SINTERED CERAMICS

Abstract

A man-made aggregate or a masonry unit may be made by adding impound residues and mixing the impound residues with other residues, ceramic materials and/or additives to form an admixture. The impound residues may also be mixed with synthetic or organic polymers. The impound residues may not conform to the requirements of ASTM C618-15. The admixture may be subjected to a thermal process that allows for a ceramic conversion of the ceramic components of the mix used.

Claims

1. A method of making a man-made aggregate comprising the steps of: adding impound residues and mixing the impound residues with other residues, ceramic materials and/or additives to form an admixture.

2. The method of claim 1 wherein the impound residues do not conform to any of the requirements of ASTM C618-15.

3. The method of claim 2 comprising the additional step of subjecting the admixture to a thermal process that allows for a ceramic conversion of the ceramic components of the mix used.

4. The method of claim 3 further comprising the step of adding an additive that is contributing to eutectic conditions.

5. The method of claim 3 further comprising the step of adding an oxidizing agent.

6. The method of claim 5 wherein the oxidizing agent is as potash.

7. The method of claim 5 wherein the oxidizing agent is soda.

8. The method of claim 3 wherein the ceramic conversion occurs in a kiln.

9. The method of claim 3 wherein the ceramic conversion process occurs with excess oxygen or under reducing conditions.

10. The method of claim 3 wherein the ceramic conversion process can occur using externally or internally fired kilns.

11. The method of claim 3 wherein the admixture of the components can be made either wet or dry.

12. The method of claim 3 wherein each one of the components of the admixture can undergo a previous treatment such as sizing, removing of impurities, grinding, annealing or a combination of sizing, removing of impurities, grinding, and annealing.

13. A method of making a man-made aggregate comprising the steps of: adding impound residues and mixing the impound residues with other residues, ceramic materials and/or synthetic polymers to form an admixture.

14. The method of claim 13 wherein the impound residues do not conform to any of the requirements of ASTM C618-15.

15. The method of claim 14 comprising the additional step of subjecting the admixture to a thermal process that allows for a ceramic conversion of the ceramic components of the mix used.

16. The method of claim 15 further comprising the step of adding an additive that is contributing to eutectic conditions.

17. The method of claim 15 further comprising the step of adding an oxidizing agent.

18. The method of claim 17 wherein the oxidizing agent is a potash.

19. The method of claim 17 wherein the oxidizing agent is soda.

20. The method of claim 15 wherein the ceramic conversion occurs in a kiln.

21. The method of claim 15 wherein the ceramic conversion process occurs with excess oxygen or under reducing conditions.

22. The method of claim 15 wherein the ceramic conversion process can occur using externally or internally fired kilns.

23. The method of claim 15 wherein the admixture of the components can be made either wet or dry.

24. The method of claim 15 wherein each one of the components of the admixture can undergo a previous treatment such as sizing, removing of impurities, grinding, annealing or a combination of sizing, removing of impurities, grinding, and annealing.

25. A method of making a masonry unit comprising the steps of: adding impound residues and mixing the impound residues with other residues, ceramic materials and/or additives to form an admixture.

26. The method of claim 25 wherein the impound residues do not conform to any of the requirements of ASTM C618-15.

27. The method of claim 26 comprising the additional step of subjecting the admixture to a thermal process that allows for a ceramic conversion of the ceramic components of the mix used.

28. The method of claim 26 further comprising the step of adding an additive that is contributing to eutectic conditions.

29. The method of claim 26 further comprising the step of adding an oxidizing agent.

30. The method of claim 29 wherein the oxidizing agent is a potash.

31. The method of claim 29 wherein the oxidizing agent is soda.

32. The method of claim 27 wherein the ceramic conversion occurs in a kiln.

33. The method of claim 27 wherein the ceramic conversion process occurs with excess oxygen or under reducing conditions.

34. The method of claim 27 wherein the ceramic conversion process can occur using externally or internally fired kilns.

35. The method of claim 27 wherein the admixture of the components can be made either wet or dry.

36. The method of claim 27 wherein each one of the components of the admixture can undergo a previous treatment such as sizing, removing of impurities, grinding, annealing or a combination of sizing, removing of impurities, grinding, and annealing.

37. A method of making a masonry unit comprising the steps of: adding impound residues and mixing the impound residues with other residues, ceramic materials and/or additives to form an admixture.

38. The method of claim 37 wherein the impound residues do not conform to any of the requirements of ASTM C618-15.

39. The method of claim 38 comprising the additional step of subjecting the admixture to a thermal process that allows for a ceramic conversion of the ceramic components of the mix used.

40. The method of claim 39 further comprising the step of adding an additive that is contributing to eutectic conditions.

41. The method of claim 39 further comprising the step of adding an oxidizing agent.

42. The method of claim 41 wherein the oxidizing agent is as potash.

43. The method of claim 41 wherein the oxidizing agent is soda.

44. The method of claim 39 wherein the ceramic conversion occurs in a kiln.

45. The method of claim 39 wherein the ceramic conversion process occurs with excess oxygen or under reducing conditions.

