TR2023008747T

TR2023008747T - DEVELOPMENT OF INSULATED CONSTRUCTION BRICKS FROM ENRICHED ELECTRIC ARC FURNACE SLAG WASTES

Info

Publication number: TR2023008747T
Application number: TR2023/008747
Authority: TR
Inventors: N Ba Lan Cet
Original assignee: Mati̇l Malzeme Test Ve İnovasyon Laboratuvarlari Anoni̇m Şi̇rketi̇
Filing date: 2022-05-25
Publication date: 2024-12-23

Abstract

Buluş, çelik üretimi atığı olan elektrik ark ocağı cürufların geri kazanılarak inşaat sektöründe halihazırda kullanılan kırmızı inşaat tuğlası yerine ısı yalıtım özelliği daha üstün, izolasyon özellikli mikro poroziteye sahip bir izole inşaat tuğlası ve üretim yöntemi ile ilgilidir.The invention relates to an insulating construction brick with superior thermal insulation properties and micro porosity, instead of the red construction brick currently used in the construction sector, and its production method by recycling electric arc furnace slag, which is a steel production waste.

Description

TARIFNAME ZENGINLESTIRILMIS ELEKTRIK ARK OCAGI CÜRUF ATIKLARINDAN IZOLE INSAAT TUGLA GELISTIRILMESI Teknik Alan Bulus, çelik üretimi atigi olan cüruIlarin geri kazanilarak insaat sektöründe halihazirda kullanilan kirmizi insaat tuglasi yerine isi yalitim özelligi daha üstün, izolasyon özellikli mikro poroziteye sahip bir izole insaat tuglasi ve üretim yöntemi ile ilgilidir. Önceki Teknik Insaat sektöründe yüksek performansta isi yalitimina sahip gaz beton, bims ve kirmizi geleneksel insaat tuglasi yaygin olarak kullanilmaktadir. Kirmizi geleneksel insaat tuglasi dogal hammadde kaynaklari olan killi topraklardan üretilmekte olup yaygin olarak delik ve farkli geometrik sekillerde kullanilmaktadir. Bims ve gaz beton tuglalari makro ve mikro gözenekli tuglalar olup bilesenleri kuvars, kireç ve çimentodur. Yüksek isil yalitima sebep olmasi gereken tuglalar bunun için yüksek oranda gözenekli yapiya sahip olmalidir. Bu özeligin kazandirilmasi için kuvars ve beraberinde kireç, çimento ve köpürtücü ajanlar kullanilmaktadir. Teknigin bilinen durumunda yer alan CN103553701B sayili Çin patent dokümaninda, köpüklü seramik isi yalitim malzemesi ve bunun malzemenin üretim yönteminden bahsedilmektedir. Ilgili dokümanda köpürtücü aj anlarin kullanimindan bahsedilmektedir. Teknigin bilinen durumunda yer alan CN102344298A sayili Çin patent dokümaninda, köpüklü beton isi koruma ve tasiyici tugla ve üretimi yönteminden bahsedilmektedir. Ilgili dokümanda köpürtme isleminden ve elde edilen ürünün kil, cüruf, alçi tasi Vb. içerdigi açiklanmaktadir. Teknikte var olan çalismalar incelendiginde çelik üretimi atigi olan cüruIlarin geri kazanilarak insaat sektöründe halihazirda kullanilan kirmizi insaat tuglasi yerine isi yalitim özelligi daha üstün ve izolasyon özellikli mikro poroziteye sahip bir izole insaat tuglasinin ve üretim yönteminin gerçeklestirilmesi ihtiyaci duyulmustur. Bulusun Amaci Bu bulusun amaci, çelik üretimi atigi olan elektrik ark ocagi cüruIlarin geri kazanilarak insaat sektöründe halihazirda kullanilan kirmizi insaat tuglasi yerine isi yalitim özelligi daha üstün ve izolasyon özellikli mikro poroziteye sahip bir izole insaat tuglasinin ve üretim yönteminin gerçeklestirilmesidir. Bulusun Ayrintili Açiklamasi Bulus, cüruf esasli bir izole insaat tuglasi ile ilgili olup; - agirlikça %5 0-70 oraninda ana granül dolgu malzemesi olarak elektrikli ark ocagi cürufu, - agirlikça %1-3 oraninda gözenek kontrolü için ve baglayici katki olarak kullanilan baglama kili, - agirlikça %8-12 oraninda hidrolik baglayici çimento, - agrilikça %0,l-0,5 oraninda metalik alüminyum (Al) tozu veya %5-15 oraninda hidrojen peroksit (H202), - agirlikça %1-3 oraninda füme silika, - agirlikça %1-3 oraninda ögütülmüs alçi tasi, - agirlikça %0,l-l oranina karisim içine düsük su oraninda akiskanligin saglanmasi ve daha yüksek mukavemetin elde edilmesi için süper akiskanlastirici, - agirlikça %12-17 oraninda su, agirlikça %1-10 oraninda organik sivi köpük ajani, içermektedir. Bulus, cüruf esasli bir izole insaat tuglasi üretim yöntemi ile ilgili