U.S. patent application number 13/685690 was filed with the patent office on 2013-04-04 for environment friendly composite construction materials.
This patent application is currently assigned to King Abdulaziz City Science and Technology. The applicant listed for this patent is King Abdulaziz City Science and Technology. Invention is credited to MOHD MUSTAFA AL BAKRI ABDULLAH, Mohammed A. Binhussain, Che Mohd Ruzaidi Ghazali, Kamarudin Hussin, Norazian Mohamed Noor, Mohammad Tamizi Selimin.
Application Number | 20130081557 13/685690 |
Document ID | / |
Family ID | 45021008 |
Filed Date | 2013-04-04 |
United States Patent
Application |
20130081557 |
Kind Code |
A1 |
ABDULLAH; MOHD MUSTAFA AL BAKRI ;
et al. |
April 4, 2013 |
ENVIRONMENT FRIENDLY COMPOSITE CONSTRUCTION MATERIALS
Abstract
Disclosed are a system, a method and/or composition of
environment friendly composite construction material. In one
aspect, a method includes providing a mixture of a pozzolanic
material and/or a kaolin clay with an activator solution to form an
alumino-silicate cementitious material through a resulting
geo-polymerization process. The alumino-silicate cementitious
material is in the form of a paste. The method also includes
processing the alumino-silicate cementitious material to transform
the alumino-silicate cementitious material that is in the form of
the paste to a form of a powder of the alumino-silicate
cementitious material. The method further includes mixing the
alumino-silicate cementitious material which is in the form of the
powder with water to control a workability of the alumino-silicate
cementitious material. Furthermore the method includes combining a
mixture of the alumino-silicate cementitious material and water
with a coarse aggregate, a fine aggregate and/or a plasticizer to
form a composite construction material.
Inventors: |
ABDULLAH; MOHD MUSTAFA AL
BAKRI; (Arau, MY) ; Binhussain; Mohammed A.;
(Riyadh, SA) ; Hussin; Kamarudin; (Arau, MY)
; Ghazali; Che Mohd Ruzaidi; (Arau, MY) ; Noor;
Norazian Mohamed; (Arau, MY) ; Selimin; Mohammad
Tamizi; (Kangar, MY) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
King Abdulaziz City Science and Technology; |
Riyadh |
|
SA |
|
|
Assignee: |
King Abdulaziz City Science and
Technology
Riyadh
SA
|
Family ID: |
45021008 |
Appl. No.: |
13/685690 |
Filed: |
November 26, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
13208363 |
Aug 12, 2011 |
8337612 |
|
|
13685690 |
|
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Current U.S.
Class: |
106/706 |
Current CPC
Class: |
Y02P 40/165 20151101;
Y02W 30/91 20150501; C04B 2111/00155 20130101; Y02W 30/92 20150501;
Y02P 40/10 20151101; C04B 12/005 20130101; C04B 28/006 20130101;
C04B 28/006 20130101; C04B 12/04 20130101; C04B 14/06 20130101;
C04B 14/106 20130101; C04B 18/08 20130101; C04B 22/064 20130101;
C04B 38/0074 20130101; C04B 40/0028 20130101; C04B 40/0082
20130101; C04B 40/0263 20130101; C04B 40/065 20130101; C04B 2103/30
20130101; C04B 2103/32 20130101 |
Class at
Publication: |
106/706 |
International
Class: |
C04B 12/00 20060101
C04B012/00 |
Claims
1. A composite construction material composition comprising: an
alumino-silicate cementitious material that is formed through
mixing a pozzolanic material, kaolin clay and sodium silicate in at
least one of a dried and pulverized form in a solution of alkali
hydroxide to form the alumino-silicate cementitious material
through a process of geopolymerization resulting from mixing the
pozzolanic material, kaolin clay and sodium silicate in at least
one of a dried and pulverized form in a solution of alkali
hydroxide; wherein the alumino-silicate cementitious material that
is in the form of a paste is processed to transform the
alumino-silicate cementitious material that is in the form of a
paste to a the form of a powder; water mixed with the
alumino-silicate cementitious material that is in the form of a
powder to control a workability of the alumino-silicate
cementitious material; a fine aggregate to increase a compressive
strength of the composite construction material when mixed with the
mixture of alumino-silicate cementitious material and water; and a
coarse aggregate to increase a compressive strength of the
composite construction material when mixed with the mixture of
alumino-silicate cementitious material and water.
2. The composition of claim 1: wherein a weight of the mixture of
the pozzolanic material and the kaolin clay that is used to form
the alumino-silicate cementitious material ranges between 350
kilograms and 400 kilograms, wherein the weight of the sodium
hyroxide that is used to form the aluminosilicate cementitious
material ranges between 30 kilograms and 60 kilograms, wherein the
weight of the sodium silicate that is used to form the
alumino-silicate cementitious material ranges between 100 kilograms
and 150 kilograms, wherein the weight of the fine aggregate used to
form the concrete ranges between 500 kilograms and 600 kilograms,
wherein the weight of the coarse aggregate used to form the
concrete ranges between 1200 kilograms and 1400 kilograms, and
wherein the weight of the water used to form the concrete ranges
between 60 kilograms and 400 kilograms.
3. The composition of claim 1, further comprising at least one of a
plasticizer, a super plasticizer and polymeric additive to make the
composite construction material self-consolidating.
4. The composition of claim 1: wherein the alumino-silicate
cementitious material that is in the form of a paste is dried at a
temperature ranging between 40.degree. C. and 100.degree. C.
through a normal drying process, and wherein the dried
alumino-silicate cementitious material reduced to the powder form
through at least one of a grinding and pulverizing the dried
aluminosilicate cementitious material when the alumino-silicate
cementitious material is dried through a normal drying process at a
temperature ranging between 40.degree. C. and 100.degree. C.
