A VEGETAL CONCRETE MASONRY UNIT AND METHOD AND SYSTEM FOR MANUFACTURE THEREOF

Abstract

A vegetal concrete masonry unit is provided which comprises cooked crop residues, binder and pulverized fuel ash in a mass ratio of 1:1:1.5 to 1:1.5:3.

Claims

1. A method for the preparation of a vegetal concrete masonry unit, the method comprising: cooking or treating a crop residue in a cooker (28) with sodium hydroxide (NaOH) (26) and water (24); mixing hydrated lime, Ground Granulated Blast Furnace Slag (GGBFS) (14), and sodium silicate activator in a ribbon blender (18) to constitute the binder; intermixing the treated crop residue, binder and pulverized fuel ash (PFA) together in a pan mixer (34) with water (38) to form an alkali activated homogeneous paste/gel; and molding the homogenous paste obtained in intermixing step using a high-pressure hydraulic press to form the vegetal concrete masonry unit; wherein the crop residues are cooked in a cooker with 0.2 M to 10M NaOH (26) aqueous solution at 150° C. for a duration of 15 to 45 minutes to improve compatibility between crop residues and binder; and wherein the binder includes hydrated lime of at least 85 percent calcium hydroxide mixed with GGBFS (14) in a 1:6 to 2:3 ratio.

2. (canceled)

3. (canceled)

4. The method as claimed in claim 1, wherein the sodium silicate activator is in an amount equal to 2.5-20% of the total mass of hydrated lime and GGBFS in a ribbon blender (18) to constitute the binder.

5. The method as claimed in claim 1, wherein the binder is further mixed with pulverized fuel ash, cooked crop residues, and water (38) in a pan mixer (34) and cast into molds using a high-pressure hydraulic press (40) with a compacting pressure of up to 10 MPa.

6. The method as claimed in claim 1, wherein the alkali activated homogeneous paste/gel is Calcium-Alumino-Silicate-Hydrate (C-A-S-H/CASH) gel/paste.

7. The method as claimed in claim 1, wherein the PFA and GGBFS reacts with an activator powder (16) to form Sodium-Alumino-Silicate-Hydrate (N-A-S-H/NASH) geopolymers, as well as CASH gel.

8. The method as claimed in claim 7, wherein the activator powder (16) is anhydrous sodium silicate powder.

9. (canceled)

10. (canceled)

11. The method as claimed in claim 1, wherein the step of cooking or treating the crop residue is carried out in the cooker (28) being a stainless-steel container constructed with a pressure lock system and designed to withstand a total internal pressure of minimum 2 atm.

12. The method as claimed in claim 1, wherein the step of cooking or treating the crop residue includes washing of crop residues until the water (24) runs clear and de-watering of the washed residues to a saturated condition.

13. The method as claimed in claim 1, wherein the step of mixing comprises mixing Hydrated lime consisting of at least 85% calcium hydroxide with ground granulated blast furnace slag (GGBFS) (14) having a specific surface area of at least 400 m.sup.2/kg in a ratio of 1:6 to 2:3, respectively.

14. The method as claimed in claim 13, wherein anhydrous sodium silicate powder of amount equal to 2.5% to 20% of the combined mass of hydrated lime and GGBFS (14) is added to the mix and blended together for a duration of 3 minutes.

15. (canceled)

16. The method as claimed in claim 1, wherein the step of molding is carried out through a hydraulic block making machine consisting of a metal die, metal press and hydraulic jack capable of delivering a compression force of 2 MPa to 10 MPa.

17. A system (10) for the manufacture of a vegetal concrete masonry unit, the system comprising: a lime silo (12) containing hydrated lime; an activator powder (16) in a ribbon blender (18) to form a binder; a binder silo (20) for storing the binder; a stainless steel cooker (28) for cooking a raw crop residue; a pan mixer (34) for obtaining the wet mix; a cooked crop residue hopper (32) for obtaining the mixture obtained from the stainless steel cooker (28); wherein the cooked crop residues from hopper (32), binder from the binder silo (20) and pulverized fuel ash, PFA, hopper (36) are mixed with water (38) in a pan mixer (34) with 0.2 M to 10M NaOH (26) aqueous solution at 150° C. for a duration of 15 to 45 minutes to improve compatibility between crop residues and binder; and wherein the binder includes hydrated lime of at least 85 percent calcium hydroxide mixed with GGBFS (14) in a 1:6 to 2:3 ratio; wherein the wet mix of the pan mixer (34) are casted into molds using hydraulic block machine (40) with a high compacting pressure, and then transported to the stock yard.

