Geopolymer Cement from Silicon Etching Effluent

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Solution Overview

Problem

The production of traditional Portland cement has a significant environmental impact due to high energy consumption and CO2 emissions, while existing geopolymer cement manufacturing methods also have room for improvement in reducing environmental impact.

Innovation Solution

A method that utilizes etching effluents from silicon-based substrate processing, specifically with a silicate solution of alkali metal having a molar ratio SiO2:M2O greater than or equal to 0.8, is mixed with aluminosilicate raw materials to produce cement, thereby reducing energy costs and environmental impact by reusing chemical waste.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If traditional Portland cement manufacturing is used, then cement production is achieved, but high energy consumption and CO2 emissions occur

Engineering Contradiction:

Improveenergy consumptionVSAvoidCO2 emissions

Core Design Contradiction:

Use of energy by moving objectVSObject-generated harmful factors

Solution Approach 1:

The invention converts harmful industrial waste effluents containing silicates and alkali metals into beneficial cementitious materials. The etching effluents from silicon substrate processing, which would normally be discarded as harmful waste, are reused as the activating solution for geopolymer cement, transforming an environmental problem into a resource.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The invention recovers valuable chemical components (silicates and alkali metals) from industrial waste effluents that would otherwise be discarded. By extracting and reusing these components in cement manufacturing, the process prevents waste discharge while reducing the need for virgin raw materials and energy-intensive production.

Inventive Principle:

Principle #34Discarding and recovering

2Object-generated harmful factors

If geopolymer cement is manufactured from aluminosilicate raw material and alkali solution, then environmental impact is reduced compared to Portland cement, but additional resources and energy are still required

Engineering Contradiction:

Improveenvironmental impactVSAvoidenergy cost

Core Design Contradiction:

Object-generated harmful factorsVSUse of energy by moving object

Solution Approach 1:

The invention makes the cement manufacturing process self-sufficient by using industrial waste effluents as the alkali activator. Instead of requiring separate production of alkali solutions (which consumes energy and resources), the process utilizes readily available waste streams from the semiconductor industry, eliminating the need for additional resource extraction and processing.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The invention creates a multi-functional system where the etching effluent serves multiple purposes: it acts as the alkali activator for geopolymerization, provides the silicate source for cement formation, and simultaneously solves the waste disposal problem of the silicon industry. This universal use of the waste stream maximizes resource efficiency.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If alkali solution is manufactured separately for geopolymer cement, then proper chemical composition is achieved, but resource consumption and manufacturing complexity increase

Engineering Contradiction:

Improvechemical compositionVSAvoidmanufacturing process

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The invention adapts the chemical parameters of the waste effluent to suit cement manufacturing requirements. By controlling the composition of the etching effluent (ensuring adequate silicate and alkali metal content) and adjusting mixing ratios with aluminosilicate raw materials, the process achieves reliable geopolymerization while simplifying the overall manufacturing system.

Inventive Principle:

Principle #35Parameter changes

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

This approach decreases the energy and resource requirements for cement production, leading to a cement with reduced environmental impact and improved mechanical properties, while also facilitating the reuse of industrial waste.

Implementation Method 1

the setting of a geopolymer cement is done via polymerisation of oligo-(sialate-siloxo) of an alkali metal, typically potassium or sodium, in poly(sialate-siloxo) of this alkali metal

Methodology Applied

Scientific EffectPolymerisation:

Data Source

PatentUS11919808B2Method for manufacturing cement from an aluminosilicate raw material

Publication Date: 2024.03.05 COMMISSARIAT A LENERGIE ATOMIQUE ET AUX ENERGIES ALTERNATIVES

AI summary

A method for manufacturing cement may include: supplying at least one etching effluent of a substrate based on silicon including a silicate of an alkali metal, M, having formula SiO2:M2O, and having a molar ratio SiO2/M2O greater than or equal to 0.8; supplying an aluminosilicate raw material, and mixing the aluminosilicate raw material with the etching effluent having a molar ratio SiO2/M2O greater than or equal to 0.8. The silicate solution of alkali metal may be recovered with an existing silicon industrial process, implementing a silicon etching. The environmental impact of the method of manufacturing cement may therefore be reduced.