Ash insulation panels

Abstract

The present invention relates to ash recycling and use in thermal insulation (decrease of thermal transmission from inside buildings into outside, and vice versa). Ash insulation panels are made of the following basic materials: ash and Polystyrene (PS) and/or waste plastics made of Polystyrene and chemical bond. These panels have many advantages beside thermal insulation such as lightweight and low water absorption rate. They are produced by mixing the mentioned basic materials, casting the mixture into molds of variable size and shape depending on the desired product, pressing the mold, and treating the final product thermally.

Claims

1. A thermal insulation panel comprising a mixture of ash and a polymeric material, wherein: the ash is 55-70% of the mixture and the polymeric material is 28-45% of the mixture, the mixture further comprises chloroform, and the thermal insulation panel is a cast panel.

2. The thermal insulation panel according to claim 1, wherein the polymeric material comprises polystyrene or plastic waste material.

3. The thermal insulation panel according to claim 1, having a density of 1.43 g/cm.sup.3 and a water absorption of 2.83%.

4. The thermal insulation panel according to claim 1, wherein the polymeric material is polystyrene.

5. The thermal insulation panel according to claim 1, wherein the mixture is homogeneous.

6. A process for producing thermal insulation panels, comprising: forming a mixture of ash and a polymeric material; gradually adding chloroform to the mixture; continuing mixing until the mixture is almost dry; casting the mixture into a mold; and molding the mixture under pressure.

7. The process according to claim 6, wherein the formed mixture comprises from 55-70% ash and from 28-45% polymeric material.

8. The process according to claim 6, wherein the polymeric material is selected from polystyrene or plastic waste material.

9. The process according to claim 6, wherein the molding the mixture under pressure comprises pressing the mold by a hydraulic piston under pressure of 3-30 tons.

10. The process according to claim 6, further comprising treating the mold in a thermal furnace at a temperature of from 160-180 C. for 2 to 4 hours, then cooling to room temperature and removing a thermal insulation panel product.

11. The process according to claim 6, wherein the chloroform is added in an amount from 10-20%.

12. The process according to claim 6, wherein the polymeric material is polystyrene.

13. The process according to claim 12, wherein the amount of ash is 60%, the amount of polystyrene is 28% and the amount of chloroform is 12%.

14. The process according to claim 6, wherein the continuing mixing comprises mixing until the mixture is homogeneous.

15. The process according to claim 6, wherein the mold used in the casting the mixture is made of iron, plastic, or metal.

16. The process according to claim 15, wherein the mold is coated with thermal insulation to prevent the components from sticking to the mold.

17. A process of recycling waste, comprising mixing ash and a polymeric material in the presence of chloroform to form a mixture, casting the mixture into a mold, pressurizing the mold, subjecting the mold to heat, cooling the mold and removing a thermal insulation panel.

Description

DETAILED DESCRIPTION OF THE INVENTION

(1) Ash insulation panels are made of the following basic materials: ash (55-70%) and polystyrene (30-45%).

(2) After preparing the desired ratios, they are mixed in an electric or mechanical mixer. During the mixing process, (10-20%) chloroform is gradually added to the mixture. The mixing process continues until the mixture becomes almost dry. Then, the mixture is casted in an iron, plastic, or metal mold coated with thermal insulation to prevent the components from sticking to the mold. The mold is then pressed by a hydraulic piston under pressure of 3-30 tons depending on the thickness of the desired product. After the pressing process, the mold is placed in a thermal furnace for treating it at a temperature of 160-180 C. and it is left for about 2 to 4 hours. Then, when the temperature decreases into room temperature, the product is taken out from the thermal furnace.

(3) Insulation panels can be characterized by the following physical and mechanical properties:

(4) TABLE-US-00002 Water Compressive Furnace Absorption Density Hardness Strength Temperature % (g/cm.sup.3) (HRG) (MPa) C. 2.83 1.43 63 26 180

(5) The insulation panels can be made of 60% ash, 28% polystyrene, and 12% chloroform.