Methods of forming synthetic aluminosilicate material are disclosed. Exemplary methods include forming a polymer solution, adding an aluminum precursor to the polymer solution, adding a silicon precursor to the polymer solution, forming a gel from the polymer solution, calcining the gel to form an aluminosilicate powder, and grinding the aluminosilicate powder to form ground aluminosilicate material. The synthetic aluminosilicate material can be used in the formation of cement and concrete.

The invention generally relates to a method of making a plastic aggregate, and its use to make concrete products. The aggregate is formed by providing a granulated waste plastic material, introducing the granulated waste plastic material into an extruder having a die, the die having a ratio of die nozzle open area to die land area of about 1:10 to about 1:40, and extruding the granulated waste plastic material through the extruder to generate an extruded plastic aggregate. The method can include the presence of controlled cooling, the addition of additives and treatment of the surface of the aggregate to produce a desired aggregate that can be used to make a concrete product with desired properties, such as compressive strength and weight.

The invention generally relates to a method of making a plastic aggregate, and its use to make concrete products. The aggregate is formed by providing a granulated waste plastic material, introducing the granulated waste plastic material into an extruder having a die, the die having a ratio of die nozzle open area to die land area of about 1:10 to about 1:40, and extruding the granulated waste plastic material through the extruder to generate an extruded plastic aggregate. The method can include the presence of controlled cooling, the addition of additives and treatment of the surface of the aggregate to produce a desired aggregate that can be used to make a concrete product with desired properties, such as compressive strength and weight.

Preparing hybrid-treated plastic particles from waste plastic includes combining waste plastic particles with bio-oil to yield a mixture, irradiating the mixture with microwave radiation to yield oil-treated plastic particles, and contacting the oil-treated plastic particles with carbon-containing nanoparticles to yield hybrid-treated plastic particles. The hybrid-treated plastic particles have a bio-oil modified surface and a coating comprising carbon-containing nanoparticles on the bio-oil modified surface of the plastic particle. In some examples, a diameter of the plastic particle is in a range between 250 m and 750 m, and a thickness of the coating is in a range of 1 nm to 20 nm. A modified binder includes an asphalt binder or a concrete binder and a multiplicity of the treated plastic particles. The modified binder typically includes 5 wt % to 25 wt % of the hybrid-treated plastic particles.

Preparing hybrid-treated plastic particles from waste plastic includes combining waste plastic particles with bio-oil to yield a mixture, irradiating the mixture with microwave radiation to yield oil-treated plastic particles, and contacting the oil-treated plastic particles with carbon-containing nanoparticles to yield hybrid-treated plastic particles. The hybrid-treated plastic particles have a bio-oil modified surface and a coating comprising carbon-containing nanoparticles on the bio-oil modified surface of the plastic particle. In some examples, a diameter of the plastic particle is in a range between 250 m and 750 m, and a thickness of the coating is in a range of 1 nm to 20 nm. A modified binder includes an asphalt binder or a concrete binder and a multiplicity of the treated plastic particles. The modified binder typically includes 5 wt % to 25 wt % of the hybrid-treated plastic particles.

A concrete composition that includes (i) a treated palm oil fuel ash, wherein the treated palm oil fuel ash is the only binder present, (ii) a fine aggregate, (iii) a coarse aggregate, and (iv) an alkali activator containing an aqueous solution of sodium hydroxide and sodium silicate. A cured concrete made from the concrete composition is also disclosed with advantageous compressive strength properties.

A concrete composition that includes (i) a treated palm oil fuel ash, wherein the treated palm oil fuel ash is the only binder present, (ii) a fine aggregate, (iii) a coarse aggregate, and (iv) an alkali activator containing an aqueous solution of sodium hydroxide and sodium silicate. A cured concrete made from the concrete composition is also disclosed with advantageous compressive strength properties.

A concrete composition that includes (i) a treated palm oil fuel ash, wherein the treated palm oil fuel ash is the only binder present, (ii) a fine aggregate, (iii) a coarse aggregate, and (iv) an alkali activator containing an aqueous solution of sodium hydroxide and sodium silicate. A cured concrete made from the concrete composition is also disclosed with advantageous compressive strength properties.

A concrete composition that includes (i) a treated palm oil fuel ash, wherein the treated palm oil fuel ash is the only binder present, (ii) a fine aggregate, (iii) a coarse aggregate, and (iv) an alkali activator containing an aqueous solution of sodium hydroxide and sodium silicate. A cured concrete made from the concrete composition is also disclosed with advantageous compressive strength properties.

The present invention refers to a manufacturing process of artificial pozzolan which has the final color gray. In order to perform the processes in the desired way, the kiln atmosphere shall contain low oxygen concentration and the presence of reducing agents. However the presence of carbon monoxide at the kiln outlet is not desirable, due to environmental impacts and the increase in specific heat consumption of the kiln. So the process described in this invention comprises the following steps: heating (1), which consists of heating the raw materials to a temperature between 100-350° C. until drying of the material to a moisture mass fraction of 0-5% (wet basis); mixing (2), which consists of mixing the dry raw materials from the heating process with the right proportion of fuel, in from 1% to 5% in mass fraction, according to the concentration of hematite present in the raw material; calcining (3), which consists of heating the fuel and raw materials blend to a temperature between 700-900° C., with oxygen concentration between 1-5% and, finally, cooling (4), which consists of an initial step of rapid decrease in pozzolan temperature until 600° C. and a final step of slow decrease in pozzolan temperature until 120° C.