WO2019195577A1 - Non-toxic hardened synthetic material containing encapsulated toxic and non-toxic particles - Google Patents

Non-toxic hardened synthetic material containing encapsulated toxic and non-toxic particles Download PDF

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Publication number
WO2019195577A1
WO2019195577A1 PCT/US2019/025833 US2019025833W WO2019195577A1 WO 2019195577 A1 WO2019195577 A1 WO 2019195577A1 US 2019025833 W US2019025833 W US 2019025833W WO 2019195577 A1 WO2019195577 A1 WO 2019195577A1
Authority
WO
WIPO (PCT)
Prior art keywords
toxic
product
fly ash
glass forming
particles
Prior art date
Application number
PCT/US2019/025833
Other languages
French (fr)
Inventor
Richard Patterson
Original Assignee
Citymix, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Citymix, Inc. filed Critical Citymix, Inc.
Publication of WO2019195577A1 publication Critical patent/WO2019195577A1/en

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
    • C03C14/00—Glass compositions containing a non-glass component, e.g. compositions containing fibres, filaments, whiskers, platelets, or the like, dispersed in a glass matrix
    • C03C14/004—Glass compositions containing a non-glass component, e.g. compositions containing fibres, filaments, whiskers, platelets, or the like, dispersed in a glass matrix the non-glass component being in the form of particles or flakes
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B20/00—Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups C04B14/00 - C04B18/00 and characterised by shape or grain distribution; Treatment of materials according to more than one of the groups C04B14/00 - C04B18/00 specially adapted to enhance their filling properties in mortars, concrete or artificial stone; Expanding or defibrillating materials
    • C04B20/10—Coating or impregnating
    • C04B20/1055—Coating or impregnating with inorganic materials
    • C04B20/1074—Silicates, e.g. glass
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B20/00—Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups C04B14/00 - C04B18/00 and characterised by shape or grain distribution; Treatment of materials according to more than one of the groups C04B14/00 - C04B18/00 specially adapted to enhance their filling properties in mortars, concrete or artificial stone; Expanding or defibrillating materials
    • C04B20/10—Coating or impregnating
    • C04B20/1055—Coating or impregnating with inorganic materials
    • C04B20/1077—Cements, e.g. waterglass
    • C04B20/1085—Waterglass
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
    • C04B26/02—Macromolecular compounds
    • C04B26/04—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • C04B26/06—Acrylates
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • C04B28/04—Portland cements
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/24—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing alkyl, ammonium or metal silicates; containing silica sols
    • C04B28/26—Silicates of the alkali metals
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00482—Coating or impregnation materials
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00767—Uses not provided for elsewhere in C04B2111/00 for waste stabilisation purposes
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/91—Use of waste materials as fillers for mortars or concrete

Definitions

  • fly ash is also commonly separated and collected from manufacturing combustion chambers. Under certain specific conditions occurring during the combustion process, the produced fly ash may contain certain toxic or otherwise undesirable particles, such as lead, arsenic, cadmium and/or other metals. Fly ash containing certain measurable levels of such toxic/undesirable waste particles can make the material unsuitable for commercial use and require costly handling, transport and disposal at special landfills certified to accept such hazardous material. Millions of tons of fly ash containing unacceptable levels of toxic particles are produced annually in the United States. But despite relocation to approved landfills, fly ash containing toxic waste particles remains an environmental risk. There is a need to reduce the quantity of toxic fly ash deposited in landfills each year, and a greater need to permanently transform this material into a non-toxic state. BRIEF DESCRIPTION OF INVENTION
  • One object of the invention is to fully encapsulate and bonded toxic fly ash within a hardened mixture that prevents any significant subsequent release or leaching of toxic elements into the environment.
  • Another object is to produce a secondary product from the fly ash which can be used for safe and useful purposes, such as a hardened material useful as a non-toxic aggregate.
  • Fig. 1 is a flow chart of an exemplary embodiment
  • toxic fly ash is coated with a glass forming silica salt.
  • the silica salt is sodium silicate.
  • other forms of silica salts such as potassium silicate and lithium silicate, amongst others, may also be used.
  • the glass forming silicate maybe sprayed onto or otherwise mixed with fly ash.
  • the fly ash and the glass forming silica salt is dried to harden.
  • the hardened fly ash and glass forming silica salt is formed or processed into an aggregate or powder.
  • a wetting agent and/or coating and/or powders are added to the fly ash and glass forming silica salt to increase the hardness of the product and increase its utility.
  • the product described herein can be blended with stucco, mortars, grouts, concrete or other cementitious mixes and/or may be suitable for use in a wide variety of both structural and non-structural cement-based mixes.
  • Non-structural usage examples could include landfill cover, decorative gravels, roadbed fill, or as a general, all-purpose lightweight aggregate.
  • a wetting agent 20 is, preferably, water mixed with a glass forming silica salt 30.
  • a thickening agent 40 such as acrylic is also added.
  • Fly ash 10 is thoroughly combined with the wetting agent 20 using a mixing device, such as a paddle mixer, or other blending method, such that the toxic fly ash is substantially and uniformly coated with the wetting agent 20.
  • a coating agent 60 may be optionally applied.
  • the coating agents may acrylic latex paint, acrylic paint slurry and/or waste paint“sludge”; and/or various cement powders; and/or various pozzolanic materials or hardeners common to the concrete products industry or some
  • coated fly ash is dried 70 and ready for shipment.
  • additional non-hazardous materials may be incorporated into the original mixture and/or later applied as an added surface coating.
  • additives may include recycled products such as calcium carbonate, pulverized/granulated tire rubber, and /or glass beads or fragments.
  • ⁇ Portland cement and fly ash are placed into a vessel for mixing.
  • Waste water such as acrylic-containing waste water generated by the manufacture or processing of acrylic paint
  • Liquid silicate is added to the pasty slurry.
  • liquid silicate is sodium silicate.
  • recycled paint sludge may add in a last step.
  • An exemplary product has the following formulation by weight 13% fly ash, 12% Portland cement, 4% Recycled acrylic paint“sludge” , 56% Waste water containing acrylic, 15% Liquid sodium silicate.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Structural Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Dispersion Chemistry (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • General Chemical & Material Sciences (AREA)
  • Geochemistry & Mineralogy (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)
  • Processing Of Solid Wastes (AREA)

