNEJAD HAMZEHKOLAEE
Original assignee: Individual
Current assignee: Individual
Priority date: 2024-05-26
Filing date: 2024-05-26
Publication date: 2024-10-10
Anticipated expiration: 2026-11-26

Abstract

A method for producing a concrete product that incorporates incinerated bottom ash as a partial replacement for cement. The method involves sieving the bottom ash to separate it into fine and coarse aggregates. The fine aggregate is used as a mineral filler in the concrete mixture to enhance it s strength, while the coarse aggregate is utilized to produce lightweight bedding blocks that help reduce the dead load of buildings.

Description

The production process of construction materials from bottom ash remaining from municipal waste incineration with the ability to strengthen concrete and lightening the buildings

Maintaining and inspecting power transmission systems is a vital task that requires expertise and attention to detail. These systems are responsible for transmitting electricity over long distances and operate at high voltages, which can pose a danger to human safety. The magnetic fields generated by the transmission lines add another layer of complexity to the maintenance and repair process, making it essential to take all necessary precautions to ensure worker and public safety.

Additionally, power transmission lines are usually situated at great heights, requiring specialized equipment and highly skilled professionals to perform maintenance and repair tasks safely. These professionals must have the appropriate knowledge and experience to identify and address any potential issues with the transmission system, ensuring that it operates efficiently.

Despite the challenges involved in power transmission system maintenance, it is a crucial aspect of ensuring the reliable and safe delivery of electricity to homes and businesses worldwide. A well-maintained and properly functioning power transmission system is essential to support the modern global economy, making it imperative that we continue to prioritize these critical infrastructure components.

E02D 5/00

WO2023275882 - A method for producing concrete using the bottom ash of thermal power plants

The present disclosure provides a method for producing concrete for structural and non-structural applications using the bottom ash of thermal power plants. The method comprising obtaining bottom ash as available from a thermal power plant, and determining the maximum extent of using the obtained bottom ash as a partial replacement material for natural river sand and/or supplementary cementitious material to prepare a blended material for producing bottom ash concrete based on material characteristics of the obtained bottom ash. The method comprises preparing a bottom ash concrete mix by including other raw materials with the blended material based on a final mix design. The final mix design is identified by performing a plurality of trials on the bottom ash concrete samples prepared based on a set of mixes. The method includes pouring the bottom ash concrete mix into formwork depending on the application of the bottom ash concrete at a construction site.

Our invention uses bottom ash and fly ash produced from incineration of municipal waste, however, the mentioned invention uses the bottom ash produced from thermal power plants.

United States Patent 11267755- Construction material with improved strength and water resistance and methods of forming the same

The invention is directed to a mine tailing and fly ash containing construction material having improved compressive strength and water resistance. The mine tailing and fly ash containing material includes mine tailing, fly ash, an alkali solution comprising sodium hydroxide and, optionally, calcium hydroxide, and water. The invention further provides a geo-polymerization method for forming a mine tailing and fly ash-containing construction material.

The present invention is about the improvement of compressive strength in construction materials containing fly ash and mine tailing. In the meanwhile, our invention is about producing construction materials using different types of ash, such as washed ash, bottom ash, and fly ash.

Both of the inventions care about preserving nature and they want to reduce unused waste, but our invention in addition to paying attention to the environment, by using the necessary methods and techniques, improves the quality of concrete, lightens the building, reduces the cost of construction and preserves the environment.

CN108503285 - Method for preparing light high-strength concrete

The invention relates to the technical field of concrete and preparation and particularly relates to a method for preparing light high-strength concrete. The method for preparing the light high-strength concrete comprises the following steps: uniformly mixing the following components in parts by weight: 25-45 parts of coal ash, 15-35 parts of cement, 15-30 parts of fine sand, 5-12 parts of kieselguhr, 3-15 parts of light calcium carbonate, 3-12 parts of polymeric aluminum, 15-48 parts of lightweight aggregate, 1-5 parts of a reinforced fiber and 1-5 parts of graphene oxide under a mechanical stirring condition so as to obtain a mixture; further uniformly mixing with a water reduction agent, aids and a foaming agent, and performing pressing molding, so as to obtain a concrete test sample. The light high-strength concrete prepared by using the method provided by the invention has the characteristics of being light in weight, high in strength, and good in weather resistance, index requirements on properties of concrete of the building industry can be met, and a relatively good application prospect can be achieved.

The invention above aims to produce lightweight concrete as well, but the used materials are different from the present invention as it uses fly ash and bottom ash produced from incineration, while the invention above uses coal ash. The other products are also different from ours, for example, kieselguhr, calcium carbonate, and other materials are not used in our invention.

CN107556046 - Preparation method of light concrete product

The invention discloses a preparation method of a light concrete product. The preparation method comprises the following steps: (1) oxidizing sulfur dioxide of flue gas in the presence of a catalyst into sulfur trioxide and oxidizing nitric oxide into nitric dioxide, and then performing dry desulfurization and denitrification by using a magnesium oxide-containing absorbent so as to form a byproduct, the primary components of which are sulfate and nitrate; (2) uniformly mixing the byproduct, a light aggregate, a sand material, coal ash, slag, building wastes and an optional additive so as to form a mixture; and (3) mixing the mixture with industrial wastewater and then forming, vibrating, demolding and maintaining the mixture so as to form the light concrete product. According to the preparation method disclosed by the invention, industrial waste liquor can be reduced, and industrial solid wastes are fully utilized, so that the qualified light concrete product is obtained.

