Fluorogypsum-Based Concrete Blends with Controlled pH
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Solution Overview
Problem
The variability in composition and properties of uncontrolled pH-adjusted fluorogypsum (U-FG) due to non-uniform alkaline material treatment and exposure to contaminants limits its reliable use in construction applications, leading to inconsistent performance and increased costs associated with neutralization and stockpiling.
Innovation Solution
A pre-cure composition is developed using fluorogypsum (FG) treated with controlled amounts of alkali materials and pozzolanic materials, mixed with hydraulic cement, which can be used to produce a concrete-like material with high compressive strength and reduced Portland cement content, thereby minimizing variability and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If uncontrolled pH-adjusted FG is used directly in construction applications, then availability and ease of manufacture are improved, but composition variability and performance consistency deteriorate
Solution Approach 1:
The patent applies parameter changes by controlling the pH of fluorogypsum to a specific range (6.5-7.5) through controlled neutralization with alkaline materials. This parameter control ensures consistent composition and performance while maintaining ease of manufacture. The controlled pH adjustment transforms the unpredictable composition of uncontrolled pH-adjusted FG into a reliable construction material with stable properties.
Solution Approach 2:
The patent creates a composite material system by combining fluorogypsum with specific alkaline materials (lime, CFBCA) and pozzolanic materials in controlled proportions. This composite approach stabilizes the composition variability inherent in raw fluorogypsum while maintaining manufacturing efficiency. The composite material achieves both availability and composition stability through controlled formulation.
2Reliability
If controlled neutralization with alkaline material is performed, then pH consistency and performance reliability are improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent simplifies the neutralization process by targeting a specific pH range (6.5-7.5) rather than complete neutralization. This parameter optimization reduces manufacturing complexity while ensuring performance reliability. The controlled pH adjustment with alkaline materials achieves consistent results without requiring complex processing equipment or procedures.
Solution Approach 2:
The patent uses alkaline materials (lime, CFBCA) as intermediaries to control the pH of fluorogypsum. These intermediary materials simplify the neutralization process by providing a controlled mechanism to adjust pH without requiring complex treatment systems. The intermediary approach maintains reliability while reducing manufacturing complexity compared to alternative treatment methods.
3Stability of the object's composition
If extensive neutralization and stockpiling are performed, then pH control and material stability are improved, but cost and time requirements worsen
Solution Approach 1:
The patent applies preliminary action by performing controlled neutralization with alkaline materials before the fluorogypsum is used in construction applications. This pre-treatment establishes the desired pH range (6.5-7.5) in advance, eliminating the need for extended stockpiling and weathering periods. The preliminary pH control reduces both time requirements and associated costs while maintaining composition stability.
Solution Approach 2:
The patent optimizes the pH parameter to a specific range (6.5-7.5) that provides adequate stability without requiring extensive neutralization or stockpiling. This parameter optimization reduces the time and cost associated with traditional fluorogypsum treatment while maintaining sufficient pH control for construction applications. The controlled parameter approach balances stability requirements with time efficiency.
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 FG-based blend achieves compressive strengths comparable to ordinary concrete, with lower unit weight and CO2 emissions, offering a sustainable and cost-effective alternative for construction applications by directly utilizing slurry FG and reducing the need for extensive neutralization and stockpiling.
Implementation Method 1
The hardened FG has a low pH and needs to be neutralized in order to avoid potentially harmful properties such as corrosiveness. This neutralization can be performed by adding a small amount (e.g., less than about 6% of dry weight) of alkaline material such as lime
Implementation Method 2
hydraulic cement, which can be used to produce a concrete-like material with high compressive strength
Implementation Method 3
The pre-cure composition can also include a pozzolanic material. For example, the pozzolanic material can be a solid fuel combustion product, a coal combustion product, fly ash, class C fly ash, class F fly ash, bottom ash, flue-gas desulfurization materials, boiler slag, incinerator bottom ash, a biomass combustion product, bagasse ash, rice hull ash, wood ash, biomass pellets ash, natural pozzolan, volcanic ash
Data Source
AI summary
High-strength concrete-like FG blends and methods for producing them are described. The blend includes FG, hydraulic cement, additional alkali material, and pozzolanic material. The blend further includes an admixture used in the formulation of concrete. The blend further includes an aggregate. The aggregate is a coarse aggregate or a fine aggregate.