18. The system (10) as claimed in claim 17, wherein the hydrated lime is mixed with ground granulated blast furnace slag (14) and the activator powder (16) in a ribbon blender (18) to form a binder which is stored in a binder silo (20).

19. The system (10) as claimed in claim 17, wherein the raw crop residue from the storage (22) is mixed with water (24) and NaOH (26) in the stainless steel cooker (28).

20. The system (10) as claimed in claim 17, wherein the cooked crop residues from stainless steel cooker (28) is fed to wet washing (30).

21. A vegetal concrete masonry unit prepared by the method as claimed in claim 1 which comprises of cooked crop residues, binder and pulverized fuel ash in a mass ratio of 1:1:1.5 to 1:1.5:3.

22. (canceled)

23. The vegetal concrete masonry unit as claimed in claim 21, wherein the binder comprises mixing hydrated lime, Ground Granulated Blast Furnace Slag (14), and sodium silicate activator in a mass ratio of 2:3:0.5 to 1:6:2.

Description

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING

[0029] FIG. 1 illustrates a system of manufacturing a vegetal concrete masonry unit according to the present invention.

[0030] FIG. 2 illustrates a process showing the steps of manufacturing a vegetal concrete masonry unit according to the present invention.

DETAILED DESCRIPTION OF THE PRESENT INVENTION

[0031] A novel, environmentally sustainable vegetal concrete masonry unit/brick and viable process and system for the preparation of the same with performance related advantage over existing products is disclosed. The vegetal concrete masonry unit/brick of the present invention finds application in civil constructions in form of blocks and pre-cast wall panels. This vegetal concrete masonry unit may be cast in a hybrid composite construction, where there shall be the core made of this material, encased in a steel frame. These hybrid panel will then be erected on site to make a pre-engineered building.

[0032] Thus, the present invention relates to an economically sustainable vegetal concrete masonry unit and the method for manufacturing the same, wherein the vegetal concrete masonry unit comprises of hydrated lime, Ground Granulated Blast Furnace Slag, pulverized fuel ash, cooked crop residues and sodium silicate used in defined amounts. Further, the process for the manufacture of vegetal concrete masonry unit employs a step of treating the crop residue with alkali such as sodium hydroxide increasing the homogeneity of the material mixture and eliminates the set-retarding extracts from the crop residues; and on further addition of binder materials improves the compressive strength of the formed vegetal concrete masonry unit.

[0033] In the present invention, lime and Ground Granulated Blast Furnace Slag (GGBFS) act as the main binding agent. The addition of sodium silicate activates the reaction between lime and GGBFS to form Calcium-Alumino-Silicate-Hydrate (C-A-S-H/CASH) gel that creates the matrix to hold the aggregates in the concrete, which are vegetal matter and pulverized fuel ash (PFA). Formation of CASH gel is a desirable hydration product that occurs when building limes or Portland cements are mixed with water. The addition of PFA also has an additional role to play. It acts as a fine aggregate as well as a binding agent. The PFA reacts with GGBFS in the presence of the activator to form Sodium-Alumino-Silicate-Hydrate (N-A-S-H/NASH) geopolymers, as well as CASH gel. For the reaction between GGBFS and pulverized fuel ash, the presence of lime (calcium hydroxide) also creates a suitable pH environment to facilitate the reaction. A part of the remaining calcium hydroxide in the mixture mineralizes the cooked crop residues and the other part subsequently turns into calcium carbonate through carbonation. The crop residue is selected from a group of crop residues comprising paddy straw, wheat straw, bagasse, cotton stalk, corn stover, sugar cane trash, sunflower stalk, soy stalk, chia stalk, kenaf stalk and jute stalk and/or a combination thereof. Therefore, changes in activator, lime, GGBFS and pulverized fuel ash content would result in varying amounts of CASH and NASH, thereby affecting the strength of the final vegetal concrete product.

[0034] FIG. 1 discloses a system 10 for manufacturing of a vegetal masonry unit according to the present invention, wherein the system comprising a lime silo 12 containing hydrated lime which is mixed with ground granulated blast furnace slag 14 and a activator powder 16 in a ribbon blender 18 to form a binder which is stored in a binder silo 20, a raw crop residue from the storage 22 is mixed with water 24 and sodium hydroxide 26 in the stainless steel cooker 28, the mixture obtained from the stainless steel cooker 28 is fed to the wet washing 30 and subsequently to the cooked crop residue hopper 32. The cooked crop residues from hopper 32, binder from the binder silo 20 and PFA pulverized fuel ash hopper 36 are mixed with water 38 in a pan mixer 34, wherein, the wet mix of the pan mixer 34 are casted into molds using hydraulic block machine 40 with a high compacting pressure, and then transported to the stock yard.