The invention above uses different materials like sand, aggregate, slag, etc. for lightening the concrete, while our invention uses only bottom ash and fly ash as the substitutional material for cement for this aim.

JP1996277153 - LIGHT-WEIGHT HIGH-STRENGTH CONCRETE

This light-weight high-strength concrete uses an artificial aggregate of fly ash having 1.8-2.2 absolute dry specific gravity as a coarse aggregate. The artificial aggregate of fly ash is obtained by baking a granule consisting essentially of fly ash and comprises <50wt.% of particles having 5-10mm particle diameter and 50wt.% of particles having 10mm particle diameters. The percentage of absolute volume of the artificial aggregate of fly ash is 65%, preferably 63-70%, the unit volume weight of the concrete is 2.0-2.2kg/1 and the unit cement (e.g. Portland cement) amount is 400kg/m3. The added amount of a high-performance water reducing agent (a polycarboxylic acid-based high- performance water reducing agent) is 0.1-10wt.% based on 100 pts.wt. of a binder. Calcium nitrite is effectively added.

The invention above uses different percentages of fly ash to produce lightweight concrete, as well as different materials like cement and aggregates. Meanwhile, our product uses both bottom ash and fly ash from the incineration of municipal waste for the same goal.

CN108117331 - Method for making light-permeable concrete building block

The invention discloses a method for making a light-permeable concrete building block and belongs to the technical field of building materials. The method comprises the following steps: drying a coconut shell fiber so as to obtain a dried coconut shell fiber; stirring and mixing the dried coconut shell fiber with tetrabutyl titanate, and filtering so as to obtain a pretreated coconut shell fiber; performing heat-preservation carbonization on the pretreated coconut shell fiber, and cooling so as to obtain a pretreated carbonized coconut shell fiber; stirring and mixing the pretreated carbonized coconut shell fiber with a calcium hydroxide saturated solution, introducing carbon dioxide, filtering, introducing nitrogen, and performing a heat-preservation reaction so as to obtain modified carbonized coconut shell fiber; stirring and mixing cement, river sand, silicon fume, coal ash, mineral slag, water, a water reduction agent, a silane coupling agent, the modified carbonized coconut shell fiber and modified sepiolite so as to obtain mixed slurry; injecting the mixed slurry into a mold, leaving to stand, and demolding so as to obtain a concrete building block; soaking the concrete building block into a resin, vacuuming, performing heating curing, and performing polishing and waxing, thereby obtaining the light-permeable concrete building block. The light-permeable concrete building block made by using the method is excellent in light permeability and mechanical properties.

CN1148578 - High fly-ash-contained foam concrete building block and production method thereof

The foamed concrete block is made up by using fly ash, cement, solidifying agent, filler, and alkaline exciting agent as raw material and adopting such processes as fining fly ash, adding a great quantity of fly ash, and foaming at normal temp. and adding filler. Said invention can regulate the relationship of the foaming quantity with volume-weight and strength, and uses a wet curing measure to obtain the light foamed concrete block with early strength, high curing quality, high fly ash content, low volume-weight, good strength, and low cost. Said invented foamed concrete block can be extensively used in buildings with frame construction as non-bearing filling and heat-insulating material.

The invention above is also a method for producing light concrete but has used different materials for this aim. Our invention uses mainly bottom ash and fly ash as fillers and ingredients. The mentioned invention is also in the form of a block, while ours is a method for producing

CN111960746 - Lightweight high-strength concrete and preparation method thereof

The invention discloses a preparation method for lightweight high-strength concrete. By using aluminum silicate ceramic fibers, concrete is prevented from cracking, the expansion of macroscopic cracks is prevented, the peeling and separating capacity of the concrete for resisting freeze-thaw cycle is improved, the compressive and flexural strength of the concrete is improved by using auxiliary agents, and the concrete has the characteristic of light weight by using prepared modified fly ash; according to the preparation method, a prepared concrete semi-finished product is crushed and refined by using a crushing and refining device; according to the crushing and refining device, a concrete semi-finished product is crushed through a slitting knife, a first shearing blade and a second shearing blade, the particle size is reduced; the semi-finished concrete is sheared and dispersed by the stirring and shearing blades, and the part with a smaller particle size is extracted by wind power generated by an air blower, so that the prepared light high-strength concrete is small in particle size, the specific surface area is reduced, the void ratio is reduced, the bonding strength is improved, and the concrete quality is improved.

The invention above is also a method for preparing light concrete with high strength, however, the ingredients and the percentages used in them are different from our invention as we have used bottom ash and fly ash produced from incineration of the municipal waste as filler and the mentioned invention has more ingredients.

CN109851301 - Method for producing super-durable concrete by using Bayer process red mud light aggregates

The invention discloses a method for producing super-durable concrete by using Bayer process red mud light aggregates, and particularly relates to the field of concrete production. The method comprises the following steps: step one, weighing 600-650 kg of Bayer process red mud light coarse aggregates, 650-750 kg of natural river sand, 350-400 kg of PO42.5 ordinary Portland cement, 100-150 kg of I-grade low-calcium fly ash, 40-60 kg of silica fume, 130-150 kg of drinking water and 15-20 kg of a polycarboxylate water reducer for later use. According to the method, durable performance such as freezing and thawing cycle resistance, chlorine ion permeation resistance, carbonization resistance, and the like of concrete material is remarkably improved, and a high-added-value application of the Bayer process red mud solid waste is realized.

