Compacted Material Production Using Calcium Aluminate Cement
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Solution Overview
Problem
Existing processes for producing compacted materials generate volatile organic compounds and secondary fine particles, and are prone to crumbling when exposed to high temperatures, leading to premature wear of machinery and unsuitable performance in industrial applications.
Innovation Solution
A process involving a dry composition of raw material particles with specific particle size distribution and hydraulic binder, mixed with water and subjected to vibration and high compressive stress, to enhance mechanical compressive strength and reduce secondary fine particle generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If roller compression machine process is used with Portland cement-type hydraulic binder or molasses, then compacted material can be produced from fine particles, but the compacted material generates volatile organic compounds and tends to crumble at high temperatures above 500°C
Solution Approach 1:
The patent changes the chemical composition parameters by replacing organic binders (molasses) and traditional hydraulic binders (Portland cement) with calcium aluminate cement, which has different thermal properties. This parameter change eliminates volatile organic compound generation and improves thermal stability above 500°C while maintaining compacted material production capability
Solution Approach 2:
The patent creates a composite material system combining calcium aluminate cement with specific fine particle sizes and distributions. This composite approach leverages the high-temperature stability of calcium aluminate cement while using fine particles as aggregates, resulting in a compacted material that resists crumbling at temperatures above 500°C
2Ease of manufacture
If building block press process is used with low compressive stress, then building blocks can be formed, but the resulting material generates secondary fine particles and is not suitable for high-temperature industrial processes
Solution Approach 1:
The patent applies preliminary high compressive stress during the compacting stage to create a dense, strong compacted material before the building block formation stage. This preliminary action ensures that the material has sufficient mechanical strength to resist crumbling and generate minimal secondary fine particles during subsequent handling and high-temperature processing
Solution Approach 2:
The patent changes the compressive stress parameter from low (building block press) to high levels during compaction, creating a material with enhanced mechanical properties. This parameter change enables the material to withstand high-temperature industrial processes without generating excessive secondary fine particles
3Quantity of substance
If fine particles of hard raw material like bauxite are used, then compacted material can be produced, but rotary machines are worn out prematurely
Solution Approach 1:
The patent applies preliminary high compressive stress and vibration during the compaction stage to create a densely packed, mechanically strong compacted material before it enters the rotary machine. This preliminary action reduces the hardness and brittleness of the compacted material, thereby reducing wear on rotary machine components while still utilizing hard raw materials like bauxite fine particles
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 process produces compacted materials with improved mechanical strength, reduced crumbling, and the ability to withstand high temperatures without emitting volatile organic compounds, optimizing their use in industrial processes.
Implementation Method 1
the mixed composition obtained in step b) is first vibrated at a frequency between 20 hertz and 80 hertz and at an amplitude greater than or equal to 0.3 millimeter
Implementation Method 2
a compressive stress is applied to said mixed composition, the value of said applied compressive stress being greater than or equal to 2 megapascals
Implementation Method 3
a dry composition is formed by mixing, on the one hand, a set of raw material particles with, on the other hand, from 1% to 50% of a hydraulic binder
Data Source
AI summary
In a method for obtaining a compacted material, a) a set of particles of raw materials is mixed with 1-50% by weight of a hydraulic binder to form a dry composition, the percentage being relative to the total weight of the dry composition, the particle size distribution of the raw material particles being characterised by a first reference diameter ≤50 millimetres and a second reference diameter ≥0.08 micrometres, b) the dry composition is mixed with 1-35% by weight of water to form a mixed composition, the percentage relative to the total weight of the dry composition, c) the mixed composition is vibrated ≥0.3 millimetres at 20-80 Hertz, while a compressive stress is applied, the value of the applied compressive stress being at least 2 MegaPascal. Also disclosed is a method for obtaining a multilayer compacted material and to the materials obtained according to the methods.