5. The composition of claim 1: wherein the alumino silicate
cementitious material that is in the form of a paste is transformed
to the form of the powder through a spray drying, wherein the
alumino silicate cementitious material that is in the form of a
paste is sprayed through a nozzle into an environment that has at a
temperature ranging between 40.degree. C. and 100.degree. C. to
transform the alumino silicate cementitious material that is in the
form of a paste to the form of powder, wherein the environment that
has at a temperature ranging between 40.degree. C. and 100.degree.
C. to which the alumino silicate cementitious material is sprayed
to dry the sprayed alumino silicate cementitious material, and
wherein the density of the composite construction material formed
from the powdered alumino silicate cementitious material that is
transformed to the form of powder through at least one of the spray
drying and the normal drying the paste form of the alumino silicate
cementitious material is based on the plasticizer that is added to
the alumino silicate cementitious material to form the composite
construction material.
6. The composition of claim 1: wherein the composite construction
material is cured through at least one of a curing process at a
room temperature and a heat curing at a temperature ranging between
40.degree. C. and 120.degree. C., wherein a resistance of the
composite construction material to an acidic environment is
increased through mixing the alkali hydroxide as activator with the
pozzolanic material to form a crystalline alumino silicate
cementitious material that is used to produce the composite
construction material, wherein the koalin clay to reinforce a
strength of the composite construction material, and wherein at
least one of the fine aggregates and coarse aggregates to increase
a compressive strength of the concrete.
Description
CLAIM OF PRIORITY
[0001] This application is a divisional application of U.S. patent
application Ser. No. 13/208,363 titled ENVIRONMENT FRIENDLY
COMPOSITE CONSTRUCTION MATERIALS filed on Aug. 12, 2011.
FIELD OF TECHNOLOGY
[0002] This disclosure relates generally to the technical fields of
concrete and cement production and in particular to environment
friendly composite construction material.
BACKGROUND
[0003] Concrete may be a composite construction material that may
be used in building. Concrete may be comprised of a mixture of
cement paste, sand and aggregates. The cement paste may comprise
cement and water. The cement may be Ordinary Portland Cement, a
type of cement made out of raw material such as limestone. The
manufacturing of Ordinary Portland Cement produces more than 13
billion tons of carbon dioxide every year. This carbon dioxide
emission is equivalent to 7% of the total global emission of carbon
dioxide to the atmosphere. This carbon dioxide emission may lead to
environmental problems such as global warming and the greenhouse
effect.
SUMMARY
[0004] Disclosed are a system, a method and/or a composition of
environment friendly composite construction material. In one
aspect, a method includes providing a mixture of a pozzolanic
material and/or a kaolin clay with an activator solution to form an
alumino-silicate cementitious material through a resulting
geo-polymerization process. The alumino-silicate cementitious
material is in the form of a paste. The method also includes
processing the alumino-silicate cementitious material to transform
the alumino-silicate cementitious material that is in the form of
the paste to a form of a powder of the alumino-silicate
cementitious material. The method further includes mixing the
alumino-silicate cementitious material which is in the form of the
powder with water to control a workability of the alumino-silicate
cementitious material. Furthermore the method includes combining a
mixture of the alumino-silicate cementitious material and water
with a coarse aggregate, a fine aggregate and/or a plasticizer to
form a composite construction material. The composite construction
material is concrete. The method of forming the composite
construction material is free of carbon dioxide emission associated
with the formation of the composite construction material.
[0005] The method further includes forming the activator solution
through mixing a dry ingredient with an alkali hydroxide solution.
The dry ingredient may be sodium silicate. The ratio of sodium
silicate to the alkali hydroxide solution in the activator solution
may be 0.5 to 3.5. The method also includes adjusting a
concentration of the alkali hyroxide solution through diluting the
alkali hydroxide solution with water. The pozzolanic material may
be a fly ash. The activator solution is an alkali hyrdroxide. The
alkali hydroxide is sodium hydroxide. The weight of the mixture of
the pozzolanic material and the kaolin clay that is used to form
the alumino-silicate cementitious material may range between 350
kilograms and 400 kilograms. The weight of the sodium hyroxide that
is used to form the alumino-silicate cementitious material may
range between 30 kilograms and 60 kilograms. The weight of the
sodium silicate that is used to form the alumino-silicate
cementitious material may range between 100 kilograms and 150
kilograms. The weight of the fine aggregate used to form the
concrete may range between 500 kilograms and 600 kilograms. The
weight of the coarse aggregate used to form the concrete may range
between 1200 kilograms and 1400 kilograms. The weight of the water
used to form the concrete may range between 60 kilograms and 400
kilograms.
[0006] The method of processing the alumino-silicate cementitious
material to transform the alumino-silicate cementitious material
that is in the form of the paste to a form of a powder of the
alumino-silicate cementitious material, further includes drying the
alumino-silicate cementitious material that is in the form of a
paste at a temperature ranging between 40C and 100 C through a
normal drying process. The method also includes reducing the dried
alumino-silicate cementitious material to the powder form through
at least one of a grinding and pulverizing the dried
alumino-silicate cementitious material when the alumino-silicate
cementitious material is dried through a normal drying process at a
temperature ranging between 40 C and 100 C.
[0007] The method of processing the alumino-silicate cementitious
material to transform the alumino-silicate cementitious material
that is in the form of the paste to a form of a powder of the
alumino-silicate cementitious material, further includes spray
drying the alumino silicate cementitious material that is in the
form of a paste to transform the alumino silicate cementitious
material that is in the form of the paste to the form of the
powder. The method of spray drying further includes spraying the
alumino silicate cementitious material that is in the form of a
paste through a nozzle into an environment that has at a
temperature ranging between 40 C and 100 C to transform the alumino
silicate cementitious material that is in the form of a paste to
the form of powder. The environment that has at a temperature
ranging between 40 C and 100 C to which the alumino silicate
cementitious material is sprayed to dry the sprayed alumino
silicate cementitious material.