olup, agirlikça % cüruIlarinin ortalama 300 mikron tane boyutuna ögütülmesi ve toz haline getirilmesi, toz haline getirilen cüruf içerisine agirlikça %8-12 oraninda hidrolik baglayici çimento, agirlikça %1-3 mikro füme silika, gözenek kontrolü ve baglayici katki olarak kullanilan agirlikça %1-3 baglama kili, agirlikça %1- 3 ögütülmüs alçi tasinin eklenmesi, karisim içine düsük su oraninda akiskanligin saglanmasi ve daha yüksek mukavemetin elde edilmesi için agirlikça %0,l-l süper akiskanlastirici ve agirlikça %12-17 su karistirilarak, 3-4 dakika boyunca karistirma islemine devam edilmesi, karisim içine 3 dakika sonunda agirlikça %1-10 organik sivi köpük ajani (sentetik sivi hava sürükleyici) ilavesinin yapilmasi, karisimin (1-5 dakika) boyunca mikserde mekanik kuvvet sayesinde köpürtülmesi, elde edilen karisima çimento ile reaksiyonu sonucunda Hz gazi açiga çikmasini ve gözenek olusumunu saglayan agirlikça %0,l-0,5 metalik alüminyum (Al) tozu ilave edilmesi, bu asamada metalik Al pasta yerine diger kimyasal köpürtücü olan HzOz agirlikça %5-15ate verilerek 20-40 sn karistirma sonrasinda hafif beton dökümü yapilmasi, hazirlanan karisimlar istenilen ölçüde hazirlanmis metal kalip içine dökülerek oda sicakliginda 30-50 dk beklemeye alinmasi, kalip içinde veya kalip disina çikanlan sekillendirilmis prekast hafif tuglalarin 25-50°C"de 1-5 gün boyunca kürleme tankinda beklemeye alinmasi, - kürleme sonunda tuglalarin oda sicakliginda 1 gün bekletilmesi ve sonrasinda etüvde llOC,de 1-3 gün yüzey ve bagil nemini atmasi saglanarak kullanima hazir duruma getirilmesi adimlarini içermektedir. Bulus konusu yöntemde; agirlikça %50-70 oraninda ana granül 300 mikrona ögütülmüs EAO cüruf dolgu malzemesi, agirlikça %8-12 oraninda hidrolik baglayici çimento, agirlikça %1-3 mikro füme silika, gözenek kontrolü ve baglayici katki olarak kullanilan agirlikça %1-3 baglama kili, agirlikça %1-3 ögütülmüs alçi tasi mikser içine alinir. 1 dakika boyunca karistirilarak homojen kuru karisim elde Karisim içine düsük su oraninda akiskanligin saglanmasi ve daha yüksek mukavemetin elde edilmesi için agirlikça %0,l-l süper akiskanlastirici ve agirlikça dakika boyunca karistirma islemine devam edilir. Karisim içine 3 dakika sonunda agirlikça %1-10 organik sivi köpük ajani (sentetik sivi hava sürükleyici) ilavesi yapilir. Karisim (1-5 dakika) boyunca mikserde mekanik kuvvet sayesinde köpürtülmesi saglanir. Ayni zamanda EAO partikülleri köpük etrafina tamamen yapismasi saglanir ve mekanik karistirma ile köpürtülmüs homojen karisim elde edilmis olur. Sivi organik köpürtücü ile karisim içindeki EAO partikülleri tamamen yapistirilmis duruma getirilir. Organik köpürtücü sayesinde karisimin yogunlugu azaltilmis olur. Bu sayede sistem içinde olusturulan gözenekler metalik Al pasta veya H202 (hidrojen peroksit) katkisi yapildigi zaman Hz gazi çikisini kolaylastiracak ve sistemdeki gözenek miktarinin artmasini saglamaktadir. Çimento ile reaksiyonu sonucunda Hz gazi açiga çikmasini ve gözenek olusumunu saglayan metalik alüminyum (Al) tozu agirlikça %0,l-0,5 ilave edilir. Karistirma islemi yüksek devirde yapilarak (1-3) dakika arasinda karistirilir. Bu asamada metalik Al pasta yerine diger kimyasal köpürtücü olan H202 agirlikça %5-15ate verilerek 20-40 sn karistirma sonrasinda hafif beton dökümü yapilabilir. Hazirlanan karisimlar istenilen ölçüde hazirlanmis metal kalip içine dökülerek oda sicakliginda 30-50 dk beklemeye alinir. Bekleme sirasinda açiga çikan Hz gazlarinin hareketi ile gözenek olusturulmasi saglanir. Ayri ayri metalik Al pasta ya da H202 kimyasal katkilari ile saglanan hacimce genlesme saglanir. Kalip içinde veya kalip disina çikarilan sekillendirilmis prekast hafif tuglalar 25- 50°C"de 1-5 gün boyunca kürleme tankinda beklemeye alinir. Kürleme sirasinda çimentonun numunelerin iç bölgelerindeki hidrolik reaksiyonlarinin tamamlamasi ve kalici mukavemet kazanmasi saglanir. Kürleme sonunda tuglalar oda sicakliginda 1 gün bekletilir, sonrasinda etüvde llOC,de 1-3 gün yüzey ve bagil nemini atmasi saglanarak kullanima