Production of construction materials from bottom mud obtained from across turkey

Abstract

The invention relates to a method of producing different types of construction materials, fired or unfired, which can be used in different parts of buildings such as walls, roofs and floors, from bottom mud obtained from across Turkey.

Description

PRODUCTION OF CONSTRUCTION MATERIALS FROM BOTTOM MUD OBTAINED FROM ACROSS TURKEYTechnical FieldThe invention relates to a method of producing different types of construction materials, fired or unfired, which can be used in different parts of buildings such as walls, roofs and floors, from bottom mud obtained from across Turkey.Prior ArtNone of the construction materials available in the technique are made with bottom mud, only the fired ones are usually produced using clay with high purity. In addition, clay material is not included in concrete or concrete paving and plaster type products during production. In addition, the recycling rate in the materials produced is almost non-existent. In Turkey, bottom mud has never been used as a recycling material in any construction material before.Bottom mud can be used in construction materials in various ways. One approach is to neutralize the alkalinity of red mud, which allows it to be used as a construction material.[7]Red mud can also be used as a cement substitute as it helps to minimize microcracks and voids.

[0011] Furthermore, red mud can be used as a construction material additive that can improve the properties of the material.

[0012] By mixing mud with binding agents such as shells and fly ash, mud-based construction materials can be created.[9]Mud can also be used as raw material for geopolymer production, which can be used as a cement substitute or pre-product.[1]Moreover, mud-based inorganic polymeric materials have been found to have promising properties and can be used as artificial structural elements in the construction industry.[3]It is important to note that the properties of the mud need to be tested and confirmed, adding the necessary components to ensure its suitability for construction purposes.[9]The use of mud in construction materials can help reduce the stockpiling of red mud, a by-product of the bauxite refining process.[6, 8]Several approaches can be considered for using the bottom mud in the production of bricks, wall and floor furring bricks, and roof tiles. One option is to use red mud, a by-product of the bauxite refining process, as a component in brick production. Studies have shown that the combination of red mud, fly ash and lime can be an ideal material for fired and unfired bricks.[2]Research on roof tiles has focused on various aspects such as heat transfer, surface temperature and cooling load. One study investigated the effect of roof tile color on heat transfer, roof top surface temperature and cooling load in residential buildings under a tropical climate.[5]The findings of this study can guide the selection of materials, including mud-based roof tiles, which can contribute to better thermal performance and energy efficiency in buildings. Recycling of industrial waste materials can be favored in the production of environmentally friendly roofing tiles. For example, bypass binder kiln dust, typically discarded from the kiln system, has been used in the preparation of roofing tiles.[4]This approach not only reduces waste but also contributes to the development of sustainable construction materials.The production of mud-based bricks, roof tiles and roofing tiles requires optimization and consideration of various factors. The studies used optimization techniques to determine the optimum factors and levels in the production process.

