Geopolymer Precursor Activation From Earth Materials

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Solution Overview

Problem

The variability in composition and morphology of industrial waste materials used for making polysialate systems poses challenges, and these materials are increasingly scarce and difficult to transport, necessitating alternative methods for producing polysialate raw materials.

Innovation Solution

Thermal treatment of earth materials, such as plasma and microwave processes, is used to transform aluminum, silicon, and oxygen-containing materials into alkali-reactive forms, allowing for the extraction of metal ions and subsequent formation of polysialate systems, which can be used in cementitious applications.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If industrial waste materials are used as raw materials for making polysialate systems, then cost is reduced and environmental impact is minimized, but composition and morphology variability increases and material availability decreases

Engineering Contradiction:

Improvemanufacturing costVSAvoidraw material composition consistency

Core Design Contradiction:

Ease of manufactureVSStability of the object's composition

Solution Approach 1:

The patent applies thermal treatment parameters (temperature, time, atmosphere) to transform the physical and chemical properties of earth materials, converting them into a consistent alkali-reactive state that enables reliable polysialate formation despite variations in original composition

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent performs preliminary thermal treatment and metal extraction on earth materials before using them to make polysialate systems, preparing the materials in advance to ensure consistent reactivity and composition in the final product

Inventive Principle:

Principle #10Preliminary action

2Ease of manufacture

If industrial waste materials are transported to application locations, then polysialate production is enabled, but transportation cost and energy consumption increase

Engineering Contradiction:

Improvepolysialate production capabilityVSAvoidtransportation energy

Core Design Contradiction:

Ease of manufactureVSUse of energy by moving object

Solution Approach 1:

Instead of transporting earth materials to centralized polysialate production facilities, the patent inverts the approach by enabling polysialate production at or near the source of earth materials through portable thermal treatment and processing equipment

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent enables earth materials to be processed and converted into polysialate systems at their source locations, making the material sources self-sufficient and eliminating the need for long-distance transportation

Inventive Principle:

Principle #25Self-service

3Reliability

If metal ions are extracted from thermally treated earth materials, then metal recovery is achieved and polysialate raw material quality is improved, but additional processing steps are required

Engineering Contradiction:

Improvepolysialate raw material qualityVSAvoidprocessing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines thermal treatment and metal extraction operations into an integrated process flow, where the thermal treatment apparatus is followed by leaching and extraction units in a continuous manner, reducing overall process complexity despite multiple functions

Inventive Principle:

Principle #5Merging (Combining)

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 method enables the efficient production of polysialate systems from locally available earth materials, enhancing metal extraction and reducing transportation needs while providing a sustainable alternative to conventional cement.

Implementation Method 1

obtaining an earth material containing a metal that has been treated using plasma, microwaves, or both

Methodology Applied

Scientific EffectPlasma: Plasma

Implementation Method 2

obtaining an earth material containing a metal that has been treated using plasma, microwaves, or both

Methodology Applied

Scientific EffectMicrowave radiation: Microwave Radiation

Implementation Method 3

removing the metal from the thermally treated earth material to form an alkali reactive earth material

Methodology Applied

Scientific EffectLeaching: Solvation

Data Source

PatentUS20260015288A1Geopolymer precursor preparation

Publication Date: 2026.01.15 SCHLUMBERGER TECH CORP

AI summary

Described herein are methods of making polysialate systems using earth materials treated by plasma or microwave to make the earth materials alkali reactive. A treated earth material is obtained, for example by treating an earth material using plasma, microwaves, or both. A metal is removed from the treated earth material, for example by mixing with an organic solvent or aqueous solution having pH less than about 9. The remaining earth material is alkali reactive and can be formed into a polysialate system by exposure to a high pH aqueous solution.