Cement Binder Using Waste Incineration Ash
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Waste incineration ash is not yet a permitted main or secondary component in standardized cements due to harmful ingredients that cause undesirable reactions such as cracking and leaching when used in concrete, limiting its economic utilization in building materials.
Innovation Solution
A binder is developed using waste incineration ash as an additive with a defined Blaine surface area of 1500 cm2/g to 6000 cm2/g, replacing a significant weight percent of cement, which provides standard-compliant strength properties and improved application properties while immobilizing environmentally relevant pollutants, and is processed to achieve the desired fineness and separation of ferrous and non-ferrous metals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If waste incineration ash is used as a component in cement, then CO2 savings and economic utilization are improved, but harmful ingredients cause undesirable reactions such as cracking and leaching
Solution Approach 1:
The patent applies this principle by taking the harmful waste incineration ash containing pollutants and heavy metals and converting it into a beneficial cement component through controlled grinding and blending. The harmful ash is transformed into a useful additive that provides CO2 savings while the harmful effects are neutralized through proper processing and dosage control (max 50% replacement).
Solution Approach 2:
The patent changes the physical and chemical parameters of the waste incineration ash by grinding it to specific fineness (Blaine surface area 2500-5000 cm²/g) and controlling its proportion in the cement mixture (max 50% by weight). These parameter changes transform the ash from a harmful waste product into a safe and effective cement component that maintains strength properties while reducing CO2 emissions.
2Strength
If waste incineration ash is ground to high fineness to improve reactivity, then strength properties are improved, but energy consumption and processing complexity increase
Solution Approach 1:
The patent optimizes the grinding fineness parameter to a specific range (Blaine surface area 2500-5000 cm²/g) that provides sufficient reactivity and strength properties without excessive energy consumption. This optimized parameter range balances the trade-off between strength improvement and energy input, avoiding both under-grinding (insufficient strength) and over-grinding (excessive energy use).
3Loss of energy
If waste incineration ash is used to replace cement, then CO2 emissions are reduced, but separation of ferrous and non-ferrous metals becomes necessary
Solution Approach 1:
The patent applies preliminary action by performing metal separation and ash processing before the ash is used as a cement component. The waste incineration ash undergoes pre-treatment including ferrous and non-ferrous metal separation, grinding to specified fineness, and quality control before being blended with cement. This preliminary processing ensures that the ash is safe for use while maintaining the CO2 reduction benefit.
4Reliability
If waste incineration ash with defined Blaine surface area is used, then reactivity and cohesion are improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent establishes a specific parameter range for Blaine surface area (2500-5000 cm²/g) that provides optimal balance between reactivity/cohesion improvement and manufacturing feasibility. This range is wide enough to allow normal manufacturing variations while still ensuring sufficient performance, thus reducing the stringency of precision requirements compared to specifying a narrow single value.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The binder achieves significant CO2 savings, standard-compliant strength, and safe immobilization of pollutants, with improved reactivity and cohesion, allowing for its use in mortar and concrete without undesirable reactions, thus enhancing its economic and environmental viability.
Implementation Method 1
processed to achieve the desired fineness
Implementation Method 2
mixing separately finely ground main and secondary components
Implementation Method 3
When fresh, after the addition of water, cement hardens both in air and under water. In the hardened state, the cement stone connects this grain structure.
Implementation Method 4
safe immobilization of pollutants
Data Source
AI summary
A binder for building materials comprising cement and mineral grinding additives, said grinding additives containing ash of burned refuse. Relative to the binder, the ash of burned refuse has a weight percent of 0.005 to 0.4 and a Blaine specific surface area of 1500 cm2/g to 6000 cm2/g. Also, a process and to a plant for carrying out the process for production of a binder for building materials comprising cement and mineral grinding additives, the grinding additives containing ash of burned refuse, the process including: preparing the ash of burned refuse provided as grinding additive by separating out the fraction having a particle size less than 1 mm and the oversize particles having a particle size greater than 40 mm; pre-crushing the ash of burned refuse which has been freed from the undersize particles and the oversize particles; removing ferrous and non-ferrous metals; further crushing of the pre-crushed ash of burned refuse which has been substantially freed from metals, in order to achieve a Blaine specific surface area from 1500 cm2/g to 6000 cm2/g, adding the ash of burned refuse prepared in this way to the cement before and/or after the further crushing of the ash of burned refuse which has been pre-crushed and substantially freed from metals.