[0035] The crop residues are cooked in a cooker with 20 percent sodium hydroxide (NaOH) and water at 150° C. for a duration of 45 minutes; wherein the binding materials —includes hydrated lime of at least 85 percent calcium hydroxide which is mixed with GGBFS in a 2:3 ratio, and sodium silicate activator of an amount equal to 2.5-20% of the total mass of hydrated lime and GGBFS in a ribbon blender to constitute the binder; wherein the binder is further mixed with pulverized fuel ash, cooked crop residues, and water in a pan mixer and cast into molds with using a high-pressure hydraulic press with a compacting pressure of 10 MPa.

[0036] FIG. 2 illustrates a process that shows the steps of manufacturing of vegetal concrete masonry unit according to the present invention which are as below:

[0037] 1. Processing of Crop Residues

[0038] Each kilogram of crop residues, either individually or as a combination of paddy straw, wheat straw, bagasse, cotton stalk, corn stover, sugar cane trash, sunflower stalk, soy stalk, chia stalk, kenaf stalk, hemp stalk and jute stalk are added to 5 liters of 0.2M to 10M NaOH solution in a stainless-steel container constructed with a pressure lock system and designed to withstand a total internal pressure of minimum 2 atm. The stainless-steel container containing the crop residues and NaOH solution is heated to a temperature of 150° C. and 1 to 2 atm pressure. The temperature and pressure are applied for a duration of 15 to 45 minutes, after which, the crop residues are removed from the container and washed until the water runs clear. The washed residues are de-watered to a saturated condition.

[0039] 2. Preparation of Binder

[0040] Hydrated lime consisting of at least 85% calcium hydroxide is mixed with ground granulated blast furnace slag (GGBFS) having a specific surface area of at least 400 m.sup.2/kg in a ratio of 1:6 to 2:3, respectively. Anhydrous sodium silicate powder of amount equal to 5% to 20% of the combined mass of hydrated lime and GGBFS is added to the mix. The three constituents are blended together for a duration of at least 5 minutes.

[0041] 3. Preparation of Vegetal Concrete Mix

[0042] The processed crop residues in the wet form, the binder, dry fly ash and water are added to a pan mixer in quantities as set out in table 1. The constituents are mixed at least for a duration of 3 minutes.

TABLE-US-00001 TABLE 1 Vegetal concrete, comprehensive Quantity Compressive Dry Density Raw Material (kg/m.sup.3) Strength (MPa) (kg/m.sup.3) Pre-mixed binder 320-400 5-7 MPa 950-1200 Treat crop residues in water 320-380 saturated condition Fly Ash 500-800 Water  60-100

[0043] 4. Production of Vegetal Masonry Unit

[0044] The wet mix is transferred to a hydraulic block making machine consisting of a metal die, metal press and hydraulic jack capable of delivering a compression force of 2 MPa to 10 MPa.

[0045] In order to more clearly describe the nature of the present invention, specific examples will hereinafter be described. It should be understood, however, that this is done solely by way of example, and is intended neither to delineate the scope of the invention nor limit the ambit of the appended claims.

SPECIFIC EXAMPLES

Example 1 (Paddy Straw)

[0046] Step 1: Processing of Crop Residues

[0047] Each kilogram of paddy straw is added to 5 litres of 1M NaOH solution and heated to a temperature of 150° C. in a stainless-steel container. The temperature is maintained for a duration of 45 minutes, after which the paddy straw is removed from the container and washed thoroughly, until the water flows clear. The straw is squeezed and excess water is drained.

[0048] Step 2: Preparation of Binder

[0049] Hydrated lime consisting of at least 85% calcium hydroxide is mixed with ground granulated blast furnace slag (GGBFS) having a specific surface area of at least 400 m.sup.2/kg in a ratio of 2:3, respectively. Anhydrous sodium silicate powder of amount equal to 20% of the combined mass of hydrated lime and GGBFS is added to the mix. The three constituents are blended together for a duration of at least 5 minutes.

[0050] Step 3: Preparation of Vegetal Concrete Mix

[0051] The processed crop residues in the wet form, the binder, fly ash and water are added to a pan mixer in quantities as set out in table 2.

[0052] Step 4: Production of Vegetal Concrete Masonry Unit

[0053] The wet mix is transferred to a hydraulic block making machine consisting of a metal die, metal press and hydraulic jack capable of delivering a compression force of 2 MPa.