Both inventions tend to produce lightweight concrete, while the processes are totally different, as the mentioned invention has used red mud and the Bayer process and ours has used bottom ash and fly ash.

CN110409695 - Lightweight foam concrete partition board and manufacturing method thereof

The invention provides a lightweight foam concrete partition board and a manufacturing method thereof. The partition board is formed by integrally pouring a three-dimensional steel wire gauze rack and lightweight foam concrete. The three-dimensional steel wire gauze rack comprises double-layered steel wire gauzes arranged in a certain separation distance and steel wires winding between the double-layered steel wire gauzes. The lightweight foam concrete is prepared from the following raw materials in parts by weight: 400-440 parts of cement, 200-220 parts of coal ash, 9.3-10.6 parts of polyphenyl granules, and 200-250 parts of water. By integrally pouring and forming the lightweight concrete and the three-dimensional steel wire gauze rack, two calcium silicate boards on the outer side of a conventional internal parting wall concrete layer are removed while stability and fastness of the partition board are guaranteed, so that the manufacturing cost is lowered, the construction process is simplified and the using cost of the internal partition board is lowered. By way of integrally forming the three-dimensional steel wire gauze rack and lightweight foam concrete, the phenomenon that the calcium silicate boards are easy to deform to be separated in long service is effectively overcome.

The invention above is about producing light concrete with different materials and ingredients, as this invention only uses bottom ash and fly ash.

CN102515824B- Super-light foam cement concrete and preparation method thereof

The invention discloses a super-light foam cement concrete and a preparation method thereof. The super-light foam cement concrete comprises the following raw materials by weight parts: 9-36 parts of dead burnt magnesium oxides, 9-32 parts of dihydric phosphates, 0.5-7 parts of adjustable solidification agents, 6-25 parts of light burnt magnesium oxides, 0.5-7 parts of sulfur-containing components, 1-25 parts of industrial slag powder, 1-20 parts of kieselguhrs, 0.3-3.9 parts of waterproof agents, 0.2-1.7 parts of foam stabilizing agents, 1.0-8.9 parts of foaming agents and 25-90 parts of water. The preparation method of the high-performance super-light foam cement concrete comprises the following steps of: metering raw materials; preparing the slurry containing the foam stabilizing agents; uniformly mixing the foaming agents; pouring and standing by; foaming and expanding; coagulating and curing; and naturally maintaining. The super-light foam cement concrete has the advantages of lightweight, high strength, heat preservation and insulation, stable volume, low production cost, energy-saving property, no environmental pollution, and the like. The super-light foam cement concrete is simple in the production process and is especially suitable for the heat-insulating material of external building wall, roof and floor.

The mentioned invention is a method for preparing super-light foam cement concrete like our invention. However, the ingredients and materials used in it are different from ours since we have only used bottom ash and fly ash as filler and ingredient and the invention above has other agents as well.

United States Patent 5772751- Cement-bound light-weight insulating structural monolithic aggregate concrete

A light-weight concrete comprising cement, highly porous coarse and/or fine aggregates, such as furnace bottom-ash from thermal power stations or other porous natural or artificial materials, with a porosity of about 20-50% and an additive, preferably fly-ash from thermal power stations and other natural or artificial finely ground materials passing a 100 μm screen, and water. According to the invention the additive is used for (i) closing (bridging) air-voids in the cement paste and pores in the light-weight aggregates which increases the concrete density and strength, although using the highly porous aggregates and low to medium cement content; (ii) increasing the durability of the concrete by closing the air-voids and pores in the hardened mortar; (iii) reducing the segregation of concrete mix constituents arising due to the difference in density of the porous aggregate and the surrounding cement paste and (iv) lowering the consumption of cement.

The mentioned invention uses highly porous coarse/ fine aggregates, cement, and ash from thermal power stations or other porous natural or artificial materials, while our invention uses the bottom ash and fly ash produced from the incineration of municipal waste as filler and ingredient.

United States Patent 8663386- Dry cement mix for forming light concretes with low thermal conductivity and concretes thus obtained

A dry cement mix based on a hydraulic binder and a glass aggregate for forming light concretes with low thermal conductivity, characterized in that said glass aggregate comprises a fine fraction consisting of granulated aggregate with a particle size from 0.5 to 2 mm, and a coarse fraction consisting of crushed aggregate with a particle size from 4 to 20 mm, obtaining for said glass aggregate a well-defined overall particle size distribution.

The invention above uses dry cement mix for light concrete production, while our invention replaces ash with cement for this aim and they differ in this aspect.

United States Patent 8357240- Method of making concrete

A method of preparing a lightweight concrete composition using expanded polymer particles that includes a) replacing from about 10 to about 50 volume percent of the coarse aggregate in the concrete composition with prepuff particles; and b) preparing the concrete composition by combining ingredients comprising 3-40 volume percent cement, 1-50 volume percent fine aggregate, 0-40 volume percent coarse aggregate, 10-22 volume percent water, and 5-40 volume percent of prepuff particles. The prepuff particles have an average particle diameter of from 0.2 mm to 5 mm, a bulk density of from 0.02 g/cc to 0.56 g/cc, an aspect ratio of from 1 to 3. The concrete composition has a density of from about 90 to about 135 lb./ft3 and after it is set for 28 days, has a compressive strength of at least 1800 psi as tested according to ASTM C39.