[0008] The method further includes curing the composite
construction material through at least one of a curing process at a
room temperature and a heat curing at a temperature ranging between
40 C and 120 C. The method also includes increasing a resistance of
the composite construction material to an acidic environment
through mixing the alkali hydroxide as activator with the
pozzolanic material to form a crystalline alumino silicate
cementitious material that is used to produce the composite
construction material. The density of the composite construction
material formed from the powdered alumino silicate cementitious
material that is transformed to the form of powder through at least
one of the spray drying and the normal drying the paste form of the
alumino silicate cementitious material is based on the plasticizer
that is added to the alumino silicate cementitious material to form
the composite construction material. The koalin clay may reinforce
the strength of the composite construction material. The fine
aggregates and/or coarse aggregates may increase a compressive
strength of the concrete.
[0009] In another aspect, a cement composition may include an
alumino-silicate cementitious material that is formed through
mixing a pozzolanic material, kaolin clay and sodium silicate in a
dried and pulverized form in a solution of alkali hydroxide to form
the alumino-silicate cementitious material through a process of
geo-polymerization resulting from mixing the pozzolanic material,
kaolin clay and sodium silicate in a dried and pulverized form in a
solution of alkali hydroxide. The alumino-silicate cementitious
material that is in the form of a paste is processed to transform
the alumino-silicate cementitious material that is in the form of a
paste to a form of a powder. The composition further includes water
mixed with the alumino-silicate cementitious material that is in
the form of a powder to control a workability of the
alumino-silicate cementitious material.
[0010] The composition also includes a fine aggregate to increase a
compressive strength of the composite construction material when
mixed with the mixture of alumino-silicate cementitious material
and water. The composition further includes a coarse aggregate to
increase a compressive strength of the composite construction
material when mixed with the mixture of alumino-silicate
cementitious material and water.
[0011] In yet another aspect, a method includes providing a mixture
of at least one of a pozzolanic material and a kaolin clay with an
activator solution to form an alumino-silicate cementitious
material through a resulting geo-polymerization process. The
alumino-silicate cementitious material is in the form of a paste.
The method also includes processing the alumino-silicate
cementitious material to transform the alumino-silicate
cementitious material that is in the form of the paste to a form of
a powder of the alumino-silicate cementitious material through a
process of a spray drying. The method also includes mixing the
alumino-silicate cementitious material which is in the form of the
powder with water to control a workability of the alumino-silicate
cementitious material. The method further includes combining a
mixture of the alumino-silicate cementitious material and water
with a coarse aggregate, a fine aggregate and/or a plasticizer to
form a composite construction material. In one embodiment, the
composite construction material is concrete. In one embodiment, the
said method of forming the composite construction material is free
of carbon dioxide emission associated with the formation of the
composite construction material.
[0012] In another aspect, a method includes providing a mixture of
at least one of a pozzolanic material and a kaolin clay with an
activator solution to form an alumino-silicate cementitious
material through a resulting geo-polymerization process. In one
embodiment, the alumino-silicate cementitious material is in the
form of a paste. The method also includes drying the
alumino-silicate cementitious material that is in the form of a
paste at a temperature ranging between 40 C and 100 C through a
normal drying process. The method further includes reducing the
dried alumino-silicate cementitious material to the form of a
powder of the alumino-silicate cementitious material through a
grinding and/or pulverizing the dried alumino-silicate cementitious
material when the alumino-silicate cementitious material is dried
through a normal drying process at a temperature ranging between 40
C and 100 C. The method also includes mixing the alumino-silicate
cementitious material which is in the form of the powder with water
to control a workability of the alumino-silicate cementitious
material. The method further includes combining a mixture of the
alumino-silicate cementitious material and water with a coarse
aggregate, a fine aggregate and/or a plasticizer to form a
composite construction material. In one embodiment, the composite
construction material is concrete. In one embodiment, the method of
forming the composite construction material is free of carbon
dioxide emission associated with the formation of the composite
construction material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] Example embodiments are illustrated by way of example and
not limitation in the figures of the accompanying drawings, in
which like references indicate similar elements and in which:
[0014] FIG. 1 is a flow diagram illustrating a method of producing
composite construction material, according to one or more
embodiments.
[0015] FIG. 2 is a flow diagram illustrating a method of preparing
the alumino silicate cementitious material, according to one or
more embodiments.
[0016] FIG. 3 is a graphical process flow diagram illustrating a
method of producing composite construction material using normal
drying process, according to one or more embodiments.
[0017] FIG. 4 is a graphical process flow diagram illustrating a
method of producing composite construction material using
spray-drying, according to one or more embodiments.
[0018] FIG. 5 is a table view illustrating the amount of materials
for producing a block of composite construction material, according
to one or more embodiments.
[0019] FIG. 6 is a table illustrating the mechanical and physical
properties of the composite construction materials, according to
one or more embodiments.
[0020] FIG. 7 is a process flow diagram illustrating a method of
producing composite construction material, according to one or more
embodiments.
[0021] FIG. 8 is a process flow diagram illustrating a method of
producing composite construction material using a spray drying
process, according to one or more embodiments.
[0022] FIG. 9 is a process flow diagram illustrating a method of
producing composite construction material using a normal drying
process, according to one or more embodiment.
[0023] Other features of the present embodiments will be apparent
from the accompanying drawings and from the detailed description
that follows.
DETAILED DESCRIPTION
[0024] Disclosed are a system, a method and/or a composition of
environment friendly composite construction material. It will be
appreciated that the various embodiments discussed herein need not
necessary belong to the same group of exemplary embodiments; and
may be grouped into various other embodiments not explicitly
disclosed herein. In the following description, for the purpose of
explanation, numerous specific details are set forth in order to
provide a thorough understanding of various embodiments.