hazir duruma getirilir. Cüruf yapisinda serbest CaO ve MgO,ya sahiptir. Bu nedenle cüruIlar beton bilesiminde kullanildiklari zaman su ile reaksiyonlari sonucunda Ca(OH)2 ve Mg(OH)2 olusmaktadir. Bunun sonucunda betonlarda genlesme meydana gelmekte ve çatlama olmaktadir. Klasik yöntemle üretilen tugla çesitlerinde ise atik niteliginde olan cüruf yerine pahali hammaddeler (kuvars, pomza tasi, kum, vb.) kullanilmasi mali dezavantaj yaratmaktadir. Mevcut uygulamalarda kullanilan kuvars yerine atik durumunda olan EAO cürufu kullanilmasi bulusun ilk avantaji olarak belirtilebilir. Yapilan ürünler %50-70 oraninda EAO cüruf esasli olup atiklarin degerlendirilmesi bakimindan çok önemlidir. Demir çelik firmalarinda atik olarak bulunan cürufun sahalarda envanter maliyetine neden oldugu ve tamamen degerlendirilemedigi bilinmektedir. Insaat sektörü için ihtiyaç yogun olmasi ve demir çelik fabrika sahalarinda yeterince EAO cürufunun olmasi ekonomik açidan ve dogal hammadde kaynaklarinin tüketilmemesi adina çok önemlidir. Demir-Çelik tesislerinde depolamasi ve imhasi ciddi bir sorun ve mali yükümlülük olan cürufun bu sekilde katma degerli kullanimi, dolayli yoldan demir-çelik tesisleri için de son derece avantajli bir durumdur. Bulus konusu ürün ile mevcut olan yalitimsiZ bina beton tavanlarina uygulama yapilabilir ve isil yalitim saglanabilir. Bu ürün klasik gaZ beton tuglasina yakin seviyede yalitim degeri ile direkt kirmizi insaat tuglasi yerine kullanim avantaj ina sahiptir. Bu bakimdan mali avantaj lariyla beraber basarili izolasyon performansinin getirdigi isil yalitim enerji verimligi açisindan avantajlidir. Gelistirilen ürün tuglanin karsilamasi gereken mekanik özelikler konusunda testlerden olumlu sonuç almistir. Tablo lade deneysel çalisma yapilan izole hafif beton tugla reçeteleri ve elde edilen test sonuçlari verilmistir. Tablo 1: Kullanilan reçete ve mekanik özellik bilgileri Reçete No 1 2 3 4 Metalik Al H202 . . . Insaat katkili katkili Reçete Bilesimi Tuglasi Gaz Beton EAO cüruf EAO cüruf tuglasi tuglasi Kuvartz + + E Alçi tasi + +/- +/- 7? Kireç + 8" Metalik Al Pasta 75 E mikron H202 + Füme Silika + + Süper akiskanlastirici + + Baglama Kili +/- +/- Çimento + + + Organik Köpük + + Q Isil islem Sinterleme Otoklav Kürleme Kürleme g kurleme kg g Dayanimi (kg/cm ) Tabloda belirtilen; 0 Reçete 1; Piyasada kullanilan kirimizi delikli insaat tuglasi o Reçete 2; Piyasada hali hazirda yapilan gaz beton beton tugla Reçete 3; Metalik A1 ve siVi köpüitücü kullanilan EAO cüruf esasli hafif o Reçete 4; HzOz ve siVi köpüitücü kullanilan EAO cüruf esasli hafif beton tugla içerigini ve özelliklerini belirtmektedir. Elde edilen ürün bina dis cephelerinde yapiskanlik artirildigi takdirde püskürtme yalitim amaçli kullanilabilir olacaktir. Ürünün bu hali ile bina tavan aralarinda ve düz zemin beton üzerinde yalitim amaçli olarak kullanimi mümkündür. Bulus konusu yöntem ile gelistirilen hafif beton tugla; mekanik, fiziksel ve kimyasal testler sonucunda dogrulandigi üzere basta insaat sektöründe yapi malzemesi olarak ve isil islem firini izolasyon amaçli kullanilan agir sanayi kollari da yaygin kullanim alanina sahip olacaktir. TR TR TR TR TR TR TR TR TR TRDESCRIPTION OF DEVELOPMENT OF INSULATED CONSTRUCTION BRICK FROM ENRICHED ELECTRIC ARC FURNACE SLAG WASTE Technical Field The invention concerns the recovery of steel production waste, specifically slag, to produce an insulated construction brick with superior thermal insulation properties and microporosity, replacing the currently used red construction brick in the construction sector, along with a production method. Previous Technical In the construction sector, aerated concrete, pumice, and red conventional construction bricks with high-performance thermal insulation are widely used. Red conventional construction bricks are produced from clay soils, which are natural raw material sources, and are commonly used in perforated and various geometric shapes. Pumice and aerated concrete bricks are macro- and micro-porous bricks, and their components are