Abstract

This application teaches a fully encapsulate and bonded toxic fly ash within a hardened mixture that prevents any significant subsequent release or leaching of toxic elements into the environment.

Description

NON-TOXIC HARDENED SYNTHETIC MATERIAL CONTAINING ENCAPSULATED
TOXIC AND NON-TOXIC PARTICLES
CROSS-REFERENCES TO RELATED APPLICATIONS
This application claims priority to US Provisional Application 62/652,761, filed on April 4, 2018, and claims priority to US Provisional Application 62/739,272, filed on September 30,2018; and in a continuation in part of US Patent Application 15/544,771, filed on July 19, 2017. Each application is hereby incorporated by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable
INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC
Not Applicable
BACKGROUND
Commercial and municipal waste is often incinerated creating a toxic fly ash. Fly ash is also commonly separated and collected from manufacturing combustion chambers. Under certain specific conditions occurring during the combustion process, the produced fly ash may contain certain toxic or otherwise undesirable particles, such as lead, arsenic, cadmium and/or other metals. Fly ash containing certain measurable levels of such toxic/undesirable waste particles can make the material unsuitable for commercial use and require costly handling, transport and disposal at special landfills certified to accept such hazardous material. Millions of tons of fly ash containing unacceptable levels of toxic particles are produced annually in the United States. But despite relocation to approved landfills, fly ash containing toxic waste particles remains an environmental risk. There is a need to reduce the quantity of toxic fly ash deposited in landfills each year, and a greater need to permanently transform this material into a non-toxic state. BRIEF DESCRIPTION OF INVENTION
One object of the invention is to fully encapsulate and bonded toxic fly ash within a hardened mixture that prevents any significant subsequent release or leaching of toxic elements into the environment.
Another object is to produce a secondary product from the fly ash which can be used for safe and useful purposes, such as a hardened material useful as a non-toxic aggregate.
DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
Other features and advantages of the present invention will become apparent in the following detailed descriptions of the preferred embodiment with reference to the accompanying drawing.
Fig. 1 is a flow chart of an exemplary embodiment
DETAILED DESCRIPTION OF THE INVENTION
In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of various embodiments. However, those skilled in the art will understand that the present invention may be practiced without these specific details, that the present invention is not limited to the described embodiments, and that the present invention may be practiced in a variety of alternate embodiments. In other instances, well known methods, procedures, components, and systems have not been described in detail. One of skill in the art will appreciate various modifications to the process, to the ingredients, and to the proportions of ingredients that are possible. One skilled in the art will further appreciate that the following steps can be scaled to allow larger or smaller quantities of product to be made.
The following description teaches a product which incorporates and neutralizes toxic fly ash or other similar toxic particles. In one embodiment, toxic fly ash is coated with a glass forming silica salt. In a preferred embodiment, the silica salt is sodium silicate. However, other forms of silica salts, such as potassium silicate and lithium silicate, amongst others, may also be used. In an embodiment, the glass forming silicate maybe sprayed onto or otherwise mixed with fly ash. In an embodiment, the fly ash and the glass forming silica salt is dried to harden. In an embodiment, the hardened fly ash and glass forming silica salt is formed or processed into an aggregate or powder. In another embodiment, a wetting agent and/or coating and/or powders are added to the fly ash and glass forming silica salt to increase the hardness of the product and increase its utility.
The product described herein can be blended with stucco, mortars, grouts, concrete or other cementitious mixes and/or may be suitable for use in a wide variety of both structural and non-structural cement-based mixes. Non-structural usage examples could include landfill cover, decorative gravels, roadbed fill, or as a general, all-purpose lightweight aggregate.
Referring to FIG. 1, in an exemplary embodiment of a method of preparing an exemplary product 100, the components of which are described in detail below, a wetting agent 20 is, preferably, water mixed with a glass forming silica salt 30. In one embodiment, a thickening agent 40 such as acrylic is also added.
Fly ash 10 is thoroughly combined with the wetting agent 20 using a mixing device, such as a paddle mixer, or other blending method, such that the toxic fly ash is substantially and uniformly coated with the wetting agent 20. After the fly ash 10 is coated with the wetting agent 20, a coating agent 60 may be optionally applied. The coating agents may acrylic latex paint, acrylic paint slurry and/or waste paint“sludge”; and/or various cement powders; and/or various pozzolanic materials or hardeners common to the concrete products industry or some
combination thereof. Finally, the coated fly ash is dried 70 and ready for shipment.
In order to increase the size, decrease the cost, and/or improve the durability or other performance enhancing property of the hardened aggregate, additional non-hazardous materials may be incorporated into the original mixture and/or later applied as an added surface coating. Examples of such additives may include recycled products such as calcium carbonate, pulverized/granulated tire rubber, and /or glass beads or fragments.
In an exemplary mixing process dry Portland cement and fly ash are placed into a vessel for mixing. Waste water, such as acrylic-containing waste water generated by the manufacture or processing of acrylic paint, may be added instead of, or in addition to, pure water forms a pasty slurry. Liquid silicate is added to the pasty slurry. In a preferred embodiment, liquid silicate is sodium silicate. In one preferred embodiment, recycled paint sludge may add in a last step. An exemplary product has the following formulation by weight 13% fly ash, 12% Portland cement, 4% Recycled acrylic paint“sludge” , 56% Waste water containing acrylic, 15% Liquid sodium silicate.
The terms and expressions which have been employed in the foregoing specification are used therein as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding equivalents of the features shown and described or portions thereof, it being recognized that the scope of the invention is defined and limited only by the claims which follow.