The mentioned invention is a method for producing light concrete as well as ours, while it uses expanded polymer particles and ours uses bottom ash and fly ash instead of cement.

CN111205036B- High-strength lightweight concrete and preparation method thereof

The invention discloses a high-strength light concrete and a preparation method thereof, relating to the technical field of concrete, and the technical scheme is that the high-strength light concrete comprises the following components in parts by weight: 200 parts of cement 180-; the light coarse aggregate is reinforced ceramsite, and the reinforced ceramsite is prepared by the following method: firstly, taking ceramsite, soaking the ceramsite in water for 20-24 hours, and then draining the ceramsite for 1-2 hours to obtain water-absorbing ceramsite; 2- adding 10-20 percent of reinforcing agent by weight into the water-absorbing ceramsite, and stirring for 30-90min at the temperature of 70-80 ℃ and the speed of 50-400r/min to obtain the reinforced ceramsite. The concrete of the invention has the advantages of high compressive strength and low dry apparent density.

The mentioned invention is a method for producing light and high-strength concrete like the present invention. They both have the same goals while the methods differ in the used material, as we know that the mentioned invention uses ceramsite and ours uses filler ash and bottom ash.

TW202210442A -Lightweight concrete and uses thereof

A lightweight concrete is produced by mixing water and a concrete composition that includes a cementing material and a mixed aggregate. The mixed aggregate includes firepower bottom ash, glass sand, and natural sand, which includes both of lightweight and non-lightweight reinforcing materials and both of recycle and natural materials. Comparing to normal-weight concrete, the lightweight concrete of the present invention has the advantages of low unit weight and high strength, accordingly, it can be used as structural or non-structural concrete.

The present invention is a mixed material including water and concrete composition (cement materials and aggregate, etc) this mixed concrete has both lightweight and non-lightweight, recycled, and natural materials which makes it a little bit lighter compared to a regular one. But our invention is a lightweight concrete using ash (washed ash, fly ash, etc) with a high compressive strength and other improved features.

KR100809804B1-Light foam concrete composition using bottom ash, used for sound absorption materials, light foam concrete product employing the same and the manufacturing method thereof

A lightweight foam concrete composition for sound-absorbing materials is provided to have heat resistance and water resistance, retain original performances and shape even after firing, and be harmless to the environment. A lightweight foam concrete composition for sound-absorbing materials includes a powder comprising 40-50 parts by weight of bottom ash powder, 40-50 parts by weight of ordinary portland cement and 2-10 parts by weight of alumina cement, 2-10 parts by weight of anhydrite, and 1-5 parts by weight of slaked lime based on 100 parts by weight of the total powder; 70-90 parts by weight of water based on 100 parts by weight of the powder except for the bottom ash; and 200-300 % by volume of foam based on 100 % by volume of the powder slurry comprising the powder and water. The foam is obtained by diluting 2-4wt%, based on water, of an alkyl ether sulfate ester salt as a foaming agent with water, and pre-foaming the mixture. Further, the size of the foam is 0.3-1.4mm and the average size of the foam is 1.2mm.

One of the most important differences the invention above and our invention have, is that the invention above is a lightweight foam concrete with different ingredients. In the meantime, ours is a lightweight concrete using ash as a main component.

US10669201B2-Structural lightweight concrete comprising waste plastics

A method of making a structural lightweight and thermal insulating concrete is described. The concrete has a coarse aggregate partly replaced by recycled plastic pieces. This enables the concrete to maintain high compressive strength, low thermal conductivity, and low weight while providing a use for waste plastic. The waste plastic pieces may comprise polyethylene in the form of flakes, fibers, or granules. Due to its low unit weight, adequate compressive strength, and high thermal resistance the developed concrete can be used as a structural lightweight and thermal insulating concrete. The use of this concrete leads to economic and environmental benefits.

One of the most important differences is that plastics are used during concrete production, while different kinds of ash are used in concrete production.

US10669201B2-Structural lightweight concrete comprising waste plastics

LT2019038A- Cement concrete with municipal waste incinerator bottom ash filler

The present invention relates to the field of building materials, and more particularly to cement concrete mixtures used in production of roads and other traffic areas, which do not require increased environmental resistance and durability. The goal of the invention is to create a cement concrete mixture using a municipal solid waste incinerator bottom ash filler having sufficiently good mechanical and physical characteristics, durability and low cost. Composition of cement concrete with a municipal waste slag coarse aggregate, comprising sand, cement, concrete plastic and water, characterized in that it also includes municipal waste incineration slag, with a component weight ratio of: 35-55 coarse slag aggregate, sand 20-40, cement 12.0-16.0, concrete plasticizer 0.04-0.20, water 6.0-12.0. The invention above refers to producing building materials, especially concrete and cement while our invention refers to producing construction materials with improved qualifications, such as water resistance, Decreased permeability, and high resilience against corrosion. Our invention's main goal is protecting nature while the present invention's main goal is creating a cement concrete mixture using a municipal solid waste incinerator bottom ash filler having sufficiently good mechanical and physical characteristics, durability, and low cost.

