Filler Made from Sorted Waste Materials for the Production of Cement-bound Shaped Bodies

Abstract

A filler for production of cement-bound shaped bodies, comprising a material group mixture of comminuted and sorted waste materials, conditioned with chemical reagents/compounds in the presence of water, wherein the material group mixture is composed of comminuted and sorted waste materials, selected from the following material groups: PPK: paper, paperboard, cardboard plastics inert material textiles wood
which are mixed according with a mass-related material group vector and then comminuted.

Claims

1. A filler for the production of cement-bound mouldings, comprising a material group mixture of comminuted and sorted residual materials, conditioned with chemical reagents/compounds in the presence of water, wherein the material group mixture is composed of comminuted and sorted residual materials selected from the material groups: PPK: paper, cardboard, cardboard packaging; plastics; inert textiles; and wood; which are mixed and then crushed according to the corresponding mass-related material group vector.

2. The filler according to claim 1, wherein the chemical reagents are aluminium sulphate and calcium oxide.

3. The filler according to claim 1, wherein the chemical reagents are calcium hydroxide.

4. The filler according to claim 1, wherein the groups of substances used are present in proportions of the relative dry matter of 20% PPK (paper, cardboard, paperboard) such as packaging, printed matter or cardboard folders, 40% plastics such as packaging, films, CD/DVD cases, 20% inert materials such as glass, ceramics, porcelain, stones and earthenware, 15% textiles such as clothing textiles, curtains, carpets, fabric remnants, and 5% wood such as wooden boxes, boards or chipboard.

5. The filler according to claim 1, wherein the substance groups used are at least partially provided as fibrous particles.

6. The filler according to claim 1, wherein 5.5 to 6% by mass of nominally anhydrous aluminium sulphate is used, based on the absolute dry mass of the comminuted mixture of groups of substances.

7. The filler according to claim 1, wherein the mass ratio of aluminium sulphate (Al.sub.2(SO.sub.4).sub.3) to calcium oxide (CaO) is 1:1.

8. The filler according to claim 1, wherein the total mixture has a moisture content of ˜30-40% by mass.

9. A moulding made from the filler according to claim 1, which is processed with cement and water to form the cement-bonded moulding.

10. The moulding according to claim 9, wherein the amount of cement is 70±1% by mass relative to the dry mass of the filler.

11. The moulding according to claim 9, wherein, in addition to filler, cement and water, kaolin and calcium formate are additionally contained to increase the mechanical strength of the moulding.

12. The moulded article according to claim 11, wherein, based on the absolute dry mass of the filler, 6 mass % calcium formate (Ca(HCOO).sub.2) dissolved in water is used.

13. The moulding according to claim 11, wherein the amount of cement is 60±1 mass-% relative to the dry mass of the filler.

14. The moulding according to claim 12, wherein the mass of the added kaolin is 9-9.5 mass % relative to the cement mass used.

15. A method for the production of a filler comprising the groups of materials PPK (paper, cardboard, cardboard packaging), plastics, inert materials and textiles, comprising the steps: homogenisation of the material group materials in a mixer; comminution of the material group materials and homogenisation of the comminuted material mixture; addition of chemical reagents aluminium sulphate, calcium oxide or calcium hydroxide and water; and storage of the mixture for a defined reaction time of preferably 1 to 3 days.

16. The method for the production of a filler according to claim 15, wherein the groups of materials used are present in proportions of the relative dry mass of the mixture of 20% PPK (paper, cardboard, paperboard) such as packaging, printed products or cardboard folders, 40% plastics such as packaging, films, CD/DVD cases, 20% inert materials such as glass, ceramics, porcelain, stones and earthenware, 15% textiles such as clothing textiles, curtains, carpets, fabric remnants, and 5% wood such as wooden boxes, boards or chipboard.

17. The method for the production of a filler according to claim 15, wherein the material group mixture used is comminuted in a cross-flow screen flaker to produce fibrous particles.

18. The method for the preparation of a filler according to claims 15, wherein the comminuted material group mixture is mixed in a conventional mixer with solid aluminium sulphate (Al.sub.2(SO.sub.4).sub.3.xH.sub.2O) and calcium oxide or calcium hydroxide are added and mixed, whereby the aluminium sulphate can be used anhydrous (x=0) or with the water contents typically encountered in commerce (x>0).

19. The method for the preparation of a filler according to claim 18, wherein 5.5 to 6 mass % of nominally anhydrous aluminium sulphate is used, based on the absolute dry mass of the comminuted material group mixture.

20. The method for the preparation of a filler according to claims 15, wherein the mass-contamination from aluminum sulphate to calcium oxide is 1:1.

21. The method for the preparation of a filler according to claim 15, wherein water is added until an absolute target moisture content of the total mixture of ˜30-40 mass % is reached.

22. A method of manufacturing a moulded article comprising the steps of: providing a filler prepared according to claim 15; mixing the filler with cement and water and incorporating the composition into mould or form to produce the moulded article; setting the moulded article and removing the mould or shuttering; curing the moulded article for a defined number of days.

23. The method of producing a moulded article according to claim 22, wherein, in addition to cement and water, kaolin and calcium formate are also mixed with the filler.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0042] Further features of the present invention will be apparent from the following non-limiting embodiments. Therein shows:

[0043] FIG. 1 a block flow diagram of the process according to the invention; and

[0044] FIG. 2 an image of the filler according to the invention.

DETAILED DESCRIPTION OF THE INVENTION

[0045] FIG. 1 shows, in the form of a block flow diagram, an embodiment of the process for producing a filler according to the invention.

[0046] In a first step 2, residual materials 4 consisting of 20% paper, cardboard, cardboard packaging, 40% plastics, 20% inert material, 15% textiles and 5% wood are sorted, whereby sorting residues 6 are separated out.

[0047] In step 5, the residual materials 4 are transferred to a cross-flow screen flaker, where they are comminuted into ground material in step 8, with the maximum expansion of the particles of the ground material preferably being less than 4 mm in 80% by mass and less than 10 mm in 98% by mass.

[0048] The ground material 9 from step 8 is then mixed in a conventional mixer in step 10 with solid aluminium sulphate (Al2(SO4)3-xH2O) dosed in step 11 and calcium oxide as additives 12. The aluminium sulphate used is anhydrous (x=0) or has the water content typically found in commerce (x>0).

[0049] The mass ratio of aluminium sulphate (Al2(SO4)3) to calcium oxide (CaO) is 1:1.

[0050] Further water is added to the mixing process in step 10 until an absolute target moisture of the total mixture of ˜30-40 mass % is reached.

[0051] Finally, in step 14, the total mixture 13 from step 10 is stored for a reaction time of 1 to 3 days, which completes the production of the filler.

[0052] FIG. 2 shows an image of the filler, in particular revealing the structure and size of the granulation. The lighter visible in the image is for size comparison only and does not form part of the disclosure.