Claims

We claim as our invention:
What is claimed is:
1. A product comprising ash fly and glass forming glass forming silica salt.
2. The product of claim 1 where the glass forming silicate salt is potassium silicate.
4. The product of claim 1 wherein glass forming silicate salt is sodium silicate.
5. The product of claim 1 is further comprised of a coating agent.
6. The product of claim 5 where the coating is taken from the group consisting of: acrylic, bio char, cementitious and pozzolanic materials, Portland cement, masonry cement, plastic, high- early slag cement, fly ash, silica fume, metakaolin, pigments, iron oxide, gypsum, fibers, PVA fibers, nylon fibers, steel fibers, fiberglass, organic materials, or a combination thereof.
PCT/US2019/025833 2018-04-04 2019-04-04 Non-toxic hardened synthetic material containing encapsulated toxic and non-toxic particles WO2019195577A1 (en)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US201862652761P 2018-04-04 2018-04-04
US62/652,761 2018-04-04
US201862739272P 2018-09-30 2018-09-30
US62/739,272 2018-09-30

Publications (1)

Publication Number Publication Date
WO2019195577A1 true WO2019195577A1 (en) 2019-10-10

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PCT/US2019/025833 WO2019195577A1 (en) 2018-04-04 2019-04-04 Non-toxic hardened synthetic material containing encapsulated toxic and non-toxic particles

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN112300608A (en) * 2020-10-30 2021-02-02 合肥工业大学 Aqueous inorganic coating based on geopolymer and preparation method thereof

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1944007A (en) * 1933-04-01 1934-01-16 Battelle Memorial Institute Light weight ceramic material and method of making the same
US3573940A (en) * 1969-01-31 1971-04-06 Us Interior Fly ash based preformed support structures
US4120735A (en) * 1974-10-25 1978-10-17 Gilbert Associates, Inc. Brick and method of making same
US8202362B2 (en) * 2006-07-28 2012-06-19 Red Lion Cement Technology Limited Geopolymeric cement based on fly ash and harmless to use
US20120172469A1 (en) * 2010-12-30 2012-07-05 United States Gypsum Company Lightweight foamed fly ash based binders and method

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1944007A (en) * 1933-04-01 1934-01-16 Battelle Memorial Institute Light weight ceramic material and method of making the same
US3573940A (en) * 1969-01-31 1971-04-06 Us Interior Fly ash based preformed support structures
US4120735A (en) * 1974-10-25 1978-10-17 Gilbert Associates, Inc. Brick and method of making same
US8202362B2 (en) * 2006-07-28 2012-06-19 Red Lion Cement Technology Limited Geopolymeric cement based on fly ash and harmless to use
US20120172469A1 (en) * 2010-12-30 2012-07-05 United States Gypsum Company Lightweight foamed fly ash based binders and method

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN112300608A (en) * 2020-10-30 2021-02-02 合肥工业大学 Aqueous inorganic coating based on geopolymer and preparation method thereof

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