TABLE-US-00002 TABLE 2 Paddy straw based vegetal concrete, Example 1 Quantity Compressive Dry Density Raw Material (kg/m.sup.3) Strength (MPa) (kg/m.sup.3) Pre-mixed binder 400 7 MPa 1086 Treated paddy straw 380 Fly Ash 556 Water 80

Example 2 (Paddy Straw)

[0054] Step 1: Processing of Crop Residues

[0055] Each kilogram of paddy straw is added to 5 litres of 0.5M NaOH solution and heated to a temperature of 150° C. in a stainless-steel container with a pressure lock lid, with a capacity to withstand 2 atm of pressure. The lid is closed tight, and the temperature is maintained for a duration of 45 minutes, after which the paddy straw is removed from the container and washed thoroughly, until the water flows clear. The straw is squeezed and excess water is drained.

[0056] Step 2: Preparation of Binder

[0057] Hydrated lime consisting of at least 85% calcium hydroxide is mixed with ground granulated blast furnace slag (GGBFS) having a specific surface area of at least 400 m.sup.2/kg in a ratio of 2:3, respectively. Anhydrous sodium silicate powder of amount equal to 20% of the combined mass of hydrated lime and GGBFS is added to the mix. The three constituents are blended together for a duration of at least 5 minutes.

[0058] Step 3: Preparation of Vegetal Concrete Mix

[0059] The processed crop residues in the wet form, the binder, fly ash and water are added to a pan mixer in quantities as set out in table 3. The constituents are mixed for a duration of 3 minutes.

[0060] Step 4: Production of Vegetal Concrete Masonry Unit

[0061] The wet mix is transferred to a hydraulic block making machine consisting of a metal die, metal press and hydraulic jack capable of delivering a compression force of 2 MPa.

TABLE-US-00003 TABLE 3 Paddy straw based vegetal concrete, Example 2 Quantity Compressive Dry Density Raw Material (kg/m.sup.3) Strength (MPa) (kg/m.sup.3) Pre-mixed binder 400 7 MPa 1086 Treated paddy straw 380 Fly Ash 556 Water 80

[0062] Please note: In the above two examples, preparation of crop residues can happen with NaOH solution having molar concentration between 0.3M to 10M. The cooking time and cooking pressure will vary depending on the concentration of the solution.

Example 3 (Paddy Straw)

[0063] Step 1: Processing of Crop Residues

[0064] Each kilogram of paddy straw is added to 5 litres of 0.5M NaOH solution and heated to a temperature of 150° C. in a stainless-steel container with a pressure lock lid, with a capacity to withstand 2 atm of pressure. The lid is closed tight, and the temperature is maintained for a duration of 45 minutes, after which the paddy straw is removed from the container and washed thoroughly, until the water flows clear. The straw is squeezed and excess water is drained.

[0065] Step 2: Preparation of Binder

[0066] Hydrated lime consisting of at least 85% calcium hydroxide is mixed with ground granulated blast furnace slag (GGBFS) having a specific surface area of at least 400 m.sup.2/kg in a ratio of 1:5.67, respectively. Anhydrous sodium silicate powder of amount equal to 15% of the combined mass of hydrated lime and GGBFS is added to the mix. The three constituents are blended together for a duration of at least 5 minutes.

[0067] Step 3: Preparation of Vegetal Concrete Mix

[0068] The processed crop residues in the wet form, the binder, fly ash and water are added to a pan mixer in quantities as set out in table 4. The constituents are mixed for a duration of 3 minutes.

[0069] Step 4: Production of Vegetal Concrete Masonry Unit

[0070] The wet mix is transferred to a hydraulic block making machine consisting of a metal die, metal press and hydraulic jack capable of delivering a compression force of 2 MPa.

TABLE-US-00004 TABLE 4 Paddy straw based vegetal concrete, Example 3 Quantity Compressive Dry Density Raw Material (kg/m.sup.3) Strength (MPa) (kg/m.sup.3) Pre-mixed binder 340 5 MPa 1173 Treated paddy straw 360 Fly Ash 713 Water 80

Example 4 (Wheat Straw)

[0071] Step 1: Processing of Crop Residues

[0072] Each kilogram of wheat straw is added to 5 litres of 0.5M NaOH solution and heated to a temperature of 150° C. in a stainless-steel container with a pressure lock lid, with a capacity to withstand 2 atm of pressure. The lid is closed tight, and the temperature is maintained for a duration of 35 minutes, after which the wheat straw is removed from the container and washed thoroughly, until the water flows clear. The straw is squeezed and excess water is drained.