[0025] FIG. 1 is a flow diagram illustrating a method of producing
a composite construction material, according to one or more
embodiments. In one or more embodiments, in operation 102 an
alumino silicate cementitious material may be prepared. In one
embodiment, the alumino silicate cementitious material may be a
geo-polymer cement. In one embodiment, the alumino silicate
cementitious material may be prepared before forming the composite
construction material. In one embodiment, the alumino silicate
cementitious material may be prepared at a different location and
then brought to the location of preparing the composite
construction material. In one embodiment, the preparation of the
alumino silicate cementitious material may be an environmentally
friendly process. In one embodiment, the environmentally friendly
process of preparing the alumino silicate cementitious material may
be free of carbon dioxide (CO2) emission. In one embodiment, the
alumino silicate cementitious material may be in the form of a
paste. In one embodiment, the alumino silicate cementitious
material that is in the form of a paste may be prepared through
mixing a pozzolanic material with an activator as shown in FIG.
2.
[0026] Now refer to FIG. 2. FIG. 2 is a flow diagram illustrating a
method of preparing the alumino silicate cementitious material,
according to one or more embodiments. In one or more embodiments, a
mixture of sodium silicate, alkali hydroxide, pozzolanic material
and clay may be prepared as a process of forming the alumino
silicate cementitious material. In one or more embodiments, an
alkali hyroxide solution may be prepared in operation 202. In one
embodiment, the alkali hydroxide solution may be the activator. In
one embodiment, the alkali hydroxide solution may be a sodium
hydroxide solution.
[0027] In one or more embodiments, alkali hydroxide may be composed
of an alkali metal cation and the hydroxide anion. In an example
embodiment, the alkali hydroxide may be Lithium hydroxide (LiOH),
Sodium hydroxide (NaOH), Potassium hydroxide (KOH), Rubidium
hydroxide (RbOH) and/or Caesium hydroxide (CsOH). In one
embodiment, the alkali hydroxide may be used in powder form. In one
embodiment, the alkali hydroxide may also be used in liquid form,
where it may be added after dry mixing of the other constituents
and before the water is added. In one example embodiment, the
alkali hydroxide may be at a concentration of 6.0 to 16.0
moles/liter (M). In another example embodiment, the alkali
hydroxide may be at a concentration of 1.0 to 18.0 moles/liter (M).
In one embodiment a concentration of the alkali hyroxide solution
is adjusted through diluting the alkali hydroxide solution with
water.
[0028] In one embodiment, the activator solution may be formed
through mixing a dry ingredient with an alkali hydroxide solution,
such as in operation 204. In one embodiment, the dry ingredient is
sodium silicate and/or potassium silicate. In a preferred
embodiment, the dry ingredient is sodium silicate. In one
embodiment, the sodium silicate may be available in an aqueous
solution and/or in solid form. The sodium silicate may increase the
force character and durability for cement as fast-drying
material.
[0029] In one embodiment, the ratio of sodium silicate to the
alkali hydroxide solution in the activator solution is 0.5 to 3.5.
In one embodiment, sodium silicate may be sodium metasilicate,
Na.sub.2SiO.sub.3 Sodium metasilicate may be in powder form and may
easily be dissolved in water. Sodium metasilicate be available in
liquid or solid form. In one or more embodiments, the sodium
metasilicate may reduce the porosity of the concrete that is
eventually formed from the mixture.
[0030] In one embodiment, such as in operation 206 the mixture of a
pozzolanic material and clay may be added to the mixture of sodium
silicate and sodium hyrdroxide. In one embodiment, the pozzolanic
material, clay and a sodium silicate may be dissolved in a solution
of alkali hydroxide. In one or more embodiments, the pozzolanic
material may be a material, that when combined with an alkali
hydroxide, exhibits cementitious properties. Pozzolanic materials
may be commonly used as an addition to cement concrete mixtures to
increase the long-term strength of the concrete. In one or more
embodiments, the pozzolanic material may include a siliceous and/or
aluminous chemical substance, and may be highly vitreous. For
example, the pozzolanic material may include a natural pozzolanic
mineral, a lava mineral, a basalt, a fly ash, a blast furnace slag,
a bottom ash, a recycled ash and a ground granulated blast furnace
slag, etc. In one or more embodiments, the clay may be a kaolin.
Kaolin may be preferred because of its ability to reinforce the
strength of the concrete. In one or more embodiments, the ratio of
the pozzolanic material to the alkali hydroxide may range from 1.0
to 3.5.
[0031] In one embodiment, mixing the pozzolanic material, clay and
the activator solution may result in a geo-polymerization process,
such as in operation 208. In one embodiment, said
geo-polymerization may result in formation of the alumino silicate
cementitious material. In one embodiment, the alumino silicate
cementitious material may be in the form of a paste. In one or more
embodiments, geo-polymerization may be the process of polymerizing
silica and alumina containing minerals using alkali solvents. In a
preferred embodiment, fly ash may be the pozzolanic material that
is mixed along with alkali hydroxide, sodium silicate and clay to
produce the alumino silicate cementitious material. Fly ash is a
fine glass-like powder recovered from burning pulverized coal in
electric power generating plants. In one embodiment, the reaction
of silicon (Si) and aluminum (Al) content in fly ash under alkaline
condition may form a three dimensional polymeric chain and ring
structure that consist of Si--O--Al--O bonds. In one embodiment,
with more bonds of Si--O--Al--O, the polymer strength increases,
thus making the alumino silicate cementitious material a suitable
composition to be used in producing the composite construction
material (e., concrete). In one embodiment, the alkali hydroxide
and sodium silicate may have the ability to disrupt the Si--O--Si
bonds and produce hydrates of alkali-lime aluminosilicates. Thus,
the combination of fly ash and clay with alkali hydroxide and
sodium silicate contributes to the enhancement of mechanical
properties of concretes, in one embodiment.
[0032] In one embodiment, the alumino silicate cementitious
material that is in the form of a paste may be changed to the form
of a powder as illustrated in FIG. 1, FIG. 3 and FIG. 4.