quartz, lime, and cement. Bricks that require high thermal insulation must have a highly porous structure. To achieve this property, quartz is used in conjunction with lime, cement, and foaming agents. A Chinese patent document, CN103553701B, described in the state of the art, details foamed ceramic thermal insulation material and its production method. The document also mentions the use of foaming agents. Another Chinese patent document, CN102344298A, also described in the state of the art, details foamed concrete thermal insulation and load-bearing bricks and their production method. This document explains the foaming process and the fact that the resulting product contains clay, slag, gypsum, etc. Existing studies in the field revealed a need to recover slag, a waste product of steel production, and to develop an insulated construction brick with superior thermal insulation and microporosity, and a production method to replace the currently used red construction brick in the construction sector. Purpose of the Invention: The purpose of this invention is to recover electric arc furnace slag, a waste product of steel production, and to develop an insulated construction brick with superior thermal insulation and microporosity, and a production method to replace the currently used red construction brick in the construction sector. Detailed Description of the Invention: The invention relates to a slag-based insulated construction brick; - 5-70% by weight of electric arc furnace slag as the main granular filling material, - 1-3% by weight of binding clay used for pore control and as a binding additive, - 8-12% by weight of hydraulic binder cement, - 0.1-0.5% by weight of metallic aluminum (Al) powder or 5-15% by weight of hydrogen peroxide (H2O2), - 1-3% fumed silica by weight, - 1-3% ground gypsum by weight, - 0.1-1% by weight super plasticizer to ensure fluidity and obtain higher strength with a low water ratio in the mixture, - 12-17% by weight ratio of water, 1-10% by weight of organic liquid foam The agent includes. The invention relates to a slag-based insulating construction brick production method, which involves grinding and pulverizing 8-12% by weight of slag to an average particle size of 300 microns, adding 1-3% by weight of hydraulic binder cement, 1-3% by weight of micro-fumed silica, 1-3% by weight of binding clay (used as pore control and binder additive), and 1-3% by weight of ground gypsum to the powdered slag. To ensure low water fluidity and higher strength, 0.1-1% by weight of superplasticizer and 12-17% by weight of water are mixed into the mixture, and the mixing process continues for 3-4 minutes. After 3 minutes, 1-10% by weight of organic liquid foaming agent is added to the mixture. The process involves adding a synthetic liquid air entrainer, foaming the mixture in a mixer for 1-5 minutes using mechanical force, adding 0.1-0.5% by weight of metallic aluminum (Al) powder to the resulting mixture to release HZ gas and create pores as a result of its reaction with cement, at this stage, instead of metallic Al paste, adding 5-15% by weight of another chemical foaming agent, HZoz, and mixing for 20-40 seconds before pouring lightweight concrete, pouring the prepared mixtures into a metal mold of the desired size and leaving them to stand at room temperature for 30-50 minutes, and then curing the shaped precast lightweight bricks inside or outside the mold in a curing tank at 25-50°C for 1-5 days. The process involves allowing the bricks to sit at room temperature for one day and then drying them in an oven at 110°C for 1-3 days to remove surface and relative moisture before making them ready for use. In the invented method, 50-70% by weight of EAO slag filler material ground to 300 microns, 8-12% by weight of hydraulic binder cement, 1-3% by weight of micro-fumed silica, 1-3% by weight of binding clay used as pore control and binder additive, and 1-3% by weight of ground gypsum are placed in a mixer. A homogeneous dry mixture is obtained by mixing for 1 