[0010] Factors such as the addition of glass powder, wood ash and the placement of roof tiles in the kiln can be optimized to achieve the desired properties and performance.As a result, by neutralizing the alkalinity of the bottom mud, it is possible to use it as an additive with cement substitution, to create mud-based construction materials, to use it for geopolymer production and to use inorganic polymeric materials in construction materials. Bottom mud, especially red mud, can be used in the production of bricks, wall and paving bricks and roof tiles. Combining red mud with other materials such as fly ash and lime makes it possible to create fired andunfired bricks with improved properties. The choice of mud-based roof tiles can contribute to better thermal performance in buildings. Furthermore, the recycling of industrial waste materials such as bypass cement kiln dust can be explored for the production of environmentally friendly roof tiles. Optimization techniques can be used to improve the production process and achieve the desired results.When the existing studies in the technique were examined, it was necessary to develop a method of producing different types of construction materials that can be used in different parts of buildings such as walls, roofs, floors, etc. from the bottom mud obtained from across Turkey.Objectives of the InventionThe aim of the present invention is to realize a method of producing different types of construction materials that can be used in different parts of buildings such as walls, roofs, floors, etc. from the bottom mud obtained from across Turkey.Another aim of the present invention is to realize a method of production of construction material that contributes to the environment and reduces the carbon footprint by recycling since the raw material used is obtained completely as waste.Detailed Description of the InventionThe invention relates to a method of producing different types of construction materials, fired or unfired, which can be used in different parts of buildings such as walls, roofs, floors, etc. from the bottom mud obtained from across Turkey, comprises the steps drying the bottom mud, grinding and sieving the dried bottom mud, mixing the sieved mud with water, binder, chemical additives and aggregate to form a dough, shaping the dough by molding, pressing and / or extrusion, firing the shaped dough in the oven, optionally glazed or coated,obtaining construction material.Drying the bottom mud used as raw material in order to use it is a priority for many products other than soil stabilization material. Here, if deemed appropriate, it is possible to process the briquette type product without drying. However, for other materials, drying must be done in terms of quality. The drying stage can be used optionally for briquettes, walling bricks, improved soil material type materials.The products subjected to the drying process are then ground and sieved through sieves. During sieving, foreign substances and coarse materials are separated. The drying process is carried out in an oven at 105±5 °C for 24 hours, an alternative drying is also possible; the aim here is to ensure complete drying of the material. For grinding, equipment to pulverize the material is sufficient. In the sieving process, it is preferred that the powder size does not exceed 1 mm. The grinding and screening stage is used in brick, furring bricks, tiles, roof tiles, ceramics, refractory bricks, screed, plaster and concrete products. In products such as briquettes, walling bricks, improved floor material, parquet, it can be used in the next stage if drying is done optionally.The material is then mixed with water, binders and additives, if necessary, to form a dough. The resulting dough is shaped by pressing, stretching (extrusion method) or molding with a machine that applies pressure.Unfired materials (such as briquettes, concrete, concrete paving, wall covering material and floor stabilization material and floor concrete) can be produced with the shaped dough.Cement, lime, gypsum, fly ash, slag, siliceous and other pozzolanic materials and polymer products, chemical admixtures and aggregates can be used as binders when producing briquettes, wall cladding material, concrete paving material. These binding materials can be used separately or together. Binder (cement, lime, gypsum, polymer, fly ash, slag, siliceous and other pozzolanic materials) / bottom mud can be used in a ratio of 1 / 1 - 1 / 8. Bottom mud can be used as it is and / or dried, ground and sieved. The bottom mud is formed by mixing the binder and additives that can beused when necessary and pressing these materials under pressure and / or putting them into molds and / or extending them by extrusion. Polycarboxylate, naphthalene, melamine, lignosulphate, acrylics, epoxy, polyester, polymethylmethacrylates, ureformaldehydes, silicones, acrylonitrile butadiene styrene, polystyrenes, polyethylene and polyurethane can be used as chemical additives. It can be kept outside or indoors for about 1-28 days for drying, if desired, by applying water, steam, or a cure that will prevent the evaporation of water by covering it. Concrete paving and wall covering material is produced without cavities according to briquette. In addition, concrete paving is more durable as it will be used on the base.For soil stabilization and production of soil concrete, bottom mud or dried and ground bottom mud, binder (cement, lime, polymer, fly ash, slag, bitumen and other pozzolanic materials), aggregates and water can be used. These materials are blended and shaped. The binder / bottom mud ratio can be preferred as 1 / 1-1 / 8. The shaped material is thoroughly compacted to gain strength.The kiln firing process can be applied to shaped bottom mud material or to dried and ground bottom mud. The shaped materials can be exposed to temperatures ranging from 500-1900 °C for 30 min to 1 week. Dried and ground bottom mud can be calcined in powder form by exposure to temperatures between 500-1200 °C for 30 minutes to 5 hours. Firing is done in bricks, furring