46. The method of claim 39 wherein the ceramic conversion process can occur using externally or internally fired kilns.

47. The method of claim 39 wherein the admixture of the components can be made either wet or dry.

48. The method of claim 39 wherein each one of the components of the admixture can undergo a previous treatment such as sizing, removing of impurities, grinding, annealing or a combination of sizing, removing of impurities, grinding, and annealing.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0068] Features, aspects and advantages of the present invention are understood when the following detailed description of the invention is read with reference to the accompanying drawings, in which:

[0069] FIG. 1 is a diagram of the production process; and

[0070] FIG. 2 is a graph which visualizes the inhomogeneity of the source materials.

DETAILED DESCRIPTION OF THE INVENTION

[0071] A preferred embodiment according to the invention is described in detail below. A typical embodiment used in the production of granulates and masonry elements may be based upon fly ash with a residual organic content that makes them unsuitable for addition to concrete. This embodiment may feature the following chemical analysis:

TABLE-US-00003 Si Al Fe Ti Na Mg K Ca S tot Sb As Ba Cd Cr.sub.tot AVG 18.31 11.05 2,315.65 0.52 0.29 424.83 1,163.24 2,614.49 0.11 10.94 2.72 1,044.16 2.13 278.31 STDEV 1.40 1.28 1,200.87 0.06 0.23 639.00 450.37 1,505.86 0.06 14.58 1.18 566.55 1.12 166.58 Max 20.95 12.58 4,756.00 0.59 0.70 1,394.00 1,473.00 4,471.00 0.22 31.30 4.50 2,491.00 3.50 586.00 Min 16.24 9.13 1.89 0.37 0.12 0.25 1.15 3.45 0.03 0.90 1.40 717.80 0.50 123.50 Co Cu Pb Mn Mo Ni Se Sr Sn Te Tl V Zn Hg AVG 58.03 390.82 47.38 231.29 4.73 53.23 0.52 767.72 15.69 1.29 1.16 108.42 159.94 0.72 STDEV 12.12 530.89 43.01 177.95 2.56 11.88 0.30 438.79 17.08 0.06 0.37 30.62 153.32 0.19 Max 81.60 1,386.00 110.80 684.00 9.30 71.90 1.10 1,904.00 38.60 1.40 1.70 152.00 411.00 1.20 Min 43.60 28.20 9.20 113.00 1.20 34.30 0.20 485.30 3.10 1.20 0.50 42.80 28.20 0.60

[0072] The graphic shown in FIG. 2 visualizes the inhomogeneity of source materials.

[0073] Using these ashes 4 different admixtures have been prepared and tested:

A17: 75% CCW 25% Sodium silicate 50 BE
B14B15: 67.5% CCW, 22.5% % Sodium silicate 50 BE, 10% clay
E05-E15: 67.5% CCW, 15% Sodium silicate 50 BE, 7.5% NaOH, 10% clay
All admixtures are cured at 120 C. for 18 hrs.

[0074] When fired at 1,175 F 2 hrs hold, the following results have been obtained:

TABLE-US-00004 Fired to 1175F - 2 Hour Hold As Received Data Dry Length Fired Length Shrinkage Initial Wt. LOI Sample ID (mm) (mm) (%) (g) (%) A17 124.12 122.26 1.499 97.5 4.614 B14 113.55 109.69 3.399 85.2 4.797 B15 117.30 116.05 1.066 86.8 4.831 E15 115.63 114.87 0.657 88.1 5.762 E05 117.37 116.25 0.954 79.6 5.710

TABLE-US-00005 Absorptions Dry Wt. 24-hr Wt. 5-hr boil CWA BWA Sample ID (g) (g) (g) (%) (%) C/B A17 93.2 105.1 110.7 12.77 18.78 0.68 B14 81.3 88.5 90 8.86 10.70 0.83 B15 82.8 90.1 91.4 8.82 10.39 0.85 E15 83.3 94.6 95.2 13.57 14.29 0.95 E05 75.3 86.8 105.4 15.27 39.97 0.38

TABLE-US-00006 Compression Length Width Peak Load Compressive Strength Sample ID (in) (in) (lbs) (psi) A17 1.17 0.69 2614 3219.4 B14 1.01 0.65 4674 7119.4 B15 1.00 0.64 3931 6172.4 E15 1.08 0.72 1063 1358.1 E05 1.13 0.76 1472 1716.6

[0075] A sintered ceramic and process of producing a sintered ceramic according to the invention has been described with reference to specific preferred embodiments and examples. Various details of the invention may be changed without departing from the scope of the invention. Furthermore, the foregoing description of the preferred embodiments of the invention and best mode for practicing the invention are provided for the purpose of illustration only and not for the purpose of limitation, the invention being defined by the claims. It is envisioned that other embodiments may perform similar functions and/or achieve similar results. Any and all such equivalent embodiments and examples are within the scope of the present invention and are intended to be covered by the appended claims.