[0033] Now refer back to FIG. 1. In one embodiment, in operation
104, the alumino silicate cementitious material that is in the form
of a paste may be dried using a normal drying process. In one
embodiment, in the normal drying process, the alumino silicate
cementitious material that is in the form of a paste may be dried
at a temperature ranging from 40.degree. to 100.degree. Celsius
(104.degree. to 212.degree. Fahrenheit). In one embodiment, the
mixture may only require heating to a temperature range of
40.degree. to 100.degree. Celsius (104.degree. to 212.degree.
Fahrenheit) because the mixture may be produced out of waste
elements such as fly ash and kaolin. In one embodiment, the dried
alumino silicate cementitious material may be ground and/or
pulverized by a grinder to form a fine dried powder of alumino
silicate cementitious material from the alumino silicate
cementitious material that is in the form of a paste that is dried
through normal drying, such as in operation 106. In one embodiment
drying at temperature ranging from 40.degree. to 100.degree.
Celsius (104.degree. to 212.degree. Fahrenheit) may consume
significantly much less energy.
[0034] In one or more embodiments, such as in operation 108, the
alumino silicate cementitious material that is in the form of a
paste may be dried by using a spray drying process. In one
embodiment, a spray drying process may be a method to convert a
solution, suspension or emulsion into a solid powder in one single
process step. In one embodiment, a spray drying process may be used
to obtain crystalline product. The dried powder may be produced by
spray drying the alumino silicate cementitious material that is in
the form of a paste at temperature between 40.degree. and
100.degree. Celsius (104.degree. to 212.degree. Fahrenheit). In one
embodiment, the spray drying process may include spraying the
mixture through a nozzle into a high temperature vapor steam. In
one embodiment, the liquid cement may be vaporized to form a
plurality of droplets. In one embodiment, the plurality of droplets
may be dried to form a dried powder, such as in operation 108.
[0035] In operation 110, a required amount of water may be added
into the dried powder to control a workability of the of the
alumino-silicate cementitious material, in one embodiment. In one
embodiment, the water may be mixed with the dried powder in a ratio
ranging from 0.35 to 0.65. In one embodiment, the alumino silicate
cementitious material paste formed through mixing the alumino
silicate cementitious material in the form of powder with water may
serve as a binder. In one embodiment, the binder may be a substance
that may set and harden independently and bind other components
together. In one embodiment, the alumino silicate cementitious
material may be mixed with aggregate materials and/or plasticizers
to produce a composite construction material (e.g., concrete), such
as operation 112.
[0036] In one embodiment, the geo-polymer cement (e.g., alumino
silicate cementitious material) paste may be mixed with one of
sand, aggregate, plasticizer and/or nano additive to form the
composite construction material (e.g., concrete), in operation 114.
In one embodiment of operation 112, the geo-polymer cement (e.g.,
alumino silicate cementitious material) paste may be mixed with a
coarse aggregate and/or a fine aggregate. In one embodiment, the
aggregate may be a coarse particulate material, such as sand,
gravel, crushed stone, slag, recycled concrete and/or geo-synthetic
aggregates. In one embodiment, the aggregate may reinforce the
structure of the composite material and strengthen the concrete
(e.g., composite construction material). In one embodiment of
operation 114, the mixture of aggregate and/or plasticizer and the
cement paste may form a concrete (e.g., composite construction
material).
[0037] In one embodiment, the plasticizer may determine a density
and/or weight of the composite construction material (e.g.,
concrete). In one embodiment, a plasticizer may be an additive that
increases the fluidity or plasticity of the concrete. The
plasticizer may increase the workability of the mix, or decrease
the amount of water required to achieve the desired workability. In
one embodiment, the plasticizer may be manufactured from
lignosulfanates. In one embodiment, the plasticizer may increase
the strength of the concrete by decreasing the water to cement
ratio. A light weight composite construction material (e.g.,
concrete) may be formed by mixing the cement paste with the
plasticizer.
[0038] The weight/or density of a concrete cube with a size of
100.times.100.times.100 mm may be 1.8 kg to 2.4 kg when the
concrete is produced from the alumino silicate cementitious
material through drying based on normal drying and/or spray drying.
In one embodiment, when plasticizer is added, weight/or density of
a concrete cube with a size of 100.times.100.times.100 mm may be
1.0 kg to 1.6 kg. In one embodiment, the concrete cube with a size
of 100.times.100.times.100 mm that weighs 1.0 kg to 1.6 kg may be
considered a light weight concrete material.
[0039] In one embodiment, a superplasticizer may be added to make a
very light weight concrete (e.g., composite construction material)
with self-consolidating properties. A superplasticizer may be
preferred because it may produce a concrete (e.g., composite
construction material) with self-consolidating properties that
enhances the performance of the concrete. In one embodiment, the
superplasticizers may be linear polymers containing sulfonic acid
groups attached to the polymer backbone. In one embodiment, the
superplasticizers may also be known as high range water reducers.
Superplasticizers may advantageously improve paste fluidity with
reduction in the amount of water consumed during the preparation of
the alumino silicate cementitious material paste. In one
embodiment, superplasticizers may also increase the workability of
the composite construction material.
[0040] In one embodiment, the mixture of alumino silicate
cementitious material paste, aggregates, plasticizer and/or
superplasticizer may be cured at room temperature and/or by heat
curing at a temperature of 40.degree. to 120.degree. Celsius
(104.degree. to 248.degree. Fahrenheit). In one embodiment, the
composite construction material may be cured through a curing
process at a room temperature and/or a heat curing at a temperature
ranging between 40 C and 120 C, such as in operation 120. In one
embodiment, a resistance of the composite construction material to
an acidic environment may be increased through mixing the alkali
hydroxide as activator with the pozzolanic material to form a
crystalline alumino silicate cementitious material that is used to
produce the composite construction material.