bricks, tiles, roof tiles, ceramics, refractory bricks. Firing can be used optionally in products such as briquettes, wall cladding bricks, parquet.Alternative applications in which the method of the invention is used are given below.Bricks, furring bricks and tiles are produced by the same process; the molds are different, bricks can be produced with or without holes, furring bricks can be produced without holes and more voids, tiles can be produced without holes and more voids. For this purpose, bottom mud can be used as it is and / or dried and ground. The product is formed by mixing water, binder and additives that can beused when necessary and aggregate if desired and pressing these materials under pressure and / or putting them into molds and / or extruding them. Products can also be produced without heat treatment. However, in order to gain strength, it may be possible to apply a temperature process in the temperature range of 500-1200 °C for 30 minutes to 1 week. The ideal process is between 750-1200 °C and the time is between 1-3 hours depending on the temperature.In refractory bricks, rich aluminum oxide, silicate and / or bauxite are added to the structure for fireproofing. Here, the ratio of aluminum oxide and bauxite can vary between 20-70%. The remaining part is bottom mud or dry bottom mud mixed with water. If desired, it can be supported with aggregates and additives. These materials are pressed under pressure and / or molded and / or extruded. For fireproofing, it may be possible to apply a temperature of 1200-1900 °C and a temperature process of 30 minutes to 1 week. The ideal process is between 1300-1800 °C and the duration is between 3 hours and 3 days depending on the temperature.For the production of tiles and ceramics, bottom mud can be used as is and / or dried and ground. The product is made by mixing water, binders, aggregates and additives that can be used when necessary, and pressing these materials under pressure and / or molding and / or extruding them. The material can be produced first at a temperature range of 800-1000 °C for 30 minutes to 10 hours and then at a temperature range of 1000-1400 °C. Glaze is applied on the product, the glaze to be applied gives an aesthetic appearance and is usually applied by spraying, dipping or brushing. This stage usually takes a short time (30 minutes-5 hours), but it may be necessary to wait a little while for the glaze to dry completely. The glaze is fired at a specific temperature. The temperature usually varies between 600 °C and 1300 °C. This stage can take between 30 minutes and 5 hours.Cement, lime, gypsum and polymer products, chemical additives, fly ash, slag, siliceous and other pozzolanic materials and aggregates can be used as binders in the production of briquettes, plaster and wall covering materials for which the inventive method is applied. For concrete, floor screed and concrete paving, cement, polymer products, chemical admixtures, fly ash, slag, siliceous and otherpozzolanic materials can be used as binders and aggregates are also used. Binding materials can be used separately or together. Bottom mud is used as dried, ground, sieved and then cooked. The cooked form of the bottom mud is mixed with the binder and any additives and aggregate that may be used as required and formed by pressing and / or molding and / or extruding these materials under pressure. It can be kept outside or indoors for about 1-28 days for drying by applying a cure that will prevent water, steam or water evaporation by covering it if desired. The fired powder form of bottom mud can be preferred by replacing up to 50% of aggregate or binder in these materials. The ratio of bottom mud / binder can be preferred as 1 / 1-1 / 200. Since the bottom mud is fired in powder form, it is considered as pozzolan, so its ratio can be much less than the binder.Since bottom mud contains a large amount of clay, it may be possible to use the expanded form of this raw material as a lightweight aggregate in construction materials. Expanded clay, used in various applications such as lightweight concrete and thermal insulation, is produced by exposing natural clay to high temperatures (700-1300 °C). The temperature range for expanded clay production is reported to be ideally between 1100 and 1300 °C.15,20Exposure to high temperatures causes the clay to expand, resulting in a significant increase in volume, typically ranging from 1.5 to 6 times the initial volume.15The production process involves the use of rotary kilns to achieve the temperatures necessary for the clay to expand.18,20The resulting expanded clay aggregate exhibits low density and is suitable for applications requiring lightweight materials such as lightweight concrete.13,16In addition, expanded clay exhibits thermal insulation potential due to its low density and alveolar structure formed during the combustion process.19Waste from all end products is recycled and enters the drying, grinding and screening system. They are then subjected to their own process again according to the origin of the waste. Wastes can enter the process in the range of l%-50% of the bottom mud to be used depending on the product quality.The products obtained as a result of the inventive method are generally addressed to the construction sector. However, it is also possible to use especially the refractory type ones for the protection of the metal elements of the machine.The invention is fully applicable to industry because it includes construction materials and can be used in the construction of all types of buildings and industrial structures. The inventive method can be used in the production of bricks, briquettes, plaster and wall coverings (wall materials), in the production of tiles and roofing products (roof materials), in the production of screed, furring bricks, concrete paving, ceramics and tiles (floor materials) and in the production of floor stabilization material and concrete (floor materials) and as concrete in horizontal and / or vertical carrier systems. In addition, materials such as bricks and refractory bricks can be used