[0073] Step 2: Preparation of Binder

[0074] Hydrated lime consisting of at least 85% calcium hydroxide is mixed with ground granulated blast furnace slag (GGBFS) having a specific surface area of at least 400 m.sup.2/kg in a ratio of 2:3, respectively. Anhydrous sodium silicate powder of amount equal to 20% of the combined mass of hydrated lime and GGBFS is added to the mix. The three constituents are blended together for a duration of at least 5 minutes.

[0075] Step 3: Preparation of Vegetal Concrete Mix

[0076] The processed crop residues in the wet form, the binder, fly ash and water are added to a pan mixer in quantities as set out in table 5. The constituents are mixed for a duration of 3 minutes.

[0077] Step 4: Production of Vegetal Concrete Masonry Unit

[0078] The wet mix is transferred to a hydraulic block making machine consisting of a metal die, metal press and hydraulic jack capable of delivering a compression force of 2 MPa.

TABLE-US-00005 TABLE 5 Wheat straw based vegetal concrete, Example 4 Quantity Compressive Dry Density Raw Material (kg/m.sup.3) Strength (MPa) (kg/m.sup.3) Pre-mixed binder 400 7 MPa 1086 Treated wheat straw 380 Fly Ash 556 Water 80

Example 5 (Bagasse)

[0079] Step 1: Processing of Crop Residues

[0080] Each kilogram of bagasse is added to 5 litres of 0.5M NaOH solution and heated to a temperature of 150° C. in a stainless-steel container with a pressure lock lid, with a capacity to withstand 2 atm of pressure. The lid is closed tight, and the temperature is maintained for a duration of 15 minutes, after which the bagasse is removed from the container and washed thoroughly, until the water flows clear. The washed bagasse is squeezed, and excess water is drained.

[0081] Step 2: Preparation of Binder

[0082] Hydrated lime consisting of at least 85% calcium hydroxide is mixed with ground granulated blast furnace slag (GGBFS) having a specific surface area of at least 400 m.sup.2/kg in a ratio of 1:5.67, respectively. Anhydrous sodium silicate powder of amount equal to 20% of the combined mass of hydrated lime and GGBFS is added to the mix. The three constituents are blended together for a duration of at least 5 minutes.

[0083] Step 3: Preparation of Vegetal Concrete Mix

[0084] The processed crop residues in the wet form, the binder, fly ash and water are added to a pan mixer in quantities as set out in table 6. The constituents are mixed for a duration of 3 minutes.

[0085] Step 4: Production of Vegetal Concrete Masonry Unit

[0086] The wet mix is transferred to a hydraulic block making machine consisting of a metal die, metal press and hydraulic jack capable of delivering a compression force of 2 MPa.

TABLE-US-00006 TABLE 6 Bagasse based vegetal concrete, Example 5 Quantity Compressive Dry Density Raw Material (kg/m.sup.3) Strength (MPa) (kg/m.sup.3) Pre-mixed binder 320 5.2 MPa 1175 Treated bagasse 335 Fly Ash 760 Water 80

Example 6 (Bagasse)

[0087] Step 1: Processing of Crop Residues

[0088] Each kilogram of bagasse is added to 5 litres of 1M NaOH solution and heated to a temperature of 100° C. in a stainless-steel container with a pressure lock lid, with a capacity to withstand 2 atm of pressure. The lid is closed tight, and the temperature is maintained for a duration of 15 minutes, after which the bagasse is removed from the container and washed thoroughly, until the water flows clear. The washed bagasse is squeezed, and excess water is drained.

[0089] Step 2: Preparation of Binder

[0090] Hydrated lime consisting of at least 85% calcium hydroxide is mixed with ground granulated blast furnace slag (GGBFS) having a specific surface area of at least 400 m.sup.2/kg in a ratio of 1:5.67, respectively. Anhydrous sodium silicate powder of amount equal to 15% of the combined mass of hydrated lime and GGBFS is added to the mix. The three constituents are blended for a duration of at least 5 minutes.

[0091] Step 3: Preparation of Vegetal Concrete Mix

[0092] The processed crop residues in the wet form, the binder, fly ash and water are added to a pan mixer in quantities as set out in table 6. The constituents are mixed for a duration of 3 minutes.

[0093] Step 4: Production of Vegetal Concrete Masonry Unit

[0094] The wet mix is transferred to a hydraulic block making machine consisting of a metal die, metal press and hydraulic jack capable of delivering a compression force of 2 MPa.

TABLE-US-00007 TABLE 6 Bagasse based vegetal concrete, Example 6 Quantity Compressive Dry Density Raw Material (kg/m.sup.3) Strength (MPa) (kg/m.sup.3) Pre-mixed binder 380 10.8 MPa 1260 Treated bagasse 335 Fly Ash 700 Water 50