[0041] Now refer to FIG. 3 and FIG. 1. FIG. 3 is a graphical
process flow diagram illustrating a method of producing composite
construction material using normal drying process, according to one
or more embodiments. In one embodiment, alkali hydroxide 302
solution that is diluted with water to form the required
concentration may be mixed with sodium silicate 304 to form the
activator solution 310. In one embodiment, preparation of the
activator solution 310 is carried out by preparing an alkali
hydroxide solution that has a concentration of 6 to 16M by adding
water to it. In one embodiment, sodium hydroxide may be the
preferred alkali hydroxide to be used. In one embodiment potassium
hydroxide may also be used. In another embodiment, the
concentration of the alkali hydroxide is 1.0 to 18M. In said
embodiment, water is added to alkali hydroxide to produce an alkali
hydroxide solution in the preferred concentration. In one
embodiment, sodium hydroxide and/or potassium hydroxide may be
used, with sodium hydroxide being the alkali hydroxide in a
preferred embodiment. In one embodiment, sodium silicate may then
be added to alkali hydroxide in a ratio of 0.5 to 3.5.
[0042] In one embodiment, clay 308 and a pozzolanic material 306
may be mixed together to form a dried powder mixture. In one
embodiment, the alkali hydroxide 302 may be one of Lithium
hydroxide (LiOH), Sodium hydroxide (NaOH), Potassium hydroxide
(KOH), Rubidium hydroxide (RbOH) and/or Caesium hydroxide (CsOH).
In one or more embodiments, a sodium silicate may be sodium
metasilicate, Na.sub.2SiO.sub.3. In one or more embodiments, the
clay 308 may be a kaolin clay. In one or more embodiments, the
pozzolanic material 306 may include a siliceous and/or aluminous
chemical substance, and may be highly vitreous. In an example
embodiment, the pozzolanic material 306 may include a natural
pozzolanic mineral, a lava mineral, a basalt, a fly ash, a blast
furnace slag, a bottom ash, a recycled ash and a ground granulated
blast furnace slag, etc. In one or more embodiments, the ratio of
the pozzolanic material 306 to the alkali hydroxide 302 may range
from 1.0 to 3.5. In one embodiment, the dried powder mixture of
clay 308 and a pozzolanic material 306 may be mixed together with
the activator solution 310 to form the alumino silicate
cementitious material (e.g., geo-polymer cement) in the form of a
paste 314, such as in operation 312.
[0043] In one embodiment, the alumino silicate cementitious
material (e.g., geo-polymer cement) in the form of a paste 314 may
be dried through a normal drying process to transform the alumino
silicate cementitious material in the form of a powder 316. In one
embodiment, in the normal drying process, the alumino silicate
cementitious material (e.g., geo-polymer cement) in the form of a
paste 314 may be dried at a temperature that ranges between
40.degree. to 100.degree. Celsius (104.degree. to 212.degree.
Fahrenheit). In one embodiment, once the alumino silicate
cementitious material (e.g., geo-polymer cement) in the form of a
paste 314 is dried, the dried alumino silicate cementitious
material (e.g., geo-polymer cement) may be ground and/or pulverized
to transform the alumino silicate cementitious material in the form
of a powder 316.
[0044] In one embodiment, a required amount of water 320 may be
added to the to transform the alumino silicate cementitious
material in the form of a powder 316 along with aggregates and/or
plasticizers 318 to create a composite construction material (e.g.,
concrete) through curing said mixture at room temperature and/or by
heat curing at a temperature of 40.degree. to 120.degree. Celsius
(104.degree. to 248.degree. Fahrenheit). In one or more
embodiments, the water 320 may be mixed with the alumino silicate
cementitious material in the form of a powder 316 in a ratio
ranging from 0.3 to 0.65. The cement (the alumino silicate
cementitious material) paste formed through mixing the alumino
silicate cementitious material in the form of a powder 316 with
water 320 may serve as a binder, a substance that may set and
harden independently and bind other components together. The cement
paste may then be mixed with an aggregate and/or plasticizer 318 to
form the composite construction material 322 (e.g., concrete). In
one embodiment, the aggregate may be a coarse particulate material,
such as sand, gravel, crushed stone, slag, recycled concrete and
geosynthetic aggregates. In one embodiment, the aggregate may
reinforce the structure of the composite material and strengthen
the composite construction material (e.g., concrete 322).
[0045] Now refer to FIG. 4 and FIG. 1. FIG. 4 is a graphical
process flow diagram illustrating a method of producing composite
construction material using spray-drying, according to one or more
embodiments. In one embodiment, alkali hydroxide 302 solution that
is diluted with water to form the required concentration may be
mixed with sodium silicate 304 to form the activator solution 310.
In one embodiment, preparation of the activator solution 310 is
carried out by preparing an alkali hydroxide solution that has a
concentration of 6 to 16M by adding water to it. In one embodiment,
sodium hydroxide may be the preferred alkali hydroxide to be used.
In one embodiment potassium hydroxide may also be used. In another
embodiment, the concentration of the alkali hydroxide is 1.0 to
18M. In said embodiment, water is added to alkali hydroxide to
produce an alkali hydroxide solution in the preferred
concentration. In one embodiment, sodium hydroxide and/or potassium
hydroxide may be used, with sodium hydroxide being the alkali
hydroxide in a preferred embodiment. In one embodiment, sodium
silicate may then be added to alkali hydroxide in a ratio of 0.5 to
3.5.
[0046] In one embodiment, clay 308 and a pozzolanic material 306
may be mixed together to form a dried powder mixture. In one
embodiment, the alkali hydroxide 302 may be one of Lithium
hydroxide (LiOH), Sodium hydroxide (NaOH), Potassium hydroxide
(KOH), Rubidium hydroxide (RbOH) and/or Caesium hydroxide (CsOH).