for partitions and fireproofing.References:1. Antoni, A., Wiyono, D., Vianthi, A., Putra, P., Kartadinata, G., & Hardjito,D. (2014). Effect of particle size on properties of sidoarjo mud-based geopolymer. Materials Science Forum, 803, 44-48. https: / / doi.org / 10.4028 / www.scientific.net / msf.803.442. Beulah, M., Sudhir, M., Mohan, M., Gayathri, G., & Jain, D. (2021). Mine waste-based next generation bricks: a case study of iron ore tailings, red mudand ggbs utilization in bricks. Advances in Materials Science and Engineering, 2021, 1-10. https: / / doi.org / 10.1155 / 2021 / 94996133. Dimas, D., Giannopoulou, I., & Panias, D. (2009). Utilization of alumina red mud for synthesis of inorganic polymeric materials. Mineral Processing and Extractive Metallurgy Review, 30(3), 211-239. https: / / doi.org / 10.1080 / 088275008024981994. El-Naggar, K., Ahmed, M., Abbas, W., & Hamid, E. (2023). Recycling of bypass cement kiln dust in the production of eco-friendly roof tiles. Materials Research Express, 10(6), 065505. https: / / doi.org / 10.1088 / 2053- 1591 / acddb95. Farhan, S., Ismail, F., Kiwan, O., Shafiq, N., Zain-Ahmed, A., Husna, N., ... & Hamid, A. (2021). Effect of roof tile colour on heat conduction transfer, roof-top surface temperature and cooling load in modern residential buildings under the tropical climate of malaysia. Sustainability, 13(9), 4665. https: / / doi.org / 10.3390 / sul30946656. Gu, H., Wang, N., & Liu, S. (2012). Radiological restrictions of using red mud as building material additive. Waste Management & Research the Journal for a Sustainable Circular Economy, 30(9), 961-965. https : / / doi . org / 10.1177 / 0734242x 124513087. Kang, S., Hye-Ju, K., & Lee, B. (2020). Effects of adding neutralized red mud on the hydration properties of cement paste. Materials, 13(18), 4107. https: / / doi.org / 10.3390 / mal31841078. Liu, D. and Wu, C. (2012). Stockpiling and comprehensive utilization of red mud research progress. Materials, 5(7), 1232-1246. https: / / doi.org / 10.3390 / ma50712329. Mendili, Y., Bouasria, M., Benzaama, M., Khadraoui, F., Guern, M., Chateigner, D., ... & Bardeau, J. (2021). Mud-based construction material: promising properties of french gravel wash mud mixed with byproducts, seashells and fly ash as a binder. Materials, 14(20), 6216. https: / / doi.org / 10.3390 / mal420621610. Rosyidi, C., Budiaji, A., & Pujiyanto, E. (2022). Multiresponse optimization on the process of roof tiles manufacture using the taguchi and pcr-topsis method. Jumal Teknologi, 84(6), 11-18. https: / / doi.Org / 10.l 1113 / jurnalteknologi.v84.1823511. Venkatesh, C., Chand, M., & Nerella, R. (2019). A state of the art on red mud as a substitutional cementitious material. Annales De Chimie Science Des Materiaux, 43(2), 99-103. https: / / doi.org / 10.18280 / acsm.43020612. Wang, X., Zhang, Y., Liu, J., Hu, P., Meng, K., Lv, F., . . . & Chu, P. (2018). Dealkalization of red mud by carbide slag and flue gas. Clean - Soil Air Water, 46(3). https: / / doi.org / 10.1002 / clen.20170063413. Burbano-Garcia, C., Hurtado, A., Silva, Y., Delvasto, S., & Araya-Letelier, G. (2021). Utilization of waste engine oil for expanded clay aggregateproduction and assessment of its influence on lightweight concrete properties. Construction and Building Materials, 273, 121677. https: / / doi.Org / 10.1016 / j.conbuildmat.2020.12167714. Esmaeili, J., Ghaffarinia, M., Nodehi, M., Gencel, O., Shi, J., & Ozbakkaloglu, T. (2022). Mechanical and fractural characteristics of structural lightweight fiber reinforced concrete. Structural Concrete, 24(2), 2420-2439. https: / / doi.org / 10.1002 / suco.20220010715. Tunc, E., Alyamag, K., & Ulucan, Z. (2020). Yapisal hafif betonun gekme dayammina sayisal bir yakla§im. El-Cezeri Fen Ve Muhendislik Dergisi. https: / / doi.org / 10.31202 / ecjse.69088216. Miryuk, O. and Zagorodnuk, L. (2022). Granular materials based on expanded sands and their production waste. Kompleksnoe Ispol'zovanie Mineral'nogo Syr'a / Complex Use of Mineral Resources / Mineraldik Shikisattardy Keshendi Paidalanu, 321(2), 14-21. https: / / doi.org / 10.31643 / 2022 / 6445.1317. Panna, W., Szumera, M., & Wyszomirski, P. (2015). The impact of modifications of the smectite-bearing raw materials on their thermal expansion ability. Journal of Thermal Analysis and Calorimetry, 123(2), 1153-1161. https: / / doi.org / 10.1007 / sl0973-015-5023-018. Pouramini, M., Torabian, A., & Tehrani, F. (2019). Application of lightweight expanded clay aggregate as sorbent for crude oil cleanup. DWT, 160, 366-377. https: / / doi.org / 10.5004 / dwt.2019.2423219. Sampaio, C., Terezo, R., Rosa, T., Burigo, M., & Andrade, L. (2018).Similitude and thermal performance on non-conventional roofs. 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Claims

CLAIMS1. The invention relates to a method for the production of building materials which can be used in different parts of buildings such as walls, roofs, floors, etc. from the bottom mud obtained from across Turkey, and is characterized in that it includes the steps of; drying the bottom mud, grinding and sieving the dried bottom mud, mixing the sieved mud with water, binder, chemical additives and aggregate to form a dough, shaping the dough by extrusion method, firing the shaped dough in the oven, obtaining the building material.

2. A method of manufacturing a building material according to claim 1, characterized in that the drying is carried out in an oven at 105±5 °C for 24 hours.

3. A method of manufacturing a building material according to claim 1, characterized in that instead of extrusion, machine pressing or molding methods can be used.

4. A method of manufacturing a construction material according to claim 1, characterized in that cement, lime, gypsum fly ash, slag, siliceous and other pozzolanic materials and polymer products are used as binders.

5. A method of manufacturing a building material according to claim 1, characterized in that, in addition to the firing process, glazing or coating processes can also be used.

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