MSWIBA Ceramic Production via Sintering and Extrusion
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Solution Overview
Problem
The growing volumes of industrial mineral solid wastes pose environmental and economic challenges due to landfilling and stockpiling, and existing efforts to reuse these wastes in ceramic production have not been successfully industrialized, particularly with Municipal Solid Waste Incinerator Bottom Ash (MSWIBA), which lacks a viable and industrially sound mass-production method.
Innovation Solution
The development of ceramic products using MSWIBA and other recycled industrial solid wastes through extrusion, dry powder compaction, and agglomeration methods, with pre-treatment processes to stabilize and prepare the feedstocks, allowing for the creation of construction and technical ceramics with specific thermal and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If industrial mineral solid wastes are landfilled or stockpiled, then they are disposed of, but environmental and sanitary problems increase and useful land is consumed
Solution Approach 1:
The patent converts harmful industrial mineral solid wastes (which cause environmental and sanitary problems when landfilled) into useful ceramic materials through controlled thermal processing. The waste materials undergo sintering at temperatures between 600-1200°C to transform them from harmful landfill candidates into valuable construction and technical ceramics, thereby eliminating the harmful effects while creating beneficial products.
Solution Approach 2:
The patent applies parameter changes by controlling the thermal processing parameters (temperature range of 600-1200°C, residence time, atmosphere composition) to transform the physical and chemical properties of industrial wastes. By adjusting these parameters, the waste materials undergo phase changes and chemical reactions that convert them from unsuitable landfill materials into ceramics with desired mechanical and chemical properties.
2Ease of manufacture
If industrial mineral solid wastes are landfilled, then they are disposed of, but production costs increase due to handling enormous volumes
Solution Approach 1:
The patent changes the physical state and density of waste materials through thermal processing. By sintering waste materials at controlled temperatures, the volume of waste is reduced and its density increases, transforming it from a bulk material requiring large handling volumes into a compact ceramic product. This parameter change eliminates the need to handle enormous volumes of waste material.
3Productivity
If conventional ceramic feedstocks are used, then ceramics are produced, but useful resources such as clay are consumed and environmental impacts increase
Solution Approach 1:
The patent recovers and reuses industrial mineral solid wastes that would otherwise be discarded or landfilled. Instead of consuming conventional resources like clay, the process recycles waste materials (such as iron and steel slags, alumina red muds, combustion ashes) into ceramic products. This recovery approach eliminates the need to extract and consume finite natural resources while maintaining ceramic production capabilities.
Solution Approach 2:
The patent creates composite ceramic materials by combining industrial waste materials with appropriate binders and additives. The resulting composite ceramics incorporate the beneficial properties of waste materials (such as alumina silicates) while achieving the desired mechanical and chemical properties for construction and technical applications, thereby replacing conventional single-source feedstocks.
4Productivity
If MSWIBA is used as ceramic feedstock, then waste reuse is achieved, but the material requires stabilization and preparation before processing
Solution Approach 1:
The patent applies preliminary action by implementing pre-treatment processes before the main ceramic forming operation. MSWIBA undergoes stabilization and preparation steps (such as size reduction, mixing with binders, and controlled drying) to make it suitable for extrusion or molding. These preliminary actions prepare the waste material for subsequent thermal processing, ensuring successful ceramic product formation.
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 enables the effective reuse of MSWIBA and other wastes, reducing landfilling, conserving conventional resources, and decreasing production costs, while producing ceramics suitable for various applications, including construction and technical uses.
Implementation Method 1
the ceramics are formed using at least one of extrusion shaping, dry powder compaction and agglomeration, any of which can be preceded by a pre-treatment process of received feedstock
Data Source
AI summary
A ceramic for construction or technical applications, composed of at least one of Municipal Solid Waste Incinerator Bottom Ash (MSWIBA) and other recycled industrial solid waste and different methods of forming such ceramics. Various techniques illustrate how ceramics are formed using at least one of extrusion shaping, dry powder compaction and agglomeration, any of which can be preceded by a pre-treatment process of received feedstock.