In one or more embodiments, a sodium silicate may be sodium
metasilicate, Na.sub.2SiO.sub.3. In one or more embodiments, the
clay 308 may be a kaolin clay. In one or more embodiments, the
pozzolanic material 306 may include a siliceous and/or aluminous
chemical substance, and may be highly vitreous. In an example
embodiment, the pozzolanic material 306 may include a natural
pozzolanic mineral, a lava mineral, a basalt, a fly ash, a blast
furnace slag, a bottom ash, a recycled ash and a ground granulated
blast furnace slag, etc. In one or more embodiments, the ratio of
the pozzolanic material 306 to the alkali hydroxide 302 may range
from 1.0 to 3.5. In one embodiment, the dried powder mixture of
clay 308 and a pozzolanic material 306 may be mixed together with
the activator solution 310 to form the alumino silicate
cementitious material (e.g., geo-polymer cement) in the form of a
paste 314, such as in operation 312.
[0047] In one embodiment, the alumino silicate cementitious
material (e.g., geo-polymer cement) in the form of a paste 314 may
be dried through the spray drying process 402 to transform the
alumino silicate cementitious material in the form of a powder 316.
In one embodiment, in the spray drying process 402, the alumino
silicate cementitious material in the form of a paste 314 may be
sprayed through a nozzle 410 into a high-temperature vapor stream.
In one embodiment, the alumino silicate cementitious material in
the form of a paste 314 may form a plurality of droplets. In one
embodiment, the plurality of droplets may be dried to form the
alumino silicate cementitious material in the form of a powder 316
from the alumino silicate cementitious material in the form of a
paste 314. The plurality of droplets may be dried at a temperature
of 40.degree. to 100.degree. Celsius (104.degree. to 212.degree.
Fahrenheit).
[0048] In one embodiment, a required amount of water 320 may be
added to the to transform the alumino silicate cementitious
material in the form of a powder 316 along with aggregates and/or
plasticizers 318 to create a composite construction material (e.g.,
concrete) through curing said mixture at room temperature and/or by
heat curing at a temperature of 40.degree. to 120.degree. Celsius
(104.degree. to 248.degree. Fahrenheit). In one or more
embodiments, the water 320 may be mixed with the alumino silicate
cementitious material in the form of a powder 316 in a ratio
ranging from 0.3 to 0.65. The cement (the alumino silicate
cementitious material) paste formed through mixing the alumino
silicate cementitious material in the form of a powder 316 with
water 320 may serve as a binder, a substance that may set and
harden independently and bind other components together. The cement
paste may then be mixed with an aggregate and/or plasticizer 318 to
form the composite construction material 322 (e.g., concrete). In
one embodiment, the aggregate may be a coarse particulate material,
such as sand, gravel, crushed stone, slag, recycled concrete and
geosynthetic aggregates. In one embodiment, the aggregate 622 may
reinforce the structure of the composite material and strengthen
the concrete 630.
[0049] Now refer to FIG. 5 and FIG. 1. FIG. 5 is a table view
illustrating the amount of materials for producing a block of
composite construction material, according to one or more
embodiments. In one or more embodiments, the material(s) 502 may be
shown with respect to their weight 516. In one embodiment, the
weight may be measured in Kilograms (KG). In one or more
embodiments, the fly ash and kaolin 504 may be added in the amount
of 350 to 400 KG. In one or more embodiments, the sodium silicate
506 may be present in the composite construction material (e.g.,
concrete) block in the amount of 100 to 150 KG. In one or more
embodiments, sodium hydroxide (NaOH) 508 may be present in the
composite construction material (e.g., concrete) block in an amount
of 30 to 60 KG. In one or more embodiments the fine aggregate 510
may be present in the range of 500 to 600 KG in the composite
construction material (e.g., concrete) block. In one or more
embodiments, coarse aggregate 512 may be present in the range of
1200 to 1400 KG in the composite construction material (e.g.,
concrete) block. In one or more embodiments, water may be present
in the range of 60 to 400 KG in the composite construction material
(e.g., concrete) block. In one embodiment, the composite
construction material (e.g., concrete) block may be cubical. In one
embodiment the size of the cubical composite construction material
(e.g., concrete) block may be 100.times.100.times.100 mm.
[0050] Now refer to FIG. 6 and FIG. 1. FIG. 6 is a table
illustrating the mechanical and physical properties of the
composite construction materials, according to one or more
embodiments. In an example embodiment, the properties 602 may refer
to the properties of the composite construction material (e.g.,
concrete) 604 and the light weight composite construction material
(e.g., concrete) 306 as mentioned in FIG. 1. In the embodiment of
FIG. 6, the properties 602 illustrated may include compressive
strength 608, density 610, water absorption 612, fire resistance
614, porosity 616, setting time 618 and/or strength gain 620.
[0051] In an example embodiment, the compressive strength 608 may
be measured by breaking a cylindrical concrete specimen in a
compression-testing machine. In one or more embodiments, the
compressive strength 608 of the composite construction material
(e.g., concrete) 604 may be 15 to 80 MPa (Mega Pascal). The
compressive strength of a light weight composite construction
material (e.g., concrete) 606 may be 10 to 40 MPa (Mega
Pascal).
[0052] The density of concrete may be a measure of its mass per
unit volume. In one or more embodiments, density 610 of the
composite construction material (e.g., concrete) 604 may be 1800 to
2400 KG/M.sup.3. In one or more embodiments, density of the light
weight composite construction material (e.g., concrete) 606 may be
1000 to 1600 KG/M.sup.3
[0053] Water absorption 612 may be a ratio of the weight of the
water absorbed by a composite material to the weight of the dry
materials in the composite material. In one embodiment, too much
water absorption may cause a composite construction material to
lose its beneficial properties, such as strength. In one or more
embodiments, the water absorption 612 of the composite construction
material (e.g., concrete) 604 may range between 0.01 to 2.00%. The
water absorption 612 of the light weight composite construction
material (e.g., concrete) 606 may range between 0.1 to 5.0%.