A concrete product made from incineration bottom ash can be used as a substitute for cement in concrete, reducing the amount of cement needed and increasing impermeability. The fine and coarse aggregates can be used as mineral fillers to strengthen the concrete. The remaining coarse aggregates can be used to create light bedding blocks that reduce the dead load of the building. Heating and drying the ash is required before use and should not exceed 5% of the cement used in the mixture.

the dead load weight is significantly important in the strength of the building at the time of the earthquake and reducing the density of the construction has always been important for engineers because it reduces the final costs. If light materials that are made of ash are used in the bedding of the buildings and brickwork, it has a direct impact on reducing the weight of the construction and the final cost. Also, by using ash filler as the additive and the compressor of the concrete mixture, the permeability will decrease, and the construction strength against the entering forces will improve and it will prevent the destruction of the construction in temperature changes, especially in cold seasons. There are limited experiences regarding the use of this type of ash in the world (Table. 1). Getting free and not using the ash, remaining from burning the garbage or their burial, hurts the environment and makes the exploitation and production of these materials slow down. This method and use of these products have not been ignored so far and that’s why we should consider the use of these products for lightening the construction and preventing the underground resources, as well as reducing natural degradation.

Solution of problem

The expansion of incinerators in developed and developing countries has attracted the attention of the managing chain of municipal waste for technical waste disposal and producing energy, in a way that in the process of this system’s operation, two kinds of ash, plus electricity is produced and they are named fly ash and bottom ash. The fly ash makes 1-3 percent, and bottom ash makes between 10-25 percent of the weight percentage of the waste entering the incinerators. knowing that the fly ash is so limited and non-consumable, despite the amount of bottom ash that is considerable and harmful to society if being released into the water sources. The best option to overcome this problem is the potential use of this ash as material in the construction industry, with effective methods and techniques proposed in the present invention’s design the reasons for this invention are explained in the following.

The laboratory plan:

sieve analysis: first, we pass the bottom ash of the municipal waste from test sieves to separate its large and non-consumable particles. Then, the gained ash is dried in the heater for 24 hours in temperatures between 100 to 110 centigrade degrees, in a way that it can be easily passed from laboratory test sieves for determination of the sand value, fineness modulus, and specific weight. (Picture. 1). With the same method, the sieve analysis of the consuming sand in laboratory samples is also done. The results of the tests are presented in (Table. 2), and the value of the sand bottom ash is 47 percent, the fineness modulus is 4/9 percent and its density is 1100 kg/m³. Also, the sand equivalent of the consuming sample aggregate material is 78 percent (the aggregate is almost coarse), the fineness modulus is 4/05 percent and its specific weight is determined as 1600 kg/m³ (Table. 2)

the analysis of the tests above shows that the bottom ash does not have proper sand equivalent and fineness modulus and is not replaceable with sand in the concrete mixture, due to its low density of 1100kg/m³, apart from making blocks and light concrete.

The XRF test: the chemical XRF test is only done to ensure the manner and the amount of the elements inside the incineration bottom ash to compare and test the components of the concrete. (Table. 3)

The premier test: the study of the previous findings shows that the researchers have done lots of tests with different methods on the bottom ash remaining from incineration and have gained favorable results. (Table. 1)

The variables in the combination and the percentage of the elements inside the ash may not be the same around the world. These changes may be the result of the waste type, different ethnicities, and geographical regions, and the accuracy of how the test was done and the features including sand equivalent, fineness modulus, and density shown in the sieving (Table. 2). These changes bolds the effects of the ash in the concrete. Doing these primitive tests to get the desired result and determining the following methods, as well as the present research to get the predetermined results (complete use of the bottom ash to improve the quality of the concrete, lightening of the construction, and environmental protection) in 5 methods below, with different sampling percentages had been tested.

1- using dry bottom ash remaining from municipal waste, passed through sieve 4 with replacement of the cement in the concrete: with the percentages 0%, 5%, 10%, and 20% at the ages of 7, 28, and 90 days.

2- using dry bottom ash remaining from municipal waste, passed through sieve 4 with replacement of sand in the concrete: with the percentages 0%, 5%, 10%, and 20% at the ages of 7, 28, and 90 days.

3- using the bottom ash remaining from municipal waste, that has passed through sieve 4 (moisturized for 24 hours) with the replacement of sand in the concrete with percentages 0% and 10% at the ages 7, 28, and 90 days.

4- using the bottom ash remaining from municipal waste, passed through sieve 4 (washed) with replacement of the sand in the concrete, with percentages 0%, and 10% at the ages 7, 28, and 90 days.

5- using the bottom ash remaining from municipal waste passed through sieves 4 and 200 as the filler in the concrete: with percentages 0%, 1/5%, 3%, and 4% at the ages 7, 28, and 90 days.

Explanation: the percentages are calculated based on the consumed cement weight in the concrete and the cement content is also 350 kilograms per cubic meter.

The mentioned tests are designed based on the mixing plan (Tables 5 and 6), four 15×15×15 centimeters molds are used for sampling.

The analysis of the primary test: the final results of the tests above are determined in (Table. 4). In analyzing and comparing the 28-day compressive strength in 5 methods compared to the blank sample with 5% ash, replacing cement (picture. 3, ingredient M) that has proper compressive strength and can have an important role in optimizing the use of cement and environment protection. Also, using 1/5 percent of the ash filler in the concrete increases its compressive strength up to 10 percent. However, replacing dry ash, humid ash, and washed ash with cement and sand did not increase the strength and they can only be used in concretes that are not expected to have high resistance. Finally, the result of the primary test shows that the test can be continued after using the material M instead of cement with more exploitation in the two sub-grades below.in this method, the fine-grained and coarse-grain are separated and 4 types of material are the result that is shown clearly in (figures 1 and 2) as the technical plan of the whole project.