minute. To ensure low water content fluidity and to obtain higher strength, 0.1-1% by weight of superplasticizer is added to the mixture. Mixing is continued for 3 minutes by weight. After 3 minutes, 1-10% by weight of organic liquid foaming agent (synthetic liquid air entrainer) is added to the mixture. The mixture is foamed in the mixer by mechanical force for 1-5 minutes. At the same time, the EAO particles are completely adhered to the foam, and a foamed homogeneous mixture is obtained by mechanical mixing. The liquid organic foaming agent ensures that the EAO particles in the mixture are completely adhered. The density of the mixture is reduced thanks to the organic foaming agent. In this way, the pores created in the system will facilitate the release of H2O2 gas when metallic Al paste or H2O2 (hydrogen peroxide) is added, and will increase the amount of pores in the system. As a result of the reaction with cement, H2O2 gas is released and pores are created. Metallic aluminum (Al) powder, which provides the formation, is added at a rate of 0.1-0.5% by weight. The mixing process is carried out at high speed and mixed for (1-3) minutes. At this stage, instead of metallic Al paste, another chemical foaming agent, H2O2, can be added at a rate of 5-15% by weight and mixed for 20-40 seconds, after which lightweight concrete can be poured. The prepared mixtures are poured into a metal mold prepared to the desired size and left to stand at room temperature for 30-50 minutes. During the waiting period, the movement of the released H2O2 gases ensures the formation of pores. Volumetric expansion is achieved with separate metallic Al paste or H2O2 chemical additives. The shaped precast lightweight bricks, either inside or outside the mold, are fired at 25-50°C. The mixture is left to stand in a curing tank for 1-5 days. During curing, the hydraulic reactions of the cement in the inner regions of the samples are completed, and permanent strength is achieved. After curing, the bricks are left at room temperature for 1 day, then placed in an oven at 11°C for 1-3 days to remove surface and relative moisture, making them ready for use. Slag contains free CaO and MgO. Therefore, when slag is used in concrete composition, Ca(OH)2 and Mg(OH)2 are formed as a result of reactions with water. As a result, expansion and cracking occur in the concrete. In brick types produced by the classical method, the use of expensive raw materials (quartz, pumice stone, sand, etc.) instead of slag, which is a waste product, creates a cost disadvantage. The first advantage of this invention is that it utilizes EAO slag, which is a waste product, instead of quartz used in current applications. The products are 50-70% EAO slag-based, which is very important in terms of waste utilization. It is known that slag, which is found as waste in iron and steel companies, causes inventory costs in the fields and cannot be fully utilized. The high demand for it in the construction sector and the availability of sufficient EAO slag in iron and steel factory sites are very important economically and in terms of not depleting natural raw material resources. This value-added use of slag, whose storage and disposal in iron and steel plants is a serious problem and financial burden, is also extremely advantageous for iron and steel plants indirectly. The product in question can be applied to existing uninsulated concrete ceilings of buildings and provide thermal insulation. This product has an insulation value close to that of classic aerated concrete bricks and offers the advantage of being used directly as a replacement for red construction bricks. In this respect, it is advantageous in terms of energy efficiency due to its successful insulation performance, along with its cost advantages. The developed product has received positive results in tests regarding the mechanical properties that a brick must meet. Table 1 shows the experimentally tested insulated lightweight concrete brick formulations and the test results obtained. Table 