[0054] Fire resistance 614 may be the ability of a composite
construction material to withstand effects of fire. In one or more
embodiments, a fire resistance 614 capacity of the composite
construction material (e.g., concrete) 604 is indicated by the fact
that the composite construction material (e.g., concrete) 604 may
be stable at temperatures up to 1000.degree. C. (1832.degree. F.).
The fire resistance 614 capacity of the light weight composite
construction material (e.g., concrete) 606 is indicated by the fact
that the light weight composite construction material (e.g.,
concrete) 606 may be stable at temperatures up to 1000.degree. C.
(1832.degree. F.). In one embodiment, a resistance of the composite
construction material to an acidic environment and/or fire is
increased through mixing the alkali hydroxide as activator with the
pozzolanic material to form a crystalline alumino silicate
cementitious material that is used to produce the composite
construction material.
[0055] In one or more embodiments, porosity 616 may be a measure of
the void spaces in a material. Porosity 616 may be expressed as a
percentage of the volume of voids in a total volume. In one
embodiment, porosity 616 may be inversely related to concrete
strength. High porosity percentage may make the composite
construction material (e.g., concrete) weaker and/or easy to break.
The porosity of the composite construction material (e.g.,
concrete) 604 may be 0.1 to 0.4%. The porosity of the light weight
composite construction material (e.g., concrete) 606 may be 0.1 to
30%.
[0056] In one or more embodiments, the required setting time 618
may be the time it takes the concrete to harden. In one or more
embodiments, the required setting time 618 for the composite
construction material (e.g., concrete) 604 may be 1-2 hours. In one
embodiment, the composite construction material (e.g., concrete)
604 may gain full strength in 1-3 days. The required setting time
618 for the light weight composite construction material (e.g.,
concrete) 606 may be between 2 to 4 hours. The light weight
composite construction material (e.g., concrete) 606 may gain full
strength within 1 to 3 days.
[0057] FIG. 7 is a process flow diagram illustrating a method of
producing composite construction material, according to one or more
embodiments. In one or more embodiments, in operation 702, a
mixture of at least one of a pozzolanic material and a kaolin clay
is provided with an activator solution to form an alumino-silicate
cementitious material through a resulting geo-polymerization
process. In one embodiment, the alumino-silicate cementitious
material is in the form of a paste. In one embodiment, in operation
704, the alumino-silicate cementitious material (e.g., geo-polymer
cement) is processed to transform the alumino-silicate cementitious
material that is in the form of the paste to a form of a powder of
the alumino-silicate cementitious material (e.g., geo-polymer
cement). In one embodiment, in operation 706 the alumino-silicate
cementitious material which is in the form of the powder is mixed
with water to control a workability of the alumino-silicate
cementitious material. In one embodiment, in operation 708, a
mixture of the alumino-silicate cementitious material (e.g.,
geo-polymer cement) and water is mixed with a coarse aggregate, a
fine aggregate and/or a plasticizer to form a composite
construction material (e.g., concrete). In one embodiment, the
composite construction material is concrete. In one embodiment, the
said method of forming the composite construction material is free
of carbon dioxide emission that is associated with the formation of
the composite construction material.
[0058] FIG. 8 is a process flow diagram illustrating a method of
producing composite construction material using a spray drying
process, according to one or more embodiment. In operation 802 a
mixture of at least one of a pozzolanic material and a kaolin clay
is provided with an activator solution to form an alumino-silicate
cementitious material through a resulting geo-polymerization
process. In one embodiment, the alumino-silicate cementitious
material is in the form of a paste. In one embodiment, in operation
804 the alumino-silicate cementitious material is processed to
transform the alumino-silicate cementitious material that is in the
form of the paste to a form of a powder of the alumino-silicate
cementitious material through a process of a spray drying. In one
embodiment, in operation 806 the alumino-silicate cementitious
material which is in the form of the powder is mixed with water to
control a workability of the alumino-silicate cementitious
material. In one embodiment, in operation 808 a mixture of the
alumino-silicate cementitious material and water is combined with a
coarse aggregate, a fine aggregate and/or a plasticizer to form a
composite construction material. In one embodiment, the composite
construction material is concrete. In one embodiment, the said
method of forming the composite construction material is free of
carbon dioxide emission associated with the formation of the
composite construction material.
[0059] FIG. 9 is a process flow diagram illustrating a method of
producing composite construction material using a normal drying
process, according to one or more embodiment. In one embodiment, in
operation 902 a mixture of at least one of a pozzolanic material
and a kaolin clay is provided with an activator solution to form an
alumino-silicate cementitious material through a resulting
geo-polymerization process. In one embodiment, the alumino-silicate
cementitious material is in the form of a paste. In one embodiment,
in operation 904 the alumino-silicate cementitious material that is
in the form of a paste is dried at a temperature ranging between 40
C and 100 C through a normal drying process. In one embodiment, in
operation 906, the dried alumino-silicate cementitious material is
reduced to the form of a powder of the alumino-silicate
cementitious material through a grinding and/or pulverizing the
dried alumino-silicate cementitious material when the
alumino-silicate cementitious material is dried through a normal
drying process at a temperature ranging between 40 C and 100 C. In
one embodiment, in operation 908, the alumino-silicate cementitious
material which is in the form of the powder is mixed with water to
control a workability of the alumino-silicate cementitious
material. In one embodiment, in operation 910, a mixture of the
alumino-silicate cementitious material and water is combined with a
coarse aggregate, a fine aggregate and/or a plasticizer to form a
composite construction material. In one embodiment, the composite
construction material is concrete. In one embodiment, the method of
forming the composite construction material is free of carbon
dioxide emission associated with the formation of the composite
construction material.
[0060] Although the present embodiments have been described with
reference to specific example embodiments, it will be evident that
various modification and changes may be made to these embodiments
without departing from the broader spirit and scope of the various
embodiments. Accordingly, the specification and drawings are to be
regarded in an illustrative rather than a restrictive sense.
* * * * *