Part A: we pass the ingredient M through the sieves 100 and 200 respectively. In this case, only two fine-grained materials are the result that can be separately used as mineral additives to improve the quality of the concrete.

Part B: we use the remaining ingredient M on the sieve 100 as the light material to construct a non-bearing light block, from the combination of the ingredients on the sieves 100 and 200, to construct light bedding concrete to lighten the building. This process is planned and has been designed and modeled as a block diagram. ( )

The mixing plan (Tables 5 and 6) is considered for preparing the samples of the test part two.

The explanation of the tests part A: making laboratory samples of part one based on the mixture of (Tables 5 and 6) is done and their compressive strength at the ages 7, 28, 42, and 90 days have been tested and the results of the test are shown on (diagram. 1) with the results of replacing the ash that has passed through the sieve4 and is visible with sand and cement as well. In the analysis of the results, it seems like replacing 5 percent of the ash that has passed through sieve 4(M) with cement, has shown its function, and using 1/5 percent of the ash filler (passed through sieve 200) in the concrete at different ages compared to blank sample, has the highest compressive strength and the quality of the concrete has been increased up to 10 percent and has placed it in grade A. and using 3 percent of the ash that has passed through the sieve 100 as the mineral additive in the concrete samples, has increased its resistance up to the blank sample and has placed in the grade A. considering that the density in this samples is more than the blank sample and its permeability is also less because the empty porous are filled, compared to the dried samples up to 6 percent and saturation samples. The process of this method also lessens the density of the ash, remaining on the sieve 100 in the tests part2. This function is also effective in environmental protection. ( )

The explanation of the tests in part 2(B): making the laboratory samples, part two, based on the mixture plan (Table. 7) and considering the national standard principles of Iran 7782 (Table. 8) is done. First, to evaluate the volume of the prepared block that was made of aggregate and ash remaining on the sieve 100 and comparing them, in a block-making workshop, a normal block made of aggregate and concrete content of 175 kilograms per cube meter in a block mold was made. With the same weights and concrete content of the ash remaining on the sieve 100, the prepared mud was poured into the block-making device, and the blocks were made. In comparison to the number of blocks made from these two materials with equal weights twice as much as the gained volume from the ash, compared to the blocks made from sand was revealed.

For dual-purpose use of these tests to evaluate the compressive strength and the water absorbing percent of the block and light concrete of bedding, the samples are made in cube shapes and have been tested. (Table. 9) of course, preparing blocks in different shapes and dimensions is not far from expectation. The results show that the F3 sample with the same concrete content as the blank sample is at the CS4 grade 4Mpa and with 16 percent water absorption, with 3 percent more benefit and weight reduction between 30-37 percent compared to the made blocks with aggregate chosen as optimized. Realization of the processes above ( ) causes all the bottom ash remaining from incineration to be used completely in applicable engineering applications and causes economic improvement and increasing the quality of the concrete, as well as lightening the construction and prevention of natural degradation and helping to save the environment and it is considered as one of the main principles of the waste disposal, which is one of the most important difficulties of urban life.

The production process:

We pass the bottom ash (1) through the sieves (4) and the large objects (2) separate from it. Then the resulting ash (4) should be dried and transferred to the oven (5) to be dried and processed for 24 hours at the temperature of 110 centigrade degrees and be used and accessible as the ingredient M (6) and in continue, the method and process of producing light and cheap material is presented. ( )

A) the processed ingredient M from the bottom ash, as material, is a good replacement for cement in concrete with a portion of 5 percent to reach the economical profit.

B) the material passed through the sieve 100 (9) is applicable as the material and mineral additive, in concrete with the portion of 3 percent to reach the increase of the density and 6 percent reduction of impermeability.

C) the material passed through the sieve 200 (12) as material and additive filler, in concrete with a portion of 1/5 percent to reach the 10 percent increase of the concrete strength, against the forces entered the concrete construction.

The remaining material on the sieve 100 (7) its volume is twice as much as the aggregate, as material, for producing light and cheap concrete with a content of 175 kilograms per cubic meter with the process of lightening the structure, is used.

D) the remaining material on the sieve 100 and 200 as a compound (13), as the material for constructing the bedding concrete with the process of lightening the building is in hand.

The processes above, like producing concrete, are done with a combination of water, cement, and aggregate, and by using separated and graded material in two parts, A and B. The dryness of the aggregate material and ash, with more water absorption than ingredient (M) and the variability of the material’s portion, makes it impossible to use the determined amount of water in the regulation (maximum 0/5), and this is why the 70mm slump index is used in making the samples. In executing this method, no other additive is used. Plus, in this method, the volume of the material in part B makes the material to be light., while the resulting material in part A fills the empty capillary pores in the concrete and lessens the impermeability increasing the density and finally increasing the strength of the concrete.