1: Information on the formulations used and mechanical properties. Formulation No. 1 2 3 4 Composition Metallic Al H2O2 . . . Construction additives Recipe Composition Aerated Concrete Brick ... Lime + 8" Metallic Al Paste 75 E micron H2O2 + Fumed Silica + + Superplasticizer + + Binding Clay +/- +/- Cement + + + Organic Foam + + Q Heat Treatment Sintering Autoclave Curing Curing g curing kg g Strength (kg/cm²) The table indicates the content and properties of: 0 Recipe 1; Commercially available red perforated construction brick o Recipe 2; Commercially available aerated concrete brick Recipe 3; Lightweight concrete brick based on EAO slag using Metallic A1 and liquid foaming agent o Recipe 4; Lightweight concrete brick based on EAO slag using 15Oz and liquid foaming agent. The resulting product can be used for spray insulation purposes on building exteriors if adhesion is increased. In this form, the product can be used on buildings. It can be used for insulation purposes in attics and on flat concrete surfaces. The lightweight concrete brick developed using this invention, as confirmed by mechanical, physical, and chemical tests, will have widespread use primarily in the construction sector as a building material and in heavy industries for insulation purposes in heat treatment furnaces.

Claims

REQUESTS

1. The invention relates to a slag-based insulating brick comprising; - electric arc furnace slag as the main granular filler material, - binder used for porosity control and as binding agent, - hydraulic binder cement, - metallic aluminum (Al) powder or hydrogen peroxide (H202), - fumed silica, - ground gypsum, - superplasticizer to provide fluidity at low water content and to obtain higher strength, - organic liquid foaming agent. The invention relates to a slag-based insulating brick as in claim 1, characterized in that the electric arc furnace (EAF) slag is 50-70% by weight. The invention relates to a slag-based insulating construction brick as in claim 1, characterized by containing 1-3% by weight of binding clay, lume silica and gypsum. The invention relates to a slag-based insulating construction brick as in claim 1, characterized by containing 0.1-0.5% by weight of metallic aluminum (Al) powder. The invention relates to a slag-based insulating construction brick as in claim 1, characterized by containing 5-15% by weight of hydrogen peroxide (H2O2). The invention relates to a slag-based insulating construction brick as in claim 1, characterized by containing 1-10% by weight of organic liquid foaming agent. The invention is related to a slag based insulating construction brick production method, - grinding slag to an average grain size of 300 microns and turning it into powder, - adding 8-12% by weight of hydraulic binder cement, 1-3% by weight of micro fumed silica, 1-3% by weight of binding clay used as pore control and binding additive, 1-3% by weight of ground gypsum into the powdered slag, - mixing with 0.1-1% by weight of super plasticizer and 12-17% by weight of water to provide fluidity at low water ratio and to obtain higher strength, - adding 1-10% by weight of organic liquid foam agent (synthetic liquid air - adding 0.1-0.5% by weight metallic aluminum (Al) powder, which provides the release of Hz gas and the formation of pores as a result of the reaction with the cement, to the obtained mixture, - at this stage, instead of metallic Al paste, another chemical foaming agent, HzOz, is given at 5-15% by weight and after mixing for 20-40 seconds, lightweight concrete is poured, - the prepared mixtures are poured into the metal mold prepared in the desired dimensions and kept at room temperature for 30-50 minutes, - the shaped precast lightweight bricks taken out of the mold or in the mold are kept in the curing tank at 25-50°C for 1-5 days, - at the end of the curing, the bricks are It includes the steps of keeping it at room temperature for 1 day and then in the oven at 110C for 1-3 days to remove the surface and relative humidity and make it ready for use.