Calcined Paper Sludge Binder for Cement-Free Flooring
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Solution Overview
Problem
The production of cement is energy-intensive and emits high levels of CO2, and it generates dust during production and use, necessitating the use of mineral oil which reduces workability and can cause surface defects in cement-based products, while existing alternatives like calcined paper waste can only replace a limited amount of cement without affecting product properties.
Innovation Solution
A multi-component composition using calcined paper sludge as a partial or complete substitute for cement in polymer cement hybrid systems, combined with polyols or epoxy resins and their respective hardeners, which reduces dust formation and maintains or improves the properties of cement-based products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If cement is used as the binder in flooring compositions, then the mechanical strength and structural integrity are maintained, but CO2 emissions and energy consumption increase significantly
Solution Approach 1:
The patent changes the chemical composition parameters of the binder by replacing cement with calcined paper sludge, which has different mineralogical composition (primarily calcium carbonate from paper fillers) but can provide similar binding properties when calcined at appropriate temperatures (900-1300°C), thereby reducing CO2 emissions and energy consumption associated with cement production
Solution Approach 2:
The patent recovers valuable mineral constituents (calcium carbonate, kaolin, talc, titanium oxide) from paper sludge waste that would otherwise be discarded, transforming it into a useful binder material for flooring compositions, thereby reducing both waste and the need for virgin cement production
2Object-affected harmful factors
If mineral oil is sprayed on cement to reduce dust formation, then dust exposure is reduced, but workability decreases and surface defects occur
Solution Approach 1:
The patent converts the harmful dust-forming property of cement into a benefit by using calcined paper sludge as the binder, which inherently produces less dust during handling and application, eliminating the need for mineral oil additives that would otherwise be required to suppress dust
Solution Approach 2:
The patent extracts and removes the dust-problematic cement component from the composition and replaces it with calcined paper sludge, thereby taking out the source of the harmful effect (dust) while maintaining the functional requirements of the binder
3Object-affected harmful factors
If calcined paper waste is used to replace cement, then CO2 emissions are reduced, but the replacement amount is limited to maintain product properties
Solution Approach 1:
The patent optimizes the calcination parameters (temperature range 900-1300°C, heating rate, residence time) of paper sludge to produce a material with specific mineralogical composition and physical properties that enable high replacement levels (up to 100% of cement) while maintaining or improving mechanical strength, workability, and surface quality of the flooring composition
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 solution allows for up to 100% replacement of cement with calcined paper sludge, reducing dust exposure and CO2 emissions, while maintaining the workability, mechanical, and surface properties of cement-based products, thus offering a sustainable alternative with improved carbon footprint.
Implementation Method 1
an organic binder selected from one or more polyols, or one or more epoxy resins and, if the organic binder is one or more polyols or one or more epoxy resins, a hardener component (C) comprising an isocyanate hardener for the polyol or an amine hardener for epoxy resin
Implementation Method 2
polyols and an isocyanate hardener
Implementation Method 3
epoxy resins and an amine hardener
Data Source
AI summary
The invention relates to a multi-component composition comprising a solid component (A) comprising calcined paper sludge and one or more aggregates, and a binder component (B) comprising an organic binder selected from one or more polyols, one or more epoxy resins and a polymer latex dispersion, and, if the organic binder is one or more polyols or one or more epoxy resins, a hardener component (C) comprising an isocyanate hardener for polyol or an amine hardener for epoxy resin, wherein the multi-component composition further comprises water which is contained in the binder component (B) or, if present, in the hardener component (C). The composition is a cement-free or cement-reduced low dust hybrid composition and is suitable as a grout or for preparing floorings or coatings. The properties obtained are comparable to corresponding polymer cement concrete systems.