Advantage effects of the invention

– Using diversity in the method

– diagnosing the potential points of each single separated seed

– effective use of the ash potential

– decreasing the use of cement and sand

– prevention of underwater pollution and natural degradation

– digging mines and protecting the environment

: illustrates the technical plan for preparing the ingredients from the bottom ash in incineration

: illustrates the technical plan for the use of ingredients, graded in parts A and B

: illustrates the block diagram of the process of producing the material from the bottom ash

: it demonstrates how the ingredient is provided from the bottom ash:

1- the bottom ash resulted from the energy power plants

2- the large objects are separated

3- sieve 4

4- the passing ash from the sieve 4

5- the heating device (oven) that the ash is heated, dried, and processed inside for 24 hours at a temperature of 110 centigrade degrees

6- ingredients M

: demonstrates the rest of the production process of the ingredients. The separation of the heavy objects happens in grade part A and the large light aggregate is placed in grade part B:

6- the M ingredients can replace cement in concrete with a weight percentage of 5% and it is also reusable in the next levels.

7- the remaining material on sieve 100 consists of coarse light aggregate and it is twice as large compared to the aggregates with a content of 175 kilograms per cubic meter, it is used for the production of light unbearable blocks

8- sieve 100

9- the passing material through the sieve 100 is used to increase density and decrease the impermeability with the portion of 3 percent as the additive mineral material

10- the ingredients and material remaining on the sieve 200 are usable in part B

11- sieve 200

12- the material passed through the sieve 200 (12) is used as filler and additive with 1/5 portion of 1/5 percent in the concrete

13- the remaining material on the sieves 100 and 200, are combined and are used for producing light bedding concrete with a content of 175 kilograms per cubic meter.

Examples

[Table. 1]: the energy-producing power plants that use coal or municipal wastes, produce mostly two types of ash: 1- bottom ash and 2- fly ash. The amount of produced ash in the power plants with coal is multiple times more than the bottom ash, while the waste-burning power plants produce 3% fly ash and 10 to 25% bottom ash. The researchers have presented different methods for using these wastes and have separated them in (Table. 1),

[Table. 2]: the sieving of the consuming material for quality control and comparing it with the instructions and regulations has been tested, and the results help to decide how to use it. This is why the used material in preparing the samples, including the aggregates (sand), and bottom ash in the laboratories with the required equipment to identify the sand equivalent, the fineness modulus, and the density of the used material has been tested and here are the results:

[Table. 3]: the studies show that using the bottom ash of the incineration has had a positive effect on the quality of the concrete and using it optimally in the field of civil engineering, prevents the negative effects of this waste on the water resources, the people’s health, and the environment. Due to the high importance of this matter and identification of the elements inside the ash, and comparing it with the cement components that have a specific role in the strength of the concrete and the progression of the project's goal, the XRF research has been done and the table below has been set based on its results:

[Table. 4]: the overall results of the primary test of using waste ash in concrete mixtures:

The researchers have already tested the effects of using the ash resulting from burning the wastes with different methods, and have analyzed the result. In the following research, to reach favorable results, we have sampled and replaced dry ash with sand, humid ash with cement, washed ash replacing cement, and ash filler (passed through sieve 200) in the concrete at the ages 7, 28, 42 and 90 days, to compare them with the blank sample in the laboratory plan and reach the results, presented in the table below. Here is the analysis:

1- Replacing more than 5% dry ash in concrete is not possible and by increasing the combination percentage, its resistance has decreased.

2- using humid ash in scales more than the concrete device was not functional and the test was stopped.

3- it was left undone because washing the ash causes underwater pollution and the final product did not have the proper resistance.

4- using 1/5 percent ash filler in the concrete as an additive, has increased the quality of the concrete up to 10 percent.

The result of the analysis:

– using 5% percent of complete ash in combination with concrete, has decreased the use of cement and is economical.

– as using the ash fine aggregate (passed through sieve 200) has filled the empty pores of the concrete has caused density increase and lessening of the impermeability, and increases the compressive resistance up to 10 percent, which is considered as an achievement.

– it is defined that the ash that has passed through the sieve 100, should also be tested with acceptable percentages to be used in concrete as an additive if it reaches a positive result.

– it is predicted that the remaining ash that has passed through sieve 100 to be used for producing block, and the remaining ash on sieves 100 and 200, to be used for producing light concrete will be tested. The rest of the process will be continued in two parts: grading and improving the quality of the concrete and lightening the building.

[Table. 5]: the mixing plan for replacing the bottom ash of incineration with cement and sand for sampling four molds 15×15×15

The mixture plan that is explained in Table 5, in the first grade for preparing the required concrete for filling four sampling laboratory molds, with dimensions 15×15×15 that the amount of one cubic meter of concrete has been shrunk 55/5 times, and by considering 1/4 kilograms of waste in all, it has reached the weight 43/700. However, it is essential to know that if the operation has no waste, to avoid a lack of sampling molds, the same amount of material should also be considered. Knowing that all the portions (percentages) have been calculated with the portion of the consuming cement content in one-meter cubic meter with a weight of 2350 kilograms and in the case of replacing cement with sand with the precise percent compared to cement content, the sand amount of the blank sample will be reduced and the same amount of ash will be replaced.

[Table. 6]: the test of the mixing plan for the bottom ash (passed through sieves 100 and 200) for sampling four molds 15×15×15 compared to consuming cement content:

In the mixing plan of the table.6, the required amount of ash to prepare concrete and to fill the four of the laboratory 15×15×15 molds with precise percentages. Here, the required amount of ash compared to cement content is calculated and operated (350 kg/m³). As an example for calculation, 1/5 percent of the required ash to prepare the sample concretes with the cement concrete of 350 kg/m³ is calculated as follows:

The required ash 350×1000÷100×1/5÷55/5-94/5 grams

[Table. 7]: This plan is used for preparing the mixed mud for two blocks that are considered for testing the compressive resistance in a time length of 7 and 28 days and calculating the amount of water absorption. If we consider the required amount of sand is1800 kilograms and the cement content is 175 kilograms, and knowing that the weight of two blocks of mud is 16/075 kilograms, the required amount of cement is 1/575 kilograms, considering that the waste amount of two blocks is 15 grams. (the required amount of cement: 175×16/075÷ 1800- 1/560+15-1/575 kg)

In this plan, the F1 sample, without using sand and replacing the 8 kilograms of remaining ash on the sieves 100, with a 50 percent reduction of using cement compared to a blank sample, the F2 sample with 8 kilograms of remaining ash on the sieves 100 and 25 percent reduction of cement compared to blank sample, and the F3 sample according to consuming cement blank sample with 8 kilograms of remaining ash on the sieve 100, is considered to do the test. The G1, G2, and G3 samples are also based on the amount of cement and the used ash in these samples are all from the ashes that have completely passed through the sieve 4.

[Table. 8]: the compressive strength of the light non-bearable cement blocks (Iran national standard 7782): is presented from the standard organization of Iran, to evaluate the resistance grade of the light non-bearable blocks. Based on the information registered in the table below, the resistance grade of the light concretes must have reached from CS2 to CS8 from 2-8 megapascal. In the tests of the present research, the compressive strength of sample F3 in CS4 resistance grade has gained the 4megapascal resistance.

[Table. 9]: It shows the results of the compressive strength and the water absorption percentage of the light. In the test of sample F3 was made of cement with a cement content of 175 kilograms per cubic meter (equal to the used cement blank sample) and from the remaining material on sieve 100, with compressive resistance of 4megapascal in the national grade, CS4, and because it had less water absorption comparing to the other samples, it was chosen as the optimal sample.

[Table. 10]: The technical features of the blocks made from the material (remaining on the sieve 100), with different portions:

Table 10 shows the technical features of the light blocks, made from the material remaining on the sieve 100, that have had an acceptable function, and each method was analyzed from different aspects, including the portion of the ash compared to the sand, sectioning the ash by the sieves, the weight percentage of the made light block, compared to the block made from aggregate and the weight percentage reduction made from ash, compared to the blank sample. The produced blocks from ash, have an average less weight in comparison to the blank sample. Therefore, they have three times more profit.

[Diagram. 1]: Evaluating the compressive strength of the samples of part (A) of the additives, passed through the sieves 100 and 200 and replacing the ingredients M, passed through the sieve 4 or sand and cement.

To analyze the results of the compressive strength relating to the replacement of the ash with sand and cement and the results of using filler and the material passed through the sieve 100 in the concrete, as a mineral additive.

The construction industry and concrete pavement provide most of the people's needs today. It seems that in construction, the remarkable problem is the reduction of the dead load weight and the construction cost which has always been a problem for the engineers to be solved.

Using 1/5 percent of the passing material from sieve 200(12) or 3 percent of the passing material from sieve 100 (9) is graded in part A separately as an additive in concrete pavement, it increases the density up to the maximum, and it increases the concrete quality up to 10 percent and lessens the impermeability up to 6 percent. ( )

The existing potential of the ingredients remaining on the sieve 100 (7) is graded in part B in producing light blocks and mixing it with the remaining material on the sieve 200 (10), and the light bedding concrete with a cement content of 175 kg/m³ that using it in the executing operations in break work and bedding, has a significant effect, compared to the lightening of the dead load in constructions and reducing the construction costs. ( )

Claims

A concrete product comprised of the incineration bottom ash that is used as the concrete material, required in the construction industry, which reduces using the cement and increases the impermeability of the concrete. The produced material with this method like block, and light bedding block, makes it possible to lighten the building. Here are its components:
– the processed ingredient that directly replaces a part of cement in the cement mixture and does the cementation process in the concrete.
The material that has passed through the sieves 100 and 200 is separated into two parts: fine aggregates and coarse aggregates. Both materials that have passed through the two sieves are used as mineral fillers in the concrete mixture to strengthen the concrete.

The coarse aggregates remaining on the sieves are used to produce a light bedding block that prevents the increase of the dead load of the building.
According to the claim. 1, the ash that its large components have been separated by the sieve 4, should be heated and dried for 24 hours at a temperature of 110 centigrade degrees and be used with a maximum portion of 5 percent used cement, replacing cement in concrete and prevents using more cement and as a result, decreases the environmental degradations caused by the process of producing cement.
According to the claim. 1, the fine aggregates that have passed through the sieve 100 with a portion of 3 percent and passed through the sieve 200 with a portion of 1/5 weight percentage of the used cement, fill the empty capillary pores and prevent the permeability of the concrete and increase its strength.
According to the claim. 1, the light coarse aggregates, remaining on the sieve 100, have less density because their size is twice as large as the normal aggregates, and it has become the proper material for producing light block with cement content of 175 kilograms per cubic meter and using it in break work, decreases the dead load of the building.
According to claims 1 and 4, with the combination of the coarse aggregates remaining on the sieve 100 and 200 with a cement content of 175 kilograms per cubic meter, the light bedding block is produced and used, so that it prevents the increase of the dead load weight of the building.